Flowserve PVML User Manual
®
Pump Division
Type: PVML
CENTRIFUGAL PUMPS
USER INSTRUCTIONS:
INSTALLATION, OPERATION, MAINTENANCE
PCN=00079591, ed. 01-05 (E)
These instructions should be read prior to installing,
operating, using and maintaining this equipment.
PVML USER INSTRUCTIONS ENGLISH 00079591 – 01/05
®
CONTENTS
PAGE
1 INTRODUCTION AND SAFETY............................3
1.1 General ...........................................................3
1.2 CE marking and approvals..............................3
1.3 Disclaimer .......................................................3
1.4 Copyright.........................................................3
1.5 Duty conditions................................................3
1.6 Safety..............................................................4
1.7 Nameplate and warning labels........................7
1.8 Specific machine performance........................8
1.9 Noise level.......................................................8
2 TRANSPORT AND STORAGE..............................9
2.1 Consignment receipt and unpacking...............9
2.2 Handling..........................................................9
2.3 Lifting...............................................................9
2.4 Storage............................................................9
2.5 Recycling and end of product life.................... 9
3 PUMP DESCRIPTION......................................... 10
3.1 Configurations...............................................10
3.2 Name nomenclature......................................10
3.3 Design of major parts....................................10
3.4 Performance and operating limits.................10
4 INSTALLATION.................................................... 11
4.1 Location.........................................................11
4.2 Part assemblies.............................................11
4.3 Foundation....................................................11
4.4 Grouting ........................................................11
4.5 Initial alignment.............................................13
4.6 Piping............................................................13
4.7 Electrical connections ...................................14
4.8 Final shaft alignment check ..........................15
4.9 Protection systems........................................15
5 COMMISSIONING, START-UP, OPERATION AND
SHUTDOWN.......................................................15
5.1 Pre-commissioning procedure......................15
5.2 Pump lubricants ............................................15
5.3 Impeller clearance......................................... 15
5.4 Direction of rotation.......................................15
5.5 Guarding .......................................................15
5.6 Priming and auxiliary supplies ......................15
5.7 Starting the pump..........................................16
5.8 Running the pump.........................................16
5.9 Stopping and shutdown.................................17
5.10 Hydraulic, mechanical and electrical duty...17
6 MAINTENANCE...................................................18
6.0 General .........................................................18
6.1 Maintenance schedule..................................18
6.2 Spare parts....................................................19
6.3 Recommended spares
and consumable items ..................................19
6.4 Tools required................................................19
6.5 Fastener torques...........................................20
6.6 Setting impeller clearances...........................20
6.7 Disassembly..................................................20
6.8 Examination of parts .....................................21
6.9 Assembly.......................................................22
PAGE
7 FAULTS; CAUSES AND REMEDIES.................. 25
8 PARTS LIST AND DRAWINGS........................... 27
8.1 Sectional drawings -PVML ........................... 27
8.2 Parts list -PVML............................................ 27
8.3 General arrangement drawing...................... 28
9 CERTIFICATION................................................. 28
10 OTHER RELEVANT DOCUMENTATION AND
MANUALS.......................................................... 28
10.1 Supplementary User Instructions ............... 28
10.2 Change notes ............................................. 28
10.3 Additional sources of information................ 28
ALPHABETICAL INDEX
PAGE
CE marking and approvals (1.2) ............................... 3
Clearances (see 6.7, Renewal clearances) ............ 20
Commissioning and operation (see 5) .................... 15
Configurations (3.1)................................................. 10
Direction of rotation (5.4)......................................... 15
Dismantling (see 6.7, Disassembly)........................ 20
Duty conditions (1.5) ................................................. 3
Electrical connections (4.7)..................................... 14
Examination of parts (6.8)....................................... 21
Faults; causes and remedies (7.0).......................... 25
General assembly drawings (see 8)........................ 28
Grouting (4.4).......................................................... 12
Guarding (5.5)......................................................... 15
Handling (2.2)............................................................ 9
Hydraulic, mechanical and electrical duty (5.10) .... 17
Lifting (2.3) ................................................................ 9
Location (4.1) .......................................................... 11
Lubrication schedule (see 5.2, Pump lubricants).... 15
Maintenance schedule (6.1).................................... 18
Piping (4.6).............................................................. 13
Priming and auxiliary supplies (5.6)........................ 15
Reassembly (see 6.9, Assembly)............................ 22
Replacement parts (see 6.2 and 6.3)...................... 19
Safety, protection systems (see 1.6 and 4.9)
Sound level (see 1.9, Noise level)............................. 8
Specific machine performance (1.8) ......................... 8
Starting the pump (5.7)............................................ 16
Stopping and shutdown (5.9).................................. 17
Storage (2.4) ............................................................. 9
Supplementary manuals or information sources..... 28
Tools required (6.4)................................................. 19
Torques for fasteners (6.5)...................................... 20
Page 2 of 29
PVML USER INSTRUCTIONS ENGLISH 00079591 – 01/05
®
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's products are designed, developed and
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great
care and commitment to continuous quality control,
utilising sophisticated quality techniques, and safety
requirements.
Flowserve is committed to continuous quality
improvement and being at service for any further
information about the product in its installation and
operation or about 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 should 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.
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 Pump Division 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 Flowserve's warranty. In
addition, any modification of Flowserve products or
removal of original components may impair the safety
of these products in their use.
1.4 Copyright
All rights reserved. No part of these instructions may
be reproduced, stored in a retrieval system or
transmitted in any form or by any means without prior
permission of Flowserve Pump Division.
1.5 Duty conditions
This product has been selected to meet the
specifications of your purchaser order. The
acknowledgement of these conditions has been sent
separately to the Purchaser. A copy should be kept
with these instructions.
The product must not be operated beyond
the parameters specified for the application. If
there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice, quoting the serial number.
If the conditions of service on your purchase order
are going to be changed (for example liquid pumped,
temperature or duty) it is requested that the user
seeks Flowserve’s written agreement before start up.
Page 3 of 29
PVML USER INSTRUCTIONS ENGLISH 00079591 – 01/05
®
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 instruct ions 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 sign is not a safety symbol but
indicates an important instruction in the assembly
process.
1.6.2 Personnel qualification and training
All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved. If the
personnel in question do not already possess the
necessary knowledge and skill, appropriate training
and instruction must be provided. If required the
operator may commission the manufacturer/supplier
to provide applicable training.
Always coordinate repair activity with operations and
health and safety personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.
1.6.3 Safety action
This is a summary of conditions and actions to
prevent injury to personnel and damage to the
environment and to equipment. For products
used in potentially explosive atmospheres
section 1.6.4 also applies.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
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.
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 b e
avoided.
NEVER APPLY HEAT TO REMOVE IMPELLER
Trapped lubricant or vapour could cause an explosion.
HOT (and cold) PARTS
If hot or freezing components or auxiliary heating
supplies can present a danger to operators and
persons entering the immediate area action must be
taken to avoid accidental contact. If complete
protection is not possible, the machine access must
be limited to maintenance staff only, with clear visual
warnings and indicators to those entering the
immediate area. Note: bearing housings must not be
insulated and drive motors and bearings may be hot.
If the temperature is greater than 68 °C (175 °F) or
below 5 °C (20 °F) in a restricted zone, or exceeds
local regulations, action as above shall be taken.
HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care must
be taken to avoid expo sure to th e liquid by appro priate
situating the pump, limiting person nel acce ss 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.
Page 4 of 29
PVML USER INSTRUCTIONS ENGLISH 00079591 – 01/05
®
appropriate. Always check that the driver, seal and
PREVENT EXCESSIVE EXTERNAL
PIPE LOAD
Do not use pump as a support for piping. Do not
mount expansion joints, unless allowed by Flowserve
in writing, so that their force, due to internal pressure,
acts on the pump flange.
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, which is quite unusual for a PVML pump due to
the closed coupled design, the Ex rating applies only
ENSURE CORRECT LUBRICATION
(See section 5, Commissioning, start-up, operation
and shutdown.)
START THE PUMP WITH OUTLET
VALVE PARTLY OPENED
(Unless otherwise instructed at a specific point in the
User Instructions.)
This is recommended to minimize the risk of
overloading and damaging the pump motor at full or
zero flow. Pumps may be started with the valve
further open only on installations where this situation
cannot occur. The pump outlet control valve may
need to be adjusted to comply with the duty following
the run-up process. (See section 5, Commissioning
start-up, operation and shutdown.)
NEVER RUN THE PUMP DRY
INLET VALVES TO BE FULLY OPEN
WHEN PUMP IS RUNNING
Running the pump at zero flow or below the
recommended minimum flow continuously will cause
damage to the seal.
DO NOT RUN THE PUMP AT
ABNORMALLY HIGH OR LOW FLOW RATES
Operating at a flow rate higher than normal or at a
flow rate with no back pressure on the pump may
overload the motor and cause cavitation. Low flow
rates may cause a reduction in pump/bearing life,
overheating of the pump, instability and cavitation/
vibration.
to the pump. The party responsible for assembling the
pump set shall select the driver and any additional
equipment, with the necessary CE Certificate/
Declaration of Conformity establishing it is suitable for
the area in which it is to be installed.
The output from a variable frequency drive (VFD) can
cause additional heating affects in the motor and so,
for pumps sets with a VFD, the ATEX Certification for
the motor must state that it is covers the situation
where electrical supply is from the VFD. This
particular requirement still applies even if the VFD is
in a safe area.
1.6.4.2 Marking
An example of ATEX equipment marking is shown
below. The actual classification of the pump will be
engraved on the nameplate.
II 2 GD c 135 ºC (T4)
Equipment Group
I = Mining
II = Non-mining
Category
2 or M2 = High level protection
3 = normal level of protection
Gas and/or Dust
G = Gas; D= Dust
c = Constructional safety
(in accordance with prEn13463-5)
1.6.4 Products used in potentially explosive atmospheres
Maximum surface temperature (Temperature Class)
(See section 1.6.4.3.)
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
1.6.4.3 Avoiding excessive surface temperatures
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE
Pumps have a temperature class as stated in the
ATEX Ex rating on the nameplate. These are based
on a maximum ambient of 40 °C (104 °F); refer to
Flowserve for higher ambient temperatures.
The surface temperature on the pump is influenced
by the temperature of the liquid handled. The
maximum permissible liquid temperature depends on
the temperature class and must not exceed the
values in the table that follows.
Use equipment only in the zone for whi ch it is
Page 5 of 29
PVML USER INSTRUCTIONS ENGLISH 00079591 – 01/05
®
The temperature rise at the seals and bearings and
due to the minimum permitted flow rate is taken into
account in the temperatures stated.
Temperature
class to
prEN 13463-1
T6
T5
T4
T3
T2
T1
Maximum
surface
temperature
permitted
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)
Temperature limit of liquid
handled (* depending on
material and construction
variant - check which is lower)
Consult Flowserve
Consult Flowserve
115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
400 °C (752 °F) *
The responsibility for compliance with the
specified maximum liquid temperature is with the
plant operator.
Temperature classification “Tx” is used when the
liquid temperature varies and the pump could be
installed in different hazarous atmospheres. In this
case the user is responsible for ensuring that the
pump surface temperature does not exceed that
permitted in the particular hazardous atmosphere.
If an explosive atmosphere exists during the
installation, do not attempt to check the direction of
rotation by starting the pump unfilled. Even a short
run time may give a high temperature resulting from
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 it is recommended that
users 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, regular checks must
be made and dirt removed from areas around close
clearances and motors.
1.6.4.4 Preventing the build up of explosive mixtures
If the operation of the system cannot avoid this
condition the fitting of an appropriate dry run
protection device is recommended (eg 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 motor stool guard must be non-sparking
and anti-static for Category 2.
To avoid the potential hazard from random induced
current generating a spark, the earth contact on the
levelling plate or base plate must be used.
Avoid electrostatic charge: do not rub non-metallic
surfaces with a dry cloth; ensure cloth is damp.
1.6.4.6 Preventing leakage
The pump must only be used to handle liquids
for which it has been approved to have the correct
corrosion resistance.
Avoid entrapment of liquid in the pump and
associated piping due to closing of suction and
discharge valves, which could cause dangerous
excessive pressures to occur if there is heat input to
the liquid. This can occur if the pump is stationary or
running.
Bursting of liquid containing parts due to freezing
must be avoided by draining or protecting the pump
and ancillary systems.
Where there is the potential 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, the installation of a liquid detection device is
recommended.
1.6.4.7 Maintenance to avoid the hazard
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.
Page 6 of 29
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.
PVML USER INSTRUCTIONS ENGLISH 00079591 – 01/05
®
To avoid potential explosion hazards during
maintenance, the tools, cleaning and painting
materials used must not give rise to sparking or
adversely affect the ambient conditions. Where there
is a risk from such tools or materials, maintenance
must be conducted in a safe area.
It is recommended that a maintenance plan and
schedule is adopted. (See section 6, Maintenance.)
1.7 Nameplate and warning labels
1.7.1 Nameplate
For details of nameplate, see the Declaration of
Conformity.
1.7.2 Warning labels
Page 7 of 29
PVML USER INSTRUCTIONS ENGLISH 00079591 – 01/05
®
1.8 Specific machine performance
For performance parameters see section 1.5, Duty
conditions. When the contract requirement specifies
these to be incorporated into User Instructions these
are included here. Where performance data has
been supplied separately to the purchaser these
should be obtained and retained with these User
Instructions if required.
1.9 Noise level
When pump noise level exceeds 85 dBA attention
must be given to prevailing Health and Safety
Legislation, to limit the exposure of plant operating
personnel to the noise. The usual approach is to
control exposure time to the noise or to enclose the
machine to reduce emitted sound. You may have
already specified a limiting noise level when the
equipment was ordered, however if no noise
requirements were defined then machines above a
certain power level will exceed 85 dBA. In such
situations consideration must be given to the fitting of
an acoustic enclosure to meet local regulations.
Pump noise level is dependent on a number of factors the type of motor fitted, the operati ng cap acit y, pipework
design and acoustic characteri stics of the buildin g.
Typical sound pressure levels measured in dB, and
A-weighted are shown in the t able below (L
). The
pfA
figures are indicative only, they are subject to a +3 dB
tolerance, and cannot be guaranteed.
The values are based on the noisiest electric motors
that are likely to be encountered. They represent
sound pressure levels at 1 m (3.3 ft) from the directly
driven pump, for "free field over a reflecting plane".
If a pump unit only has been purchased, for fitting
with your own driver, then the "pump only" noise
levels from the table should be combined with the
level for the driver obtained from the supplier. If the
motor is driven by an inverter, it may show an
increase in noise level at some speeds. Consult a
Noise Specialist for the combined calculation.
For units driven by equipment other than electric
motors or units contained within enclosures, see the
accompanying information sheets and manuals.
Typical sound pressure level, dBA (LpA at 1 m reference 20µPa)
Motor size
and speed
KW (hp)
2.2 (3) 78 72 71 68 71 68 68 68
3 (4) 81 74 74 70 74 70 70 70
4 (5) 82 75 75 71 75 71 71 71
5.5 (7.5) 90 77 83 73 76 73 72 71
7.5 (10) 90 78 83 74 77 74 73 72
11 (15) 91 80 84 76 78 76 74 73
15 (20) 92 83 85 79 80 79 76 75
18.5 (25) 92 83 85 79 80 79 76 75
22 (30) 92 83 85 79 81 79 77 75
30 (40) 100 85 93 81 84 80 80 76
37 (50) 100 86 93 82 84 80 80 76
45 (60) 100 87 93 83 84 80 80 76
55 (75) 102 88 95 84 86 81 82 77
75 (100) 100 90 95 86 88 81 83 78
90 (120) 100 90 95 86 90 81 85 78
110 (150) 100 91 95 87 91 83 86 79
150 (200) 101 92 96 88 91 83 86 79
200 (270)
300 (400) - - - -
3550 r/min 2900 r/min 1750 r/min 1450 r/min
Pump and
motor
dBA
← ← ← ← ←
Pump
only
dBA
Pump and
motor
dBA
Pump
only
dBA
Pump and
motor
dBA
←
Pump
only
dBA
83
84
Pump and
motor
dBA
←
←
Pump
only
dBA
80
81
← Motors in this range are generally job specific and noise levels should be calculated based on actual equipment installed.
For 960 rpm reduce 1450 rpm values by 5 dBA.
Page 8 of 29
PVML USER INSTRUCTIONS ENGLISH 00079591 – 01/05
®
2 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be
checked against the delivery and 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 received
in writing within one month of receipt of the
equipment. Later claims cannot be accepted.
Check any crate, boxes and wrappings for any
accessories or spare parts that may be packed
separately with the equipment or attached to side
walls of the box or equipment.
Each product has a unique serial number. Check that
this number corresponds with that advised and always
quote this number in correspondence as well as when
ordering spare parts or further accessories.
Typical lifting of a PVML with base plate or
extended levelling plate
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
To avoid distortion, the pump unit
should be lifted as shown.
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.
Unsafe lifting is never allowed!
2.4 Storage
Store the pump in a clean , dry
location away from vibration. Leave piping
connection covers in place to keep dirt and other
foreign material out of pump casing. Turn pump at
intervals to prevent brinelling of the bearings and
the seal faces, if fitted, from sticking.
The pump may be stored as above for up to 6
months. Consult Flowserve for preservative
actions when a longer storage period is needed.
2.5 Recycling and end of product life
At the end of the service life of the product or its
parts, the relevant materials and parts should be
recycled or disposed of using an environmentally
acceptable method and local regulations. If the
product contains substances that are harmful to the
Page 9 of 29
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