Polybase baseplates
Non-metallic, solid polymer concrete AMSE B73.1 and ISO 3661 dimensions
PCN=71569284 – 12-10 Original instructions
USER 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 |
6.3Recommended spares and consumable
|
items ........................................................... |
17 |
6.4 |
Tools required ............................................. |
17 |
6.5 |
Field thread insert installation procedure.... |
17 |
6.6Field installed thread insert testing
(Optional) .................................................... |
18 |
6.7Recommended 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 |
Page 2 of 24 |
flowserve.com |
Polybase Baseplate INSTRUCTIONS ENGLISH 71569284 – 12-10
1 INTRODUCTION AND SAFETY
1.1General
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.
1.2CE 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.)
1.3Disclaimer
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.
1.4Copyright
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.
1.5Duty 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.
Page 3 of 24 |
flowserve.com |
Polybase Baseplate INSTRUCTIONS ENGLISH 71569284 – 12-10
1.6Safety
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.
1.6.2Personnel 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.
1.6.3Safety 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.
Page 4 of 24 |
flowserve.com |
Polybase Baseplate INSTRUCTIONS ENGLISH 71569284 – 12-10
1.6.4Products 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.
1.6.4.1Scope 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.
1.6.4.2Marking
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.)
1.6.4.3Avoiding excessive surface temperatures
ENSURE THE EQUIPMENT TEMPERATURE CLASS IS SUITABLE FOR THE HAZARD ZONE
1.6.4.4Preventing 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.
Page 5 of 24 |
flowserve.com |
Polybase Baseplate INSTRUCTIONS ENGLISH 71569284 – 12-10
1.6.4.5Maintenance 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.)
1.7Nameplate and safety labels
1.7.1Safety labels
2 TRANSPORT AND STORAGE
2.1Consignment 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.
2.2Handling
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.
Page 6 of 24 |
flowserve.com |
Polybase Baseplate INSTRUCTIONS ENGLISH 71569284 – 12-10
2.3.1Lifting 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.
2.3.2Lifting 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.
2.3.3Lifting 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
Page 7 of 24 |
flowserve.com |
Polybase Baseplate INSTRUCTIONS ENGLISH 71569284 – 12-10
2.4Storage
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.
2.5Recycling 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
3.1Configurations
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.
Page 8 of 24 |
flowserve.com |
Loading...