Flowserve Polybase baseplates User Manual

USER INSTRUCTIONS

Polybase baseplates

Non-metallic, solid polymer concrete
AMSE B73.1 and ISO 3661 dimensions

PCN=71569284 – 12-10 Original instructions

Installation

Operation

Maintenance

Polybase Baseplate USER INSTRUCTIONS ENGLISH 71569284 USER – 12-10

CONTENTS

1 INTRODUCTION AND SAFETY.......................3

1.1 General.........................................................3

1.2 CE marking and approvals ...........................3

1.3 Disclaimer.....................................................3

1.4 Copyright ......................................................3

1.5 Duty conditions .............................................3

1.6 Safety............................................................4

1.7 Nameplate and safety labels........................6

2 TRANSPORT AND STORAGE.........................6

2.1 Consignment receipt and unpacking............6

2.2 Handling........................................................6

2.3 Lifting ............................................................6

2.4 Storage .........................................................8

2.5 Recycling and end of product life .................8

3 DESCRIPTION .................................................8

3.1 Configurations...............................................8

3.2 Nomenclature ...............................................9

3.3 Design of major parts....................................9

3.4 Performance and operation limits.................9

4 INSTALLATION ..............................................11

4.1 Location ......................................................11

4.2 Part Assemblies..........................................11

4.3 Foundation..................................................11

4.4 Grouting......................................................15

5 COMMISSIONING, STARTUP, OPERATION

AND SHUTDOWN...................................................16

6 MAINTENANCE..............................................16

6.1 Maintenance schedule................................16

6.2 Spare parts..................................................16

6.3 Recommended spares and consumable

items ...........................................................17

6.4 Tools required.............................................17

6.5 Field thread insert installation procedure....17

6.6 Field installed thread insert testing

(Optional)....................................................18

6.7 Recommended fastener mounting

torques........................................................19

7 FAULTS: CAUSES AND REMEDIES............. 20

8 PARTS LIST AND DRAWINGS...................... 21

9 CERTIFICATION ............................................22

10 OTHER RELEVANT DOCUMENTATION AND

MANUALS ...............................................................22

10.1 Supplementary user instructions............22

10.2 Change Notes ........................................22

10.3 Additional sources of information...........22

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Polybase Baseplate INSTRUCTIONS ENGLISH 71569284 – 12-10

1 INTRODUCTION AND SAFETY

1.1 General

These instructions must always be kept

close to the product's operating location or
directly with the product.

Flowserve products are designed, developed and
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great
care and commitment to continuous quality control,
utilizing sophisticated quality techniques, and safety
requirements.

Flowserve is committed to continuous quality
improvement and being at service for any further
information about the product in its installation and
operation or about its support products, repair and
diagnostic services.

These instructions are intended to facilitate
familiarization with the product and its permitted use.
Operating the product in compliance with these
instructions is important to help ensure reliability in
service and avoid risks. The instructions may not
take into account local regulations; ensure such
regulations are observed by all, including those
installing the product. Always coordinate repair
activity with operations personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.

These instructions must be read prior to

installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment must not be put into service until all
the conditions relating to safety noted in the
instructions, have been met. Failure to follow and
apply the present user instructions is considered
to be misuse. Personal injury, product damage,
delay or failure caused by misuse are not covered
by the Flowserve warranty.

1.2 CE marking and approvals

It is a legal requirement that machinery and equipment
put into service within certain regions of the world shall
conform with the applicable CE Marking Directives
covering Machinery and, where applicable, Low Voltage
Equipment, Electromagnetic Compatibility (EMC),
Pressure Equipment Directive (PED) and Equipment for
Potentially Explosive Atmospheres (ATEX).

Where applicable the Directives and any additional
Approvals cover important safety aspects relating to
machinery and equipment and the satisfactory provision
of technical documents and safety instructions. Where

applicable this document incorporates information
relevant to these Directives and Approvals.
To confirm the Approvals applying and if the product is
CE marked, check the serial number plate markings
and the Certification. (See section 9, Certification.)

1.3 Disclaimer

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 the
Flowserve warranty. In addition, any modification of
Flowserve products or removal of original components
may impair the safety of these products in their use.

1.4 Copyright

All rights reserved. No part of these instructions may
be reproduced, stored in a retrieval system or
transmitted in any form or by any means without prior
permission of Flowserve.

1.5 Duty conditions

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

The product must not be operated beyond

the parameters specified for the application. If
there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice, quoting the serial number.

If the conditions of service on your purchase order
are going to be changed (for example liquid pumped,
temperature or duty) it is requested that the user
seeks the written agreement of Flowserve before
start up.

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Polybase Baseplate INSTRUCTIONS ENGLISH 71569284 – 12-10

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 and toxic fluid”
safety instructions where non-compliance would affect
personal safety and could result in loss of life.

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

This symbol indicates explosive atmosphere
zone marking according to ATEX. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.

This symbol is used in safety instructions to
remind not to rub non-metallic surfaces with a dry
cloth; ensure the cloth is damp. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.

This sign is not a safety symbol but indicates

an important instruction in the assembly process.

1.6.2 Personnel qualification and training

All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved. If the
personnel in question do not already possess the
necessary knowledge and skill, appropriate training
and instruction must be provided. If required the
operator may commission the manufacturer/supplier
to provide applicable training.

Always coordinate repair activity with operations and
health and safety personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.

1.6.3 Safety action

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

NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
(Lock Out)

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.

HOT (and cold) PARTS
If hot or freezing components or auxiliary heating
equipment can present a danger to operators and
persons entering the immediate area, action must be
taken to avoid accidental contact (such as shielding).
If complete protection is not possible, the machine
access must be limited to maintenance staff only with
clear visual warnings and indicators to those entering
the immediate area. Note: bearing housings must not
be insulated and drive motors and bearings may be
hot.

If the temperature is greater than 80°C (175 °F) or
below -5 °C (23 °F) in a restricted zone, or
exceeds local regulations, action as above shall
be taken.

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.

HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care
must be taken to avoid exposure to the liquid by
appropriate pump placement, limiting personnel
access and by operator training. If the liquid is
flammable and/or explosive, strict safety procedures
must be applied.

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Polybase Baseplate INSTRUCTIONS ENGLISH 71569284 – 12-10

1.6.4 Products used in potentially explosive
atmospheres

Measures are required to:

• Avoid excess temperature

• Prevent build up of explosive mixtures

• Prevent the generation of sparks

• Prevent leakages

• Maintain the pump to avoid hazard

The following instructions for pumps and pump units
when installed in potentially explosive atmospheres
must be followed to help ensure explosion protection.
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/CSA.

1.6.4.1 Scope of compliance

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

Where Flowserve has supplied only the bare shaft
pump, the Ex rating applies only to the pump. The party
responsible for assembling the pump set shall select the
coupling, driver and any additional equipment, with the
necessary CE Certificate/ Declaration of Conformity
establishing it is suitable for the area in which it is to be
installed. That party are also responsible for CE
Marking the complete machine.

The output from a variable frequency drive (VFD) can
cause additional heating effects in the motor and so,
for pumps sets with a VFD, the ATEX Certification for
the motor must state that it is covers the situation
where electrical supply is from the VFD. This
particular requirement still applies even if the VFD is
in a safe area.

1.6.4.2 Marking

An example of ATEX equipment marking is shown
below. The actual classification of the pump will be
engraved on the nameplate.

II 2 GD c IIC T135 ºC (T4)

Equipment Group
I = Mining
II = Non-mining

Category
2 or M2 = high level protection
3 = normal level of protection

Gas and/or dust
G = Gas
D = Dust

c = Constructional safety

(in accordance with EN13463-5)

Gas Group
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)

Maximum surface temperature (Temperature Class)
(see section 1.6.4.3.)

1.6.4.3 Avoiding excessive surface
temperatures

ENSURE THE EQUIPMENT TEMPERATURE

CLASS IS SUITABLE FOR THE HAZARD ZONE

1.6.4.4 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 earth contact on the
baseplate must be used.

Avoid electrostatic charge: do not rub non-metallic

surfaces with a dry cloth; ensure cloth is damp.
The coupling must be selected to comply with 94/9/EC

and correct alignment must be maintained.

Additional requirement for metallic pumps on
non-metallic baseplates

When metallic components are fitted on a non­metallic baseplate they must be individually earthed.

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Polybase Baseplate INSTRUCTIONS ENGLISH 71569284 – 12-10

1.6.4.5 Maintenance to avoid the hazard

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

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

To avoid potential explosion hazards during
maintenance, the tools, cleaning and painting
materials used must not give rise to sparking or
adversely affect the ambient conditions. Where there
is a risk from such tools or materials, maintenance
must be conducted in a safe area.

It is recommended that a maintenance plan and
schedule is adopted. (See section 6, Maintenance.)

1.7 Nameplate and safety labels

1.7.1 Safety labels

2 TRANSPORT AND STORAGE

2.1 Consignment receipt and unpacking

Immediately after receipt of the equipment it must be
checked against the delivery/shipping documents for
its completeness and that there has been no damage
in transportation. Any shortage and/or damage must
be reported immediately to Flowserve Pump Division
and must be received in within ten days of receipt of
the equipment. Later claims cannot be accepted.
Check all crates, boxes or wrappings for any
accessories or spare parts that may be packed
separately from the equipment or attached to side
walls of the box or equipment. After unpacking,
protection will be the responsibility of the user.

Each product has a unique serial number. Check
that this number corresponds with your order. Use
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 depending on their
size and construction.

2.3 Lifting

Fully trained personnel must carry out lifting in
accordance with local regulations. The Polybase
baseplate dimensions and weights are shown in
Section 8 PARTS LIST AND DRAWINGS.

.Do not install eye bolts in the Polybase
thread inserts for the purpose of lifting the base. This
practice imposes lateral loads on the inserts which
they were not designed to withstand. Also, do not use
hooks in the baseplate anchor bolt holes.

Pumps and motors often have integral
lifting lugs or eye bolts. These are intended for use in
only lifting the individual piece of equipment.

Do not use eye bolts or cast-in lifting
lugs to lift pump, motor and baseplate assemblies.

Polybase units should be transported
via fork truck to the area of their intended installation
on the wooden pallets on which they were shipped.
Never transport a Polybase over long distances or
over rough terrain while it is suspended from slings.

Care must be taken to lift components
or assemblies above the center of gravity to prevent
the unit from flipping.

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Polybase Baseplate INSTRUCTIONS ENGLISH 71569284 – 12-10

2.3.1 Lifting Polybase baseplates with no
mounted equipment

a) Remove the fasteners that hold the Polybase to

the wooden pallet.

b) Slip two slings under the baseplate between

pallet cross-members as shown in Figure 2.1.
Slings should be positioned approximately one­quarter to one-third the baseplate length from
each end.

c) Lift the Polybase a few inches off the pallet and

verify that it hangs reasonably level and that the
slings are not prone to slipping out of position.

d) If this slinging appears to be unstable, set the

baseplate back on the pallet and reposition the
slings. After satisfactory slinging has been
achieved, the baseplate may be hoisted onto its
foundation.

2.3.2 Lifting the Polybase baseplate with pump
and motor installed

a) Remove the fasteners that hold the Polybase to

the wooden pallet.

b) Install slings around the pump discharge nozzle

(except for PGRP pumps where the slings must
go around and through the adapter) and around
the outboard end of the motor frame using
choker hitches pulled tight. The motor sling
should be positioned so the weight is not carried
through the fan housing. Make sure the
completion of the choker hitch on the discharge
nozzle (or adapter arms) is toward the coupling
end of the pump shaft as shown in Figure 2.2.

2.3.3 Lifting the Polybase baseplate with only
the pump installed

a) Remove the fasteners that hold the Polybase to

the wooden pallet.

b) Install a sling around the pump discharge nozzle

using a choker hitch pulled tight (except for
PGRP pumps where the slings must go around
and through the adapter).

c) Install a second sling around the motor end of

the Polybase using a basket hitch (see Figure

2.2). Make sure the completion of the choker
hitch on the discharge nozzle is toward the
coupling end of the pump shaft. Refer to section

4.0 INSTALLATION for setting the base on the
foundation.

d)

Figure 2.1

Figure 2.2

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Polybase Baseplate INSTRUCTIONS ENGLISH 71569284 – 12-10

2.4 Storage

This section addresses the storage procedures for
the Polybase baseplate only. When storing a
Polybase baseplate with mounted pump assemblies,
it is extremely important that the proper storage
procedures for the pump be observed as well. Refer
to the User Instruction for the particular pump that is
mounted on your baseplate. Flowserve's normal
packaging is designed to protect the Polybase
baseplate during shipment and handling from the
time it is assembled at the factory to installation at the
end user's jobsite. If the Polybase baseplate is to be
stored for a period of time prior to installation, it is
recommended that the following procedures be
followed:
a) Leave the baseplate bolted to its wooden

shipping pallet.

b) Place the pallet on a solid, dry, level surface in a

location where the base cannot be struck by
passing fork trucks, falling objects, etc. Make
sure that the pallet does not rock.

c) Do not stack heavy objects on top of the

baseplate.

d) If the Polybase will be installed in an indoor

location, but is to be stored in an outdoor
location, cover the base completely with a
tarpaulin or dark plastic sheeting to prevent UV
degradation of the surface. NOTE: UV
degradation (bleaching) of the polymer concrete
is the normal result of exposure to sunlight. This
phenomenon is purely a visual change in the
color of the material which in no way
compromises the performance or corrosion
resistance characteristics of the Polybase
baseplate.

e) Multiple Polybase baseplates without installed

equipment may be stacked, provided the bases
are level and the stacking is done in a manner
which uniformly distributes the weight of the
upper base to the top surface of the base on
which it rests. A minimum of two pallet cross­members should contact the entire width of the
lower base. Cross members must not rest on
fasteners or on the corners of the lower base.

Do not attempt to stand a Polybase
baseplate on end to make more efficient use of
storage space. Neither the base nor the fasteners
that hold the base to its wooden pallet have been
designed for vertical storage. Severe personal
injury or death, as well as irreparable damage to
Polybase baseplate, may result if it tips over.

f) After unpacking, protection will be the

responsibility of the user.

2.5 Recycling and end of product life

At the end of the service life of the product or its
parts, the relevant materials and parts should be
recycled or disposed of using an environmentally
acceptable method and in accordance with local
regulations. If the product contains substances that
are harmful to the environment, these should be
removed and disposed of in accordance with current
local regulations. This also includes the liquids
and/or gases that may be used in the "seal system"
or other utilities.

Make sure that hazardous substances are
disposed of safely and that the correct personal
protective equipment is used. The safety
specifications must be in accordance with the current
local regulations at all times.

3 DESCRIPTION

3.1 Configurations

The Flowserve Polybase baseplate is a solid,
polymer concrete baseplate that is manufactured in
versions that conform to both ASME B73.1 and ISO

3661.
ASME Polybase units are manufactured with integral

drain basin and grout hole. Integral leveling screw
thread inserts facilitate proper installation. Twelve
sizes are available ranging from 139 through 398.

ISO Polybase units are manufactured with integral
drain basin, and are available in sizes ISO 3, 4, 5, 6,
7 and 8.

Metallic thread inserts are provided in the mounting
surfaces for particular combinations of pump and
motors. Multiple motor insert patterns are also
available, and custom insert configurations can be
produced per customer specifications. The standard
thread insert material is 304SS (18.10 CrNi stainless
steel), with higher alloys available upon request.

Three different epoxy vinyl ester resin materials are
available to support the use of Polybase baseplates
in most chemical applications (see 3.3.2).

Additional available options include stilt mounting and
flush plan mounting.

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