Page 1
USER INSTRUCTIONS
PolyChem GRP
Installation
Operation
Maintenance
ANSI B73.5M standard horizontal and self-priming
non-metallic, frame-mounted pump
PCN=71569132 12-04A (E). Original instructions.
These instructions must be read prior to installing,
operating, using and maintaining this equipment.
Page 2
USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
CONTENTS
Page
1 INTRODUCTION AND SAFETY ........................... 4
1.1 General ......................................................... 4
1.2 CE marking and approvals ............................. 4
1.3 Disclaimer...................................................... 4
1.4 Copyright ....................................................... 4
1.5 Duty conditions .............................................. 4
1.6 Safety ............................................................ 5
1.7 Nameplate and safety labels .......................... 8
1.8 Specific machine performance ....................... 9
1.9 Noise level ..................................................... 9
2 TRANSPORT AND STORAGE ........................... 10
2.1 Consignment receipt and unpacking ............ 10
2.2 Handling ...................................................... 10
2.3 Lifting .......................................................... 10
2.4 Storage........................................................ 10
2.5 Recycling and end of product life ................. 11
3 DESCRIPTION .................................................. 11
3.1 Configurations ............................................. 11
3.2 Name nomenclature .................................... 11
3.3 Design of major parts ................................... 12
3.4 Performance and operating limits ................. 12
4 INSTALLATION .................................................. 13
4.1 Location....................................................... 13
4.2 Part assemblies ........................................... 13
4.3 Foundation .................................................. 13
4.4 Grouting ...................................................... 15
4.5 Initial alignment............................................ 16
4.6 Piping .......................................................... 17
4.7 Electrical connections .................................. 23
4.8 Final shaft alignment check .......................... 23
4.9 Protection systems ...................................... 23
Page
6 MAINTENANCE ................................................ 31
6.1 General ....................................................... 31
6.2 Maintenance schedule ................................ 32
6.3 Spare parts ................................................. 32
6.4 Recommended spares and
consumable items ..................................... 33
6.5 Tools required ............................................. 33
6.6 Fastener torques ......................................... 33
6.7 Setting impeller clearance ........................... 34
6.8 Disassembly ............................................... 35
6.9 Examination of parts ................................... 38
6.10 Assembly of pump and seal ....................... 40
7 FAULTS; CAUSES AND REMEDIES ................. 45
8 PARTS LISTS AND DRAWINGS........................ 48
8.1 PolyChem GRP pump, Group 1................... 48
8.2 PolyChem GRP pump, Group 2................... 49
8.3 PolyChem GRP pump, Group 3................... 50
8.4 General arrangement drawing ..................... 51
9 CERTIFICATION ............................................... 51
10 OTHER RELEVANT DOCUMENTATION
AND MANUALS ............................................. 51
10.1 Supplementary User Instruction manuals .. 51
10.2 Change notes............................................ 51
10.3 Additional sources of information ............... 51
5 COMMISSIONING, START-UP, OPERATION
AND SHUTDOWN .......................................... 24
5.1 Pre-commissioning procedure ...................... 24
5.2 Pump lubricants ........................................... 24
5.3 Impeller clearance ....................................... 26
5.4 Direction of rotation ...................................... 27
5.5 Guarding ..................................................... 27
5.6 Priming and auxiliary supplies ...................... 28
5.7 Starting the pump ........................................ 29
5.8 Running or operation ................................... 29
5.9 Stopping and shutdown ............................... 30
5.10 Hydraulic, mechanical and electrical duty ... 30
Page 2 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
INDEX
Page
Additional sources (10.3) ....................................... 51
Alignment (see 4.3, 4.5 and 4.8)
Assembly (6.10) ..................................................... 40
ATEX marking (1.6.4.2) ............................................ 7
CE marking and approvals (1.2) ............................... 4
Certification (9) ...................................................... 51
Change notes (10.2) .............................................. 51
Clearances, impeller (6.7) ...................................... 34
Commissioning and operation (5) ........................... 24
Compliance, ATEX (1.6.4.1) ..................................... 7
Configurations (3.1) ............................................... 11
Copyright (1.4) ......................................................... 4
Design of major parts (3.3) ..................................... 12
Direction of rotation (5.4) ........................................ 27
Disassembly (6.8) .................................................. 35
Disclaimer (1.3)........................................................ 4
Dismantling (6.8, Disassembly) .............................. 35
Drawings (8) .......................................................... 48
Duty conditions (1.5) ................................................ 4
Electrical connections (4.7) .................................... 23
End of product life (2.5) .......................................... 11
Examination of parts (6.9) ...................................... 38
Fastener torques (6.6)............................................ 33
Faults; causes and remedies (7) ............................ 45
Foundation (4.3) .................................................... 13
General arrangement drawing (8.4) ........................ 51
General assembly drawings (8) .............................. 48
Grouting (4.4) ........................................................ 15
Guarding (5.5) ....................................................... 27
Handling (2.2) ........................................................ 10
Hydraulic, mechanical and electrical duty (5.10) ..... 30
Impeller clearance (see 5.3 and 6.7)
Inspection (6.2.1 and 6.2.2) .................................... 32
Installation (4) ........................................................ 13
Lifting (2.3)............................................................. 10
Location (4.1) ......................................................... 13
Lubrication (see 5.2) .............................................. 24
Maintenance (6) ..................................................... 31
Maintenance schedule (6.2) ................................... 32
Name nomenclature (3.2)....................................... 11
Nameplate (1.7.1) .................................................... 8
Operating limits (see 3.4) ....................................... 12
Ordering spare parts (6.3.1) ................................... 32
Part assemblies (4.2) ............................................. 13
Parts lists (see 8) ................................................... 48
Performance (3.4) .................................................. 12
Piping (4.6) ............................................................ 17
Pre-commissioning (5.1) ........................................ 24
Priming and auxiliary supplies (5.6) ........................ 28
Protection systems (4.9) ........................................ 23
Page
Reassembly (see 6.10, Assembly) ......................... 40
Receipt and unpacking (2.1) .................................. 10
Recommended fill quantities (figure 5-2) ................ 25
Recommended oil lubricants (figure 5.3) ................ 25
Recommended spares (6.4) .................................. 33
Recycling (2.5) ...................................................... 11
Replacement parts (see 6.3 and 6.4) ................. 32/33
Running the pump (5.8) ......................................... 29
Safety action (1.6.3) ................................................ 5
Safety labels (1.7.2) ................................................ 8
Safety markings (1.6.1) ........................................... 5
Safety, protection systems (see 1.6 and 4.9)
Sectional drawings (8) ........................................... 48
Setting impeller clearance (6.7) ............................. 34
Sound pressure level (1.9, Noise level) .................... 9
Sources, additional information (10.3) .................... 51
Spare parts (6.3) ................................................... 32
Specific machine performance (1.8) ........................ 9
Starting the pump (5.7) .......................................... 29
Stopping and shutdown (5.9) ................................. 30
Storage, pump (2.4) .............................................. 10
Storage, spare parts (6.3.2) ................................... 32
Supplementary manuals or information sources..... 51
Supplementary User Instructions (10.1) ................. 51
Tools required (6.5) ................................ ............... 33
Torques for fasteners (6.6) .................................... 33
Trouble-shooting (see 7) ....................................... 45
Vibration (5.8.8) ..................................................... 30
Page 3 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
1 INTRODUCTION AND SAFETY
1.1 General
These instructions must always be kept
close to the product's operating location or
directly with the product.
Flowserve products are designed, developed and
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great
care and commitment to continuous quality control,
utilising sophisticated quality techniques and safety
requirements.
Flowserve is committed to continuous quality
improvement and being at service for any further
information about the product in its installation and
operation or about its support products, repair and
diagnostic services.
These instructions are intended to facilitate
familiarization with the product and its permitted use.
Operating the product in compliance with these
instructions is important to help ensure reliability in
service and avoid risks. The instructions may not
take into account local regulations; ensure such
regulations are observed by all, including those
installing the product. Always coordinate repair
activity with operations personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.
These instructions must be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment must not be put into service until all
the conditions relating to safety, noted in the
instructions, have been met. Failure to follow and
apply the present user instructions is considered
to be misuse. Personal injury, product damage,
delay or failure caused by misuse are not covered
by the Flowserve warranty.
1.2 CE marking and approvals
It is a legal requirement that machinery and equipment
put into service within certain regions of the world shall
conform with the applicable CE Marking Directives
covering Machinery and, where applicable, Low Voltage
Equipment, Electromagnetic Compatibility (EMC),
Pressure Equipment Directive (PED) and Equipment for
Potentially Explosive Atmospheres (ATEX).
Where applicable, the Directives and any additional
Approvals, cover important safety aspects relating to
machinery and equipment and the satisfactory provision
of technical documents and safety instructions. Where
applicable this document incorporates information
relevant to these Directives and Approvals.
To confirm the Approvals applying and if the product is
CE marked, check the serial number plate markings
and the Certification. (See section 9, Certification.)
1.3 Disclaimer
Information in these User Instructions is believed
to be reliable. In spite of all the efforts of
Flowserve Corporation to provide sound and all
necessary information the content of this manual
may appear insufficient and is not guaranteed by
Flowserve as to its completeness or accuracy.
Flowserve manufactures products to exacting
International Quality Management System Standards
as certified and audited by external Quality
Assurance organisations. Genuine parts and
accessories have been designed, tested and
incorporated into the products to help ensure their
continued product quality and performance in use.
As Flowserve cannot test parts and accessories
sourced from other vendors the incorrect
incorporation of such parts and accessories may
adversely affect the performance and safety features
of the products. The failure to properly select, install
or use authorised Flowserve parts and accessories is
considered to be misuse. Damage or failure caused
by misuse is not covered by the Flowserve warranty.
In addition, any modification of Flowserve products or
removal of original components may impair the safety
of these products in their use.
1.4 Copyright
All rights reserved. No part of these instructions may
be reproduced, stored in a retrieval system or
transmitted in any form or by any means without prior
permission of Flowserve Pump Division.
1.5 Duty conditions
This product has been selected to meet the
specifications of your 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.
Page 4 of 52 flowserve.com
Page 5
USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
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.
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 help
prevent injury to personnel and damage to the
environment and to equipment. For products used
in potentially explosive atmospheres section 1.6.4
also applies.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS OPERATIONAL
DRAIN THE PUMP AND ISOLATE PIPEWORK
BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be taken
where the pumped liquids are hazardous.
FLUORO-ELASTOMERS (When fitted.)
When a pump has experienced temperatures over
250 ºC (482 ºF), partial decomposition of fluoroelastomers (example: Viton) will occur. In this
condition these are extremely dangerous and skin
contact must be avoided.
HANDLING COMPONENTS
Many precision parts have sharp corners and the
wearing of appropriate safety gloves and equipment
is required when handling these components. To lift
heavy pieces above 25 kg (55 lb) use a crane
appropriate for the mass and in accordance with
current local regulations.
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 greater than 80 ºC (175 ºF) or
below -5 ºC (20 ºF) in a restricted zone, or exceeds
local regulations, action as above shall be taken.
Page 5 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
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.
HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care
must be taken to avoid exposure to the liquid by
appropriate siting of the pump, limiting personnel
access and by operator training. If the liquid is
flammable and or explosive, strict safety procedures
must be applied.
Gland packing must not be used when pumping
hazardous liquids.
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, startup, operation and
shutdown.)
THE PUMP SHAFT MUST TURN
CLOCKWISE WHEN VIEWED FROM THE MOTOR
END
It is absolutely essential that the rotation of the motor
be checked before installation of the coupling spacer
and starting the pump. Incorrect rotation of the pump
for even a short period can unscrew the impeller,
which can cause significant damage.
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.
Both electrical and non-electrical equipment must meet
the requirements of European Directive 94/9/EC.
1.6.4.1 Scope of compliance
NEVER EXCEED THE MAXIMUM
DESIGN PRESSURE (MDP) AT THE
TEMPERATURE SHOWN ON THE PUMP
NAMEPLATE
See section 3 for pressure versus temperature
ratings based on the material of construction.
NEVER OPERATE THE PUMP WITH
THE DISCHARGE VALVE CLOSED
(Unless otherwise instructed at a specific point in the
user instructions.) See section 5, Commissioning
start-up, operation and shutdown.
NEVER OPERATE THE PUMP WITH
THE SUCTION VALVE CLOSED
It should be fully opened when the pump is running.
NEVER RUN THE PUMP DRY OR
WITHOUT PROPER PRIME (Casing Flooded)
NEVER OPERATE THE PUMP AT
ZERO FLOW OR FOR EXTENEDED PERIODS
BELOW THE MINIMUM CONTINUOUS FLOW
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.
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.
Page 6 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Temperature class
to EN13463-1
Maximum surface
temperature permitted
Temperature limit of
liquid handled
T6
T5
T4
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
Consult Flowserve
Consult Flowserve
115 °C (239 °F) *
1.6.4.2 Marking
An example of ATEX equipment marking is shown
below. The actual classification of the pump will be
engraved on the nameplate.
II 2 GD c IIC 135 ºC (T4)
Equipment Group
I = Mining
II = Non-mining
Category
2 or M2 = high level protection
3 = normal level of protection
Gas and/or dust
G = Gas
D = Dust
c = Constructional safety
(in accordance with EN13463-5)
Gas Group (Equipment Category 2 only)
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)
Maximum surface temperature (Temperature Class)
(see section 1.6.4.3.)
1.6.4.3 Avoiding excessive surface temperatures
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE
Pumps have a temperature class as stated in the
ATEX Ex rating on the nameplate. These are based
on a maximum ambient of 40 ºC (104 ºF); refer to
Flowserve for higher ambient temperatures.
The surface temperature on the pump is influenced
by the temperature of the liquid handled. The
maximum permissible liquid temperature depends on
the ATEX temperature class and must not exceed the
values in the table that follows:
* The table only takes the ATEX temperature class into
consideration. Pump design or material, as well as component
design or material, may further limit the maximum working
temperature of the liquid.
The temperature rise at the seals and bearings and
due to the minimum permitted flow rate is taken into
account in the temperatures stated.
The responsibility for compliance with the specified
maximum liquid temperature is with the plant
operator.
Temperature classification “Tx” is used when the liquid
temperature varies and when the pump is required to be
used in differently classified potentially explosive
atmospheres. In this case the user is responsible for
ensuring that the pump surface temperature does not
exceed that permitted in its actual installed location.
Do not attempt to check the direction of rotation with the
coupling element/pins fitted due to the risk of severe
contact between rotating and stationary components.
Where there is any risk of the pump being run against a
closed valve generating high liquid and casing external
surface temperatures fit an external surface
temperature protection device.
Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, temperature monitor or a
power monitor and make routine vibration monitoring
checks.
In dirty or dusty environments make regular checks
and remove dirt from areas around close clearances,
bearing housings and motors.
1.6.4.4 Preventing 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, fit an appropriate dry run protection device
(for example liquid detection or a power monitor).
To avoid potential hazards from fugitive emissions of
vapour or gas to atmosphere the surrounding area
must be well ventilated.
1.6.4.5 Preventing sparks
To prevent a potential hazard from mechanical
contact, the coupling guard must be non-sparking for
Category 2.
Page 7 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
To avoid the potential hazard from random induced
current generating a spark, the baseplate must be
properly grounded.
Avoid electrostatic charge: do not rub non-metallic
surfaces with a dry cloth; ensure cloth is damp.
For ATEX, the coupling must be selected to comply
with 94/9/EC. Correct coupling alignment must be
maintained.
Additional requirement for metallic pumps on
non-metallic baseplates
When metallic components are fitted on a nonmetallic baseplate they must be individually earthed.
1.6.4.6 Preventing leakage
A pump with mechanical seal 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 hazard of a loss of a seal
barrier fluid or external flush, the fluid must be monitored.
If leakage of liquid to atmosphere can result in a
hazard, install a liquid detection device.
1.6.4.7 Maintenance to avoid the hazard
1.7 Nameplate and safety labels
1.7.1 Nameplate
For details of nameplate, see the Declaration of
Conformity and section 3.
1.7.2 Safety labels
CORRECT MAINTENANCE IS REQUIRED TO
AVOID POTENTIAL HAZARDS WHICH GIVE A
RISK OF EXPLOSION
Oil lubricated units only:
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
DurcoShieldTM (splash/shaft guard
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.)
Page 8 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Motor size
and speed
kW (hp)
Typical sound pressure level LpA at 1 m reference 20 μPa, dBA
3 550 r/min
2 900 r/min
1 750 r/min
1 450 r/min
Pump
only
Pump and
motor
Pump
only
Pump and
motor
Pump
only
Pump and
motor
Pump
only
Pump and
motor
<0.55(<0.75)
72
72
64
65
62
64
62
64
0.75 (1)
72
72
64
66
62
64
62
64
1.1 (1.5)
74
74
66
67
64
64
62
63
1.5 (2)
74
74
66
71
64
64
62
63
2.2 (3)
75
76
68
72
65
66
63
64
3 (4)
75
76
70
73
65
66
63
64
4 (5)
75
76
71
73
65
66
63
64
5.5 (7.5)
76
77
72
75
66
67
64
65
7.5 (10)
76
77
72
75
66
67
64
65
11(15)
80
81
76
78
70
71
68
69
15 (20)
80
81
76
78
70
71
68
69
18.5 (25)
81
81
77
78
71
71
69
71
22 (30)
81
81
77
79
71
71
69
71
30 (40)
83
83
79
81
73
73
71
73
37 (50)
83
83
79
81
73
73
71
73
45 (60)
86
86
82
84
76
76
74
76
55 (75)
86
86
82
84
76
76
74
76
75 (100)
87
87
83
85
77
77
75
77
90 (120)
87
88
83
85
77
78
75
78
110 (150)
89
90
85
87
79
80
77
80
150 (200)
89
90
85
87
79
80
77
80
200 (270)
85
87
83
85
300 (400)
–
87
90
85
86
1.8 Specific machine performance
For performance parameters see section 1.5, Duty
conditions. Where performance data has been supplied
separately to the purchaser these should be obtained
and retained with these User Instructions if required.
1.9 Noise level
Attention must be given to the exposure of personnel
to the noise, and local legislation will define when
guidance to personnel on noise limitation is required,
and when noise exposure reduction is mandatory.
This is typically 80 to 85 dBA.
The usual approach is to control the exposure time to
the noise or to enclose the machine to reduce emitted
sound. You may have already specified a limiting
noise level when the equipment was ordered,
however if no noise requirements were defined, then
attention is drawn to the following table to give an
indication of equipment noise level so that you can
take the appropriate action in your plant.
Pump noise level is dependent on a number of
operational factors, flow rate, pipework design and
acoustic characteristics of the building, and so the
values given are subject to a 3 dBA tolerance and
cannot be guaranteed.
Similarly the motor noise assumed in the “pump and
motor” noise is that typically expected from standard
and high efficiency motors when on load directly driving
the pump. Note that a motor driven by an inverter may
show an increased noise at some speeds.
If a pump unit only has been purchased for fitting with
your own driver then the “pump only” noise levels in
the table should be combined with the level for the
driver obtained from the supplier. Consult Flowserve
or a noise specialist if assistance is required in
combining the values.
It is recommended that where exposure approaches
the prescribed limit, then site noise measurements
should be made.
The values are in sound pressure level LpA at 1 m
(3.3 ft) from the machine, for “free field conditions
over a reflecting plane”.
For estimating sound power level LWA (re 1 pW) then
add 14 dBA to the sound pressure value.
The noise level of machines in this range will most likely be of values which require noise exposure control, but typical values are inappropriate.
Note: for 1 180 and 960 r/min reduce 1 450 r/min values by 2 dBA. For 880 and 720 r/min reduce 1 450 r/min values by 3 dBA.
Page 9 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
2 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be
checked against the delivery/shipping documents for
its completeness and that there has been no damage
in transportation. Any shortage and/or damage must
be reported immediately to Flowserve Pump Division
and must be received in writing within one month of
receipt of the equipment. Later claims cannot be
accepted.
Check any crate, boxes or wrappings for any
accessories or spare parts that may be packed
separately with the equipment or attached to side
walls of the box or equipment.
Each product has a unique serial number. Check
that this number corresponds with that advised and
always quote this number in correspondence as well
as when ordering spare parts or further accessories.
2.2 Handling
Boxes, crates, pallets or cartons may be unloaded
using fork lift vehicles or slings dependent on their
size and construction.
2.3 Lifting
A crane must be used for all pump sets in
excess of 25 kg (55 lb). Fully trained personnel must
carry out lifting, in accordance with local regulations.
The driver and pump weights are recorded on their
respective nameplates.
Pumps and motors often have integral
lifting lugs or eye bolts. These are intended for use in
only lifting the individual piece of equipment.
2.3.1.2 Rear cover [1220]
Use a choker hitch slung through the central seal
chamber hole to lift large rear covers.
2.3.1.3 Bearing housing [3200]
Group 1. Insert a sling between the upper and lower
support ribs between the housing barrel and the
casing attachment flange. Use a choker hitch when
slinging. (Make sure there are no sharp edges on the
bottom side of the ribs which could cut the sling.)
Group 2 and 3. Insert either a sling or hook through
the lifting lug located on the top of the housing.
2.3.1.4 Power end
Same as bearing housing.
2.3.1.5 Bare pump
Horizontal pumps. Sling under the casing and
around the outboard end of the bearing housing with
separate slings. Choker hitches must be used at
both attachment points and pulled tight. The sling
lengths should be adjusted to balance the load before
attaching the lifting hook.
2.3.2 Lifting pump, motor and baseplate assembly
If the baseplate has lifting holes cut in the sides at the
end (type A Group 3, type D, and type E bases) insert
lifting S hooks at the four corners and use slings or
chains to connect to the lifting eye. Do not use slings
through the lifting holes because of sharp edges.
Other styles of baseplates can be lifted by placing
slings slightly outboard from the center of mass of the
motor and pump. A spreader bar may be required to
maintain the sling spacing during lifting.
2.4 Storage
Do not use eye bolts or cast-in lifting
lugs to lift pump, motor and baseplate assemblies.
To avoid distortion, the pump unit
should be lifted as described in this section.
Care must be taken to lift components
or assemblies above the center of gravity to prevent
the unit from flipping.
2.3.1 Lifting pump components
2.3.1.1 Casing [1100]
Use a choker hitch through the suction hole and
around the casing body.
Page 10 of 52 flowserve.com
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 six
months. Consult Flowserve for preservative actions
when a longer storage period is needed.
2.4.1 Short term storage and packaging
Normal packaging is designed to protect the pump
and parts during shipment and for dry, indoor storage
for up to six months or less. The following is an
overview of our normal packaging:
Store the pump in a clean, dry
Page 11
USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
All loose unmounted items are packaged in a
waterproof plastic bag and placed under the
coupling guard. Larger items are boxed and
metal banded to the baseplate. For pumps not
mounted on a baseplate, the bag and/or box is
placed inside the shipping container.
Inner surfaces of the bearing housing, shaft (area
through bearing housing) and bearings are
coated with Cortec VCI-329 rust inhibitor, or
equal. (Note: bearing housings are not filled with
oil prior to shipment.)
Regreasable bearings are packed with grease.
(EXXON POLYREX EM for horizontal pumps.)
Exposed shafts are taped with Polywrap.
Flange covers are secured to both the suction
and discharge flanges.
Assemblies ordered with external piping, in some
cases components may be disassembled for
shipment.
The pump must be stored in a covered, dry location.
2.4.2 Long term storage
Long term storage is defined as more than six
months, but less than 12 months. The procedure
Flowserve follows for long term storage of pumps is
given below. These procedures are in addition to the
short term procedure.
Each assembly is hermetically (heat) sealed from
the atmosphere by means of tack wrap sheeting
and rubber bushings (mounting holes).
Desiccant bags are placed inside the tack
wrapped packaging.
A solid wood box is used to cover the assembly.
This packaging will provide protection for up to twelve
months from humidity, salt laden air, dust etc.
After unpacking, protection will be the responsibility of
the user. Addition of oil to the bearing housing will
remove the inhibitor. If units are to be idle for
extended periods after addition of lubricants, inhibitor
oils and greases should be used. Every three
months, the pump shaft should be rotated
approximately 10 revolutions.
2.5 Recycling and end of product life
At the end of the service life of the product or its
parts, the relevant materials and parts should be
recycled or disposed of using an environmentally
acceptable method and local requirements. 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 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
regulations at all times.
3 DESCRIPTION
3.1 Configurations
PolyChem GRP chemical process pumps are end
suction, single stage, centrifugal pumps. The GRP
family conforms to ASME B73.5M as a non-metallic
wet end, end suction, centerline discharge
arrangement. There is also a self-priming option
available. These pumps are made of a glassreinforced polymer that is designed to handle a wide
range of chemicals. PolyChem GRP pumps may
often be used as a cost-effective solution where
stainless steel, Alloy 20, Monel, Nickel, Hastelloy ™,
and even titanium metal pumps are used.
3.2 Name nomenclature
The pump size will be engraved on the nameplate
typically as below:
2K 4 X 3G – 13 / 12.5
Frame size:
“2K’ indicates a medium size pump frame with a
Mark3 power end - in this example, a Group 2.
1J or 1K = Group 1 (small frame)
2K = Group 2 (medium frame)
3J = Group 3 (large frame – 2 ⅜ in. shaft)
4J = Group 4 (large frame – 2 ¾ in. shaft)
Power end:
Mark 3A – Standard
ANSI 3A – Optional (3 year guarantee)
“4” = Nominal suction port size.
“3” = Nominal discharge port size.
“G” = PolyChem GRP pump line
“GS” = Self-primer version
Nominal maximum impeller diameter:
“13” = 13 in. diameter
Actual impeller size:
“12.5” = 12 ½ in. diameter
An example of the nameplate used on the PolyChem
GRP pump is shown below. This nameplate, which is
always mounted on the Mark 3 bearing housing, is
shown in figure 3-1.
Page 11 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Figure 3-2
Bar (psi)
Size
-46 °C
(-50 °F)
66 °C
(150 °F)
121 °C
(250 °F)
1J1.5x1G-6
13.79 (200)
13.79 (200)
10.34 (150)
1J3x1.5G-6
13.79 (200)
13.79 (200)
10.34 (150)
1J3x2G-6
13.79 (200)
13.79 (200)
10.34 (150)
1J1.5x1G-8
13.79 (200)
13.79 (200)
10.34 (150)
2K3x1.5G-8
13.79 (200)
13.79 (200)
10.34 (150)
2K3x2G-8
13.79 (200)
13.79 (200)
10.34 (150)
2K4x3G-8
13.79 (200)
13.79 (200)
10.34 (150)
2K2x1G-10
17.24 (250)
17.24 (250)
13.79 (200)
2K3x1.5G-10
6.89 (100)
6.89 (100)
5.17 (75)
2K4x3G-10
6.89 (100)
6.89 (100)
5.17 (75)
2K6x4G-10
6.89 (100)
6.89 (100)
5.17 (75)
2K3x1.5G-13
8.62 (125)
8.62 (125)
6.89 (100)
2K4x3G-13
8.62 (125)
8.62 (125)
6.89 (100)
3J8x6G-13
10.34 (150)
10.34 (150)
8.62 (125)
3J12x10G-15
6.89 (100)
6.89 (100)
5.17 (75)
4J12x10G-15B
6.89 (100)
6.89 (100)
5.17 (75)
Size
-29 °C
(-20 °F)
66 °C
(150 °F)
107 °C
(225 °F)
1K3x2GS-7
9.31 (135)
9.31 (135)
9.31 (135)
2K4X3G-13/12.5
Serial No.
Equipment No.
Purchase Order
Model
Size
MDP
Material
Date DD/MMM/YY
3.3.8 Driver
The driver is normally an electric motor. Different drive
configurations may be fitted such as internal combustion
engines, turbines, hydraulic motors etc driving via
couplings, belts, gearboxes, drive shafts etc.
3.3.9 Accessories
Accessories may be fitted when specified by the
customer.
Figure 3-1
3.3 Design of major parts
3.3.1 Pump casing
The pump casing is designed with a horizontal
centerline suction inlet and a vertical centerline top
discharge which makes it self venting.
Removal of the casing is not required when
performing maintenance of the rotating element. The
pump is designed with a gasket perpendicular to the
shaft allowing the rotating element to be easily
removed (back pull out).
3.3.2 Impeller
An open impeller design is the only offering.
3.3.3 Shaft/sleeve
The pump shafts are sleeved, supported on rolling
element bearings, with both threaded and polygon
3.4 Performance and operating limits
This product has been selected to meet the
specification of your purchase order. (See section 1.5.)
Typical materials used in the PolyChem GRP include:
Casing, impeller, rear cover, and glands. Glass
reinforced plastic (GRP) composed of chopped
fiberglass strands in a Derakane 470™ vinyl ester
resin. (Durcon 730, a glass reinforced thermo-setting
epoxy resin, is used for the 1K3x2GS-7.)
Shaft sleeves. Ryton plastic (Polyphenylene
sulfide) or high alloy steels are available.
Shafting. 4140 carbon steel as standard with 17-4
PH stainless steel as an option. (Superchlor 77 is the
standard shaft material for the 1K3x2GS-7 pump.)
3.4.1 Pressure-temperature ratings
drive ends for the impeller and a keyed drive end.
3.3.4 Pump bearings and lubrication
Ball bearings are fitted as standard and may be either
oil or grease lubricated.
3.3.5 Bearing housing
Options include a large reservoir for oil bath
lubrication or the use of zerk fittings for regreasable
bearings. A micrometer shaft adjustment allows
external setting of the impeller gap.
3.3.6 Seal chamber (cover plate)
The seal chamber has a spigot (rabbet) fit between
the pump casing and bearing housing (adapter) for
optimum concentricity. The design enables a number
of sealing options to be fitted.
3.3.7 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.
Page 12 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Figure 3-3
MCF (% of BEP)
Size
3 600
r/min
3 000
r/min
1 800
r/min
1 200
r/min
1J1.5x1G-6
10
10
10
10
1J3x1.5G-6
10
10
10
10
1J3x2G-6
10
10
10
10
1J3x2GS-7
10
10
10
10
1J1.5x1G-8
10
10
10
10
2K3x1.5G-8
10
10
10
10
2K3x2G-8
10
10
10
10
2K4x3G-8
20
20
20
20
2K2x1G-10
10
10
10
10
2K3x1.5G-10
N/A
10
10
10
2K4x3G-10
N/A
25
25
25
2K6x4G-10
N/A
25
25
25
2K3x1.5G-13
N/A
N/A
25
25
2K4x3G-13
N/A
N/A
25
25
3J8x6G-13
N/A
N/A
25
25
3J12x10G-15
N/A
N/A
N/A
25
4J12x10G-15B
N/A
N/A
25
25
The pressure-temperature charts for PolyChem GRP
pumps are shown in figure 3-2. Maximum fluid
temperature for Derakane 470™ material is 121 °C
(250 °F) and for Durcon 730 is 107 °C (225 °F).
The following data are typical, and factors such as
liquid being pumped, temperature, and seal type may
influence them. If required, a definitive statement for
your application can be obtained from Flowserve.
3.4.2 Minimum continuous flow
The minimum continuous flow (MCF) is based on a
percentage of the best efficiency point (BEP). Figure
3-3 identifies the MCF for all PolyChem GRP pump
models.
3.4.3 Minimum suction pipe submergence
The minimum submergence is shown in figure 3-4 and
3-5 for the 1K3x2GS-7 unitized self-priming pump.
Figure 3-4: Minimum submergence
Figure 3-5: Minimum submergence
3.4.4 Suction pressure limits
Open style impellers typically create a thrust load
towards the suction of the pump. This reduces the axial
loading on the bearings so that the suction pressure
limit is equal to the pressure-temperature rating.
4 INSTALLATION
Equipment operated in hazardous locations
must 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
The supply of motors and baseplates is optional. As
a result, it is the responsibility of the installer to
ensure that the motor is assembled to the pump and
aligned as detailed in sections 4.5 and 4.8.
4.3 Foundation
4.3.1 Protection of openings and threads
When the pump is shipped, all threads and all
openings are covered. This protection/covering
should not be removed until installation. If, for any
reason, the pump is removed from service, this
protection should be reinstalled.
4.3.2 Rigid baseplates - overview
The function of a baseplate is to provide a rigid
foundation under a pump and its driver that maintains
alignment between the two. Baseplates may be
generally classified into two types:
Foundation-mounted, grouted design (figure 4-1)
Stilt mounted, or free-standing (figure 4-2)
Page 13 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Figure 4-3
1. Stilt bolt
2. Nuts
3. Lock washer
4. Floor cup
capability at the motor to obtain a “perfect” final
alignment when the installer puts the baseplate
assembly into its original, top leveled, unstressed
condition.
4.3.3 Stilt and spring mounted baseplates
Flowserve offers stilt and spring mounted baseplates.
Figure 4-1
(See Figure 4-2 for stilt mounted option.) The low
vibration levels of PolyChem GRP pumps allow the use
of these baseplates - provided they are of a rigid design.
The baseplate is set on a flat surface with no tie down
bolts or other means of anchoring it to the floor.
Figure 4-2
Baseplates intended for grouted installation are
designed to use the grout as a stiffening member.
Stilt mounted baseplates, on the other hand, are
designed to provide their own rigidity. Therefore, the
designs of the two baseplates are usually different.
Regardless of the type of baseplate used, it must
provide certain functions that ensure a reliable
installation. Three of these requirements are:
The baseplate must provide sufficient rigidity to
assure the assembly can be transported and
installed, given reasonable care in handling,
without damage. It must also be rigid enough
when properly installed to resist operating loads.
The baseplate must provide a reasonably flat
mounting surface for the pump and driver.
Uneven surfaces will result in a soft-foot condition
that may make alignment difficult or impossible.
Flowserve experience indicates that a baseplate
that has a top surface flatness of 1.25 mm/m
(0.015 in./ft) across the diagonal corners of the
baseplate provides such a mounting surface.
Therefore, this is the tolerance to which we supply
our standard baseplate. Some users may desire
an even flatter surface, which can facilitate
installation and alignment. Flowserve will supply
flatter baseplates upon request at extra cost. For
example, mounting surface flatness of 0.17 mm/m
General instructions for assembling these baseplates
are given below. For dimensional information, please
refer to the appropriate Flowserve “Sales Print.”
4.3.3.1 Stilt mounted baseplate assembly
instructions
(Refer to figure 4-3.)
a) Raise or block up baseplate/pump above the floor
to allow for the assembly of the stilts.
b) Predetermine or measure the approximate
desired height for the baseplate above the floor.
c) Set the bottom nuts (item 2) above the stilt bolt
head (item 1) to the desired height.
d) Assemble lock washer (item 3) down over the stilt
bolt.
e) Assemble the stilt bolt up through hole in the
bottom plate and hold in place.
f) Assemble the lock washer (item 3) and nut (item 2)
on the stilt bolt. Tighten the nut down on the lock
washer.
g) After all four stilts have been assembled, position
the baseplate in place, over the floor cups (item 4)
under each stilt location, and lower the baseplate
to the floor.
h) Level and make final height adjustments to the
suction and discharge pipe by first loosening the
top nuts and turning the bottom nuts to raise or
lower the baseplate.
i) Tighten the top and bottom nuts at the lock
washer (item 3) first then tighten the other nuts.
(0.002 in./ft) is offered on the Flowserve Type E
“Ten Point” baseplate shown in figure 4-1.
The baseplate must be designed to allow the user
to final field align the pump and driver to within
their own particular standards and to compensate
for any pump or driver movement that occurred
during handling. Normal industry practice is to
achieve final alignment by moving the motor to
match the pump. Flowserve practice is to confirm
in our shop that the pump assembly can be
accurately aligned. Before shipment, the factory
verifies that there is enough horizontal movement
Page 14 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
1. Stilt bolt
2. Bottom spring 3 ¼ in.
(83 mm) OD x 4 in.
(102 mm) floor cups
3. Top spring 2 in. (51 mm)
OD x 4 in. (102 mm) floor
cups
4. Nuts
5. Flat washer
6. Lock washer
7. Floor cup
j) It should be noted that the connecting pipelines
must be individually supported, and that the stilt
mounted baseplate is not intended to support
total static pipe load.
4.3.3.2 Stilt/spring mounted baseplate assembly
instructions
(Refer to figure 4-4.)
a) Raise or block up baseplate/pump above the floor
to allow for the assembly of the stilts.
b) Set the bottom nuts (item 4) above the stilt bolt
head (item 1). This allows for 51 mm (2 in.)
upward movement for the final height adjustment
of the suction/discharge flange.
c) Assemble the lock washer (item 6) flat washer
(item 5) and bottom spring/cup assembly (item 2)
down over the stilt bolt (item 1).
d) Assemble the stilt bolt/bottom spring up through
hole in the bottom plate and hold in place.
e) Assemble top spring/cup assembly (item 3) down
over stilt bolt.
f) Assemble flat washer (item 5), lock washer (item 6)
and nuts (item 4) on the stilt bolt.
g) Tighten down top nuts, compressing the top
spring approximately 25 mm (1 in.).
h) After all four stilts have been assembled, position
the baseplate in place, over the floor cups (item 7)
under each stilt location, and lower the baseplate
down to the floor.
i) Level and make final height adjustments to the
suction and discharge pipe by first loosening the
top nuts, and turning the bottom nuts to raise or
lower the baseplate.
j) To make the stilt bolts more stable, tighten down
on the top nuts, compressing the top spring
approximately 25 mm (1 in.), and lock the nuts in
place.
k) It should be noted that the connecting pipelines
must be individually supported, and that the
spring mounted baseplate is not intended to
support total static pipe loads.
Page 15 of 52 flowserve.com
Figure 4-4
4.3.3.3 Stilt/spring mounted baseplates - motor
alignment
The procedure for motor alignment on stilt or spring
mounted baseplates is similar to grouted baseplates.
The difference is primarily in the way the baseplate is
leveled.
a) Level the baseplate by using the stilt adjusters.
(Shims are not needed as with grouted
baseplates.) After the base is level, it is locked in
place by locking the stilt adjusters.
b) Next the initial pump alignment must be checked.
The vertical height adjustment provided by the
stilts allows the possibility of slightly twisting the
baseplate. If there has been no transit damage
or twisting of the baseplate during stilt height
adjustment, the pump and driver should be within
0.38 mm (0.015 in.) parallel, and 0.0025 mm/mm
(0.0025 in./in.) angular alignment. If this is not
the case, check to see if the driver mounting
fasteners are centered in the driver feet holes.
c) If the fasteners are not centered there was likely
shipping damage. Re-center the fasteners and
perform a preliminary alignment to the above
tolerances by shimming under the motor for
vertical alignment, and by moving the pump for
horizontal alignment.
d) If the fasteners are centered, then the baseplate
may be twisted. Slightly adjust (one turn of the
adjusting nut) the stilts at the driver end of the
baseplate and check for alignment to the above
tolerances. Repeat as necessary while maintaining
a level condition as measured from the pump
discharge flange. Lock the stilt adjusters.
e) The remaining steps are as listed for new grouted
baseplates.
4.4 Grouting
a) The pump foundation should be located as close to
the source of the fluid to be pumped as practical.
There should be adequate space for workers to
install, operate, and maintain the pump. The
foundation should be sufficient to absorb any
vibration and should provide a rigid support for the
pump and motor. Recommended mass of a
concrete foundation should be three times that of
the pump, motor and base. (Refer to figure 4-5.)
Figure 4-5
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
baseplate or if they were not removed from the
Foundation bolts are imbedded in the
concrete inside a sleeve to allow some
movement of the bolt.
b) Level the pump baseplate assembly. If the
baseplate has machined coplanar mounting
surfaces, these machined surfaces are to be
referenced when leveling the baseplate. This may
require that the pump and motor be removed from
the baseplate in order to reference the machined
faces. If the baseplate is without machined
coplanar mounting surfaces, the pump and motor
are to be left on the baseplate. The proper
surfaces to reference when leveling the pump
baseplate assembly are the pump suction and
discharge flanges. DO NOT stress the baseplate.
Do not bolt the suction or discharge flanges of the
pump to the piping until the baseplate foundation
is completely installed. If equipped, use leveling
jackscrews to level the baseplate. If jackscrews
are not provided, shims and wedges should be
used (see figure 4-5). Check for levelness in both
the longitudinal and lateral directions. Shims
should be placed at all base anchor bolt locations,
and in the middle edge of the base if the base is
more than 1.5 m (5 ft) long. Do not rely on the
bottom of the baseplate to be flat. Standard
baseplate bottoms are not machined, and it is not
likely that the field mounting surface is flat.
c) After leveling the baseplate, tighten the anchor
bolts. If shims were used, make sure that the
baseplate was shimmed near each anchor bolt
before tightening. Failure to do this may result in
a twist of the baseplate, which could make it
impossible to obtain final alignment. Check the
level of the baseplate to make sure that
tightening the anchor bolts did not disturb the
level of the baseplate. If the anchor bolts did
change the level, adjust the jackscrews or shims
as needed to level the baseplate. Continue
adjusting the jackscrews or shims and tightening
the anchor bolts until the baseplate is level.
d) Check initial alignment. If the pump and motor
were removed from the baseplate proceed with
step e) first, then the pump and motor should be
reinstalled onto the baseplate using Flowserve’s
factory preliminary alignment procedure as
described in section 4.5, and then continue with
the following. As described above, pumps are
given a preliminary alignment at the factory. This
preliminary alignment is done in a way that
ensures that, if the installer duplicates the factory
conditions, there will be sufficient clearance
between the motor hold down bolts and motor foot
holes to move the motor into final alignment. If the
pump and motor were properly reinstalled to the
baseplate and there has been no transit damage,
and also if the above steps where done properly,
the pump and driver should be within 0.38 mm
(0.015 in.) FIM (Full Indicator Movement) parallel,
and 0.0025 mm/mm (0.0025 in./in.) FIM angular.
If this is not the case, first check to see if the driver
mounting fasteners are centered in the driver feet
holes. If not, re-center the fasteners and perform
a preliminary alignment to the above tolerances by
shimming under the motor for vertical alignment,
and by moving the pump for horizontal alignment.
e) Grout the baseplate. A non-shrinking grout
should be used. Make sure that the grout fills the
area under the baseplate. After the grout has
cured, check for voids and repair them.
Jackscrews, shims and wedges should be
removed from under the baseplate at this time. If
they were to be left in place, they could rust,
swell, and cause distortion in the baseplate.
f) Run piping to the suction and discharge of the
pump. There should be no piping loads
transmitted to the pump after connection is made.
Recheck the alignment to verify that there are no
significant loads.
4.5 Initial alignment
Pump and driver must be isolated
electrically and the half couplings disconnected.
The alignment MUST be checked.
4.5.1 Horizontal initial alignment procedure
The purpose of factory alignment is to ensure that the
user will have full utilization of the clearance in the
motor holes for final job-site alignment. To achieve
this, the factory alignment procedure specifies that
the pump be aligned in the horizontal plane to the
motor, with the motor foot bolts centered in the motor
holes. This procedure ensures that there is sufficient
clearance in the motor holes for the customer to field
align the motor to the pump, to zero tolerance. This
philosophy requires that the customer be able to
place the base in the same condition as the factory.
Thus the factory alignment will be done with the base
sitting in an unrestrained condition on a flat and level
surface. This standard also emphasizes the need to
ensure the shaft spacing is adequate to accept the
specified coupling spacer.
The factory alignment procedure is summarized
below:
a) The baseplate is placed on a flat and level
workbench in a free and unstressed position.
Page 16 of 52 flowserve.com
Page 17
USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
b) The baseplate is leveled as necessary. Leveling
is accomplished by placing shims under the rails
of the base at the appropriate anchor bolt hole
locations. Levelness is checked in both the
longitudinal and lateral directions.
c) The motor and appropriate motor mounting
hardware is placed on the baseplate and the motor
is checked for any planar soft-foot condition. If any
is present it is eliminated by shimming
d) The motor feet holes are centered on the motor
mounting fasteners. This is done by using a
centering nut as shown in figure 4-6.
Figure 4-6
e) The motor is fastened in place by tightening the
nuts on two diagonal motor mounting studs.
f) The pump is put onto the baseplate and leveled.
The foot piece under the bearing housing is
adjustable. If an adjustment is necessary, add or
remove shims [109A] between the foot piece and
the bearing housing.
g) The spacer coupling gap is verified.
h) The parallel and angular vertical alignment is
made by shimming under the motor.
i) The motor feet holes are again centered on the
motor mounting studs using the centering nut.
At this point the centering nut is removed and
replaced with a standard nut. This gives
maximum potential mobility for the motor to be
horizontally moved during final, field alignment.
All four motor feet are tightened down.
j) The pump and motor shafts are then aligned
horizontally, both parallel and angular, by moving
the pump to the fixed motor.
k) The pump feet are tightened down.
l) Both horizontal and vertical alignment is again
final checked as is the coupling spacer gap.
See section 4.8 for Final Shaft Alignment
4.6 Piping
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
Never use pump as a support for
piping.
All piping must be independently supported,
accurately aligned and preferably connected to the
pump by a short length of flexible piping. The pump
should not have to support the weight of the pipe or
compensate for misalignment. It should be possible
to install suction and discharge bolts through mating
flanges without pulling or prying either of the flanges.
All piping must be tight.
Pumps may air-bind if air is allowed to leak into the
piping. If the pump flange(s) have tapped holes,
select flange fasteners with thread engagement at
least equal to the fastener diameter, but that do not
bottom out in the tapped holes before the joint is tight.
Maximum forces and moments allowed on the pump
flanges vary with the pump size and type. To
minimize these forces and moments that may, if
excessive, cause misalignment, hot bearings, worn
couplings, vibration and the possible failure of the
pump casing, the following points should be strictly
followed:
Prevent excessive external pipe load
Never draw piping into place by applying force to
pump flange connections
Do not mount expansion joints so that their force,
due to internal pressure, acts on the pump flange
Ensure piping and fittings are flushed
before use.
Ensure piping for hazardous liquids is arranged
to allow pump flushing before removal of the pump.
The GRP suction and discharge flanges require full
flat face gaskets with a minimum thickness of 3.2 mm
(0.125 in.) and a hardness 70 durometer (Shore A).
Check that the gasket material is compatible with the
fluid and that the inner diameter of the gasket is
centered before assembly.
Use flat washers behind the pump flanges and do not
exceed 41 Nm (30 lbf•ft) torque on the flange bolting.
4.6.2 Suction piping
To avoid NPSH and suction problems, suction piping
must be at least as large as the pump suction
connection. Never use pipe or fittings on the suction
that are smaller in diameter than the pump suction size.
Page 17 of 52 flowserve.com
Page 18
USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Figure 4-7 illustrates the ideal piping configuration
with a minimum of 10 pipe diameters between the
source and the pump suction. In most cases,
horizontal reducers should be eccentric and mounted
with the flat side up as shown in figure 4-8 with a
maximum of one pipe size reduction. Never mount
eccentric reducers with the flat side down.
Horizontally mounted concentric reducers should not
be used if there is any possibility of entrained air in
the process fluid. Vertically mounted concentric
reducers are acceptable. In applications where the
fluid is completely de-aerated and free of any vapor
or suspended solids, concentric reducers are
preferable to eccentric reducers
Figure 4-7 Figure 4-8
Avoid the use of throttling valves and strainers in the
suction line. Start up strainers must be removed
shortly before start up. When the pump is installed
below the source of supply, a valve should be
installed in the suction line to isolate the pump and
permit pump inspection and maintenance. However,
never place a valve directly on the suction nozzle of
the pump.
Refer to the Durco Pump Engineering Manual and
the Centrifugal Pump IOM section of the Hydraulic
Institute Standards for additional recommendations
on suction piping, section 10. Refer to section 3.4 for
performance and operating limits.
4.6.3 Discharge piping
Install a valve in the discharge line. This valve is
required for regulating flow and or to isolate the pump
for inspection and maintenance.
When fluid velocity in the pipe is high,
for example, 3 m/s (10 ft/sec) or higher, a rapidly
closing discharge valve can cause a damaging
pressure surge. A dampening arrangement should
be provided in the piping.
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.
4.6.4 Allowable nozzle loads - PolyChem GRP
pumps (ASME B73.5)
Flowserve chemical process pumps meet or exceed
the allowable nozzle loads given by ANSI/HI 9.6.2.
The following paragraphs describe how to calculate
the allowable loads for each pump type and how to
determine if the applied loads are acceptable.
The following steps are based upon ANSI/HI 9.6.2.
All information necessary to complete the evaluation
is given below. For complete details please review
the standard.
a) Find the “Baseplate Correction Factor” in figure
4-10. The correction factor depends upon how
the baseplate is to be installed
b) The casing material correction factor for the GRP
material is 0.9.
c) Select the lowest correction factor from steps a)
and b). For example:
If the pump is mounted on a Type A grouted
baseplate, the correction factor used is 0.9.
If the pump is mounted on a Type D stilt
mounted baseplate, the correction factor is 0.75.
d) Locate the pump model being evaluated in
figures 4-12 through 4-15 and multiply each load
rating by the lowest correction factor. Record the
adjusted loads for each table.
e) Calculate the applied loads at the casing flanges
according to the coordinate system depicted in
figure 4-9. The 12 forces and moments possible
are Fxs, Fys, Fzs, Mxs, Mys, Mzs, Fxd, Fyd, Fzd,
Mxd, Myd and Mzd. For example, Fxd
designates Force in the “x” direction on the
discharge flange. Mys designates the Moment
about the “y”-axis on the suction flange.
f) Figure 4-11 gives the acceptance criteria
equations. For long coupled pumps, equation
sets 1 through 5 must be satisfied.
g) Equation set 1. Each applied load is divided by
the corresponding adjusted figure 4-12 value.
The absolute value of each ratio must be less
than or equal to one.
h) Equation set 2. The summation of the absolute
values of each ratio must be less than or equal to
two. The ratios are the applied load divided by
the adjusted figure 4-13 values.
i) Equation sets 3 and 4. These equations are
checking for coupling misalignment due to nozzle
loading in each axis. Each applied load is divided
by the corresponding adjusted load from figure 4-14
and 4-15. The result of each equation must be
between one and negative one.
j) Equation set 5. This equation calculates the total
shaft movement from the results of equations 3 and
4. The result must be less than or equal to one.
Page 18 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Base type
Grouted
Bolted
Stilt
mounted
Type A
1.0
0.7
0.65
Type B - Polybase
1.0
n/a
0.95
Type C
n/a
1.0
1.0
Type D
1.0
0.8
0.75
Type E - PIP
1.0
0.95
n/a
Polyshield - baseplate
/foundation
1.0
n/a
n/a
Set
Equations
Figure
Remarks
1
0.1,0.1,0.1,0.1,0.1,0.1
,0.1,0.1,0.1,0.1,0.1,0.1
______
______
adjzd
zd
adjyd
yd
adjxd
xd
adjzd
zd
adjyd
yd
adjxd
xd
adjzs
zs
adjys
ys
adjxs
xs
adjzs
zs
adjys
ys
adjxs
xs
M
M
M
M
M
M
F
F
F
F
F
F
M
M
M
M
M
M
F
F
F
F
F
F
Adjusted
4-12
Maximum
individual
loading
2
0.2
______
______
adjzd
zd
adjyd
yd
adjxd
xd
adjzd
zd
adjyd
yd
adjxd
xd
adjzs
zs
adjys
ys
adjxs
xs
adjzs
zs
adjys
ys
adjxs
xs
M
M
M
M
M
M
F
F
F
F
F
F
M
M
M
M
M
M
F
F
F
F
F
F
Adjusted
4-13
Nozzle stress,
bolt stress,
pump slippage
3
adjzd
zd
adjyd
yd
adjxd
xd
adjyd
yd
adjzs
zs
adjys
ys
adjxs
xs
adjys
ys
M
M
M
M
M
M
F
F
M
M
M
M
M
M
F
F
A
____
____
0.10.1 A
Adjusted
4-14
y-axis
movement
4
adjzd
zd
adjyd
yd
adjxd
xd
adjzd
zd
adjyd
yd
adjxd
xd
adjzs
zs
adjys
ys
adjxs
xs
adjzs
zs
adjxs
xs
M
M
M
M
M
M
F
F
F
F
F
F
M
M
M
M
M
M
F
F
F
F
B
______
_____
0.10.1 B
Adjusted
4-15
z-axis
movement
5
0.122 BA
-
Combined axis
movement
Figure 4-9: Coordinate system
Figure 4-11: Acceptance criteria equations
Figure 4-10: Baseplate correction factors
Note: All of the above equations are found by dividing the applied piping loads by the adjusted figure values.
Page 19 of 52 flowserve.com
Page 20
USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Pump size
Suction flange
Discharge flange
Forces N (lbf)
Moments Nm (lbf•ft)
Forces N (lbf)
Moments Nm (lbf•ft)
Fxs
Fys
Fzs
Mxs
Mys
Mzs
Fxd
Fyd
Fzd
Mxd
Myd
Mzd
1J 1.5x1G-6
4 670
(1 050)
3 336
(750)
3 336
(750)
976
(720)
231
(170)
231
(170)
3 558
(800)
6 005
(1350)
13 344
(3 000)
556
(410)
556
(410)
556
(410)
1J 3x1.5G-6
4 670
(1 050)
5 516
(1 240)
5 560
(1 250)
1 220
(900)
664
(490)
664
(490)
3 558
(800)
6 005
(1 350)
13 344
(3 000)
678
(500)
746
(550)
692
(510)
1J 3x2G-6
4 670
(1 050)
4 670
(1 050)
4 670
(1 050)
1 220
(900)
298
(220)
298
(220)
3 558
(800)
6 005
(1 350)
13 344
(3 000)
678
(500)
1 356
(1 000)
692
(510)
1K 3x2GS-7
4 670
(1 050)
4 670
(1 050)
4 670
(1 050)
1 220
(900)
298
(220)
298
(220)
3 558
(800)
6 005
(1 350)
13 344
(3 000)
678
(500)
1 356
(1 000)
692
(510)
1J 1.5x1G-8
4 670
(1 050)
5 382
(1 210)
5 382
(1 210)
976
(720)
258
(190)
258
(190)
3 558
(800)
6 005
(1 350)
13 344
(3 000)
488
(360)
488
(360)
488
(360)
2K 3x1.5G-8
12 010
(2 700)
6 005
(1 350)
6 672
(1 500)
1 763
(1 300)
502
(370)
502
(370)
6 227
(1 400)
6 005
(1 350)
14 456
(3 250)
624
(460)
624
(460)
624
(460)
2K 3x2G-8
12 010
(2 700)
6 005
(1 350)
6 672
(1 500)
1 763
(1 300)
814
(600)
814
(600)
6 227
(1 400)
6 005
(1 350)
14 456
(3 250)
895
(660)
895
(660)
895
(660)
2K 4x3G-8
12 010
(2 700)
6 005
(1 350)
6 672
(1 500)
1 763
(1 300)
475
(350)
475
(350)
6 227
(1 400)
6 005
(1 350)
14 456
(3 250)
1 627
(1 200)
1 980
(1 460)
936
(690)
2K 2x1G-10
10 408
(2 340)
4 270
(960)
4 270
(960)
1 722
(1 270)
298
(220)
298
(220)
6 227
(1 400)
6 005
(1 350)
14 456
(3 250)
895
(660)
895
(660)
895
(660)
2K 3x1.5G-10
12 010
(2 700)
6 005
(1 350)
6 672
(1 500)
1 763
(1 300)
570
(420)
570
(420)
6 227
(1 400)
6 005
(1 350)
14 456
(3 250)
502
(370)
502
(370)
502
(370)
2K 4x3G-10
10 230
(2 300)
6 005
(1 350)
6 672
(1 500)
1 763
(1 300)
420
(310)
420
(310)
6 227
(1 400)
6 005
(1 350)
14 456
(3 250)
1 627
(1 200)
1 980
(1 460)
936
(690)
2K 6x4G-10
12 010
(2 700)
6 005
(1 350)
6 672
(1 500)
1 763
(1 300)
1 492
(1 100)
1 492
(1 100)
6 227
(1 400)
6 005
(1 350)
14 456
(3 250)
1 627
(1 200)
2 034
(1 500)
936
(690)
2K 3x1.5G-13
12 010
(2 700)
6 005
(1 350)
6 672
(1 500)
1 763
(1 300)
909
(670)
909
(670)
6 227
(1 400)
6 005
(1 350)
14 456
(3 250)
719
(530)
719
(530)
719
(530)
2K 4x3G-13
12 010
(2 700)
6 005
(1 350)
6 672
(1 500)
1 763
(1 300)
542
(400)
542
(400)
6 227
(1 400)
6 005
(1 350)
14 456
(3 250)
1 627
(1 200)
2 034
(1 500)
936
(690)
3J 8x6G-13
15 568
(3 500)
14 145
(3 180)
8 896
(2 000)
2 034
(1 500)
1 587
(1 170)
1 587
(1 170)
6 672
(1 500)
13 344
(3 000)
15 568
(3 500)
1 695
(1 250)
3 851
(2 840)
3 851
(2 840)
3J & 4J 12x10G-15
15 568
(3 500)
14 145
(3 180)
8 896
(2 000)
2 034
(1 500)
1 532
(1 130)
1 532
(1 130)
6 672
(1 500)
13 344
(3 000)
15 568
(3 500)
1 695
(1 250)
3 851
(2 840)
3 851
(2 840)
4.6.5 Pump and shaft alignment check
After connecting the piping, rotate the pump drive
shaft clockwise (view from motor end) by hand
several complete revolutions to be sure there is no
binding and that all parts are free. Recheck shaft
alignment (see section 4.5). If piping caused unit to
be out of alignment, correct piping to relieve strain on
the pump.
4.6.6 Auxiliary piping
4.6.6.1 Mechanical seal
When the pump is intended to be equipped with a
mechanical seal, it is Flowserve standard practice to
install the mechanical seal in the pump prior to
shipment. Specific order requirements may specify
that the seal be shipped separately, or none be
supplied. It is the pump installer’s responsibility to
determine if a seal was installed. If a seal was
supplied but not installed, the seal and installation
instructions will be shipped with the pump.
may result in serious leakage of the pumped fluid.
Seal and seal support system must be installed and
operational as specified by the seal manufacturer.
The stuffing box/seal chamber/gland may have ports
that have been temporarily plugged at the factory to
keep out foreign matter. It is the installer’s
responsibility to determine if these plugs should be
removed and external piping connected. Refer to the
seal drawings and or the local Flowserve
representative for the proper connections.
When installing piping, do not install metal pipe
fittings directly into the non metallic threaded
connections on the pump. If metal pipe fittings must
be used, then install a non metallic pipe nipple into
the connection on the pump and then connect metal
pipework to this nipple.
Failure to ensure that a seal is installed
Figure 4-12: Maximum individual loading
Page 20 of 52 flowserve.com
Page 21
USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Pump size
Suction flange
Discharge flange
Forces N (lbf)
Moments Nm (lbf•ft)
Forces N (lbf)
Moments Nm (lbf•ft)
Fxs
Fys
Fzs
Mxs
Mys
Mzs
Fxd
Fyd
Fzd
Mxd
Myd
Mzd
1J 1.5x1G-6
8 985
(2 020)
3 336
(750)
3 336
(750)
2 481
(1 830)
231
(170)
231
(170)
8 985
(2 020)
6 005
(1 350)
27 756
(6 240)
556
(410)
556
(410)
556
(410)
1J 3x1.5G-6
8 985
(2 020)
5 516
(1 240)
9 385
(2 110)
3 105
(2 290)
664
(490)
664
(490)
8 985
(2 020)
6 005
(1 350)
27 756
(6 240)
746
(550)
746
(550)
692
(510)
1J 3x2G-6
8 985
(2 020)
4 670
(1 050)
4 670
(1 050)
3 105
(2 290)
298
(220)
298
(220)
8 985
(2 020)
6 005
(1 350)
27 756
(6 240)
1 397
(1 030)
1 397
(1 030)
692
(510)
1K 3x2GS-7
8 985
(2 020)
4 670
(1 050)
4 670
(1 050)
3 105
(2 290)
298
(220)
298
(220)
8 985
(2 020)
6 005
(1 350)
27 756
(6 240)
1 397
(1 030)
1 397
(1 030)
692
(510)
1J 1.5x1G-8
8 985
(2 020)
5 382
(1 210)
5 382
(1 210)
2 481
(1 830)
258
(190)
258
(190)
8 985
(2 020)
6 005
(1 350)
27 756
(6 240)
488
(360)
488
(360)
488
(360)
2K 3x1.5G-8
12 010
(2 700)
6 005
(1 350)
8 095
(1 820)
5 058
(3 730)
814
(370)
502
(370)
8 985
(2 020)
6 005
(1 350)
27 756
(6 240)
624
(460)
624
(460)
624
(460)
2K 3x2G-8
12 010
(2 700)
6 005
(1 350)
11 076
(2 490)
5 058
(3 730)
814
(600)
814
(600)
8 763
(1 970)
6 005
(1 350)
27 756
(6 240)
895
(660)
895
(660)
895
(660)
2K 4x3G-8
12 010
(2 700)
6 005
(1 350)
8 184
(1 840)
5 058
(3 730)
475
(350)
475
(350)
8 985
(2 020)
6 005
(1 350)
27 756
(6 240)
1 980
(1 460)
1 980
(1 460)
936
(690)
2K 2x1G-10
10 408
(2 340)
4 270
(960)
4 270
(960)
4 936
(3 640)
298
(220)
298
(220)
8 985
(2 020)
6 005
(1 350)
27 756
(6 240)
895
(660)
895
(660)
895
(660)
2K 3x1.5G-10
12 010
(2 700)
6 005
(1 350)
8 496
(1 910)
5 058
(3 730)
570
(420)
570
(420)
8 629
(1 940)
6 005
(1 350)
27 756
(6 240)
502
(370)
502
(370)
502
(370)
2K 4x3G-10
10 230
(2 300)
6 005
(1 350)
7 295
(1 640)
5 058
(3 730)
420
(310)
420
(310)
8 985
(2 020)
6 005
(1 350)
27 756
(6 240)
1 980
(1 460)
1 980
(1 460)
936
(690)
2K 6x4G-10
12 010
(2 700)
6 005
(1 350)
27 756
(6 240)
5 058
(3 730)
1 492
(1 100)
1 492
(1 100)
8 985
(2 020)
6 005
(1 350)
27 756
(6 240)
4 204
(3 100)
4 204
(3 100)
936
(690)
2K 3x1.5G-13
12 010
(2 700)
6 005
(1 350)
13 611
(3 060)
5 058
(3 730)
909
(670)
909
(670)
8 985
(2 020)
6 005
(1 350)
27 756
(6 240)
719
(530)
719
(530)
719
(530)
2K 4x3G-13
12 010
(2 700)
6 005
(1 350)
10 631
(2 390)
5 058
(3 730)
542
(400)
542
(400)
8 985
(2 020)
6 005
(1 350)
27 756
(6 240)
2 346
(1 730)
2 346
(1 730)
936
(690)
3J 8x6G-13
28 289
(6 360)
14 145
(3 180)
22 596
(5 080)
12 163
(8 970)
1 587
(1 170)
1 587
(1 170)
28 289
(6 360)
14 145
(3 180)
59 870
(13 460)
9 194
(6 780)
5 221
(3 850)
3 851
(2 840)
3J & 4J 12x10G-15
28 289
(6 360)
14 145
(3 180)
22 818
(5 130)
12 163
(8 970)
1 532
(1 130)
1 532
(1 130)
28 289
(6 360)
14 145
(3 180)
59 870
(13 460)
12 163
(8 970)
12 285
(9 060)
3 851
(2 840)
Pump size
Suction flange
Discharge flange
Forces N (lbf)
Moments Nm (lbf•ft)
Forces N (lbf)
Moments Nm (lbf•ft)
Fxs
Fys
Fzs
Mxs
Mys
Mzs
Fxd
Fyd
Fzd
Mxd
Myd
Mzd
Group 1
-8 896
(-2 000)
1 220.4
(900)
1 627.2
(1 200)
1 695
(1 250)
6 672
(1 500)
-678
(-500)
2 034
(1 500)
1 695
(1 250)
Group 2
-15 568
(-3 500)
1 762.8
(1 300)
1 762.8
(1 300)
4 068
(3 000)
11 120
(2 500)
-1 627
(-1 200)
2 034
(1 500)
4 068
(3 000)
Group 3
-22 240
(-5 000)
2 034
(1 500)
2 712
(2 000)
5 424
(4 000)
13 344
(3 000)
-1 695
(-1 250)
6 780
(5 000)
5 424
(4 000)
Pump size
Suction flange
Discharge flange
Forces N (lbf)
Moments Nm (lbf•ft)
Forces N (lbf)
Moments Nm (lbf•ft)
Fxs
Fys
Fzs
Mxs
Mys
Mzs
Fxd
Fyd
Fzd
Mxd
Myd
Mzd
Group 1
4 670
(1 050)
-5 560
(-1 250)
2 034
(1 500)
1 627
(1 200)
-3 390
(-2 500)
3 558
(800)
8 896
(2 000)
-13 344
(-3 000)
-2 034
(-1 500)
1 356
(1 000)
-3 390
(-2 500)
Group 2
15 568
(3 500)
-6 672
(-1 500)
2 034
(1 500)
1 763
(1 300)
-4 746
(-3 500)
6 227
(1 400)
11 120
(2 500)
-14 456
(-3 250)
-2 034
(-1 500)
2 915
(2 150)
-4 746
(-3 500)
Group 3
15 568
(3 500)
-8 896
(-2 000)
2 034
(1 500)
5 560
(4 100)
-5 424
(-4 000)
6 672
(1 500)
17 792
(4 000)
-15 568
(-3 500)
-2 034
(-1 500)
6 780
(5 000)
-5 424
(-4 000)
Figure 4-13: Maximum combined loading
Figure 4-14: Maximum Y-axis loading for shaft deflection
Figure 4-15: Maximum Z-axis loading for shaft deflection
Page 21 of 52 flowserve.com
Page 22
USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Single seals requiring re-circulation will normally be
provided with the auxiliary piping from the pump
casing already fitted.
Seal housings/covers having an auxiliary quench
connection require connection 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.
Double seals require a barrier liquid between the
seals, compatible with the pumped liquid.
With back-to-back double seals, the barrier liquid
should be at a minimum pressure of 1 bar above the
maximum pressure on the pump side of the inner
seal. The barrier liquid pressure must not exceed
limitations of the seal on the atmospheric side. For
toxic service the barrier liquid supply and discharge
must be in a safe area.
Special seals may require modification to auxiliary
piping described above. Consult 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.
Tandem seals require a barrier liquid between the
seals compatible with the pumped liquid.
4.6.6.2 Packing
When the pump is intended to be equipped with shaft
packing, it is not Flowserve standard practice to
install the packing in the stuffing box prior to
shipment. The packing is shipped with the pump. It
is the pump installer’s responsibility to install the
packing in the stuffing box.
The gland should be adjusted to give a flow rate of 20
to 30 drops per minute for clean fluid. For abrasive
applications, the regulated flow rate should be 0.22 to
0.47 m3/h (1 to 2 US gpm)
Grease lubrication, when compatible with the liquid
being pumped, may be used. In non-abrasive
applications the liquid being pumped may be
sufficient to lubricate the packing without the need for
external lines.
4.6.6.4 Piping connection - Oil mist lubrication
system
The piping connections for an oil mist lubrication
system are shown below.
Oil mist ready housing wet sump
Oil mist ready housing dry sump
Failure to ensure that packing is
installed may result in serious leakage of the pumped
fluid.
4.6.6.3 Piping connection – seal/packing support
system
If the pump has a seal support system
it is mandatory that this system be fully installed and
operational before the pump is started.
Packing lubrication. Water, when compatible with the
4.6.6.5 Piping connection – air bleed line
The 1K3x2GS-7 self-priming pump evacuates the air
from the suction line when it primes. The length of
the line and diameter determine the volume of air and
the time required for priming. Flowserve
recommends that a small air bleed line be fitted from
the discharge piping to the sump if the air is not able
to freely vent out the discharge pipe.
pumpage, should be introduced into the seal gland at
pressure 0.69 to 1.03 bar (10 to 15 psi) above the
stuffing box pressure.
Page 22 of 52 flowserve.com
Page 23
USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Pumped fluid temperature
Set the driver shaft
Up to 93 °C (200 °F)
Equal to the pump shaft
93 °C to 121 °C
(200 °F to 250 °F)
0.13 mm (0.005 in.)
below pump shaft
4.7 Electrical connections
Electrical connections must be made
by a qualified Electrician in accordance with relevant
local national and international regulations.
It is important to be aware of the EUROPEAN
DIRECTIVE on potentially explosive areas where
compliance with IEC60079-14 is an additional
requirement for making electrical connections.
It is important to be aware of the EUROPEAN
DIRECTIVE on electromagnetic compatibility when
wiring up and installing equipment on site. Attention
must be paid to ensure that the techniques used during
wiring/installation do not increase electromagnetic
emissions or decrease the electromagnetic immunity of
the equipment, wiring or any connected devices. If in
any doubt contact Flowserve for advice.
The motor must be wired up in
accordance with the motor manufacturer's
instructions (normally supplied within the terminal
box) including any temperature, earth leakage,
current and other protective devices as appropriate.
The identification nameplate should be checked to
ensure the power supply is appropriate.
A device to provide emergency stopping must
be fitted.
If not supplied pre-wired to the pump unit, the
controller/starter electrical details will also be supplied
within the controller/starter.
See section 5.4, Direction of rotation
before connecting the motor to the electrical supply.
4.8 Final shaft alignment check
a) Level baseplate if appropriate.
b) Mount and level pump if appropriate. Level the
pump by putting a level on the discharge flange.
If not level, adjust the footpiece by adding or
deleting shims from between the footpiece and
the bearing housing.
c) Check initial alignment. If pump and driver have
been remounted or the specifications given below
are not met, perform an initial alignment as
described in section 4.5. This ensures there will
be sufficient clearance between the motor hold
down bolts and motor foot holes to move the
motor into final alignment. The pump and driver
should be within 0.38 mm (0.015 in.) FIM (Full
Indicator Movement) parallel, and 0.0025 mm/mm
(0.0025 in./in.) FIM angular.
Stilt mounted baseplates. If initial alignment
cannot be achieved with the motor fasteners
centered, the baseplate may be twisted. Slightly
adjust (one turn of the adjusting nut) the stilts at
the driver end of the baseplate and check for
alignment to the above tolerances. Repeat as
necessary while maintaining a level condition as
measured from the pump discharge flange.
d) Run piping to the suction and discharge to the
pump. There should be no piping loads
transmitted to the pump after connection is made.
Recheck the alignment to verify that there are no
significant changes.
e) Perform final alignment. Check for soft-foot under
the driver. An indicator placed on the coupling,
reading in the vertical direction, should not indicate
more than 0.05 mm (0.002 in.) movement when
any driver fastener is loosened. Align the driver
first in the vertical direction by shimming
underneath its feet. When satisfactory alignment
is obtained the number of shims in the pack should
be minimized. It is recommended that no more
than five shims be used under any foot. Final
horizontal alignment is made by moving the driver.
Maximum pump reliability is obtained by having
near perfect alignment. Flowserve recommends
no more than 0.05 mm (0.002 in.) parallel, and
0.0005 mm/mm (0.0005 in./in.) angular
misalignment. (See section 6.8.4.7).
f) The pump and motor will normally
have to be aligned at ambient temperature with
an allowance for thermal expansion at operating
temperature. (See chart below) In pump
installations involving high liquid temperatures,
the unit should be run at the actual operating
temperature, shut down and the alignment
checked immediately. See chart below for
recommended offset:
4.9 Protection systems
The following protection systems are
recommended particularly if the pump is installed in a
potentially explosive area or is handling a hazardous
liquid. If in any 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.
Page 23 of 52 flowserve.com
Page 24
USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
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
These operations must be carried
out by fully qualified personnel.
5.1 Pre-commissioning procedure
5.1.1 Pre start-up checks
Prior to starting the pump it is essential that the
following checks be made. These checks are all
described in detail in section 6, Maintenance.
Pump and motor properly secured to the
baseplate
All fasteners tightened to the correct torque
Coupling guard in place and not rubbing
Rotation check. (See section 5.4.)
This is absolutely essential
Impeller clearance setting
Shaft seal properly installed
Seal support system operational
Bearing lubrication
Pump instrumentation is operational
Pump is primed
Rotation of shaft by hand
As a final step, in preparation for operation, it is
important to rotate the shaft by hand to be certain that
all rotating parts move freely, and that there are no
foreign objects in the pump casing.
5.2 Pump lubricants
5.2.1 Oil bath
Oil bath is available on all product lines with the
exception of the In-line pump. The standard bearing
housing bearings are oil bath lubricated and are not
lubricated by Flowserve. Before operating the pump,
fill the bearing housing to the center of the oil sight
glass with the proper type oil. (See figure 5-2 for
approximate amount of oil required - do not overfill.)
On the Mark 3A design, an optional oil slinger is
available. The oil slinger is not necessary; however,
if used, it provides an advantage by allowing a larger
tolerance in acceptable oil level. Without an oil
slinger, the oil level in the bearing housing must be
maintained at ±3 mm (±1/8 in.) from the center of the
sight glass. The sight glass has a 6 mm (¼ in.) hole
in the center of its reflector. The bearing housing oil
level must be within the circumference of the center
hole to ensure adequate lubrication of the bearings.
See figure 5-3 for recommended lubricants.
DO NOT USE DETERGENT OILS.
The oil must be free of water, sediment, resin, soaps,
acid and fillers of any kind. It should contain rust and
oxidation inhibitors. The proper oil viscosity is
determined by the bearing housing operating
temperature as given in figure 5-4.
To add oil to the housing, clean and then remove the
vent plug [6521] at the top of the bearing housing,
pour in oil until it is visually half way up in the sight
glass [3856]. Fill the constant level oiler bottle [3855],
if used, and return it to its position. The correct oil
level is obtained with the constant level oiler in its
lowest position, which results in the oil level being at
the top of the oil inlet pipe nipple, or half way up in
the sight glass window. Oil must be visible in the
bottle at all times.
On ANSI 3A™ power ends there is no
constant level oiler. As stated above, proper oil level
is the center of the “bull’s eye” sight glass [3856].
(See figure 5-1.)
Figure 5-1
In many pumping applications lubricating oil becomes
contaminated before it loses its lubricating qualities or
breaks down. For this reason it is recommended that
the first oil change take place after approximately 160
hours of operation, at which time, the used oil should
be examined carefully for contaminants. During the
initial operating period monitor the bearing housing
operating temperature.
Page 24 of 52 flowserve.com
Page 25
USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Size
Volume
Group 1
250 ml (8.5 oz)
Group 2
950 ml (32 oz)
Group 3
1420 ml (48 oz)
Group 4
1420 ml (48 oz)
Centrifugal pump
lubrication
Oil
Splash lubrication
Oil mist lubrication
Viscosity
mm²/s 40 ºC
32
68
46
Temp. max. ºC (ºF)
65 (149)
80 (176)
-
Designation
according to
DIN51502 ISO VG
HL/HLP 32
HL/HLP 68
HL/HLP 46
Oil companies and lubricants
BP
BP Energol HL32
BP Energol HLP32
BP Energol HL68
BP Energol HLP68
BP Energol HL46
BP Energol HLP46
DEA
Anstron HL32
Anstron HLP32
Anstron HL68
Anstron HLP68
Anstron HL46
Anstron HLP46
Elf
OLNA 32
HYDRELEF 32
TURBELF 32
ELFOLNA DS32
TURBELF SA68
ELFOLNA DS68
TURBELF SA46
ELFOLNA DS46
Esso
TERESSO 32
NUTO H32
TERESSO 68
NUTO H68
TERESSO 46
NUTO H46
Mobil
Mobil DTE oil light
Mobil DTE13
MobilDTE24
Mobil DTE oil heavy medium
Mobil DTE26
Mobil DTE oil medium
Mobil DTE15M
Mobil DTE25
Q8
Q8 Verdi 32
Q8 Haydn 32
Q8 Verdi 68
Q8 Haydn 68
Q8 Verdi 46
Q8 Haydn 46
Shell
Shell Tellus 32
Shell Tellus 37
Shell Tellus 01 C 68
Shell Tellus 01 68
Shell Tellus 01 C 46
Shell Tellus 01 46
Texaco
Rando Oil HD 32
Rando Oil HD-AZ-32
Rando Oil 68
Rando Oil HD C-68
Rando Oil 46
Rando Oil HD B-46
Wintershall
(BASF Group)
Wiolan HN32
Wiolan HS32
Wiolan HN68
Wiolan HS68
Wiolan HN46
Wiolan HS46
Mineral oil
Quality mineral oil with rust and oxidation
inhibitors. Mobil DTE Heavy/Medium (or
equivalent)
Synthetic
Royal Purple or Conoco SYNCON (or
equivalent). Some synthetic lubricants require
Viton O-rings.
Grease
EXXON POLYREX EM (or compatible)
Maximum oil
temperature
ISO viscosity
grade
Minimum
viscosity index
Up to 71 °C (160 °F)
46
95
71 - 80 °C (160 - 175 °F)
68
95
80 - 94 °C (175 - 200 °F)
100
95
Lubrication
Temperature
Oil bath
82 °C (180 °F)
Oil mist
82 °C (180 °F)
Grease
94 °C (200 °F)
Lubricant
Under 71 °C
(160 °F)
71 - 80 °C
(160 - 175 °F)
80 - 94 °C
(175 - 200 °F)
Grease
6 months
3 months
1.5 months
Mineral oil
6 months
3 months
1.5 months
Synthetic oil **
18 months
18 months
18 months
Record the external bearing housing temperature.
(See figure 5-6 for maximum acceptable
temperatures.) The normal oil change interval is
based on temperature and is shown in figure 5-7.
Figure 5-3: Recommended oil lubricants
Figure 5-2: Amount of oil required
Figure 5-4: General lubricant description
Figure 5-5: Oil viscosity grades
Page 25 of 52 flowserve.com
Figure 5-6: Maximum external housing
temperatures
The maximum temperature that the
bearing can be exposed to is 105 °C (220 °F).
Figure 5-7: Lubrication intervals *
* Assuming good maintenance and operation practices, and no
contamination.
** May be increased to 36 months with ANSI 3A™ power end.
Page 26
USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Housing
Initial lube
Relubrication
Group 1 Inboard
Until grease comes out
of plug
7.5 cm
3
(0.46 in.3)
Group 1 Outboard
Until grease comes out
of plug
14 cm
3
(0.85 in.3)
Group 1 Duplex
34 cm3 (2.1 in3)
17 cm
3
(1.0 in.3)
Group 2 Inboard
Until grease comes out
of plug
17 cm
3
(1.0 in.3)
Group 2 Outboard
Until grease comes out
of plug
28 cm
3
(1.7 in.3)
Group 2 Duplex
68 cm3 (4.1 in3)
34 cm
3
(2.1 in.3)
Group 3 and 4
Inboard
Until grease comes out
of plug
30 cm
3
(1.8 in.3)
Group 3 and 4
Outboard
Until grease comes out
of plug
54 cm
3
(3.3 in.3)
Group 3 and 4
Duplex
115 cm3 (7.0 in.3)
60 cm
3
(3.7 in.3)
5.2.2 Grease
5.2.2.1 Regreasable
Single shielded regreasable bearings. When the
grease lubrication option is specified, single shielded
bearings, grease fittings and vent pipe plugs are
installed inboard and outboard.
Figure 5-8: Horizontal pump shield orientation
Horizontal pump bearings are packed with Exxon
POLYREX EM grease prior to assembly. For
relubrication, a grease with the same type base
(polyurea) and oil (mineral) should be used. To
regrease, remove the pipe plug from both the inboard
and outboard bearing location. (See figure 5-9.)
After relubricating the bearings three times, it is
typically recommended that the old grease be
cleaned out of the bearing housing.
Make sure to be electrically grounded
prior to regreasing in an explosive atmosphere. To
regrease bearings under coupling guard, stop pump,
lock the motor, remove coupling guard, and then
regrease the bearings.
Figure 5-9: Regreasable configuration
The amount of grease required for horizontal pumps
is shown in figure 5-10.
Figure 5-10: Horizontal lubrication amounts
Do not fill the housing with oil when
greased bearings are used. The oil will leach the
grease out of the bearings and the life of the bearings
may be drastically reduced.
5.2.2.2 Grease for life
Double shielded or double sealed bearings
These bearings are packed with grease by the
bearing manufacturer and should not be relubricated.
The replacement interval for these bearings is greatly
affected by their operating temperature and speed.
Shielded bearings typically operate cooler.
5.2.3 Oil mist
The inlet port for all horizontal pumps is the plugged
½ in. NPT located at the top of the bearing housing.
A vent fitting has been supplied on the bearing
carrier, as well as a plugged ¼ in. NPT bottom drain
on the bearing housing. (See section 4.6.6.4, Oil mist
lubrication system.) Do not allow oil level to remain
above the center of the bearing housing sight glass
window with purge mist (wet sump) systems.
The optional oil slinger must not be used with an oil
mist system.
5.3 Impeller clearance
Before carrying out this procedure ensure that the
mechanical seal(s) fitted can tolerate a change in
their axial setting, otherwise it will be necessary to
dismantle the unit and reset the seal axial position
after adjusting the impeller clearance.
5.3.1 Final impeller clearance
The open impeller design used by the PolyChem
GRP is set off the casing to achieve the final
operational gap. The impeller clearance was set at
the factory. (See figure 5-11.)
Page 26 of 52 flowserve.com
Page 27
USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Pump frame size
Impeller gap to casing
Group 1 and 2
0.38 mm (0.015 in.)
3J 8x6G-14
0.51 mm (0.020 in.)
3J 12x10G-15 and 4J 12x10G-15B
0.63 mm (0.025 in.)
Pump size
Setting distance
1J1k1½ x 1 x 6
3.22 mm (0.127 in.)
1J3 x 1½ x 6
0.91 mm (0.036 in.)
1J3 x 2 x 6K
13.16 mm (0.518 in.)
1J1½ x 1 x 8
0.91 mm (0.036 in.)
2K3 x 1½ x 8
4.16 mm (0.164 in.)
2K3 x 2 x 8
3.17 mm (0.125 in.)
2K4 x 3 x 8
5.51 mm (0.217 in.)
2K2 x 1 x 10
2.36 mm (0.093 in.)
2K3 x 1½ x 10
15.54 mm (0.612 in.)
2K4 x 3 x 10
15.54 mm (0.612 in.)
2K6 x 4 x 10
11.70 mm (0.461 in.)
2K3 x 1½ x 13
0.79 mm (0.031 in.)
2K4 x 3 x 13
0.79 mm (0.031 in.)
3J8 x 6 x 13
1.57 mm (0.062 in.)
3J12 x 10 x 15
17.45 mm (0.687 in)
4J12 x 10 x 15B
17.45 mm (0.687 in)
Figure 5-11: Final impeller clearance setting
The rotation of bearing carrier from center of one lug
on the bearing carrier to center of next lug results in
axial shaft movement of 0.1 mm (0.004 in.).
5.3.2 Initial impeller setting
Initial impeller clearance is set off the rear cover since
the casing is typically left in the piping during servicing
of the power end and seal. The initial setting is meant
to get the impeller close to the casing so that final
adjustment does not upset the mechanical seal
setting. The tabulated dimension “X” (see fig. 5-12
and 5-13) can be preset during assembly of the power
end prior to installation into the casing.
Figure 5-12: Initial impeller setting
5.4 Direction of rotation
5.4.1 Rotation check
It is absolutely essential that the
rotation of the motor is checked before connecting
the shaft coupling. Incorrect rotation of the pump, for
even a short time, can dislodge and damage the
impeller, casing, shaft and shaft seal. All PolyChem
GRP pumps turn clockwise as viewed from the motor
end. Make sure the motor rotates in the same
direction.
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.
5.4.2 Coupling installation
The coupling (figure 5-14) should be
installed as advised by the coupling manufacturer.
Pumps are shipped without the spacer installed. If
the spacer has been installed to facilitate alignment,
then it must be removed prior to checking rotation.
Remove all protective material from the coupling and
shaft before installing the coupling.
Figure 5-13: Initial impeller back setting “X”
Figure 5-14
5.5 Guarding
Power must never be applied to the
driver when the coupling guard is not installed.
5.5.1 Clam shell guard - standard
The standard coupling guard for all PolyChem pumps is
the “clam shell” design and is shown in figure 5-15. It is
hinged at the top and can be removed by loosening one
of the foot bolts and sliding the support leg out from
under the cap screw. (Note that the foot is slotted).
The leg can then be rotated upward and half of the
guard can be disengaged (unhinged) from the other.
(Note that only one side of the guard needs to be
removed.) To reassemble simply reverse the above
Page 27 of 52 flowserve.com
procedure.
Page 28
USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Figure 5-17: ClearGuard™ trimming
Figure 5-15
Flowserve coupling guards are safety devices intended
to protect workers from inherent dangers of the rotating
pump shaft, motor shaft and coupling. It is intended to
prevent entry of hands, fingers or other body parts into a
point of hazard by reaching through, over, under or
around the guard. No standard coupling guard provides
complete protection from a disintegrating coupling.
Flowserve cannot guarantee their guards will
completely contain an exploding coupling.
The coupling guard shown in figure 5-15 conforms to
the USA standard ASME B15.1, “Safety Standard for
Mechanical Power Transmission Apparatus.”
Flowserve manufacturing facilities worldwide conform
to local coupling guard regulations.
5.5.2 ClearGuard™ - option
Flowserve offers as an option a ClearGuard™ which
allows you to see the condition of the coupling. (See
figure 5-16.) This guard can be used in place of the
existing clamshell guard described above. The
following instructions enable the user to properly fit
this guard to the pump and motor.
Figure 5-16: ClearGuard™
5.5.2.1a Trimming
a) Measure minimum distance from the center of
mounting hole in the baseplate to the motor at
diameter as shown above.
b) Locate a reference center of the slot in the coupling
guard flange. Transfer measurement from step 1 to
the guard using this reference center.
c) Trim the motor end of guard according to the above
measurement. Trimming is best done with a band
saw, but most other types of manual or power saws
give acceptable results. Care must be taken to
ensure that there is no gap larger than 6 mm (0.24
in.) between the motor and the coupling guard.
d) Note - if motor diameter is smaller than the guard
diameter, trim guard so that it extends over the
end of the motor as far as possible.
e) Deburr the trimmed end with a file or a sharp knife.
Care must be taken to eliminate all sharp edges.
5.5.2.1b Assembly
a) Place the bottom and top halves of the
ClearGuard around the coupling.
b) Install the support legs by inserting and then
rotating the top flange of the leg through the slot
in the shell flange until it comes all the way
through and locks the top and bottom together.
c) Attach the support legs to the baseplate using the
fasteners and washers provided.
d) Install fasteners in the holes provided to secure
the guard flanges together.
5.6 Priming and auxiliary supplies
5.5.2.1 Trimming and assembly instructions
In order to correctly fit the pump/motor configuration,
each ClearGuard must be trimmed to a specific
length. This trimming is done on the motor end of the
guard as described below. (See figure 5-17.)
The PolyChem GRP pump will not move liquid unless
the pump is primed. A pump is said to be “primed”
when the casing and the suction piping are
completely filled with liquid.
Open discharge valves a slight amount. This will allow
any entrapped air to escape and will normally allow the
pump to prime if the suction source is above the pump.
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
When a condition exists where the suction pressure
may drop below the pump’s capability, it is advisable
to add a low-pressure control device to shut the pump
down when the pressure drops below a
predetermined minimum.
1K3x2GS-7 unitized self-priming
PolyChem GRP pump
This has a different requirement regarding priming. The
initial priming liquid must be added to the pump casing
until the liquid has reached the bottom of the suction
nozzle. Once the initial prime is in place, the pump will
automatically replenish itself and be self-priming.
The time required to prime can range
from a several seconds to several minutes. If the
fluid being pumped is sensitive to temperature
change, please contact Flowserve engineering to
verify that the temperature increase will not create a
dangerous condition inside the pump casing.
When in service, pumps using inlet pipes with foot
valves may be primed by passing liquid back from the
outlet pipe through the pump.
5.7 Starting the pump
a) Open the suction valve to full open position. It is
very important to leave the suction valve open while
the pump is operating. Any throttling or adjusting of
flow must be done through the discharge valve.
Partially closing the suction valve can create
serious NPSH and pump performance problems.
b) Never operate pump with both the
suction and discharge valves closed. This could
cause an explosion.
c) Ensure the pump is primed. (See section 5.6.)
d) All flush lines must be started and regulated.
e) Start the driver (typically, the electric motor).
f) Slowly open the discharge valve until the desired
flow is reached, keeping in mind the minimum
continuous flow listed in section 3.4.
g) It is important that the discharge
valve be opened within a short interval after
starting the driver. Failure to do this could cause
a dangerous build up of heat, and possibly an
explosion.
5.8 Running or operation
5.8.1 Minimum continuous flow
Minimum continuous stable flow is the lowest flow at
which the pump can operate and still meet the bearing
life, shaft deflection and bearing housing vibration limits
documented in the latest version of ASME B73.1M.
Pumps may be operated at lower flows, but it must be
recognized that the pump may exceed one or more of
these limits. For example, vibration may exceed the
limit set by the ASME standard. The size of the
pump, the energy absorbed, and the liquid pumped
are some of the considerations in determining the
minimum continuous flow (MCF).
The minimum continuous flow (capacity) is
established as a percentage of the best efficiency
point (BEP). (See section 3.4.2.)
5.8.2 Minimum thermal flow
All PolyChem GRP pumps also have a minimum
thermal flow. This is defined as the minimum flow
that will not cause an excessive temperature rise.
Minimum thermal flow is application dependent.
Do not operate the pump below
minimum thermal flow, as this could cause an excessive
temperature rise. Contact a Flowserve Sales Engineer
for determination of minimum thermal flow.
Avoid running a centrifugal pump at drastically reduced
capacities or with discharge valve closed for extended
periods of time. This can cause severe temperature
rise and the liquid in the pump may reach its boiling
point. If this occurs, the mechanical seal will be
exposed to vapor, with no lubrication, and may score or
seize to the stationary parts. Continued running under
these conditions when the suction valve is also closed
can create an explosive condition due to the confined
vapor at high pressure and temperature.
Thermostats may be used to safeguard against over
heating by shutting down the pump at a
predetermined temperature.
Safeguards should also be taken against possible
operation with a closed discharge valve, such as
installing a bypass back to the suction source. The
size of the bypass line and the required bypass flow
rate is a function of the input horsepower and the
allowable temperature rise.
5.8.3 Reduced head
Note that when discharge head drops, the pump’s
flow rate usually increases rapidly. Check motor for
temperature rise as this may cause overload. If
overloading occurs, throttle the discharge.
5.8.4 Surging condition
A rapidly closing discharge valve can cause a
damaging pressure surge. A dampening
arrangement should be provided in the piping.
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Vibration velocity –
unfiltered r.m.s.
Motor 15 kW
mm/s (in./sec)
Motor > 15 kW
mm/s (in./sec)
Normal N
3.0 (0.12)
4.5 (0.18)
Alarm N x 1.25
3.8 (0.15)
5.6 (0.22)
Shutdown trip N x 2.0
6.0 (0.24)
9.0 (0.35)
5.8.5 Operation in sub-freezing conditions
When using the pump in sub-freezing conditions
where the pump is periodically idle, the pump should
be properly drained or protected with thermal devices
which will keep the liquid in the pump from freezing.
5.8.6 Pumps fitted with a 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 pressurized.
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 begin to overheat. If overheating
takes place the pump should be stopped and allowed
to cool 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 ten minutes with steady
leakage and the gland nuts tightened by 10 degrees at a
time until leakage is reduced to an acceptable level,
normally 30 to 120 drops per minute. Bedding in of the
packing may take another 15 minutes.
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.
Never run gland packing dry, even for
a short time.
5.8.7 Bearing monitoring
If the pumps are working in a potentially
explosive atmosphere temperature or vibration
monitoring at the bearings 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 stabilized.
Record the bearing temperature (t) and the
ambient temperature (ta)
Estimate the likely maximum ambient
temperature (tb)
Set the alarm at (t+tb-ta+5) ºC ((t+tb-ta+10) ºF)
and the trip at 100 ºC (212 ºF) for oil lubrication
and 105 ºC (220 ºF) for grease lubrication.
It is important, particularly with grease lubrication, to
keep a check on bearing temperatures. After start up
the temperature rise should be gradual, reaching a
maximum after approximately 1.5 to 2 hours. This
temperature rise should then remain constant or
marginally reduce with time.
5.8.8 Normal vibration levels, alarm and trip
For guidance, pumps generally fall under a classification
for rigid support machines within the International
rotating machinery standards and the recommended
maximum levels below are based on those standards.
Alarm and trip values for installed
pumps should be based on the actual measurements
(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.
5.9 Stopping and shutdown
5.9.1 Shutdown considerations
When the pump is being shut down, the procedure
should be the reverse of the start-up procedure.
a) Slowly close the discharge valve
b) Shut down the driver, and then close the suction
valve to isolate the pump if necessary.
Remember that closing the
suction valve while the pump is running is a
safety hazard and could seriously damage the
pump and other equipment.
c) Switch off flushing liquid supplies at a time
appropriate to the process.
d) For prolonged shut-downs and
especially when ambient temperatures are likely
to drop below freezing point, the pump and any
and flushing arrangements must be drained or
otherwise protected.
5.10 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 decide
how to evaluate the implications of any change. If in
doubt contact your nearest Flowserve office.
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
5.10.1 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.
5.10.2 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
NPSHR by the suggested margin will greatly enhance
pump performance and reliability. It will also reduce
the likelihood of cavitation, which can severely
damage the pump.
5.10.5 Pumped flow
Flow must not fall outside the minimum and
maximum continuous safe flow shown on the pump
performance curve and or data sheet.
6 MAINTENANCE
6.1 General
Ensuring that NPSHA is larger than
checks are made with your nearest Flowserve office if
changes in viscosity are planned.
5.10.3 Pump speed
Changing pump speed effects flow, total head, power
absorbed, NPSHR, noise and vibration. Flow varies in
direct proportion to 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.
5.10.4 Net positive suction head (NPSH)
Net positive suction head - available (NPSHA) is the
measure of the energy in a liquid above the vapor
pressure. It is used to determine the likelihood that a
fluid will vaporize in the pump. It is critical because a
centrifugal pump is designed to pump a liquid, not a
vapor. Vaporization in a pump will result in damage
to the pump, deterioration of the Total differential
head (TDH), and possibly a complete stopping of
pumping.
Net positive suction head - required (NPSHR) is the
decrease of fluid energy between the inlet of the
pump, and the point of lowest pressure in the pump.
This decrease occurs because of friction losses and
fluid accelerations in the inlet region of the pump and
particularly accelerations as the fluid enters the
impeller vanes. The value for NPSHR for the specific
pump purchased is given in the pump data sheet, and
on the pump performance curve.
For a pump to operate properly the NPSHA must be
greater than the NPSHR. Good practice dictates that
this margin should be at least 1.5 m (5 ft) or 20%,
whichever is greater.
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 5.9.
On completion of work all guards and safety devices
must be re-installed and made operative again.
Before restarting the machine, the relevant
instructions listed in section 5, Commissioning, start
up, operation and shut down, must be observed.
Oil and grease leaks may make the ground
slippery. Machine maintenance must always
begin and finish by cleaning the ground and the
exterior of the machine.
If platforms, stairs and guard rails are required for
maintenance, they must be placed for easy access to
areas where maintenance and inspection are to be
carried out. The positioning of these accessories
must not limit access or hinder the lifting of the part to
be serviced.
When air or compressed inert gas is used in the
maintenance process, the operator and anyone in the
vicinity must be careful and have the appropriate
protection.
Do not spray air or compressed inert gas on skin.
Do not direct an air or gas jet towards other people.
Never use air or compressed inert gas to clean clothes.
Page 31 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
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
open 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.
Refer to the parts list shown in section 8 for item
number references used throughout this section.
6.2 Maintenance schedule
It is recommended that a maintenance plan
and schedule is adopted, in line with these User
Instructions, to include the following:
a) Any auxiliary systems installed must be monitored,
if necessary, to ensure they function correctly.
b) Gland packings 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 leaks from gaskets and seals.
The correct functioning of the shaft seal must be
checked regularly.
d) Check bearing lubricant level, and if the hours
run show a lubricant change is required.
e) Check that the duty condition is in the safe
operating range for the pump.
f) Check vibration, noise level and surface temperature
at the bearings to confirm satisfactory operation.
g) Check dirt and dust is removed from areas around
close clearances, bearing housings and motors.
h) Check coupling alignment and re-align if necessary.
Our specialist 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.
6.2.1 Preventive maintenance
The following sections of this manual give instructions
on how to perform a complete maintenance overhaul.
However, it is also important to periodically repeat the
Pre start-up checks listed in section 5.1. These
checks will help extend pump life as well as the
length of time between major overhauls.
6.2.2 Need for maintenance records
A procedure for keeping accurate maintenance
records is a critical part of any program to improve
pump reliability. There are many variables that can
contribute to pump failures. Often long term and
repetitive problems can only be solved by analyzing
these variables through pump maintenance records.
6.2.3 Cleanliness
One of the major causes of pump failure is the
presence of contaminants in the bearing housing. This
contamination can be in the form of moisture, dust, dirt
and other solid particles such as metal chips.
Contamination can also be harmful to the mechanical
seal (especially the seal faces), as well as other parts
of the pump. For example, dirt in the impeller threads
could cause the impeller to not be seated properly
against the shaft. This, in turn, could cause a series
of other problems. For these reasons, it is very
important that proper cleanliness be maintained.
Some guidelines are listed below.
After draining the oil from the bearing housing,
periodically send it out for analysis. (If it is
contaminated, determine the cause and correct.)
The work area should be clean and free from
dust, dirt, oil, grease etc.
Hands and gloves should be clean.
Only clean towels, rags, and tools should be used.
6.3 Spare parts
The decision on what spare parts to stock varies
greatly depending on many factors such as the
criticality of the application, the time required to buy
and receive new spares, the erosive/corrosive nature
of the application, and the cost of the spare part.
Section 8 identifies all of the components that make
up each pump addressed in this manual.
6.3.1 Ordering of spares
Flowserve keeps records of all pumps that have been
supplied. Spare parts can be ordered from your local
Flowserve Sales Engineer or from a Flowserve
Distributor or Representative.
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Item
Description
Group 1
Non-lubricated
Group 2
Non-lubricated
Group 3
Non-lubricated
n/a
Suction and discharge flange bolting
41 Nm (30 lbf•ft)
41 Nm (30 lbf•ft)
41 Nm (30 lbf•ft)
[6570.2]
Bearing retainer cap screws
3
/16 in. - 6 Nm (4 lbf•ft)
3
/16 in. - 6 Nm (4 lbf•ft)
5
/16 in. - 16 Nm (12 lbf•ft)
[6570.6]
Bearing housing to adapter cap screws
n/a
½ in - 54 Nm (40 lbf•ft)
⅝in - 122 Nm (90 lbf•ft)
[6580.2]
Seal gland nuts
7 Nm (5 lbf•ft)
14 Nm (10 lbf•ft)
14 Nm (10 lbf•ft)
[3712.2]
Impeller nut, polygon drive
27 Nm (20 lbf•ft)
48 Nm (35 lbf•ft)
48 Nm (35 lbf•ft)
[6570.1]
Casing-to-cover bolting
14 Nm (10 lbf•ft)
14 Nm (10 lbf•ft)
14 Nm (10 lbf•ft)
[2912]
Impeller nose cone nut – non-metallic
3 Nm (2 lbf•ft)
3 Nm (2 lbf•ft)
n/a
[6570.3]
Bearing carrier set screws
⅜in. - 16 Nm (12 lbf•ft)
½ in. - 41 Nm (30 lbf•ft)
½ in. - 41 Nm (30 lbf•ft)
6570.5]
Rear foot cap screw
½ in. - 54 Nm (40 lbf•ft)
¾ in. - 217 Nm (160 lbf•ft)
1 in. - 300 Nm (228 lbf•ft)
[6570]
Cap screws – all other with GRP contact
20 Nm (15 lbf•ft)
20 Nm (15 lbf•ft)
20 Nm (15 lbf•ft)
When ordering spare parts the following information
should be supplied:
1) Pump serial number.
2) Pump size.
3) Part name – taken from section 8.
4) Part number – taken from section 8.
5) Number of parts required.
The pump size and serial number can be found on
the name plate located on the bearing housing. (See
figure 3-1.)
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.
6.3.2 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 at 6 monthly intervals.
6.4 Recommended spares and
consumable items
Recommended spares include: mechanical process
fluid seals, bearing housing lip seals, bearings,
shafting, impeller, and gaskets.
6.6 Fastener torques
Figure 6-2: Recommended bolt torques - ISO (US)
6.5 Tools required
A typical range of tools that will be required to
maintain these pumps is listed below.
Standard hand tools:
Hand wrenches
Socket spanners (wrenches)
Allen keys (wrenches)
Range of screwdrivers
Soft mallet
More specialized equipment:
Bearing pullers
Bearing induction heater
Dial test indicator
Flowserve Mark 3 tool kit. (See 6.1 below.)
Figure 6-1: Flowserve Mark 3 tool kit
Note: 1.) For lubricated threads, use 75 % of the values given.
2.) Gasket joint torque values are for Aflas or 60 - 70 durometer Viton gaskets. Other gasket materials may require additional torque
to seal. Exceeding metal joint torque values is not recommended.
Page 33 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
FIGURE 6-5
Rotation equivalent to 0.1 mm
(0.004 in) axial movement
Indicator
pattern
6.7 Setting impeller clearance
A new impeller gasket [4590] must be installed
whenever the impeller has been removed from the
shaft. (Impeller clearance settings are in section 5.3.)
6.7.1 Initial clearance setting for PolyChem GRP
pumps
Install the impeller [2200] by screwing it onto the shaft
until it firmly seats against the shaft shoulder.
The impeller could have sharp edges
which could cause an injury. It is very important to
wear heavy gloves.
Tighten the impeller with the impeller wrench from the
Flowserve Mark 3 tool kit. To do this, grasp the
impeller in both hands and, with the impeller wrench
handle to the left (viewed from the impeller end of the
shaft) spin the impeller forcefully in a clockwise
direction to impact the impeller wrench handle on the
work surface to the right. (See figure 6-3.)
Lastly, uniformly tighten the set screws
[6570.3] in incremental steps up to the final torque
value to lock the bearing carrier in place.
Figure 6-5
Do not attempt to tighten the impeller
on the shaft by hitting the impeller with a hammer or
any other object or by inserting a pry bar between the
impeller vanes. Serious damage to the impeller may
result from such actions.
Figure 6-3
Now set the initial impeller clearance by loosening the
set screws [6570.3] and rotating the bearing carrier
[3240] to obtain the proper clearance. Turn the bearing
carrier counter-clockwise to move the impeller towards
the rear cover and clockwise to move it away. Use a
scale, caliper, or depth gage to measure from the rear
cover to the impeller as shown in figure 5-12. Refer to
the charted values in figure 5-13 for the proper initial
impeller clearance as shown in figure 5-12. Rotating
the bearing carrier the width of one of the indicator
patterns cast into the bearing carrier moves the impeller
axially 0.1 mm (0.004 in.). (See figure 6-5.)
Tightening the set screws [6570.3] will cause the
impeller to move 0.05 mm (0.002 in.) closer to the
rear cover because of the internal looseness in the
bearing carrier threads. This must be considered
when setting the impeller clearance.
Figure 6-6
Example: First, measure the initial distance “X” as
shown in figure 5-12. To determine the number of
indicator patterns that you will need to rotate the carrier,
divide 0.10 (for mm or 0.004 for in.) into the desired
setting. Flowserve suggests that a felt tip pen be used
to mark an initial reference point on the bearing housing
and the bearing carrier as shown in figure 6-6.
Then make a second mark on the bearing carrier the
required number of indicator patterns from the initial
reference point. Rotate the bearing carrier until the
second mark on the bearing carrier lines up with the
initial reference point mark on the bearing housing.
Tighten the set screws [6570.3] in incremental steps
to lock the bearing carrier in place. The impeller is
now set relatively close to its final location. The seal
can now be set.
6.7.2 Final clearance setting
Like all front vane semi-open style impellers, the final
PGRP open impeller clearance must be set off the
casing. The casing must be installed to accurately
set the impeller clearance.
Attach the power end/rear cover/impeller assembly to
the casing. Now set the impeller clearance by
loosening the set screws [6570.3] and rotating the
bearing carrier [3240] to obtain the proper clearance.
Turn the bearing carrier clockwise until the impeller
comes into light rubbing contact with the casing.
Rotating the shaft at the same time will accurately
determine this zero setting.
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Pump size
Impeller fixing
1J1.5 x 1G - 6
Polygon
1J3 x 1.5G - 6
Threaded
1J3 x 2G - 6K
Polygon
1K3 x 2GS - 7
Threaded
1J1.5 x 1G - 8
Polygon
2K3 x 1.5G - 8
Polygon
2K3 x 2G - 8
Threaded
2K4 x 3G - 8
Polygon
2K2 x 1G - 10
Threaded
2K3 x 1.5G - 10
Polygon
2K4 x 3G - 10
Polygon
2K6 x 4G - 10
Polygon
2K3 x 1.5G - 13
Threaded
2K4 x 3G - 13
Threaded
3J8 x 6G - 13
Threaded
3J12 x 10G – 15
Threaded
4J12 x 10G – 15B
Threaded
Now, rotate the bearing carrier counter-clockwise to
get the proper clearance. Refer to figure 5-11 for the
proper impeller clearance. Rotating the bearing carrier
the width of one of the indicator patterns cast into the
bearing carrier moves the impeller axially 0.1 mm
(0.004 in.). (See figure 6-5.)
Determine how far to rotate the bearing carrier by
dividing the desired impeller clearance by 0.1 mm
(0.004 in.) (one indicator pattern). Tightening the set
screws [6570.3] will cause the impeller to move
0.05 mm (0.002 in.) away from the casing because of
the internal looseness in the bearing carrier threads.
This must be considered when setting the impeller
clearance. Rotate the bearing carrier counterclockwise the required amount to get the desired
clearance to the casing.
Lastly, uniformly tighten the set screws
[6570.3] in incremental steps up to the final torque
value to lock the bearing carrier in place.
See section 5.3 for impeller clearance settings.
6.8 Disassembly
6.8.1 Power end removal
a) Before performing any maintenance, disconnect the
driver from its power supply and lock it off line.
Lock out power to driver to
prevent personal injury.
b) Close the discharge and suction valves, and
drain all liquid from the pump.
c) Close all valves on auxiliary equipment and
piping, then disconnect all auxiliary piping.
d) Decontaminate the pump as necessary.
If Flowserve PolyChem pumps
contain dangerous chemicals, it is important to
follow plant safety guidelines to avoid personal
injury or death.
e) Remove the coupling guard. (See section 5.5.)
f) Remove the spacer from the coupling.
g) Remove casing fasteners [6570.1].
h) Remove the fasteners holding the bearing
housing foot to the baseplate.
i) Move the power end, rear cover, and impeller
assembly away from the casing. Discard the
casing/cover O-ring [4610.1].
The power end and rear cover
assembly is heavy. It is important to follow plant
safety guidelines when lifting it.
Figure 6-7
6.8.2 Impeller removal
a) Remove the coupling hub from the pump shaft
[2100].
Do not apply heat to the impeller.
If liquid is entrapped in the hub, an explosion
could occur.
b) Threaded impellers. (See fig ure 6-7 and 6-8.) Use
a shaft key [6700] and mount the impeller wrench
from the Flowserve Mark 3 tool kit (figure
6-1) to the end of the shaft. With the wrench handle
pointing to the left when viewed from the impeller
end, grasp the impeller [2200] firmly with both
hands (wear heavy gloves). By turning the impeller
in the clockwise direction move the wrench handle
to the 11:00 o’clock position and then spin the
impeller quickly in a counter-clockwise direction so
that the wrench makes a sudden impact with a hard
surface on the bench. After several sharp raps, the
impeller should be free. Unscrew the impeller and
remove from the shaft. Discard the impeller-tosleeve gasket [4590.3].
c) Polygon drive impellers. (See figure 6-7.)
Unscrew impeller nose cone nut [2912] and
remove impeller nose cone nut gasket [4590.4].
d) Unscrew impeller stud [2913.1] on Group 1 units,
or impeller locknut [3712.2] and washer [6541.6]
on Group 2 units.
e) Rotate the bearing carrier [3240] counter clockwise
until the impeller makes contact with the rear cover
[1220]. Further rotation will completely loosen the
impeller from the shaft [2100].
f) Remove the impeller-to-sleeve gasket [4590.3].
g) If a cartridge type mechanical seal [153] is used
(see figure 6-9), the spacing clips or tabs should
be installed prior to loosening the set screws
which attach the seal to the shaft and before
removing it from the cover. This will ensure that
the proper seal compression is maintained.
Page 35 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
h) Remove the seal or packing gland nuts [6580.2] if
so equipped.
Figure 6-8
Figure 6-9
6.8.3 Removing the rear cover and seal
a) Remove the cover bolts [6570.4] and lockwashers
[6541.3] from the bearing housing [3200] (on Group
1 units) or support head [1340] and remove the
cover. Sizes 2K3x1.5G-10, 2K4x3G-10 and
2K6x4G-10 do not have bolts so remove the nuts
and eccentric washers instead, but there is no need
to remove the studs. (See figure 6-10.)
Figure 6-11
e) If a component type outside mechanical seal is
used, remove the gland and the stationary seat.
Remove the stationary seat from the gland.
Loosen the set screws in the rotating unit and
remove it from the shaft. Discard all O-rings and
gaskets.
f) If packing [4130] is used, remove it and the seal
cage [4134]. Remove the gland [4120].
g) The shaft sleeve [2400] can now be removed.
Unit now appears as shown in figure 6-12.
Figure 6-12
6.8.4 Power end disassembly
a) If the power end is oil lubricated, remove the
drain plug [6569] and drain the oil from the
bearing housing [3200].
b) If the pump has lip seals, a deflector [2540] may
be present. Slide it off the shaft.
c) Loosen the three set screws [6570.3] on the
bearing carrier [3240]. The bearing carrier must be
completely unscrewed from the bearing housing.
Figure 6-10
b) Remove the shaft sleeve [2400], gland [4120],
and seal [4200].
c) Remove cover nose gasket [4590.1] (or gland to
cover gasket on Group 3) together with the gland
[4120] and sleeve-to-shaft O-ring [4610.4]
(Groups 1 and 2).
d) If a component type inside mechanical seal [153]
is used, loosen the set screws on the rotating unit
and remove it from the shaft (see figure 6-11).
Then pull the gland [4120] and stationary seat off
the shaft. Remove the stationary seat from the
gland. Discard all O-rings and gaskets.
Mark 3A and ANSI 3A design. The face of the
bearing carrier has three square lugs that protrude
from the surface. The bearing carrier is turned by
using an open end wrench on one of the square
lugs as shown in figure 6-13. Because the O-rings
[4610.2] will cause some resistance in removing
the bearing carrier assembly from the housing,
hold the bearing carrier flange firmly and with
slight rotation, pull it out of the bearing housing.
The bearing carrier assembly with the shaft and
bearings should come free.
Do not pry against the shaft.
Page 36 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
This unit will appear as shown in figure 6-14.
Further disassembly is not required unless the
bearings are to be replaced.
Figure 6-13
Figure 6-14
d) Remove the snap ring [2530.1] (figure 6-15) on
Group 1 and 2 pumps, or the bearing retainer
[2530.2] on Group 3 pumps.
h) On Group 2 and 3 pumps, the bearing housing
[3200] must be separated from the bearing
housing adapter [1340]. The adapter O-ring
[4610.3] should be discarded.
Mark 3A and ANSI 3A design. This is
accomplished by removing the cap screws
[6570.6], which thread into the bearing housing.
i) If lip seals [4310.1 and 4310.2] (figure 6-16) are
used, they should be removed from the bearing
carrier and adapter and discarded.
Figure 6-16
j) If the bearing isolators are removed from either
the bearing carrier or adapter they must not be
reused, discard appropriately.
k) If magnetic seals are used, maintain the seals as
specified by the manufacturer.
l) Remove site gage, oil level tag and oiler (if used).
Mark 3A design. Remove the Trico oiler/site
gage [3855] (figure 6-17) and oil level tag (figure
6-18) from the bearing housing.
ANSI 3A design. Remove the site gage [3856]
(figure 5-1) and oil level tag (figure 6-18) from the
bearing housing. Save these parts for reuse.
Figure 6-15
Group 1 and 2 pumps equipped with
duplex angular contact bearings use a bearing
retainer [2530.2] instead of the snap ring.
Remove the carrier from the bearing.
e) The bearing locknut [3712.1] and lockwasher
[6541.1] may now be removed from the shaft
[2100]. Discard the lockwasher.
f) An arbor or hydraulic press may be used to
remove the bearings [3011 and 3013] from the
shaft. It is extremely important to apply even
pressure to the inner bearing race only. Never
apply pressure to the outer race as this exerts
excess load on the balls and causes damage.
Applying pressure to the outer
race could permanently damage the bearings.
g) The Mark 3A design has an optional oil slinger
[2541] located between the bearings. If present,
inspect it for damage or looseness. Remove if it
needs to be replaced.
Page 37 of 52 flowserve.com
Figure 6-17
Figure 6-18
Page 38
USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Topic
ASME
B73.5M
Standard
mm (in.)
Suggested
by major
seal vendors
mm (in.)
Suggested and
or provided by
Flowserve
mm (in.)
Shaft
Diameter tolerance,
under bearings
N.S.
0.005 (0.0002)
Impeller
Balance
See note 1
Bearing housing
Diameter (ID) tolerance
at bearings
N.S.
0.013 (0.0005)
Power end assembly
Shaft runout
Shaft sleeve runout
Radial deflection - static
Shaft endplay
0.05 (0.002)
0.05 (0.002)
N.S.
N.S.
0.03 (0.001)
0.05 (0.002)
0.076 (0.003)
0.05 (0.002)
0.05 (0.002)
0.05 (0.002)
0.05 (0.002)
Seal chamber
Face squareness to shaft
Register concentricity
0.08 (0.003)
0.03 (0.001)
0.13 (0.005)
0.08 (0.003)
0.13 (0.005)
Complete pump
Shaft movement caused by
pipe strain
Alignment
Vibration at bearing housing
N.S.
N.S.
See note3
0.05 (0.002)
0.05 (0.002)
See note 2
See note 3
Group 1
Group 2
Group 3
OB bearing/
shaft
mm (in.)
Bearing
30.000/29.990
(1.1811/1.1807)
50.000/49.987
(1.9685/1.9680)
70.000/69.985
(2.7559/2.7553)
Shaft
30.013/30.003
(1.1816/1.1812)
50.013/50.003
(1.9690/1.9686)
70.015/70.002
(2.7565/2.7560)
Fit
0.023T/0.003T
(0.0009T/0.0001T)
0.026T/0.003T
(0.0010T/0.0001T)
0.030T/0.002T
(0.0012T/0.0001T)
IB bearing/
shaft
mm (in.)
Bearing
35.000/34.989
(1.3780/1.3775)
50.000/49.987
(1.9685/1.9680)
70.000/69.985
(2.7559/2.7553)
Shaft
35.014/35.004
(1.3785/1.3781)
50.013/50.003
(1.9690/1.9686)
70.015/70.002
(2.7565/2.7560)
Fit
0.025T/0.004T
(0.0010T/0.0001T)
0.026T/0.003T
(0.0010T/0.0001T)
0.030T/0.002T
(0.0012T/0.0001T)
6.9 Examination of parts
6.9.1 Cleaning/inspection
All parts should now be thoroughly cleaned and
inspected. New bearings, O-rings, gaskets, and lip
seals should be used. Any parts that show wear or
corrosion should be replaced with new genuine
Flowserve parts.
It is important that only nonflammable, non-contaminated cleaning fluids are
used. These fluids must comply with plant safety and
environmental guidelines. Aggressive solvents may
damage the GRP material.
6.9.2 Critical measurements and tolerances
To maximize reliability of pumps, it is important that
certain parameters and dimensions are measured
and maintained within specified tolerances. It is
important that all parts be checked. Any parts that do
not conform to the specifications should be replaced
with new Flowserve parts.
6.9.3 Parameters that should be checked by users
Flowserve recommends that the user check the
measurements and tolerances in figure 6-19
whenever pump maintenance is performed. Each of
these measurements is described in more detail on
the following pages.
6.9.4 Additional parameters checked by
Flowserve
The parameters listed below are somewhat more
difficult to measure and or may require specialized
equipment. For this reason, they are not typically
checked by our customers, although they are
monitored by Flowserve during the manufacturing
and or design process.
6.9.4.1 Shaft and sleeve (if fitted)
Replace if grooved, pitted or worn. Prior to mounting
bearings or installing the shaft into the bearing
housing, check the following parameters.
Diameter/tolerance, under bearings
In order to ensure proper fit between the shaft and
bearings, verify that both the inboard (IB) and
outboard (OB) shaft diameter is consistently within
the minimum/maximum values shown in figure 6-20.
A micrometer should be used to check these outside
diameter (OD) dimensions on the shaft.
6.9.4.2 Bearings
It is recommended that bearings not be re-used after
removal from the shaft. Prior to mounting bearings,
check the following parameters.
Figure 6-19
N.S. = not specified.
Notes.
1) The maximum values of acceptable unbalance are:
1 500 r/min: 40 g•mm/kg (1 800 r/min: 0.021 oz•in./lb.) of mass.
2 900 r/min: 20 g•mm/kg (3 600 r/min: 0.011 oz•in./lb.) of mass.
The PolyChem GRP impellers conform to the ISO 1940 Grade
6.3 tolerance criteria as molded and do not require balancing.
2) The ASME B73.5M standard does not specify a recommended
level of alignment. Flowserve recommends that the pump and
motor shafts be aligned to within 0.05 mm (0.002 in.) parallel FIM
(full indicator movement) and 0.0005 mm/mm (0.0005 in./in.)
angular FIM. Closer alignment will extend MTBPM. For a detailed
discussion of this subject see the Alignment section of this manual.
3) The ASME B73.5M, paragraph 5.1.3.
Figure 6-20
Diameter/tolerance, inside diameter
In order to ensure proper fit between bearings and
the shaft, verify that the inside diameter (ID) of both
the IB and OB bearing are consistently within the
minimum/maximum values shown in figure 6-20. An
inside caliper should be used to check these ID
diameters on the bearings.
Page 38 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Group 1
Group 2
Group 3
OB
bearing/
carrier
mm (in.)
Bearing
71.999/71.986
(2.8346/2.8341)
110.000/109.985
(4.3307/4.3301)
150.000/149.979
(5.9055/5.9047)
Carrier
71.999/72.017
(2.8346/2.8353)
110.007/110.022
(4.3310/4.3316)
150.002/150.030
(5.9056/5.9067)
Fit
0.031L/0.000L
(0.0012L/0.0000L)
0.037L/0.007L
(0.0015/0.0003L)
0.051L/0.002L
(0.0020L/0.0001L)
IB
bearing/
housing
mm (in.)
Bearing
71.999/71.986
(2.8346/2.8341)
110.000/109.985
(4.3307/4.3301)
150.000/149.979
(5.9055/5.9047)
Housing
71.999/72.017
(2.8346/2.8353)
110.007/110.022
(4.3310/4.3316)
150.007/150.025
(5.9058/5.9065)
Fit
0.031L/0.000L
(0.0012L/0.0000L)
0.037L/0.007L
(0.0015L/0.0003L)
0.046L/0.007L
(0.0018L/0.0003L)
Diameter/tolerance, outside diameter
In order to ensure proper fit between bearings and
the bearing housing, verify that the OD on both the IB
and OB bearings are consistently within the
minimum/maximum values shown in figure 6-21. A
micrometer should be used to check these outside
diameter (OD) dimensions on the bearings.
6.9.4.3 Impeller balancing
Shaft whip is deflection where the centerline of the
impeller is moving around the true axis of the pump.
It is not caused by hydraulic force but rather by an
imbalance with the rotating element. Shaft whip is
very hard on the mechanical seal because the faces
must flex with each revolution in order to maintain
contact. To minimize shaft whip it is imperative that
the impeller is balanced. All impellers manufactured
by Flowserve are balanced after they are trimmed. If
for any reason, a customer trims an impeller, it must
be re-balanced. See note 1 under figure 6-19
regarding acceptance criteria.
6.9.4.4 Bearing housing and carrier
Prior to installing the shaft into the bearing housing,
check the following parameters.
Diameter/tolerance, at bearing surface
In order to ensure proper fit between the bearing
housing/carrier and the bearings, verify that the ID of
both the IB and OB bearing surfaces are consistently
within the minimum/maximum values shown in figure
6-21. An inside caliper should be used to check
these ID dimensions in the bearing housing.
6.9.4.5 Power end
Assembled bearing housing, carrier, bearings, and
shaft.
Shaft and shaft sleeve run-out
Shaft run-out is the amount the shaft is “out of true”
when rotated in the pump. It is measured by attaching a
dial indicator to a stationary part of the pump so that its
contact point indicates the radial movement of the shaft
surface as the shaft is rotated slowly. If a shaft sleeve is
used then shaft sleeve run-out must be checked. It is
analogous to shaft run-out. Measurement of shaft runout/shaft sleeve run-out will disclose any out of
roundness of the shaft, any eccentricity between the
shaft and the sleeve, any permanent bend in the shaft,
and or any eccentricity in the way the shaft or bearings
are mounted in the bearing housing.
Shaft run-out can shorten the life of the bearings and
the mechanical seal.
Figure 6-21
The following diagram shows how to measure shaft/shaft
sleeve run-out. Note that both ends need to be checked.
The run-out should be 0.025 mm (0.001 in.) FIM or less.
Runout
Radial deflection - static
Radial movement of the shaft can be caused by a loose
fit between the shaft and the bearing and/or the bearing
and the housing. This movement is measured by
attempting to displace the shaft vertically by applying an
upward force of approximately 4.5 kg (10 lb) to the
impeller end of the shaft. While applying this force, the
movement of an indicator is observed as shown in the
following diagram. The movement should be checked
at a point as near as possible to the location of the seal
faces. A movement of more than 0.05 mm (0.002 in.) is
not acceptable.
Deflection
Shaft endplay
The maximum amount of axial shaft movement, or
endplay, on a Durco pump should be 0.03 mm
(0.001 in.) and is measured as shown below.
Observe indicator movement while tapping the shaft
from each end in turn with a soft mallet. Shaft
endplay can cause several problems. It can cause
fretting or wear at the point of contact between the
shaft and the secondary sealing element. It can also
cause seal overloading or underloading and possibly
chipping of the seal faces. It can also cause the
faces to separate if significant axial vibration occurs.
Page 39 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Many companies today are using laser alignment
which is a more sophisticated and accurate
technique. This method uses a laser and sensor to
measure misalignment. This is fed to a computer
with a graphic display that shows the required
adjustment side-to-side and shim stock for each of
Endplay
6.9.4.6 Seal chamber
Assembled power end and rear cover are checked for
face squareness to shaft and register concentricity as
in figure 6-19.
6.9.4.7 Installed pump
Measurements with the complete pump installed.
Shaft movement caused by pipe strain
Pipe strain is any force put on the pump casing by the
piping. Pipe strain should be measured as shown
below. Install the indicators as shown before attaching
the piping to the pump. The suction and discharge
flanges should now be bolted to the piping separately
while continuously observing the indicators. Indicator
movement should not exceed 0.05 mm (0.002 in.).
the motor feet to achieve near-perfect alignment.
See section 4.8 for recommended final shaft
alignment limits.
Vibration analysis
Vibration analysis is a type of condition monitoring
where a pump’s vibration “signature” is monitored on
a regular, periodic basis. The primary goal of
vibration analysis is extension on MTBPM. By using
this tool Flowserve can often determine not only the
existence of a problem before it becomes serious, but
also the root cause and possible solution.
Modern vibration analysis equipment not only detects
if a vibration problem exists, but can also suggest the
cause of the problem. On a centrifugal pump, these
causes can include the following: unbalance,
misalignment, defective bearings, resonance,
hydraulic forces, cavitation and recirculation. Once
identified, the problem can be corrected, leading to
increased MTBPM for the pump.
Flowserve does not make vibration analysis
Pipe strain movement
Alignment
Misalignment of the pump and motor shafts can
cause the following problems:
Failure of the mechanical seal
Failure of the motor and/or pump bearings
Failure of the coupling
Excessive vibration/noise
The schematics below show the technique for a
typical rim and face alignment using a dial indicator.
It is important that this alignment be done after the
flanges are loaded, and at typical operating
temperatures. If proper alignment cannot be
maintained a C-flange motor adapter and or
stilt/spring mounting should be considered.
equipment, however Flowserve strongly urges
customers to work with an equipment supplier or
consultant to establish an on-going vibration analysis
program. See note 3 under figure 6-19 regarding
acceptance criteria.
6.10 Assembly of pump and seal
It is important that all pipe threads be
sealed properly. PTFE tape provides a very reliable
seal over a wide range of fluids, but it has a serious
shortcoming if not installed properly. If, during
application to the threads, the tape is wrapped over the
end of the male thread, strings of the tape will be formed
off when threaded into the female fitting. These strings
can then tear away and lodge in the piping system.
If this occurs in the seal flush system, small orifices
can become blocked effectively shutting off flow. For
this reason, Flowserve does not recommend the use
of PTFE tape as a thread sealant. Flowserve has
investigated and tested alternate sealants and has
identified two that provide an effective seal, have the
same chemical resistance as the tape, and will not
plug flush systems. These are La-co Slic-Tite and
Alignment
Bakerseal.
Page 40 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Group
Type of bearing
Inboard single row,
deep groove 5
Outboard double row, angular
contact, deep groove
5 & 9
Optional outboard duplex
angular contact 5
1
Oil bath/mist - open 1
6207-C3
5306-AC3 or 3306-AC3
7306-BECBY
Regreasable - single shielded 2
6207-ZC3
5306-AZC3 or 3306-AZC3
NA6
Greased for life - double shielded 3
6207-2ZC3
5306-A2ZC3 or 3306-A2ZC3
NA7
Sealed for life - double sealed 4
6207-2RS1C3
5306-A2RSC3 or 3306-A2RS1C3
NA7 2 Oil bath/mist - open 1
6310-C3
5310-AC3 (AHC3) or 3310-AC3
7310-BECBY
Regreasable - single shielded 2
6310-ZC3
5310-AZC3 or 3310-AZC3
NA6
Greased for life - double shielded 3
6310-2ZC3
5310-A2ZC3 or 3310-A2ZC3
NA7
Sealed for life - double sealed 4
6310-2RS1C3
5310-A2RSC3 or 3310-A2RS1C3
NA7 3 Oil bath/mist - open 1
6314-C3
5314-AC3 or 3314-AC3
7314-BECBY
Regreasable - single shielded 2
6314-ZC3
5314-AZC3 or 3314-AZC3
NA6
Greased for life - double shielded 3
6314-2ZC3
5314-A2ZC3 or 3314-A2ZC3
NA7
Sealed for life - double sealed 4
6314-2RS1C3
5314-A2RSC3 or 3314-A2RS1C3
NA7
Both products contain finely ground PTFE particles in
an oil based carrier. They are supplied in a paste
form which is brushed onto the male pipe threads.
Flowserve recommends using one of these paste
sealants. Full thread length engagement is required
for all fasteners.
Refer to figure 6-2 for recommended bolt
torques.
6.10.1 Power end assembly
The Mark 3A design has an optional oil slinger. If the
slinger was removed during disassembly, install a
new slinger [2541]. (See figure 6-22.)
6.10.1.1 Bearing installation
Mounting of bearings on shafts must be done in a
clean environment. Bearing and power end life can
be drastically reduced if even very small foreign
particles work their way into the bearings. Wear
clean gloves.
Figure 6-23: Flowserve Mark 3 bearings
Bearings should be removed from their protective
packaging only immediately before assembly to limit
exposure to possible contamination. After removing
the packaging they should only come in contact with
clean hands, fixtures, tools and work surfaces.
Figure 6-22
The chart shown in figure 6-23 gives the SKF part
numbers for bearings in Flowserve Mark 3 pumps.
Note that the term “inboard bearing” refers to the
bearing nearest to the casing. “Outboard bearing”
refers to the bearing nearest to the motor. (See
figure 6-22.)
Notes:
1) These bearings are open on both sides. They are lubricated by oil bath or oil mist.
2) These bearings are pre-greased by Flowserve. Replacement bearings will generally not be pre-greased, so grease must be applied by
the user. They have a single shield, which is located on the side next to the grease buffer, or reservoir. The bearings draw grease
from the reservoir as it is needed. The shield protects the bearing from getting too much grease, which would generate heat. The
grease reservoir is initially filled with grease by Flowserve. Lubrication fittings are provided, to allow the customer to periodically
replenish the grease, as recommended by the bearing and/or grease manufacturer.
3) These bearings are shielded on both sides. They come pre-greased by the bearing manufacturer. The user does not need to regrease
these bearings. The shields do not actually contact the bearing race, so no heat is generated.
4) These bearings are sealed on both sides. They come pre-greased by the bearing manufacturer. The user does not need to regrease
these bearings. The seals physically contact and rub against the bearing race, which generates heat. These bearings are not
recommended at speeds above 1 750r/min.
5) The codes shown are SKF codes. Inboard and outboard bearings have the C3, greater than “Normal” clearance. These clearances
are recommended by SKF to maximize bearing life.
6) Regreasable - single shielded bearings are not available in the duplex configuration; however, open oil bath-type bearings can be used
for the regreasable configuration. These bearings must be pre-greased during assembly. Lubrication fittings are provided, to allow the
user to periodically replenish the grease, as recommended by the bearing and/or grease manufacturer.
7) Not available.
8) All bearing configurations are supplied only with steel cages
9) SKF - the 5300 and 3300 bearing series are identical and therefore can be used interchangeably.
Page 41 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Pump
Press force
N (lbf)
Locknut torque
Nm (lbf▪ft)
Group 1
5 780 (1 300)
27 +4/-0 (20 +5/-0)
Group 2
11 100 (2 500)
54 +7/-0 (40 +5/-0)
Group 3
20 000 (4 500)
95 +7/-0 (70 +5/-0)
Both bearings have a slight interference
fit which requires that they be pressed on the shaft with
an arbor or hydraulic press. Figure 6-20 identifies the
bearing fits. Even force should be applied to only the
inner race. Never press on the outer race, as the force
will damage the balls and races.
An alternate method of installing bearings is to heat
the bearings to 93 °C (200 °F) by means of an oven
or induction heater. With this approach the bearing
must be quickly positioned on the shaft. Never heat
the bearings above 110 °C (230 °F). To do so will
likely cause the bearing fits to permanently change,
leading to early failure.
a) Install the inboard bearing [3011] on the shaft
[2100] against the shoulder as shown in figure
6-22. If the power end is equipped with single
shielded regreasable bearings. (See figure 5-8
for proper orientation of the shields.)
b) Install the outboard bearing retaining device onto
the shaft.
Double row bearings. Place the snap ring
[2530.1] onto the outboard end of the shaft and
slide down to the inboard bearing. Note, the
proper orientation of the snap ring must be
assured in this step. The flat side of the snap
ring must face away from the inboard bearing.
Duplex angular contact bearings. Place the bearing
retainer [2530.2] onto the outboard end of the shaft
and slide down to the inboard bearing.
The proper orientation of the bearing
retainer must be assured in this step. The small
side of the retainer must face away from the
inboard bearing.
c) Install the outboard bearing.
Double row bearings. Install the outboard bearing
[3013] firmly against the shoulder as shown in
Figure 6-22. If hot bearing mounting techniques are
used, steps must be taken to ensure the outboard
bearing is firmly positioned against the shaft
shoulder. The outboard bearing, while still hot, is to
be positioned against the shaft shoulder.
Duplex angular contact bearings. Duplex angular
contact bearings must be mounted back-to-back
with the wider thrust sides of the outer races in
contact with each other as shown in figure 6-24.
Only bearings designed for universal mounting
should be used. SKF’s designation is “BECB”.
NTN’s designation is “G”.
A special shaft is required when using
duplex angular contact bearings.)
It must be understood that fixtures
and equipment used to press the bearing must be
designed so no load is ever transmitted through the
bearing balls. This would damage the bearing.
Figure 6-24
d) After the bearing has cooled below 38 °C (100 °F)
the bearing should be pressed against the shaft
shoulder. Figure 6-25 identifies the approximate
force needed to seat the bearing against the shaft
shoulder. If a press is not available the locknut
[3712.1] should be installed immediately after the
bearing is placed on the shaft and tightened to
ensure the bearing remains in contact with the
shaft shoulder. The locknut should then be
retightened repeatedly during the time the bearing
is cooling. Once cool the locknut should be
removed.
Figure 6-25
e) Install lockwasher [6541.1] and locknut [3712.1].
The locknut should be torqued to the value shown
in figure 6-26. One tang on the lockwasher must be
bent into a corresponding groove on the locknut.
6.10.1.2 Bearing housing seals
6.10.1.2a Lip seals.
If lip seals were used (see figure 6-16), install new lip
seals in the bearing carrier [3240] and the housing
[3200 - Group 1] or the adapter [1340 - Group 2 and
3]. The lip seals [4310.1 and 4310.2] are double lip
style, the cavity between these two lips should be 1/2
to 2/3 filled with grease. When installing this part, the
large metal face on the lip seal must face away from
the bearings.
6.10.1.2b Labyrinth seals.
The following are general installation instructions
regarding the VBXX Inpro seal. Follow the
instructions provided with the seal by the
manufacturer.
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
The elastomer O-ring located on the OD of the seal
has been sized to overfill the groove in which it is
located. When installing the seal into its
corresponding housing, in addition to compressing
the O-ring a certain amount of material may shear off.
This sheared material should be removed. An arbor
press should be used to install the seal.
Install the inboard seal in the bore of the bearing
housing (Group 1) or adapter (Group 2 and Group 3)
with the single expulsion port positioned at the 6
o’clock position.
Install the outboard seal in the bore of the bearing
carrier. There are no orientation issues since this is a
multiport design seal.
6.10.1.2c Magnetic seals
Follow the installation instructions provided by the
manufacturer.
6.10.1.3 Bearing carrier/power end assembly
a) Install new O-rings [4610.2] onto the bearing
carrier. Slide the bearing carrier [3240] over the
outboard bearing [3013].
b) Install the outboard bearing retaining device.
Double row bearings on Group 1 and 2 pumps.
Slide the snap ring [2530.1] in place with its flat
side against the outboard bearing and snap it into
its groove in the bearing carrier.
Duplex angular contact bearings on Group 1 and
2 pumps and all bearings on Group 3 pumps.
Slide the bearing retainer [2530.2] against the
outboard bearing and install and tighten the
socket head capscrews [6570.2]. (See figure 6-2
for correct torque values.)
Never compress the snap ring
unless it is positioned around the shaft and between
the bearings. In this configuration, it is contained
therefore if it should slip off the compression tool it
is unlikely to cause serious injury.
c) The shaft, bearings, and bearing carrier
assembly (figure 6-14) can now be installed into
the bearing housing [3200]. The bearing carrier
[3240] should be lubricated with oil on the O-rings
and threads before installing the assembly into
the bearing housing. Thread the bearing carrier
into the bearing housing by turning it clockwise to
engage the threads. Thread the carrier onto the
housing until the carrier flange is approximately
3mm (1/8in.) from the housing. Install the set
screws [6570.3] loosely.
d) Reinstall any tags, plugs, site gages and oiler.
Mark 3A design. Install the following items onto
the bearing housing; oil level tag (figure 6-18)
and combination Trico oiler/site gage [3855],
vent/breather [6521] and drain plug [6569].
ANSI 3A design. Install the following items onto
the bearing housing; oil level tag (figure 6-18)
and site gage [3855], plug [6521] and magnetic
drain plug [6559].
e) On Group 2 and 3 pumps, assemble the bearing
housing adapter [1340] to the bearing housing
[3200]. Be sure to install a new O-ring [4610.3].
Mark 3A and ANSI 3A design. Thread the
capscrews [6570.6] through the adapter and into
the tapped holes in the bearing housing.
f) If the power end used lip seals, install the flinger
(deflector) [2540] onto the shaft [2100].
g) Slide the sleeve [2400] onto the shaft ensuring
that the flinger o-ring and flinger slip under the
end of the sleeve.
6.10.2 Seal and rear cover assembly
a) With an external seal slide the rotating part of the
seal over the sleeve but do not tighten the
setscrews at this time.
b) Position the seat to gland gasket [4590.2] and
seal seat into the gland [4120] and slide this
assembly over the sleeve.
c) With a cartridge seal, slide the seal over the sleeve,
but do not tighten the setscrews at this time.
d) For non-cartridge internal seals, install the stationary
seal face and its gasket or O-ring into the gland.
e) Place the cover nose gasket into the gland (or
the cover to gland gasket on Groups 3 and 4)
and slide them all over the sleeve.
f) With an internal seal, position the rotating portion
of the seal on the sleeve as shown on the seal
drawing provided, or as marked on the sleeve
during disassembly. It may be necessary to
assemble the pump to the impeller clearance
setting stage to properly locate the shaft (if the
rotor has been moved). Mark the end of the box
on the shaft and then disassemble the pump
back to this stage. This is because seal setting is
measured from the end of the box.
g) If they were removed, assemble the gland studs
[6572] into the cover [1220], replace the box
extension onto the cover and slide the gland over
the sleeve.
h) Assemble the cover onto the bearing housing
[3200] on Group 1 or support head [1340] using
bolts [6570.4] and lockwashers [6541.3] and
torque up to 20 Nm (15 lbf•ft). (For 2K3x1.5G-10,
2K4x3G-10 and 2K6x4G-10 units use eccentric
washers and nuts instead.)
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Angle cut for sizes
2K6x4G-10,
3J12x10G-15
4J12x10G-15B
Depth of cut, roughing
5.10 mm (0.200 in.)
Feed rate per revolution
0.38 mm (0.015 in.)
Depth of cut, finishing
0.51 mm (0.020 in.)
Feed rate per revolution
0.08 mm (0.003 in.)
Surface speed per minute
91 to 213 m (300 to 700 ft)
6.10.3 Impeller assembly
If a new impeller of maximum diameter has been
acquired and needs reducing, or if the existing
impeller diameter needs reducing, they must both be
machined down to the correct size. It is preferred to
send the impeller to your Flowserve representative
for machining, but when this is not possible, the
following procedure can be used:
a) Obtain the correct machining mandrel from your
Flowserve representative or use the pump shaft
and impeller bolting.
b) Carefully mount the mandrel or shaft in a lathe
suitable for machining GRP.
c) Mount the impeller and, using a dial indicator,
verify the outer diameter run-out and impeller
face run-out (on the vanes at the outer diameter)
are each less than 0.13 mm (0.005 in.) TIR.
d) Prepare to machine. All impellers are machined
straight across, parallel to the shaft except sizes
2K6x4G-10, 3J12x10G-15 and 4J12x10G-15B
which have angled cuts. The 2K6x4G-10 vanes
are machined at an angle of 15 degrees to the
shaft axis whilst the 3J12x10G-15 and
4J12x10G-15B vanes are machined at an angle
of 10 degrees to the shaft axis with the larger
diameter at the open vane face and the smaller
diameter at the back impeller shroud. The listed
impeller diameter is the mid-point of the vane.
Refer to the sketch for these details:
Midpoint (listed) diameter = A + B
2
Angle = 15 degrees (2K6x4G-10) or
10 degrees (3J12x10G-15 and 4J12x10G-15B)
e) Machining the GRP material produces dust that can
be irritating to the operator, but is not hazardous.
Dust vacuum systems, skin protection and a dust
mask are recommended. A typical machining setup
would be as described below.
f) Start machining across the outer diameter.
Machine from both sides to the middle. Continue
with additional cuts until the required impeller
diameter is achieved.
g) The finished impeller can then be removed from the
lathe and installed in the pump. No mechanical
balancing or resin coating of the vane tips is required.
6.10.3.1 Polygon impeller drive units
a) Position the impeller to sleeve gasket [4590.3]
into the groove on the impeller and push impeller,
hand tight, onto the shaft. The impeller is a slight
interference fit with the shaft and its face should
extend 0.38 to 0.89 mm (0.015 to 0.035 in.) from
the end of the shaft.
b) Seat the impeller by fitting the impeller stud
[2913.1] on Group 1 and torque up to 27 Nm (20
lbf•ft) or on Group 2 fit the washer [6541.6] and
locknut [3712.2] and torque up to 48 Nm (35
lbf•ft). This will push the impeller face down until
it lines up with the end of the shaft.
c) Install the impeller nose cone nut gasket [4590.4]
on the impeller, fit the impeller nose cone [2912]
and tighten hand tight 3 Nm (2 lbf•ft) as this nut
does not hold the impeller in place but merely
seals the shaft from the fluid.
6.10.3.2 Threaded impeller drive units
a) Position the impeller to sleeve gasket [4590.3]
into the groove on the sleeve or impeller.
b) Lubricate the impeller threads and pilot fit with
light oil having a light graphite suspension.
c) Locate the impeller on the shaft and thread on.
d) The impeller clearance should now be pre-set to
the tabulated dimensions in section 6.6.
6.10.4 Gland fastening to the cover
a) For mechanical seals, assemble the gland [4120]
onto the gland studs [6572], fit the gland backing
plate (if supplied), then fit the gland washers
[6541.5] and nuts [6580.2] and torque up evenly
to 7 Nm (5 lbf•ft) on Group 1 units and 14 Nm
(10 lbf•ft) on all other sizes.
b) For external seals, position the seal rotating
assembly against the seal stationary face,
compress the springs as specified on the seal
drawing and tighten the seal setscrews evenly.
c) For cartridge seals, tighten the setscrews evenly
and remove the gland centering tabs, but retain
for future maintenance.
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Pump not reaching design flow rate
Pump not reaching design head (TDH)
No discharge or flow with pump running
Pump operates for short period, then loses prime
Excessive noise from wet end
Excessive noise from power end
PROBABLE CAUSES
POSSIBLE REMEDIES
Insufficient NPSH. (Noise may not be
present.)
Recalculate NPSH available. It must be greater than the
NPSH required by pump at desired flow. If not, redesign
suction piping, holding number of elbows and number of
planes to a minimum to avoid adverse flow rotation as it
approaches the impeller.
System head greater than anticipated.
Reduce system head by increasing pipe size and/or
reducing number of fittings. Increase impeller diameter.
(NOTE: Increasing impeller diameter may require use of
a larger motor.)
Entrained air. Air leak from atmosphere on
suction side.
1. Check suction line gaskets and threads for tightness.
2. If vortex formation is observed in suction tank, install
vortex breaker.
3. Check for minimum submergence.
Entrained gas from process.
Process generated gases may require larger pumps.
Speed too low.
Check motor speed against design speed.
d) For packing, install 4 packing rings [4130], then the
seal cage [4134] and then 2 more rings of packing.
Pump size 4J12x10G-15B only has 5
rings of packing followed by the seal cage and
then 2 more rings of packing.)
6.10.5 Final back pullout assembly steps
a) Refit the constant level oiler, if supplied.
b) Fit the main casing O-ring [4610.1] onto the cover
[1200].
c) The complete back pullout assembly can now be
installed into the casing. Fit the casing bolts
[6570.1] or use the studs [6572] (on some
pumps) together with washers [6541.4],
lockwashers [6541.2] and nuts [6580.3] and
torque up evenly to 14 Nm (10 lbf•ft).
d) Finally, adjust the impeller running clearance as
described in section 6.6.
7 FAULTS; CAUSES AND REMEDIES
Troubleshooting
The following is a guide to troubleshooting problems with Flowserve Mark 3 pumps. Common problems are
analyzed and solutions offered. Obviously, it is impossible to cover every possible scenario. If a problem
exists that is not covered by one of the examples then refer to one of the books listed in section 10.3, Sources
of additional information, or contact a Flowserve Sales Engineer or Distributor/Representative for assistance.
Fault symptom
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Pump not reaching design flow rate
Pump not reaching design head (TDH)
No discharge or flow with pump running
Pump operates for short period, then loses prime
Excessive noise from wet end
Excessive noise from power end
PROBABLE CAUSES
POSSIBLE REMEDIES
Direction of rotation wrong.
After confirming wrong rotation, reverse any two of three
leads on a three phase motor. The pump should be
disassembled and inspected before it is restarted.
Impeller too small.
Replace with proper diameter impeller. (NOTE:
Increasing impeller diameter may require use of a larger
motor.)
Impeller clearance too large.
Reset impeller clearance.
Plugged impeller, suction line or casing which
may be due to a product or large solids.
1. Reduce length of fiber when possible.
2. Reduce solids in the process fluid when possible.
3. Consider larger pump.
Wet end parts (casing cover, impeller) worn,
corroded or missing.
Replace part or parts.
Not properly primed.
Repeat priming operation, recheck instructions. If pump
has run dry, disassemble and inspect the pump before
operation.
Impeller rubbing.
1. Check and reset impeller clearance.
2. Check outboard bearing assembly for axial end play.
Damaged pump shaft, impeller.
Replace damaged parts.
Abnormal fluid rotation due to complex suction
piping.
Redesign suction piping, holding the number of elbows
and planes to a minimum to avoid adverse fluid rotation
as it approaches the impeller.
Bearing contamination appearing on the
raceways as scoring, pitting, scratching or
rusting caused by adverse environment and
entrance of abrasive contaminants from
atmosphere.
1. Work with clean tools in clean surroundings.
2. Remove all outside dirt from housing before exposing
bearings.
3. Handle with clean dry hands.
4. Treat a used bearing as carefully as a new one.
5. Use clean solvent and flushing oil.
6. Protect disassembled bearing from dirt and moisture.
7. Keep bearings wrapped in paper or clean cloth while
not in use.
8. Clean inside of housing before replacing bearings.
9. Check oil seals and replace as required.
10. Check all plugs and tapped openings to make sure
that they are tight.
Brinelling of bearing identified by indentation on
the ball races, usually caused by incorrectly
applied forces in assembling the bearing or by
shock loading such as hitting the bearing or
drive shaft with a hammer.
When mounting the bearing on the drive shaft use a
proper size ring and apply the pressure against the inner
ring only. Be sure when mounting a bearing to apply the
mounting pressure slowly and evenly.
False brinelling of bearing identified again by
either axial or circumferential indentations
usually caused by vibration of the balls between
the races in a stationary bearing.
1. Correct the source of vibration.
2. Where bearings are oil lubricated and employed in
units that may be out of service for extended periods, the
drive shaft should be turned over periodically to
relubricate all bearing surfaces at intervals of one to three
months.
Page 46 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Pump not reaching design flow rate
Pump not reaching design head (TDH)
No discharge or flow with pump running
Pump operates for short period, then loses prime
Excessive noise from wet end
Excessive noise from power end
PROBABLE CAUSES
POSSIBLE REMEDIES
Thrust overload on bearing identified by flaking
ball path on one side of the outer race or in the
case of maximum capacity bearings, may
appear as a spalling of the races in the vicinity
of the loading slot. (Please note: maximum
capacity bearings are not recommended in
Mark 2I pumps.) These thrust failures are
caused by improper mounting of the bearing or
excessive thrust loads.
Follow correct mounting procedures for bearings.
Misalignment identified by fracture of ball
retainer or a wide ball path on the inner race
and a narrower cocked ball path on the outer
race. Misalignment is caused by poor mounting
practices or defective drive shaft. For example,
bearing not square with the centerline or
possibly a bent shaft due to improper handling.
Handle parts carefully and follow recommended mounting
procedures. Check all parts for proper fit and alignment.
Bearing damaged by electric arcing identified
as electro- etching of both inner and outer ring
as a pitting or cratering. Electrical arcing is
caused by a static electrical charge emanating
from belt drives, electrical leakage or short
circuiting.
1. Where current shunting through the bearing cannot be
corrected, a shunt in the form of a slip ring assembly
should be incorporated.
2. Check all wiring, insulation and rotor windings to be
sure that they are sound and all connections are properly
made.
3. Where pumps are belt driven, consider the elimination
of static charges by proper grounding or consider belt
material that is less generative.
Bearing damage due to improper lubrication,
identified by one or more of the following:
1. Abnormal bearing temperature rise.
2. A stiff cracked grease appearance.
3. A brown or bluish discoloration of the
bearing races.
1. Be sure the lubricant is clean.
2. Be sure proper amount of lubricant is used. The
constant level oiler supplied with Durco pumps will
maintain the proper oil level if it is installed and operating
properly. In the case of greased lubricated bearings, be
sure that there is space adjacent to the bearing into
which it can rid itself of excessive lubricant, otherwise the
bearing may overheat and fail prematurely.
3. Be sure the proper grade of lubricant is used.
Page 47 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Item
Description
1100
Casing
1220
Cover
2100
Shaft
2200
Impeller
2400
Sleeve
2530.1
Retainer – bearing, snap ring
2530.2
Retainer – duplex bearing
2540
Deflector – inboard
2541
Slinger (optional)
2912
Impeller nose cone
2913.1
Impeller stud
3011
Bearing – inboard (radial)
3013
Bearing – outboard (thrust)
3126.1
Shim – rear foot
3134
Foot – bearing housing
3200
Bearing housing
3240
Bearing carrier
3712.1
Locknut – bearing
3712.2
Locknut - impeller
3855
Oiler (optional)
3856
Sight gage – bearing housing
4120
Gland – clamped seat
4200
Mechanical seal
4310.1
Oil seal – inboard
4310.2
Oil seal – outboard
4590.1
Gasket – cover (nose)
4590.2
Gasket – seat to gland
4590.3
Gasket – impeller to sleeve
4590.4
Gasket – nose cone nut
4610.1
O-ring – cover
4610.2
O-ring – bearing carrier
4610.4
O-ring – sleeve to shaft
6521
Vent plug
6541.1
Lockwasher – bearing
6541.2
Lockwasher – casing
6541.3
Lockwasher – adapter to cover
6541.4
Washer – casing
6541.5
Washer – gland
6541.6
Washer – impeller locknut
6569
Plug – housing drain
6570.1
Fastener – casing
6570.2
Fastener – bearing retainer
6570.3
Fastener – carrier setscrews
6570.4
Fastener – adapter to cover
6570.5
Fastener – foot
6570.6
Fastener – gland
6575
Jackscrew – cover (not shown)
6580.2
Hexnut – gland
6580.3
Hexnut – casing
6700
Key – drive shaft
8 PARTS LISTS AND DRAWINGS
8.1 PolyChem GRP pump, Group 1
1K3x2GS-7 Wet end
Polygon impeller design
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Item
Description
1100
Casing
1220
Cover
2100
Shaft
2200
Impeller
2400
Sleeve
2530.1
Retainer – bearing, snap ring
2530.2
Retainer – duplex bearing
2540
Deflector – inboard
2541
Slinger (optional)
2912
Impeller nose cone
2913.1
Impeller stud
3011
Bearing – inboard (radial)
3013
Bearing – outboard (thrust)
3126.1
Shim – rear foot
3134
Foot – bearing housing
3200
Bearing housing
3240
Bearing carrier
3712.1
Locknut – bearing
3712.2
Locknut – impeller
3855
Oiler (optional)
3856
Sight Gage – bearing housing
4120
Gland – clamped seat
4200
Mechanical seal
4310.1
Oil seal – inboard
4310.2
Oil seal –outboard
4590.1
Gasket – cover (nose)
4590.2
Gasket – seat to gland
4590.3
Gasket – impeller to sleeve
4590.4
Gasket – nose cone nut
4610.1
O-ring – cover
4610.2
O-ring – bearing carrier
4610.3
O-ring – adapter to bearing housing
4610.4
O-ring – sleeve to shaft
6521
Vent plug
6541.1
Lockwasher – bearing
6541.2
Lockwasher – casing
6541.3
Lockwasher – adapter to cover
6541.4
Washer – casing
6541.5
Washer – gland
6541.6
Washer – impeller locknut
6569
Plug – housing drain
6570.1
Fastener – casing
6570.2
Fastener – bearing retainer
6570.3
Fastener – carrier setscrews
6570.4
Fastener – adapter to cover
6570.5
Fastener – foot
6570.6
Fastener – gland
6575
Jackscrew – cover (not shown)
6580.2
Hexnut – gland
6580.3
Hexnut – casing
6700
Key – drive shaft
8.2 PolyChem GRP pump, Group 2
(3x1.5-8, 4x3-8, 3x1.5-10, 4x3-10, 6x4-10)
Polygon impeller design
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Item
Description
1100
Casing
1220
Cover
2100
Shaft
2200
Impeller
2400
Sleeve
2530.1
Retainer – bearing, snap ring
2530.2
Retainer – duplex bearing
2540
Deflector – inboard
2541
Slinger (optional)
2912
Impeller nose cone
2913.1
Impeller stud
3011
Bearing – inboard (radial)
3013
Bearing – outboard (thrust)
3126.1
Shim – rear foot
3134
Foot – bearing housing
3200
Bearing housing
3240
Bearing carrier
3712.1
Locknut – bearing
3712.2
Locknut – impeller
3855
Oiler (optional)
3856
Sight gage – bearing housing
4120
Gland – clamped seat
4200
Mechanical seal
4310.1
Oil seal – inboard
4310.2
Oil seal – outboard
4590.1
Gasket – cover (nose)
4590.2
Gasket – seat to gland
4590.3
Gasket – impeller to sleeve
4590.4
Gasket – nose cone nut
4610.1
O-ring – cover
4610.2
O-ring – bearing carrier
4610.3
O-ring – adapter to bearing housing
4610.4
O-ring – sleeve to shaft
6521
Vent plug
6541.1
Lockwasher – bearing
6541.2
Lockwasher – casing
6541.3
Lockwasher – adapter to cover
6541.4
Washer – casing
6541.5
Washer – gland
6541.6
Washer – impeller locknut
6569
Plug – housing drain
6570.1
Fastener – casing
6570.2
Fastener – bearing retainer
6570.3
Fastener – carrier setscrews
6570.4
Fastener – adapter to cover
6570.5
Fastener – foot
6570.6
Fastener – gland
6575
Jackscrew – cover (not shown)
6580.2
Hexnut – gland
6580.3
Hexnut – casing
6700
Key – drive shaft
8.3 PolyChem GRP pump, Group 3
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
8.4 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 Instruction
manuals
Supplementary instruction determined from the contract
requirements for inclusion into User Instructions such as
for a driver, instrumentation, controller, sub-driver, seals,
sealant system, mounting component etc are included
under this section. If further copies of these are
required they should be obtained from the purchaser for
retention with these User Instructions.
Where any pre-printed set of User Instructions are
used, and satisfactory quality can be maintained only
by avoiding copying these, they are included at the
end of these User Instructions such as within a
standard clear polymer software protection envelope.
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.
10.3 Additional sources of information
The following are excellent sources for additional
information on centrifugal pumps in general.
Pump Engineering Manual
R.E. Syska, J.R. Birk,
Flowserve Corporation, Dayton, Ohio, 1980.
Specification for Horizontal End Suction Centrifugal
Pumps for Chemical Process, ASME B73.5M
The American Society of Mechanical Engineers,
New York, NY.
American National Standard for Centrifugal Pumps
for Nomenclature, Definitions, Design and Application
(ANSI/HI 1.1-1.3)
Hydraulic Institute, 9 Sylvan Way, Parsippany,
New Jersey 07054-3802.
American National Standard for Centrifugal Pumps
for Installation, Operation, and Maintenance
(ANSI/HI 1.4)
Hydraulic Institute, 9 Sylvan Way, Parsippany,
New Jersey 07054-3802.
RESP73H Application of ASME B73.5M-1991,
Specification for Horizontal End Suction Centrifugal
Pumps for Chemical Process, Process Industries
Practices
Construction Industry Institute, The University of
Texas at Austin, 3208 Red River Street, Suite 300,
Austin, Texas 78705.
Pump Handbook
2nd edition, Igor J. Karassik et al, McGraw-Hill, Inc.,
New York, NY, 1986.
Centrifugal Pump Sourcebook
John W. Dufour and William E. Nelson,
McGraw-Hill, Inc., New York, NY, 1993.
Pumping Manual, 9th edition
T.C. Dickenson, Elsevier Advanced Technology,
Kidlington, United Kingdom, 1995
Page 51 of 52 flowserve.com
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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A
Your Flowserve factory contact:
Flowserve Pump Division
3900 Cook Boulevard
Chesapeake, VA 23323-1626 USA
Telephone +1 757 485 8000
Fax +1 757 485 8149
Flowserve Pumps
Flowserve GB Limited
Lowfield Works, Balderton
Newark, Notts NG24 3BU
United Kingdom
Telephone (24 hours) +44 1636 494 600
Sales & Admin Fax +44 1636 705 991
Repair & Service Fax +44 1636 494 833
Email newarksales@flowserve.com
Your local Flowserve representative:
To find your local Flowserve representative please
use the Sales Support Locator System found at
www.flowserve.com
FLOWSERVE REGIONAL
SALES OFFICES:
USA and Canada
Flowserve Corporation
5215 North O’Connor Blvd.,
Suite 2300
Irving, Texas 75039-5421, USA
Telephone +1 972 443 6500
Fax +1 972 443 6800
Europe, Middle East, Africa
Flowserve FSG - Italy
Worthington S.r.l.
Via Rossini 90/92
20033 Desio (Milan), Italy
Telephone +39 0362 6121
Fax +39 0362 628 882
Latin America and Caribbean
Flowserve Corporation
6840 Wynnwood Lane
Houston, Texas 77008, USA
Telephone +1 713 803 4434
Fax +1 713 803 4497
Asia Pacific
Flowserve Pte. Ltd
10 Tuas Loop
Singapore 637345
Telephone +65 6771 0600
Fax +65 6779 4607
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