Torques for fasteners (6.5) ...................................... 22
7 FAULTS; CAUSES AND REMEDIES................... 27
Page 2 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
1 INTRODUCTION AND SAFETY
1.1 General
These instructions shall always be kept
close to the product's operating location or
directly with the product.
Flowserve's products are designed, developed and
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great care
and commitment to continuous quality control,
utilising sophisticated quality techniques, and safety
requirements.
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 product support, repair and
diagnostic services.
These instructions are intended to facilitate
familiarization with the product and its use. Operating
the product in compliance with these instructions is
important to help ensure reliability in service and to
avoid risks. The instructions may not take into
account local regulations: ensure such regulations
are observed by all, including the people installing the
product. Always coordinate repair activities with
operations personnel, and follow all plant safety
requirements and applicable safety and health laws
and regulations.
These instructions should be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment shall not be put into service until all
the conditions in relation with safety, noted in the
instructions, have been met.
1.2 CE marking and approvals
It is a legal requirement that machinery and
equipment put into service within certain regions of
the world shall conform with the applicable CE
Marking Directives covering Machinery and, where
applicable, Low Voltage Equipment, Electromagnetic
Compatibility (EMC), Pressure Equipment Directive
(PED) and Equipment for Potentially Explosive
Atmospheres (ATEX).
Where applicable, these Directives and any additional
Approvals cover important safety aspects in relation
with 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 applicable Approvals
and if the product is CE marked, check the serial
number plate markings and the Certification. (See
section 9, Certification.)
1.3 Disclaimer
Information in these User Instructions is believed
to be reliable. In spite of all the efforts of
Flowserve Pump Division to provide sound and
necessary information, the content of this manual
may prove to be insufficient and is not
guaranteed by Flowserve as to its completeness
or accuracy.
Flowserve manufactures products to existing
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 incorporation of such
parts and accessories may adversely affect the
performance and safety features of the products. The
failure to properly select, install or use authorised
Flowserve parts and accessories is considered to be
misuse. Damage or failure caused by misuse is not
covered by Flowserve's warranty. In addition, any
modification of Flowserve products or removal of
original components may impair the safety of these
products in their use.
1.4 Copyright
All rights reserved. No part of these instructions may
be reproduced, stored in a retrieval system or
transmitted in any form or by any means without prior
permission of Flowserve Pump Division.
1.5 Duty conditions
This product has been selected to meet the
specifications of your purchase order. The
acknowledgement of these conditions has been sent
separately to the Purchaser. A copy should be kept
with these instructions.
The product shall 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
needs Flowserve’s written agreement before start up.
Page 3 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
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 substances and toxic fluid” safety instructions where noncompliance would affect personal safety and could
result in loss of life.
This symbol indicates safety
instructions where non-compliance will involve some
risk to safe operation and personal safety and would
damage the equipment or property.
This symbol indicates explosive atmosphere
marking according to ATEX. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
This sign is not a safety symbol but
indicates an important instruction in the assembly
process.
1.6.2 Personnel qualification and training
All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved. If the
personnel in question do not already have the
necessary knowledge and skills, appropriate training
and instruction shall be provided. If required the
operator may commission the manufacturer/supplier
to provide applicable training.
Always coordinate repair activities with operations
and health and safety personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.
1.6.3 Safety action
This is a summary of conditions and actions to
prevent injury to personnel and damage to the
environment and to equipment. For products
used in potentially explosive atmospheres
section 1.6.4 also applies.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS IN OPERATION
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 fluorelastomers (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.
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 higher than 68 °C (175 °F) or
below 5 °C (20 °F) in a restricted zone, or exceeds
local regulations, action as above shall be taken.
HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care shall
be taken to avoid exposure to the liquid by appropriate
situating the pump, limiting personnel access and by
operator training. If the liquid is flammable and/or
explosive, strict safety procedures shall be applied.
Gland packing shall not be used when pumping
hazardous liquids.
Page 4 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
appropriate. Always check that the driver, seal and
PREVENT EXCESSIVE EXTERNAL
PIPE LOAD
Do not use pump as a support for piping. Do not
mount expansion joints, unless allowed by Flowserve
in writing, so that their force, due to internal pressure,
acts on the pump flange.
ENSURE CORRECT LUBRICATION
(See section 5, Commissioning, start-up, operation and shutdown.)
START THE PUMP WITH OUTLET
VALVE PARTLY OPENED
(Unless otherwise instructed at a specific point in the
User Instructions.)
This is recommended to minimize the risk of
overloading and damaging the pump motor at full or
zero flow. Pumps may be started with the valve
further open only on installations where this situation
cannot occur. The pump outlet control valve may
need to be adjusted to comply with the duty following
the run-up process. (See section 5, Commissioning start-up, operation and shutdown.)
NEVER RUN THE PUMP DRY
INLET VALVES TO BE FULLY OPEN
WHEN PUMP IS RUNNING
Running the pump at zero flow or below the
recommended minimum flow continuously will cause
damage to the seal.
DO NOT RUN THE PUMP AT
ABNORMALLY HIGH OR LOW FLOW RATES
Operating at a flow rate higher than normal or at a
flow rate with no 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.
1.6.4 Products used in potentially explosive
atmospheres
Measures are required to:
Avoid excess temperature
Prevent build up of explosive mixtures
Prevent the generation of sparks
Prevent leakages
Maintain the pump to avoid hazard
The following instructions for pumps and pump units
when installed in potentially explosive atmospheres
shall be followed to help ensure explosion protection.
Both electrical and non-electrical equipment shall
meet the requirements of European Directive
94/9/EC.
1.6.4.1 Scope of compliance
pump equipment are suitably rated and/or certified for
the classification of the specific atmosphere in which
they are to be installed.
Where Flowserve has supplied only the bare shaft
pump, the Ex rating is only applicable to the pump.
The party responsible for assembling the pump set
shall select the driver and any additional equipment,
with the necessary CE Certificate/ Declaration of
Conformity establishing it is suitable for the area in
which it is to be installed.
The output from a variable frequency drive (VFD) can
cause additional heating affects in the motor and so,
for pumps sets with a VFD, the ATEX Certification for
the motor must state that it covers the situation where
electrical supply is from the VFD. This particular
requirement is applicable, 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 135 ºC (T4)
Equipment Group
I = Mining
II = Non-mining
Category
2 or M2 = High level protection
3 = normal level of protection
Gas and/or Dust
G = Gas; D= Dust
c = Constructional safety
(in accordance with prEn13463-5)
Maximum surface temperature (Temperature Class)
(See section 1.6.4.3.)
1.6.4.3 Avoiding excessive surface temperatures
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE
Pumps have a temperature class as stated in the
ATEX Ex rating on the nameplate. These are based
on a maximum ambient of 40 °C (104 °F); refer to
Flowserve for higher ambient temperatures.
The surface temperature on the pump is influenced
by the temperature of the liquid handled. The
maximum permissible liquid temperature depends on
the temperature class and shall not exceed the
values in the table that follows.
Use equipment only in the zone for which it is
Page 5 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
Temperature
class to
prEN 13463-1
Maximum
surface
temperature
permitted
Temperature limit of liquid
handled (* depending on
material and construction
variant - check which is lower)
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) *
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
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 not completely filled.
Even a short run time may give a high temperature
resulting from contact between rotating and stationary
components.
If there is any possibility of risk of the pump being run
against a closed valve, generating high liquid and
casing external surface temperatures it is
recommended that an external surface temperature
protection device will be mounted.
Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, temperature monitoring or
power monitoring and make routine vibration
monitoring checks.
In dirty or dusty environments, regular checks must
be made and dirt removed from areas around close
clearances and motors.
1.6.4.4 Preventing the build up of explosive
mixtures
ENSURE THE PUMP IS PROPERLY FILLED
AND VENTED AND DOES NOT RUN DRY
Ensure the pump and relevant suction and discharge
pipeline system is totally filled with liquid at all times
during the pump operation, so that an explosive
atmosphere is prevented. In addition it is essential to
make sure that seal chambers, auxiliary shaft seal
systems and any heating and cooling systems are
properly filled.
If the operation of the system cannot avoid this
condition the fitting of an appropriate dry running
protection device is recommended (eg liquid
detection or a power monitor).
To avoid potential hazards from fugitive emissions of
vapour or gas to the atmosphere, the surrounding
area must be well ventilated.
1.6.4.5 Preventing sparks
To prevent a potential hazard from mechanical
contact, the motor stool guard shall be non-sparking
and anti-static for Category 2.
To avoid the potential hazard from random induced
current generating a spark, the earth contact on the
base plate must be used.
Avoid electrostatic charge: do not rub non-metallic
surfaces with a dry cloth; ensure cloth is damp.
1.6.4.6 Preventing leakage
The pump must only be used to handle liquids
for which it has been approved to have the correct
corrosion resistance.
Avoid entrapment of liquid in the pump and
associated piping due to closing of suction and
discharge valves, which could cause dangerous
excessive pressures to occur if there is heat input to
the liquid. This can occur if the pump is stationary or
running.
Bursting of liquid containing parts due to freezing
must be avoided by draining or protecting the pump
and ancillary systems.
Where there is the potential risk of a loss of a seal
barrier fluid or external flush, the fluid must be
monitored.
If leakage of liquid to the atmosphere can result in a
hazard, the installation of a liquid detection device is
recommended.
1.6.4.7 Maintenance to avoid the hazard
CORRECT MAINTENANCE IS REQUIRED TO
AVOID POTENTIAL HAZARDS WHICH GIVE A
RISK OF EXPLOSION
The responsibility for compliance with
maintenance instructions is with the plant
operator.
Page 6 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
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 warning labels
1.7.1 Nameplate
For details of nameplate, see the Declaration of
Conformity.
1.7.2 Warning labels
Page 7 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
Motor size
and speed
3550 r/min
2900 r/min
1750 r/min
1450 r/min
Pump and
motor
dBA
Pump
only
dBA
Pump and
motor
dBA
Pump
only
dBA
Pump and
motor
dBA
Pump
only
dBA
Pump and
motor
dBA
Pump
only
dBA
KW
(hp)
2.2
(3)
78
72
71
68
71
68
68
68 3 (4)
81
74
74
70
74
70
70
70 4 (5)
82
75
75
71
75
71
71
71
5.5
(7.5)
90
77
83
73
76
73
72
71
7.5
(10)
90
78
83
74
77
74
73
72
11
(15)
91
80
84
76
78
76
74
73
15
(20)
92
83
85
79
80
79
76
75
18.5
(25)
92
83
85
79
80
79
76
75
22
(30)
92
83
85
79
81
79
77
75
30
(40)
100
85
93
81
84
80
80
76
37
(50)
100
86
93
82
84
80
80
76
45
(60)
100
87
93
83
84
80
80
76
55
(75)
102
88
95
84
86
81
82
77
75
(100)
100
90
95
86
88
81
83
78
90
(120)
100
90
95
86
90
81
85
78
110
(150)
100
91
95
87
91
83
86
79
150
(200)
101
92
96
88
91
83
86
79
200
(270)
83 80
300
(400) - - - - 84 81
1.8 Specific machine performance
For performance parameters see section 1.5, Duty
conditions. When the contract requirement specifies
these to be incorporated into User Instructions these
are included here. Where performance data has
been supplied separately to the purchaser these
should be obtained and retained with these User
Instructions if required.
1.9 Noise level
When pump noise level exceeds 85 dBA attention
must be given to prevailing Health and Safety
Legislation, to limit the exposure of plant operating
personnel to the noise. The usual approach is to
control exposure time to the noise or to enclose the
machine to reduce emitted sound. You may have
already specified a limiting noise level when the
equipment was ordered, however if no noise
requirements were defined then machines above a
certain power level will exceed 85 dBA. In such
situations consideration must be given to the fitting of
an acoustic enclosure to meet local regulations.
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 (L
figures are indicative only, they are subject to a +3 dB
tolerance, and cannot be guaranteed.
The values are based on the noisiest electric motors
that are likely to be encountered. They represent
sound pressure levels at 1 m (3.3 ft) from the directly
driven pump, for "free field over a reflecting plane".
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.
For units driven by equipment other than electric
motors or units contained within enclosures, see the
accompanying information sheets and manuals.
Typical sound pressure level, dBA (LpA at 1 m reference 20μPa)
). The
pfA
Motors in this range are generally job specific and noise levels should be calculated based on actual equipment installed.
For 960 rpm reduce 1450 rpm values by 5 dBA.
Page 8 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
2 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be
checked with the delivery and shipping documents for
its completeness and to ensure that there has been no
damage during transportation.
Any shortage and or damage shall be reported
immediately to Flowserve Pump Division and received
in writing within one month of receipt of the equipment.
Claims coming in afterwards cannot be accepted.
Check any crate, box and 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 Lifting the pump
2.3.2 Lifting the back pull out unit
Lift the back pull out unit by the bearing support,
see Figure 2.
Figure 2
2.3.3 Lifting with foundation frame
The unit must be lifted at the lifting lugs or eye bolts
of the base plate. For lifting of the total unit a lifting
beam or lifting frame shall be used to avoid
damaging of the E-motor, seal plan, interconnecting
piping and/or instruments).
Unsafe lifting is never allowed!
Attach the lifting cables behind the suction flange and
through the bearing support, see Figure 1.
Figure 1
A crane shall be used for all pump sets in
excess of 25 kg (55 lb). Fully trained personnel
must carry out lifting, in accordance with local
regulations. The driver and pump weights are
recorded on their respective nameplates.
2.4 Storage
Store the pump in a clean, dry
location away from vibration. Leave piping
connection covers in place to keep dirt and other
foreign material out of pump casing. Turn pump at
intervals to prevent brinelling of the bearings and
the seal faces, if fitted, from sticking.
The pump may be stored as above for up to 6
months. Consult Flowserve for preservative actions
when a longer storage period is needed.
2.5 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, in accordance with
environmentally acceptable methods and local
regulations. If the product contains substances that
are harmful to the environment, these should be
removed and disposed of in accordance with
current regulations. This also includes the liquids
Page 9 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
Pumped liquid temperature limits*
up to +450 ºC (842 ºF)
Maximum ambient temperature*
up to +40 ºC (104 ºF)
Maximum soft solids in
suspension*
up to 1 % by volume
(refer for size limits)
Maximum pump speed
up to 3600
Pump size
Impeller
maximum
size
mm (in.)
Nominal wear
ring diameter
Small / large
mm (in.)
Min.
diametral
wear ring
clearance
mm (in.)
PHL 25.08.05
240 (9.45
90/130 (3.54/5.12)
0.35/0.43 (0.014/0.017)
PHL 25.10.08
235 (9.25)
130/-- (5.12/--)
0.43/-- (0.017/--)
PHL 25.15.10
242 (9.53
165/200 (6.50/7.87)
0.45/0.50 (0.018/0.020)
PHL 30.20.15
290 (11.4)
220/265 (8.66/10.43)
0.50/0.55 (0.020/0.022)
PHL 35.08.05
370 (14.57)
100/130 (3.93/5.12
0.35/0.43 (0.014/0.017)
PHL 35.10.08
370 (14.57)
130/140 (5.12/5.51)
0.43/0.43 (0.017/0.017)
PHL 35.15.10
354 (13.93)
180/200 (7.09/7.87)
0.48/0.50 (0.019/0.020)
PHL 40.10.08
420 (16.54)
140 / 140 (5.51/5.51)
0.43/0.43 (0.017/0.017)
PHL 40.15.10
420 (16.54)
170/195 (8.66/10.83)
0.48/0.50 (0.019/0.020)
PHL 40.20.15
420 (16.54)
220/290 (8.66/11.41)
0.50/0.60 (0.020/0.025)
and or gases that may be used in the "seal system" or
other utilities.
Make sure that hazardous substances are
disposed of safely and that the correct personal
protective equipment is used. The safety
specifications shall be in accordance with the current
regulations at all times.
3 PUMP DESCRIPTION
3.1 Configuration
The PHL type pump is a heavy duty, single stage,
horizontal centrifugal pump, designed for the
Petrochemical Industry, chemical plants, general
service and circulating applications.
3.2 Name nomenclature
The pump size will be engraved on the nameplate
typically as below:
PHL 30.20.15.30F
Configuration – see 3.1 above.
Max. impeller size (cm)
Nominal suction branch size (cm)
Nominal discharge branch size (cm)
Specific hydraulic design
The typical nomenclature above is the general guide
to the PHL configuration description. Identify the actual
pump size and serial number from the pump
nameplate. Check that this agrees with the applicable
certification provided.
3.3 Design of major parts
3.3.1 Pump casing
The pump has its main casing gasket axial to the shaft
allowing maintenance to the rotating element by
removing the back pull out unit. Suction and discharge
branches are at the casing and therefore its piping
remain undisturbed at maintenance.
3.3.2 Impeller
The impeller is fully shrouded and is fitted with
impeller wear rings.
3.3.3 Diffuser
The diffuser is tuned to the impeller and the multi
channel diffuser is concentric aligned around the
impeller
3.3.4 Pump Shaft
The pump is of the dry shaft design and has a keyed
drive end.
3.3.5 Stuffing box
The stuffing box has a spigot (rabbet) fit between
the pump casing and seal plate for optimum
concentricity. The design enables a number of
sealing options to be fitted.
3.3.6 Shaft seal
The mechanical seal(s) attached to the pump shaft
seals the pumped liquid from the environment.
Gland packing may be fitted as an option, for nonhazardous service only.
3.3.7 Driver
The driver can be an electric motor or diesel motor
or turbine.
3.3.8 Accessories
Accessories may be fitted when specified by the
customer.
3.4 Performance and operating limits
This product has been selected to meet the
specifications of your purchase order. See section
1.5.
The following data are included as additional
information to help with your installation. It is typical,
and factors such as temperature, materials, and seal
type may influence these data. If required, a definitive
statement for your particular application can be
obtained from Flowserve.
3.4.1 Operating limits
3.4.2 Pump and impeller data
Page 10 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
Figure: foundation bolts
4 INSTALLATION
Equipment operated in hazardous locations shall
comply with the relevant explosion protection
regulations. See section 1.6.4, Products used in
potentially explosive atmospheres.
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
It is the responsibility of the installer to ensure that the
seal system is properly installed to the pump.
4.3 Foundation
There are many methods of installing
pump units to their foundations. The correct method
depends on the size of the pump unit, its location and
noise vibration limitations. Non-compliance with the
provision of correct foundation and installation may
lead to failure of the pump and, as such, would be
outside the terms of the warranty. Ensure the following
requirements are met.
The base plate should be mounted onto a firm
foundation, either an appropriate thickness of quality
concrete or sturdy steel framework. (It should NOT be
distorted or pulled down onto the surface of the
foundation, but should be supported to maintain the
original alignment.) Concrete is the most suitable
material for the base.
The base should contain recesses for the grouting of
the foundation bolts. Figure 3 shows a number of
variations on the design of the foundation bolts.
Make these recesses in the base in accordance
with the above figure, referring to the dimensional
drawing of the pump unit.
If a concrete base is used, observe the following
points:
do not place the pump unit on the base until it
is completely set;
fill the recesses with water at least 24 hours
before grouting the foundation bolts. Wetting
the recesses will strengthen the bond between
the mortar of the foundation bolts and the base;
remove the water from the recesses when the
foundation bolts are being grouted;
4.3.1 Positioning the foundation bolts
Lift the pump unit above the base in
accordance with the lifting instructions
described in § 3.1.
Place the foundation bolts with nuts and
washers in the foundation frame.
Take the following points into account when
positioning the pump unit:
The foundation bolts should be suspended
freely in the recesses of the base.
The level of the center line of the suction and
discharge nozzles should correspond with the
center line of the pipes to be connected.
The position of the suction and discharge
nozzles in the y and z directions (see Figure 2)
and
The vertical distance between the base and the
foundation frame (40 mm) before filling with
mortar.
Lay steel filler blocks 25 mm thick on the base
on either side of the foundation bolts.
Place the pump unit on the filler blocks.
Lay thin filler plates under the adjusting bolts.
Adjust the pump unit so that it is roughly level
and at the required height by turning the
adjusting bolts in the welded-on adjusting
bosses of the foundation frame so that the
suction and discharge flange can be mounted
on the pipe flanges without stress. There
should be a parallelism of 0.1 mm between the
flanges to be connected.
Page 11 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
Not supplied
BLOCK TO BE REMOVED
AFTER THE SEALING
Figure 3: Adjusting foundation frame
BLOCK TO BE REMOVED AFTER
APPLYING THE FILLER GROUT
Fill the space between the filler blocks and the
foundation frame with filler plates.
Check that the bolts fit easily into the bolt holes of
the flanges.
Fix the foundation bolts by filling the recesses with
non-shrinkable mortar.
Let the mortar set in accordance with the
specifications.
4.4 Adjusting the foundation frame
To make sure that the unit is leveled, use a calibrated
machine levelwith an accuracy of 0.02 mm/m1.
Measure along the shaft of the electric motor in both
directions, or, if this is not possible, along the seal
plate. If the mechanical seal is fitted with a guard, this
should be removed.
Level the foundation frame in the direction A-B
with an accuracy of 0.05 mm/m1 using the
adjusting bolts, see Figure 3. Fill the space
between the filler blocks and the foundation frame
with thin filler plates.
Tighten the foundation nuts, along the A-B axis, by
applying a moment equal to ¼ the maximum
permissible moment (M
) of the foundation bolt.
max
Level the foundation frame in the directions C-D,
E-F and G-H with an accuracy of 0.05 mm/m1
using the adjusting bolts. Fill the space between
the filler blocks and the foundation frame with thin
filler plates.
Tighten the other foundation nuts by applying a
moment equal to ¼ the maximum permissible
moment (M
) of the foundation bolt.
max
Check that the nuts of the foundation bolts are still
tight.
Place the electric motor on the pump center line,
using shims between the supporting faces of the
foundation frame and the motor base.The
maximum allowable deviation in axial or radial
direction is 0.05 mm and depends on the type of
coupling.
Retract all foundation bolts and check that the
foundation frame is level in all directions with
an accuracy of 0.05 mm/m1.
Check the position and level along the center
line of the suction and discharge nozzles.
Adjust, if necessary, by following the
procedures given above.
Fill in the outer edges of the foundation frame,
including filler plates, completely, using nonshrinkable mortar (e.g. Pagel V1 or equivalent)
and let this set in accordance with the
specifications.
Grout the foundation frame, via the fill opening
(see Figure 3), completely, using nonshrinkable concrete and let this set in
accordance with the specifications.
Check that the nuts of the foundation bolts are
still tight and tighten, if necessary, by applying
the correct moment (¼ M
max
).
If the guard of the mechanical seal was
removed for levelling, replace it in the correct
position.
If necessary, draw up a report on the whole
adjustment procedure.
4.4.1 Baseplate not Intended for Grouting but
Installed on Concrete Foundations
According to the figure 4.3.1 and 4.4.1 the
baseplate will not be grouted but only a sealing
shall be provided. During the preparation, as
indicated on the General Arrangement drawing a
certain number of openings into the sealing must
be guaranteed. After the sealing the blocks used to
realise the openings must be removed. Blocks has
to be wider than the baseplate longitudinal beam in
order to guarantee the opening for the drainage.
The filler grout must be of a nonshrinkable kind and fill up the space between the
beams and the concrete poor. Make sure that filler
grout is dry before removing the blocks.
Figure 4.3.1
Page 12 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
TOP OF FOUNDATION
PRIMARY
CONCRETE
SEALING
FILLER GROUT
Figure 4.4.1
4.5 Initial alignment
4.5.1 Thermal expansion
The PHL pump and motor are designed such that they
will cope with the thermal expansion for pump
application and cope with the pumping temperature as
specified on the pump data sheet. There is no need to
check the alignment at normal service conditions.
4.5.2 Alignment methods
4.5.2.1.1 Types of misalignment
There are two types of shaft misalignment: angular
and offset. Therefore, two sets of measurements
and corrections are required. Both types of
misalignment can occur in horizontal and vertical
planes and are present in most applications.
A) Angular misalignment
In angular misalignment, the centre line of the
shafts intersect, but are not on the same axis.
Figure 4.5
B) Offset misalignment
In offset misalignment, the shaft centre lines are
parallel but do not intersect.
Ensure pump and driver are isolated
electrically and the half couplings are disconnected.
The alignment MUST be checked.
Although the pump will have been aligned at the
factory it is most likely that this alignment will have
been disturbed during transportation or handling. If
necessary, align the motor to the pump, not the pump
to the motor.
4.5.2.1 Shaft/Coupling alignment
Shaft alignment must be correct for
successful operation. Rapid wear, noise, vibration
and actual damage to the equipment may be
caused by shaft misalignment. The shafts must be
aligned within the limits given within this section.
Adjustment to correct the alignment in one
direction may alter the alignment in another direction.
Always check in all directions after making any
adjustment.
Coupled equipment must be aligned to minimise
unnecessary stresses in shafts, bearings and
coupling. Flexible couplings will not compensate for
appreciable misalignment. Foundation settling,
thermal expansion or nozzle loads resulting in
baseplate/foundation deflection and vibration during
operation may require the full coupling misalignment
capability.
Figure 4.6.1 – offset misalignment
Figure 4.6.2 – combination of offset and angular misalignment
4.5.2.2 Alignment using the Reverse Alignment
Method
The following practices are recommended when
using the reverse method of alignment. These
should be carried out prior to main alignment.
Figure 4.7
Page 13 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
Paral lel
Angul ar
CHECK FOR SOFT FOOT
This is a check to ensure that there is no undue stress
on the driver holding down bolts; owing to non-level
baseplate or twisting. To check, remove all shims and
clean surfaces and tighten down driver to the
baseplate. Set a dial indicator as shown in sketch and
loosen off the holding down bolt while noting any
deflection reading on the Dial Test Indicator - a
maximum of 0.05 mm ( 0.002 in.) is considered
acceptable but any more will have to be corrected by
adding shims, for example, if the Dial Test Indicator
shows the foot lifting 0.15 mm ( 0.006 in.) then this is
the thickness of shim to be placed under that foot.
Tighten down and repeat the same procedure on all
other feet until all are within tolerance
If the driver is an electric motor with sleeve
bearings then the magnetic centre at which the rotor
will run must be set. This is usually done by lining up a
groove in the shaft to a pointer fixed to the motor body
(refer to Motor Manufacture’s instructions).
4.5.2.3 Alignment using a graph (Reverse
Alignment)
Ensure pump and driver are isolated
electrically and the half couplings are disconnected.
The alignment MUST be checked.
Although the pump will have been aligned at the
factory it is most likely that this alignment will have
been disturbed during transportation or handling. If
necessary, align the motor to the pump, not the pump
to the motor.
The alignment is achieved by adding or removing
shims under the motor feet and also moving the motor
horizontally as required. In some cases where the
alignment cannot be achieved it will be necessary to
move the pump before recommencing the above
procedure.
For couplings with narrow flanges use a dial indicator
as shown below to check both parallel and angular
alignment.
Figure 4.8
Maximum permissible misalignment at working
temperature:
Parallel 0.05 mm (0.002 in.) TIR
Angular 0.025 mm (0.001 in.) TIR
Pumps with thick flanged non-spacer couplings can
be aligned by using a straight-edge across the
outside diameters of the coupling hubs and
measuring the gap between the machined faces
using feeler gauges, measuring wedge or calipers.
When the electric motor has sleeve bearings it is
necessary to ensure that the motor is aligned to run
on its magnetic centreline.
Refer to the motor manual for details.
A button (screwed into one of the shaft ends) is
normally fitted between the motor and pump shaft
ends to fix the axial position.
If the motor does not run in its
magnetic centre the resultant additional axial force
may overload the pump thrust bearing.
Complete piping as below and see sections
4.7, “Final shaft alignment check” up to and
including section 5, “Commissioning, start-up, operation and shutdown” before connecting driver
and checking actual rotation.
4.5.3 Shims
The shims between the equipment feet and
mounting surface should be clean and dry. This is
especially critical for pumps in service for sometime
and need to be realigned. Water, dirt and rust may
change the height of the shim pack over a period of
time. Shims should be made large enough to
support the weight of the equipment on its
mounting foot. Do not use many thin shims as this
may result in a spongy mounting.
Figure 4.9
Recommended shim design
Move the equipment vertically by adding or
removing the calculated thickness of shims. Torque
holding down bolts to required values.
4.5.4 Assemble coupling
a) Assemble coupling as per the manufacturer's
instructions included in Appendix of this
manual.
b) Install coupling guard
4.5.5 Installation check list
a) Level Baseplate?
b) Grout Baseplate - Check Foundation Bolts?
c) Alignment Shaft/Coupling?
Protective covers are fitted to the pipe
connections to prevent foreign bodies entering during
transportation and installation. Ensure that these
covers are removed from the pump before connecting
any pipes.
4.6.1 Suction and discharge pipework
In order to minimize friction losses and hydraulic noise
in the pipework it is good practice to choose pipework
that is one or two sizes larger than the pump suction
and discharge. Typically, main pipework velocities
should not exceed 2 m/s (6 ft/sec) suction and 3 m/s
(9 ft/sec) on the discharge.
Take into account the available NPSH which shall be
higher than the required NPSH of the pump.
Never use the pump as a support for
piping.
Maximum allowable forces and moments on the pump
flanges vary with the pump size and type. To minimize
these forces and moments, which, if excessive, cause
misalignment, hot bearings, vibration and the possible
failure of the pump casing, the following points should
be strictly followed:
Prevent excessive external pipe load
Never bring piping into place by applying forces to
the pump flange connections
Do not mount expansion joints so that their force,
due to internal pressure, acts on the pump flange
The table on the general arrangement drawing
summarizes the maximum allowable forces and
moments on the pump casing. The allowable forces
and moments are also listed in the addendum (Tab 1).
Refer to Flowserve for other configurations.
Mount the flanges of the pipes and pump so that they
are parallel with a tolerance of 0.1 mm. Make sure that
the centrelines of the flanges are in line with each
other.
Ensure piping and fittings are flushed
before use.
Ensure piping for hazardous liquids is arranged
to allow pump flushing before removal of the pump.
4.6.2 Suction piping
a) The inlet pipe should be one or two sizes larger
than the pump inlet bore and pipe bends
should be of a radius as large as possible.
b) Pipework reducers should have a maximum
total angle of divergence of 15 degrees.
c) Keep the total length of the suction pipe as
short as possible.
d) A bend in the suction pipe should be located at
a distance of at least 5 times the pipe bore from
the suction flange
e) Install as few bends as possible in the suction
pipe and select the largest possible radius
f) On suction lift the piping should be inclined up
towards the pump inlet with eccentric reducers
incorporated to prevent air locks.
g) On positive suction, the inlet piping must have
a constant fall towards the pump.
h) Inlet strainers, when used, should have a net
`free area' of at least three times the inlet pipe
area.
i) Do not install elbows at an angle other than
perpendicular to the shaft axis. Elbows parallel
to the shaft axis will cause uneven flow.
j) In the case of contaminated liquids, install a
suction strainer or dirt trap with a bore which
matches the bore of the pump.
k) Fitting an isolation valve will allow easier
maintenance.
l) Never throttle pump on suction side and never
place a valve directly on the pump inlet nozzle.
4.6.3 Maximum allowable forces and
moments on PHL pump flanges
Refer to the General Arrangement drawing (tab 1)
4.6.4 Discharge piping
A non-return valve should be located in the
discharge pipework to protect the pump from
excessive back pressure and hence reverse
rotation when the unit is stopped.
Pipework reducers should have a maximum total
angle of divergence of 9 degrees.
Fitting an isolation valve will allow easier
maintenance.
4.6.5 Auxiliary piping
4.6.5.1 Drains
Pipe casing drains and gland leakage to a
convenient disposal point.
4.6.5.2 Pumps fitted with gland packing
When suction pressure is below atmospheric
pressure, it is necessary to feed the gland packing
with liquid to provide lubrication and prevent the
ingress of air. This is normally achieved with a
supply from the pump discharge volute to the
stuffing box. A control valve or orifice plate may
have been fitted into the supply line to control the
pressure to the gland / stuffing box.
Page 15 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
If the pumped liquid is dirty and cannot be used for
sealing, a separate clean compatible liquid supply to
the gland at 1.5 – 2.0 bar (20 –30 psi) above suction
pressure is recommended.
4.6.5.3 Pumps fitted with mechanical seals
Single seals requiring re-circulation will normally be
provided with the auxiliary piping from pump casing
already fitted.
If the seal requires an auxiliary quench then a
connection must be made to a suitable source of liquid
flow, low pressure steam or static pressure from a
header tank. Recommended pressure is 0.35 bar (5
psi) or less. Check General arrangement drawing.
Special seals may require auxiliary piping different to
that described above. Consult separate User
Instructions and/or Flowserve if unsure of correct
method or arrangement.
For pumping hot liquids, to avoid seal damage, it is
recommended that any external flush/cooling supply
be continued after stopping the pump.
4.6.6 Final checks
Check the tightness of all bolts in the suction and
discharge pipework. Check also the tightness of all
foundation bolts.
4.7 Electrical connections
4.7.1 Electrical connections must be
made by a qualified Electrician in accordance with
relevant local national and international regulations.
4.7.2 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.
4.7.3 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.
4.7.5 A device to provide emergency
stopping must be fitted.
4.7.6 If not supplied pre-wired to the pump unit, the
controller/starter electrical details will also be
supplied within the controller/starter.
4.7.7 For electrical details on pump sets with
controllers see the separate wiring diagram.
4.7.8 See section 5.3, Direction of
rotation before connecting the motor to the
electrical supply.
4.7.9 This base plate has an earthing boss for
discharging (static) electricity. Connect the earthing
boss of the pump unit in accordance with the
applicable instructions or commission an approved
electrical engineer to carry out the work.
4.8 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
relevant if the pump is handling a flammable liquid.
If leakage of product from the pump or its
associated sealing system 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 are carried out.
5 COMMISSIONING, START-UP,
OPERATION AND SHUTDOWN
4.7.4 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.
Page 16 of 31
These operations must be carried
out by fully qualified personnel.
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
5.1 Pre-commissioning procedure
BEFORE START-UP REMOVE
TEMPORARY RUBBER GASKET ABOVE SEAL
DRIVE COLLAR.
GASKET CAN BE EASILY REMOVED BY USING A
KNIFE OR SCISSOR TO MAKE A RADIAL INCISION.
Before using the pump, flush it with hot water to
remove any preservatives or contaminants. Drain off
the flushing water from underneath the pump.
5.2 Pump lubricants
See lubrication schedule under
Appendix 1.
5.3 Impeller clearance
No functional adjustments are to be considered.
5.4 Direction of rotation
Ensure the pump is given the same
rotation as the pump direction arrow mounted on the
pump casing.
To avoid dry running the pump must be filled with
liquid.
If maintenance work has been carried
out to the site's electricity supply, the direction of
rotation should be re-checked as above in case the
supply phasing has been altered.
5.5 Guarding
Guarding is supplied fitted to the pump set.
If this has been removed or disturbed ensure that all
the protective guards around the exposed parts of the
shaft are securely fixed.
5.6 Priming and auxiliary supplies
Ensure all electrical, hydraulic,
pneumatic, sealant and lubrication systems (as
applicable) are connected and operational.
Ensure the inlet pipe and pump casing
are completely full of liquid before starting continuous
duty operation.
De-aerate the pump via the chamber of the
mechanical seal or via the flange of a pipe connected
to the mechanical seal
5.7 Warming-up instructions for hot
pumps
5.7.1 Prefix
For pumps with a duty temperature above 200 oC,
bearing cooling is required as to be specified on the
pump data sheet. Stuffingbox cooling is required
depending on the sealselection and conditions
required to the seal. In general, this means that
stuffingbox cooling is not required, when a cooling
system on the sealharness is sufficient to maintain
a constant duty temperature of the seal, which is
lower than the design temperature of the seal.
However, because not all factors which have their
impact on the temperature and duty of the seal are
constant factors, such as heat flux pump, heatload
seal, ambient temperature, the wear of the seal and
friction of the sealfaces etc. or in case that process
fluid cooling is required, jackets on the
stuffingboxes might be applied.
5.7.2 Warming-up procedure
When a cooling jacket is applied on the stuffingbox,
the pump with a duty temperature above 100 oC
has to be warmed-up, to avoid difficulties caused
by thermal expansion of the relevant pump parts
through thermal shock (pumphousing, cover, shaft,
jacket, seal and connection parts etc.).
Follow below mentioned instructions punctual:
First- Check if cooling medium to the jacket is
connected and with the required flow.
Second- Bring the pump to the working
temperature from 100 oC at a time
schedule of 5 oC per minute. Up to 100
o
C no special time schedule is required.
(see also chapter commissioning).
Third- Check at duty of the pump that no major
thermal fluctuations appear with a time
schedule larger than described under
“second”.
for stopping the pump, the time schedule
as described for warming-up should be
held in opposite time-temp. schedule
(cooling-down 5 oC per minute).
5.8 Starting the pump
a) Ensure flushing and/or cooling/
heating liquid supplies are turned ON before
starting the pump.
b) CLOSE the outlet valve.
c) OPEN all inlet valves.
d) Prime the pump.
e) Start motor and check outlet pressure.
f) If the pressure is satisfactory, slowly OPEN
outlet control valve.
Page 17 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
Vibration velocity – unfiltered
mm/s (in./s) r.m.s.
Overhung pumps
Normal N
3.0 (0.12)
Alarm N x 1.25
3.9 (0.15)
Shutdown trip N x 2.0
6.0 (0.18)
Motor rating kW (hp)
Maximum stop/starts
per hour
Up to 15 (20)
6
Between 15 (20) and 90 (120)
6
Above 90 (120)
4
5.9.3 Bearings
g) Do not run the pump with the outlet
valve closed for a period longer than 30 seconds.
h) If NO pressure, or LOW pressure, STOP the
pump. Refer to section 7, Faults; causes and remedies, for fault diagnosis.
5.9 Running the pump
5.9.1 Pumps fitted with packed gland
If the pump has a packed gland there must be some
leakage from the gland. Gland nuts should initially be
finger-tight only. Leakage should take place soon after
the stuffing box is pressurised.
If the pumps are working in a potentially
explosive atmosphere, temperature or vibration
monitoring is recommended.
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 been 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) C [(t+tb-ta+10) F]
and the trip at 100 C (212 F) for oil lubrication
The gland must be adjusted evenly to give visible
leakage and concentric alignment of the gland ring to
avoid excess temperature. If no leakage takes place
the packing will start overheating. If overheating takes
place the pump should be stopped and allowed to cool
down before being re-started. When the pump is restarted, check to ensure leakage is taking place at the
packed gland.
If hot liquids are being pumped it may be necessary to
slacken the gland nuts to achieve leakage.
The pump should be run for 30 minutes with steady
leakage and the gland nuts tightened by 10 degrees at
a time until leakage is reduced to an acceptable level,
normally a minimum of 120 drops per minute is
and 105 C (220 F) 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 reduced with time. (Refer to
section 6.1.1 for further information.)
5.9.4 Normal vibration levels, alarm and trip
For guidance, pumps generally fall under a
classification for rigid support machines within the
International rotating machinery standards (API
610, latest ed./ISO 13709, latest ed.) and the
recommended maximum levels below are based on
those standards.
required. Bedding in of the packing may take another
30 minutes.
Alarm and trip values for installed
pumps should be based on the actual
Care must be taken when adjusting the gland on
an operating pump. Safety gloves are essential.
Loose clothing must not be worn to avoid being caught
up by the pump shaft. Shaft guards must be replaced
after the gland adjustment is complete.
measurements (N) 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.
Never run gland packing dry, not even
for a short time.
5.9.2 Pumps fitted with mechanical seal
Mechanical seals are not adjustable. Any slight initial
leakage will stop when the seal is run in.
Before pumping dirty liquids, it is advisable, if possible,
to run in the pump mechanical seal using clean liquid
to safeguard the seal faces.
External flush or quench should be
5.9.5 Stop/start frequency
Pump sets are normally suitable for the number of
equally spaced stop/starts per hour shown in the
table below. Check actual capability of the driver
and control/starting system before commissioning.
started before the pump is run and allowed to flow for
a period after the pump has been stopped.
even for a short time.
Never run a mechanical seal dry, not
Where duty and standby pumps are installed it is
recommended that they are run alternately every
week.
Page 18 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
5.10 Stopping and shutdown
a) Close the outlet valve, but ensure
that the pump runs in this condition not longer
than a few seconds.
b) Stop the pump.
c) Switch off flushing and/or cooling/heating liquid
supplies at a time appropriate to the process.
d) For longer prolonged shut-downs
and especially when ambient temperatures are
likely to drop below freezing point, the pump and
any cooling and flushing arrangements must be
drained or otherwise protected.
5.11 Hydraulic, mechanical and electrical
duty
This product has been supplied to meet the
performance specifications of your purchase order,
however it is understood that during the life of the
product these may change. The following notes may
help the user to decide how to evaluate the
implications of any change. If in doubt, contact your
nearest Flowserve office.
5.11.1 Specific gravity (SG)
Pump capacity and total head in metres (feet) 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.
5.11.2 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 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.
5.11.3 Pump speed
Changing pump speed effects flow, total head, power
absorbed, NPSHR, noise and vibration. The flow is
directly proportion of the pump speed, head varies as
speed ratio squared and power varies as speed ratio
cubed. The new duty, however, will also be dependent
on the system curve. If increasing the speed, it is
important therefore to ensure the maximum pump
working pressure is not exceeded, the driver is not
overloaded, NPSHA > NPSHR, and that noise and
vibration are within local requirements and regulations.
5.11.4 Net positive suction head (NPSHA)
NPSH available (NPSHA) is a measure of the head
available in the pumped liquid, above vapour
pressure, at the pump suction branch.
NPSH required (NPSHR) is a measure of the head
required in the pumped liquid, above its vapour
pressure, to prevent the pump from cavitating. It is
important that NPSHA > NPSHR. The margin
between NPSHA > NPSHR should be as large as
possible.
If any change in NPSHA is proposed, ensure these
margins are not significantly eroded. Refer to the
pump performance curve to determine exact
requirements, particularly if flow has changed. If in
doubt, please consult your nearest Flowserve office
for advice and details of the minimum allowable
margin for your application.
5.11.5 Pumped flow
Flow must not fall outside the minimum and
maximum continuous safe flow shown on the pump
performance curve and or data sheet.
Page 19 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
6 MAINTENANCE
6.0 General
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 1.6.2.)
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.
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 leakage can make the floor
slippery. Machine maintenance must always
begin and finish by cleaning the floor 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 wear 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 an uncontrolled start. Put a warning board on
the starting device with the words:
"Machine under repair: do not start".
With electric drive equipment, lock the main switch
and withdraw any fuses. Put a warning board on the
fuse box or main switch with the words:
"Machine under repair: do not connect".
Never clean equipment with inflammable solvents or
carbon tetrachloride. Protect yourself against toxic
fumes when using cleaning agents.
6.1 Maintenance schedule
It is recommended that a maintenance plan
and schedule is adopted, in line with these User
Instructions. It should include the following:
a) Any auxiliary systems installed must be
monitored, if necessary, to ensure they function
correctly.
b) Gland packings (if applied instead of a
mechanical seal) must be adjusted correctly to
give visible leakage and concentric alignment
of the gland follower to prevent excessive
temperature of the packing or follower.
c) Check for any leakage from gaskets and seals.
The correct functioning of the shaft seal must
be checked regularly.
d) Check pump bearing lubricant and relevant
provisions (such as constant level oiler).
e) Check motorbearing lubricant at intervals as
described in the motor instructions.
f) Check that the duty condition is in the safe
operating range for the pump.
g) Check vibration, noise level and surface
temperature at the bearings to confirm
satisfactory operation.
h) Check dirt and dust is removed from areas
around close clearances and motors.
Our specialised service personnel can help with
preventative maintenance records and provide
condition monitoring for temperature and vibration
to identify the onset of potential problems.
If any problems are found the following sequence of
actions should take place:
a) Refer to section 7, Faults; causes and
remedies, for fault diagnosis.
b) Ensure equipment complies with the
recommendations in this manual.
c) Contact Flowserve if the problem persists.
6.1.1 Routine inspection (daily/weekly)
The following checks should be
made and the appropriate action taken to remedy
any deviations:
a) Check operating behaviour. Ensure noise,
vibration and bearing temperatures are normal.
b) Check that there are no abnormal fluid or
lubricant leaks (static and dynamic seals) and
that any sealant systems (if fitted) are full and
operating normally.
c) Check that shaft seal leakage is within
acceptable limits.
d) Check pumpbearing lubricant level.
e) For motors with regreasable bearings, check
number of running hours since last recharge of
grease or since complete grease change.
f) Check any auxiliary supplies e.g.
heating/cooling, if fitted, are functioning
correctly.
Page 20 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
Refer to the manuals of any associated
equipment for routine checks needed.
6.1.2 Periodic inspection (every 6 months)
a) Check foundation bolts for security
of attachment and corrosion.
b) Check pump running records for hourly usage to
determine if motor bearing lubricant requires
changing.
Refer to the manuals of any associated
equipment for periodic checks needed.
6.1.3 Mechanical seals
No adjustment is possible. When leakage reaches an
unacceptable level the seal will need replacement.
6.1.4 Gland packing
The stuffing box split gland can be completely
removed for re-packing or to enable the addition of
extra rings of packing.
The stuffing box is normally supplied with a lantern
ring to enable a clean or pressurised flush to the
centre of the packing. If not required, this can be
replaced by an extra 2 rings of packing.
There must always be a small leakage; normally a
minimum of 120 drops per minute to lubricate and cool
the packing is required.
6.2 Spare parts
6.2.1 Ordering of spares
Flowserve keep records of all pumps that have been
supplied. When ordering spares the following
information should be quoted:
1) Pump serial number.
2) Pump size.
3) Part name – taken from section 8 and
relevant P.O. related parts list. (Tab 1)
4) Part number – taken from relevant P.O.
related parts list. (Tab 1)
5) Number of parts required.
The pump size and serial number are shown on the
pump nameplate.
To ensure continued satisfactory operation,
replacement parts to the original design specification
should be obtained from Flowserve.
Any change to the original design specification
(modification or use of a non-standard part) will
invalidate the pump’s safety certification.
6.2.2 Storage of spares
Spares should be stored in a clean dry area away from
vibration. Inspection and re-treatment of metallic
surfaces (if necessary) with preservative is
recommended every 6 months.
6.3 Recommended spares and
consumable items
For start up purposes (Initial spares):
1 - set of gaskets and seals
(optional: 1 - complete set of gland packing)
For initial stock (Normal spares):
1 - set of pump and motor bearings (line and
thrust)
1 - mechanical seal or set of seal faces
2 - sets of pump- and sealsgaskets
2 - casing wear rings
(optional: 2 - sets of gland packing
1 - set of pump and motor bearings (line and
thrust)
1 - mechanical seal
2 - sets of pump- and sealgaskets
2 - casing wear rings
2 - impeller wear rings
1 - impeller
1 - diffuser
(optional: 2 - sets of gland packing
As wear takes place between the impeller and casing
ring the overall efficiency of the pump set will
decrease. To maintain optimum efficiency it is
recommended that rings are replaced and the impeller
renovated when the diametral clearance detailed in
section 3.4.2 has doubled to 0.7 to 1.1 mm (0.028 to
0.043 in.), depending on pump size and wearing ring
diameter.
6.7 Disassembly
Refer to section 1.6, Safety, before dismantling
the pump.
Before dismantling the pump for
overhaul, ensure genuine Flowserve replacement
parts are available.
Refer to sectional drawings for part numbers and
identification.
6.7.1 Removing the spacer
If applicable, remove the spacer of the coupling
between the pump unit and the electric motor
according to the suppliers documentation.
6.7.2 Removing the 'back pull out' unit
The 'back pull out' unit is removed by following the
procedure given below:
remove the nuts [6581.1] from the casing cover.
attach the lifting devices to the appropriate lifting
points, see Figure 1. Observe the lifting
instructions described in section 2.3.
lift the casing cover up. Work carefully as there is
not much clearance between the diffuser and the
pump casing.
6.7.3 Removing the diffuser
This procedure describes removal of the diffuser
from the casing cover.
Bend open the lock washers [6541] and
remove the hexagon head bolts [6577.1] from
the diffuser.
Remove the diffuser.
6.7.4 Removing the impeller
This procedure describes removal of the impeller
from the pump shaft.
fix the mechanical seal to the shaft sleeve by
using the setting plates on top of the
mechanical cover
undo the impeller screw [2913] with left-hand
thread. The impeller screw is locked in the bore
hole in the impeller by twisting the impeller
screw.
remove the impeller screw and the packing ring
[4590.1] between impeller and impeller screw.
This type of packing may only be used
once. Dispose of the packing ring in the proper
way.
push the impeller from the pump shaft and
remove the released key [6700.1].
remove packing ring [4590.3] between the
impeller and the stub sleeve of the mechanical
seal.
This type of packing may only beused once. Dispose of the packing ring in
the proper way.
6.7.5 Removing the bearing bracket
The mechanical seal is mounted on the back of the
casing cover which means that the bearing bracket
has to be detached from the casing cover before
disassembling the mechanical seal.
Place the bottom of the casing cover on a flat
surface.
Remove the set screws from the shaft sleeve to
make the mechanical seal cartridge loose.
Remove the bolts [6577.5].
Lift the pump bracket up vertically. Work
carefully as long as the pump shaft is still
inserted in the shaft sleeve.
remove the packing ring [4590.2] from the pump
casing and dispose of this in the proper way.
used once.
This type of packing may only be
Page 22 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
Figure : Drilling of the case wearing
Figure : Removing the case
wearing ring
6.7.6 Removing the mechanical seal
This procedure describes removal of the mechanical
seal from the casing cover.
Remove the nuts [6581.2] from the mechanical
seal on top of the cover.
Remove the mechanical seal.
Do not dismantle the mechanical seal any further.
For further information on the mechanical seal, please
refer to the instructions for use provided by the
mechanical seal supplier.
6.7.7 Removing the case wearing rings
This is the procedure to be followed when removing
the case wearing ring (2300.1) from the diffuser and, if
applicable, the wearing ring in the casing cover
(2300.2).
The case wearing ring (2300.2) has been pressed or
shrunk into the centring rim during assembly which
means that it will be necessary to drill or cut into the
case wearing ring in order to weaken the upright edge.
Remove the set screws [6570.1/3]. These set
screws lock the case wearing ring on the diffuser
[1410].
Measure width & height of the case wearing ring.
6.7.8 Removing the impeller wearing rings
The impeller wearing rings [2300.1/2] have been
shrunk or pressed onto the impeller during
assembly. Therefore a suitable extraction tool must
be used for disassembly.
Remove set screws [6570.2]. These set screws
lock the impeller wearing ring on the impeller.
Remove the impeller wearing ring from the
impeller using the extraction tool.
Drill 3 holes at 120 intervals in the partition
between impeller wearing ring and impeller.
Drill the holes to a depth such that the set
screws [6570.2] do not protrude above the
surface of the impeller wearing ring and
impeller.
6.7.9 Removing the throat bush
This procedure describes removal of the throat
bush from the casing cover.
Remove set screws [6570.3] from the bottom of
the casing cover. These set screws lock the
throat bush [4132] in the casing cover.
Remove the throat bush from the casing cover.
If this cannot be done by hand, remove it from
the casing cover by tapping with a suitable
copper rod and a hammer.
Take a drill with a slightly smaller diameter than
the width of the case wearing ring.
Drill two holes along
the centre line of the
upright edge of the
case wearing ring,
see Figure. Drill both
holes not deeper than
the measured height
of the case wearing
ring.
Chip off the remaining
edges of the drilled
holes using a
hammer and chisel,
see Figure. Make
sure that the centring
rim is not damaged.
Remove the halves of
the case wearing ring
and the metal chips
from the diffuser or
casing cover.
6.7.10 Removing the throwers
This procedure describes removing the throwers
from the pump shaft.
Untighten the set screws from the throwers
(2540.1/2)
Remove the throwers from the pump shaft.
6.7.11 Removing the bearing covers
This procedure describes removing the bearing
cover from the bearing housing.
Remove the bolts (6577.2 and 6577.3) from the
bearing housing (3200).
Remove the bearing covers (3260.1 and
3260.2).
6.7.12 Removing the bearings from the bearing
housing
This procedure describes removing the radial roller
bearing and the axial ball bearing from the bearing
housing.
Remove the pump shaft from the bearing
housing by hitting carefully, with a plastic or
lead hammer, the impeller side of the pump
shaft. The inner ring of the radial roller bearing
(3012) and the complete axial ball bearing
(3013) will shove out of the bearing housing.
Remove the outer ring of the radial roller
bearing (3012) from the bearing housing.
Page 23 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
6.7.13 Removing the bearings from the shaft
This procedure describes removing the radial roller
bearing and the axial ball bearing from the pump shaft.
Bend open the lips of the lock washer (2911) and
remove the bearing nut (2910) from the pump
shaft.
Remove the lock washer.
Remove the axial ball bearing from the pump shaft
by using the right tools.
Remove the lock washer (6545) from the pump
shaft, which is placed for locking the inner
raceway of the radial roller bearing (3012).
Remove the inner ring of the radial roller bearing
from the pump shaft.
6.8 Examination of parts
Used parts must be inspected before
assembly to ensure the pump will subsequently run
properly.
In particular, fault diagnosis is essential to enhance
pump and plant reliability.
6.8.1 Casing, seal plate, diffuser and impeller
a) Inspect for excessive wear, pitting, corrosion,
erosion or damage and any sealing surface
irregularities.
b) Replace as necessary.
6.8.2 Pump shaft and stub sleeve (if fitted)
Although the pump is of the “dry shaft design” Replace
if grooved, pitted or worn.
6.8.3 Gaskets and O-rings
After dismantling, discard and replace.
6.8.4 Pump bearings
It is recommended that bearings are not re-used after
any removal from the shaft.
6.9 Assembly
To assemble the pump consult the sectional drawings,
see section 8, Parts list and drawings.
Ensure threads, gasket and O-ring mating faces are
clean. Clean all parts carefully before assembly and
replace any which are worn or damaged. Apply thread
sealant to non-face sealing pipe thread fittings.
6.9.1 Fitting the bearings on the shaft
This procedure describes the assembly of the radial
roller bearing and the axial ball bearing on the pump
shaft.
Clean the mounting faces of the pump shaft
(2110), the radial roller bearing (3012) and the
axial ball bearing (3013).
Push the inner ring of the radial roller bearing on
the pump shaft.
Put the spring washer (6545) on the pump shaft
for the radial roller bearing.
Push the axial ball bearing on the pump shaft.
Push the lock washer (2911) for the axial ball
bearing and install the bearing nut (2910) on
the pump shaft.
Lock the bearing nut by bending the lips of the
lock washer into the openings of the bearing
nut.
6.9.2 Fitting the bearings in the bearing
housing
This procedure describes the assembly of the axial
ball bearing and the radial roller bearing into the
bearing housing.
Clean the mounting faces of the bearing
housing (3200), the radial roller bearing (3012)
and the axial ball bearing (3013).
Install the outer ring of the radial roller bearing
into the bearing housing.
Push the pump shaft (2110), completely
mounted with the inner ring of the radial roller
bearing and the axial ball bearing into the
bearing housing.
6.9.3 Fitting the bearing covers
This procedure describes the assembly of the
bearing covers.
Clean the mounting faces of the bearing
housing (3200) and the bearing covers (3260.1
and 3260.2)
Put some locktite 5926 or 510 or equal on the
faces between cover and housing
Install the bearing covers on the bearing
housing.
Install the bolts (6577.2 and 6577.3).
6.9.4 Fitting the throwers
This procedure describes the fitting of the throwers
on the pump shaft.
Clean the bore of the throwers (2540.1/2) and
the pump shaft (2110).
Push the throwers on the pump shaft.
Fit the set screws.
6.9.5 Fitting the throat bush
This procedure describes the fitting of the throat
bush into the casing cover.
Clean the mounting surfaces of the throat bush
[4132] and the casing cover (1221).
Fit the throat bush in the casing cover on the
top side.
The throat bush should be fixed in relation to the
casing cover using 3 set screws [6570.3].
Drill 3 holes at 120 intervals in the partition
between throat bush and casing cover. Drill the
holes to a depth such that the set screws
Page 24 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
[6570.3] do not protrude above the surface of the
throat bush and the casing cover.
Tap screw thread into the 3 holes and remove the
metal chips.
Mount the set screws.
Fix the set screws using a centre point.
6.9.6 Fitting the impeller wearing rings
The procedure specified below is to be followed
with regard to the impeller wearing rings [2300.1 & 2]
on one or both sides of the impeller.
Clean the mounting surfaces of the impeller
wearing ring and the impeller.
Use the appropriate personal
protection equipment when heating and positioning the impeller wearing ring.
Heat the impeller wearing ring to a temperature of
120 to 150C. Take care if the impeller wearing
ring has a sprayed-on layer of chrome as this may
break away if heating or cooling is carried out
quickly.
Push the impeller wearing ring right over the
impeller and let the whole assembly cool down.
Tap screw thread into the 3 holes and remove the
metal chips.
Mount the set screws [6570.2].
Fix the set screws using a centre point.
6.9.7 Fitting the case wearing rings
The procedure specified below is to be followed with
regard to the installation of the case wearing ring
[1500.1] in the diffuser. The same procedure can be
followed when installing the case wearing ring in the
casing cover. Read casing cover instead of diffuser.
Clean the mounting surfaces of the case wearing
ring [1500.1 & 2], the diffuser gland and the pump
casing.
Use the correct personal protection
equipment when cooling and positioning the case
wearing ring.
Cool the case wearing ring using liquid nitrogen.
Lower the case wearing ring vertically in the
diffuser and wait until the case wearing ring is
tight.
Drill 3 holes at 120 intervals in the partition
between the case wearing ring and diffuser. Drill
the holes to a depth such that the set screws
[6570.2] do not protrude above the surface of
the case wearing ring and the diffuser plate.
Tap screw thread into the 3 holes and remove
the metal chips.
Mount the set screws [6570.2].
Fix the set screws using a centre point.
6.9.8 Installing the mechanical seal
This procedure describes assembly of the
mechanical seal to the casing cover.
Clean the supporting surfaces of the
mechanical seal and the casing cover.
Place a new packing ring [see seal dwg.] in the
casing cover or O-ring on the seal plate,
dependent from the seal type.
Place the mechanical seal in the casing cover
in accordance with the instructions for use
provided by the supplier.
Tighten the nuts [6581.2] for fixing the
mechanical seal to the casing cover by
applying the prescribed torque, see section 6.5.
6.9.9 Fitting the bearing bracket
This procedure describes assembly of the bearing
bracket to the casing cover.
Clean the mounting surfaces of the bearing
bracket and the casing cover.
Carefully place the pump shaft in the shaft
sleeve so that the pump bracket is resting.
Tighten the bolts [6577.5].
6.9.10 Fitting the impeller
This procedure describes assembly of the impeller
to the pump shaft.
Attach the lifting devices to the appropriate
lifting points and observe the lifting instructions
described in section 2.3.
Lift up the pump back pull-out unit as a single
assembly so that the end of the pump shaft is
easily accessible.
Place the key [6700.1] in the pump shaft. See
Figure.
Place a new packing ring [4590.3] against the
stub sleeve of the mechanical seal.
Slide the impeller over the pump shaft.
Fit a new packing ring [4590.1] according to
Figure.
Page 25 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
Figure: Locking impeller screw
4590.1
4590.1
4590.3
Place the packing ring [4590.1] on the impeller
screw [2913] with the cut off edge at the bore hole.
Turn the impeller screw to the left by applying the
prescribed torque, see section 6.5. Make sure that
the cut off edge of the packing ring [4590.1]
remains in place.
Lock the impeller screw by knocking the edge of
the impeller screw into the bore hole in the
impeller using a hammer and a centre punch.
Fix the shaft sleeve to the shaft and disengage the
setting plates on top of the mechanical seal cover.
6.9.11 Fitting the diffuser
This procedure describes assembly of the diffuser into
the casing cover.
Clean the surfaces of the diffuser and the casing
cover.
Clean internally machined surfaces which come
into contact with liquid and surfaces where
there is only a narrow gap between them and
other finished surfaces. Treat these surfaces
with e.g. Molykote G (spray or paste).
Place a new packing ring [4590.2] onto the rim
of the pump casing.
Attach lifting devices at the appropriate lifting
points. Observe the lifting instructions
described in section 2.3.
Lift the casing cover towards the pump casing
and make sure that the casing cover is in the
correct position in relation to the pump casing.
There is only one way for the casing cover to fit
onto the pump casing.
Carefully place the casing cover on the pump
casing. Work carefully as there is little
clearance between the diffuser and the pump
casing. Also make sure that the centering rim of
the casing cover is not damaged.
Tighten the nuts [6581.1] evenly across the
casing cover by applying the prescribed
tightening torque in accordance with table per
section 6.5.
6.9.13 Fitting other parts
Connect all auxiliary pipes in accordance with
the dimensioned drawing, the “Process and
Instrumentation Diagram” (P&ID) or the
“Auxiliary Piping Arrangement Drawing”.
Reconnect the electric motor in accordance
with the instructions for use provided by the
relevant supplier.
Place the diffuser [1410] on the casing cover.
Make sure that the centring rim is not damaged.
Mount the hexagon head bolts [6577.1] with lock
washers [6541].
Lock the hexagon head screws [6577.1] against
the diffuser using the lock washers [6541].
6.9.12 Fitting the back pull out unit
This procedure describes assembly of the 'back pull
out' unit to the pump casing.
Clean the supporting surfaces of the casing cover
and the pump casing.
Install the coupling between the pump unit and
the electric motor according the suppliers
documentation.
If applicable, renew the gaskets between the
flanges of the piping.
Connect all auxiliary piping according the
general arrangement drawing, the 'Process and
Instrumentation Diagram' (P&ID) or the
'Auxiliary Piping Arrangement Drawing'.
Install the coupling guard on the coupling.
Follow the instructions for putting into operation
as specified in Chapter 5.
Page 26 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
FAULT SYMPTOM
Pump overheats and seizes
Bearings have sh ort life
Pump vibrates or is noisy
Mechanical se al has short life
Mechanical se al lea ks excessively
Pump requires exces sive powe r
Pump loses prime after starting
Insufficient pre ssure dev eloped
Insufficient capacity d eli ver ed
Pump does not deliver liq uid
PROBABLE CAUSES
POSSIBLE REMEDIES
A. System troubles
Pump not primed.
Check complete filling. Vent and/or prime.
Pump or suction pipe not completely filled with
liquid.
Suction lift too high or level too low.
Check NPSHA>NPSHR, proper submergence,
losses at strainers and fittings.
Insufficient margin between suction pressure and
vapour pressure.
Excessive amount of air or gas in liquid.
Check and purge pipes and system.
Air or vapour pocket in suction line.
Check suction line design for vapour pockets.
Air leaks into suction line.
Check suction pipe is airtight.
Air leaks into pump through mechanical seal,
sleeve joints, casing joint or pipe plugs.
Check and replace faulty parts.
CONSULT FLOWSERVE.
Foot valve too small.
Investigate replacing the foot valve.
Foot valve partially clogged.
Clean foot valve.
Inlet of suction pipe insufficiently submerged.
Check out system design.
Speed too low.
CONSULT FLOWSERVE.
Speed too high.
CONSULT FLOWSERVE.
Total head of system higher than differential head
of pump.
Check system losses.
Remedy or CONSULT FLOWSERVE.
Total head of system lower than pump design
head.
Specific gravity of liquid different from design.
Check and CONSULT FLOWSERVE.
Viscosity of liquid differs from that for which
designed.
Operation at very low capacity.
Measure value and check minimum permitted.
Remedy or CONSULT FLOWSERVE.
Operation at high capacity.
Measure value and check maximum permitted.
Remedy or CONSULT FLOWSERVE.
B. Mechanical troubles
Misalignment due to pipe strain.
Check the flange connections and eliminate strains
using elastic couplings or a method permitted.
Improperly designed foundation.
Check setting of levelling or base plate: tighten,
adjust, grout base as required.
Shaft bent.
Check shaft runouts are within acceptable values.
CONSULT FLOWSERVE.
Rotating part rubbing on stationary part internally.
Check and CONSULT FLOWSERVE, if necessary.
Bearings worn
Replace bearings.
Wearing ring surfaces worn.
Replace worn wear ring/surfaces.
7 FAULTS; CAUSES AND REMEDIES
Page 27 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
FAULT SYMPTOM
Pump overheats and seizes
Bearings have sh ort life
Pump vibrates or is noisy
Mechanical se al has short life
Mechanical se al lea ks excessively
Pump requires exces sive powe r
Pump loses prime after starting
Insufficient pre ssure dev eloped
Insufficient capacity d eli ver ed
Pump does not deliver liq uid
PROBABLE CAUSES
POSSIBLE REMEDIES
Impeller damaged or eroded.
Replace or CONSULT FLOWSERVE for improved
material selection.
Leakage under sleeve due to joint failure.
Replace joint and check for damage.
Shaft sleeve worn or scored or running off centre.
Check and renew defective parts.
Mechanical seal improperly installed.
Check alignment of faces or damaged parts and
assembly method used.
Incorrect type of mechanical seal for operating
conditions.
CONSULT FLOWSERVE.
Shaft running off centre because of worn bearings.
Check misalignment and correct if necessary. If
alignment satisfactory check bearings for excessive
wear.
Impeller out of balance resulting in vibration.
Check and CONSULT FLOWSERVE.
Abrasive solids in liquid pumped.
Internal misalignment of parts preventing seal ring
and seat from mating properly.
Mechanical seal was run dry.
Check mechanical seal condition and source of dry
running and repair.
Internal misalignment due to improper repairs
causing impeller to rub.
Check method of assembly, possible damage or
state of cleanliness during assembly.
Remedy or CONSULT FLOWSERVE, if necessary.
Excessive thrust caused by a mechanical failure
inside the pump.
Check wear condition of impeller, its clearances and
liquid passages.
Excessive grease in ball bearings.
Check method of regreasing.
Lack of lubrication for bearings.
Check hours run since last change of lubricant, the
schedule and its basis.
Improper installation of bearings (damage during
assembly, incorrect assembly, wrong type of
bearing etc).
Check method of assembly, possible damage or
state of cleanliness during assembly and type of
bearing used. Remedy or CONSULT
FLOWSERVE, if necessary.
Damaged bearings due to contamination.
Check contamination source and replace damaged
bearings.
C. MOTOR ELECTRICAL PROBLEMS
Wrong direction of rotation.
Reverse 2 phases at motor terminal box.
Motor running on 2 phases only.
Check supply and fuses.
Motor running too slow.
Check motor terminal box connections and voltage.
Page 28 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
Ref.no.
Description
Ref.no.
Description
1100
Casing
4590.2
Gasket
1221
Casing cover
4590.3
Gasket
1410
Diffuser
4610
O-ring
1500.1
Casing wear ring
6515
Drain plug
1500.2
Casing wear ring
6522
Vent filter
2110
Pump shaft
6541
Lock washer
2200
Impeller
6545
Shaft circlip
2300.1
Impeller wear ring
6562
Guard
2300.2
Impeller wear ring
6569.1
Plug
2430
Throttling sleeve
6569.2
Plug
2540.1
Deflector
6570.1/3
Screw
2540.2
Deflector
6570.2
Screw
2910
Shaft nut
6570.4
Screw
2911
Shaft nut washer
6572.1
Stud
2913
Impeller screw
6572.2
Stud
3012
Radial roller bearing
6575
Jack screw
3013
Thrust ball bearing
6577.1
Hexagon head bolt
3120
Bearing support stool
6577.2
Hexagon head bolt
3200
Bearing housing
6577.3
Hexagon head bolt
3260.1
Bearing cover
6577.4
Hexagon head bolt
3260.2
Bearing cover
6577.5
Hexagon head bolt
3711.1
Bearing labyrinth ring
6579
Socket head cap screw
3711.2
Bearing labyrinth ring
6581.1
Hexagon nut
3855
Constant level oiler
6581.2
Hexagon nut
3858
Oil level sight glass
6700.1
Key
4132
Stuffing box bushing
6700.2
Key
4590.1
Gasket
8220
Direction of rotation indicator
8 PARTS LIST AND DRAWINGS
8.1 Typical Sectional drawing
Page 29 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
8.2 Typical Parts list
For P.O. related parts list see table on page 29.
8.3 General arrangement drawing
The typical general arrangement drawing and any
specific drawings required by the contract will be
sent to the Purchaser separately unless the
contract specifically calls for these to be included
into the User Instructions. If required, copies of
other drawings sent separately to the Purchaser
should be obtained from the Purchaser and
retained with these User Instructions.
9 CERTIFICATION
Certificates determined from the Contract
requirements are provided with these Instructions
where applicable. Examples are certificates for CE
marking, ATEX marking etc. If required, copies of
other certificates sent separately to the Purchaser
should be obtained from the 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 system
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.
10.3 Additional sources of information
Reference 1:
API 610, 9th edition / ISO 13709, January 2003
Reference 2:
NPSH for Rotordynamic Pumps: a reference guide,
Europump Guide No. 1, Europump & World
Pumps, Elsevier Science, United Kingdom, 1999.
Pump Handbook, 2nd edition, Igor J. Karassik et al,
McGraw-Hill Inc., New York, 1993.
Reference 5:
ANSI/HI 1.1-1.5
Centrifugal Pumps - Nomenclature, Definitions,
Application and Operation.
Reference 6:
ANSI B31.3 - Process Piping.
Reference 7:
Europump Terminology standard
10.2 Change notes
If any changes, agreed with Flowserve Pump
Division, are made to the product after its supply, a
record of the details should be maintained with
these User Instructions.
Page 30 of 31
PHL USER INSTRUCTIONS ENGLISH 00079593 – 10/10
FLOWSERVE REGIONAL
SALES OFFICES:
USA and Canada
Flowserve Corporation
Pump
5215 North O’Connor Blvd.,
Suite 2300
Irving, Texas 75039-5421 USA
Telephone 1 972 443 6500
Fax 1 972 443 6800