Flowserve PolyChem GRP User Manual

PolyChem GRP

ANSI B73.5M standard horizontal and self-priming non-metallic, frame-mounted pump

PCN=71569132 12-04A (E). Original instructions.

USER INSTRUCTIONS

Installation

Operation

Maintenance

These instructions must be read prior to installing, operating, using and maintaining this equipment.

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
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
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

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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

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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.

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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.

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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.)

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

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

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.

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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:

Temperature class	Maximum surface	Temperature limit of
to EN13463-1	temperature permitted	liquid handled
T6	85 °C (185 °F)	Consult Flowserve
T5	100 °C (212 °F)	Consult Flowserve
T4	135 °C (275 °F)	115 °C (239 °F) *

*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.

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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

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

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

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

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

1.7 Nameplate and safety labels

1.7.1 Nameplate

For details of nameplate, see the Declaration of Conformity and section 3.

1.7.2 Safety labels

Oil lubricated units only:

DurcoShieldTM (splash/shaft guard

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USER INSTRUCTIONS POLYCHEM GRP ENGLISH 71569132 12-04A

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.

Motor size			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
and speed
kW (hp)		Pump	Pump and		Pump	Pump and	Pump	Pump and		Pump	Pump and
		only	motor		only	motor	only	motor		only	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

 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.

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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.

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.

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.

2.3.1.4Power end

Same as bearing housing.

2.3.1.5Bare 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

Store the pump in a clean, dry location away from vibration. Leave piping connection covers in place to keep dirt and other foreign material out of pump casing. Turn pump at intervals to prevent brinelling of the bearings and the seal faces, if fitted, from sticking.

The pump may be stored as above for up to 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:

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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.

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Serial No.

Equipment No.

Purchase Order

Model

Size 2K4X3G-13/12.5

MDP

Material

Date DD/MMM/YY

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 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.

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.

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

	Figure 3-2		Bar (psi)
	Size	-46 °C	66 °C	121 °C
		(-50 °F)	(150 °F)	(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	66 °C	107 °C
		(-20 °F)	(150 °F)	(225 °F)
	1K3x2GS-7	9.31 (135)	9.31 (135)	9.31 (135)

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The pressure-temperature charts for PolyChem GRP Figure 3-5: Minimum submergence 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						3.4.4 Suction pressure limits
models.						Open style impellers typically create a thrust load
						towards the suction of the pump. This reduces the axial
Figure 3-3		MCF (% of BEP)
						loading on the bearings so that the suction pressure
Size	3 600	3 000	1 800	1 200
						limit is equal to the pressure-temperature rating.
	r/min	r/min	r/min	r/min
1J1.5x1G-6	10	10	10	10
1J3x1.5G-6	10	10	10	10		4 INSTALLATION
1J3x2G-6	10	10	10	10
1J3x2GS-7	10	10	10	10		Equipment operated in hazardous locations
1J1.5x1G-8	10	10	10	10
						must comply with the relevant explosion protection
2K3x1.5G-8	10	10	10	10
						regulations. See section 1.6.4, Products used in
2K3x2G-8	10	10	10	10
						potentially explosive atmospheres.
2K4x3G-8	20	20	20	20
2K2x1G-10	10	10	10	10
2K3x1.5G-10	N/A	10	10	10		4.1 Location
2K4x3G-10	N/A	25	25	25		The pump should be located to allow room for access,
2K6x4G-10	N/A	25	25	25		ventilation, maintenance and inspection with ample
2K3x1.5G-13	N/A	N/A	25	25		headroom for lifting and should be as close as
2K4x3G-13	N/A	N/A	25	25
						practicable to the supply of liquid to be pumped. Refer
3J8x6G-13	N/A	N/A	25	25
						to the general arrangement drawing for the pump set.
3J12x10G-15	N/A	N/A	N/A	25
4J12x10G-15B	N/A	N/A	25	25		4.2 Part assemblies

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.

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.

Figure 3-4: Minimum submergence

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)

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Figure 4-1

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 (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

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. (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.

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.

1.Stilt bolt

2.Nuts

3.Lock washer

4.Floor cup

Figure 4-3

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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.

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

Figure 4-4

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.

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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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 or if they were not removed from 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.

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