Flowserve QLQ User Manual

USER INSTRUCTIONS

®

Worthington
centrifugal pumps

Vertical QLQ and QLQC

Installation

Operation

multiple stage, double suction, vertical wet pit and canned
centrifugal pumps

PCN=87900027 – 06/14 (E ) Original instructions

Maintenance

These instructions must be read prior to installing,

operating, using and maintaining this equipment.

QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

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 .................... .... 8

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 ................................................ .......... 12

2.5 Recycling and end of product life .................. 14

3 PUMP DESCRIPTION ......................................... 15

3.1 Configurations ............................................... 15

3.2 Nomenclature ................................................ 15

3.3 Design of major parts .................................... 16

3.4 Performance and operating limits ................. 18

6 MAINTENANCE ................................................... 42

6.1 Maintenance schedule ...................................42

6.2 Spare parts ....................................................44

6.4 Tools required ................................................44

6.5 Fastener torque .............................................44

6.6 Setting impeller clearance .............................45

6.7 Disassembly ..................................................45

6.8 Examination of parts .......................... ... .... .... .46

6.9 Reassemble procedure .................................50

7 FAULTS; CAUSES AND REMEDIES ................... 52

8 PARTS LIST AND DRAWINGS ............................ 54

PAGE

4 INSTALLATION .................................................... 19

4.1 Location ......... ................................................ 19

4.2 Part assemblies............................................. 23

4.3 Foundation .................................................... 23

4.4 Grouting ........................................................ 25

4.5 Initial alignment ............................................. 26

4.6 Piping ............................................................ 28

4.7 Electrical connections ................................. .. 30

4.8 Protection systems ........................................ 30

5 COMMISSIONING, STARTUP, OPERATION AND

SHUTDOWN ................................... ......................... 32

5.1 Pre-commissioning procedure ...................... 32

5.2 Pump Lubricants ........................................... 32

5.3 Lubrication of thrust bearing ......................... 33

5.4 Impeller adjustment ....................................... 34

5.5 Direction of rotation ....................................... 36

5.6 Guarding ....................................................... 36

5.7 Priming and auxiliary supplies ............ .... .... .. 36

5.8 Starting the pump .......................................... 36

5.9 Running or operation .................................... 39

5.10 Stopping and shutdown .............................. 40

5.11 Hydraulic, mechanical and electrical duty ... 40

Page 2 of 61

QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

INDEX:

PAGE

Alignment (4.5) .................................................. ...... 25

Assembly (6.9) ......................................................... 49

ATEX marking (1.6.4.2) ............................................. 7

CE marking and approvals (1.2) ................................ 4

Clearances (6.6) ................................................ ...... 44

Commissioning and operation (5) ............................ 31

Compliance, ATEX (1.6.4.1) ...................................... 6

Configurations (3.1) ........................................... ...... 15

Copyright (1.4) ........................................................... 4

Design of major parts (3.3) ...................................... 16

Direction of rotation (5.5) ......................................... 35

Disassembly (6.7) ............................... ..................... 44

Disclaimer (1.3) .......................................................... 4

Dismantling (see 6.7, Disassembly) ........................ 44

Drawings (8) .................... .... .... ... .... .... .... ....... .... .... .. 55

Duty conditions (1.5) .................................................. 4

Electrical connections (4.7) ....................... .............. 29

End of product life (2.5) ........................................... 14

Examination of parts (6.8) ....................................... 45

Fastener torques (6.5) ............................................. 43

Faults; causes and remedies (7) ............................. 51

General assembly drawings (8.1) ............................ 53

Grouting (4.4) ............................................. .............. 25

Guarding (5.6) .................................................... ...... 35

Handling (2.2) .......................................................... 10

Hydraulic, mechanical and electrical duty (5.10) ..... 39

Impeller clearance (6.6) ........................................... 44

Inspection (see 6.1, Maintenance schedule) ........... 41

Installation (4) .......................................................... 19

Lifting (2.3) ............................................................... 10

Location (4.1) ........................................................... 19

Lubrication, thrust bearings (5.3) ............................. 33

Lubrication, pump (see 5.2, Pump lubricants) ......... 31

Maintenance (6) ....................................................... 41

Maintenance schedule (6.1) .................................... 41

Name nomenclature (3.2) ........................................ 15

Nameplate (1.7.1) ................................... ... .... .... .... ... . 8

Operating limits (3.4) ....... .... .... ... .... .... ....... .... .... .... .. 18

Ordering spare parts (6.2.1) .................................... 43

Part assemblies (4.2) ............................................... 23

Parts lists (8) ............................................................ 53

Performance (3.4) .................................................... 18

Piping (4.6) .............. ................................................ 27

Pre-commissioning (5.1) .......................................... 31

Protection systems (4.8) .......................................... 30

Priming and auxiliary supplies (5.7) ......................... 35

Reassembly (see 6.9, Assembly) ............................ 49

Receipt and unpacking (2.1) .................................... 10

Recommended oil lubricants (5.2.2) ........................ 31

Recommended spares (6.3) .................................... 43

Recycling (2.5) ......................................................... 14

Replacement parts (see 6.2 and 6.3) ...................... 43

Running and operation (5.9) .................................... 38

PAGE

Safety action (1.6.3) ................................................... 5

Safety labels (1.7.2) ... ................................................ 8

Safety markings (1.6.1) .............................................. 5

Safety, protection systems ....................................... 30

Sectional drawings (8) .............................................. 53

Sound level (see 1.9, Noise level) .............................. 8

Spare parts (6.2) ................... .... ....... .... .... .... ... .... .... . 43

Specific machine performance (1.8) .......................... 8

Starting the pump (5.8) ............................................ 35

Stop/start frequency (5.8.8) ...................................... 38

Stopping and shutdown (5.10) ................................. 39

Storage, pump (2.4) ................................................. 12

Storage, spare parts (6.2.2) ..................................... 43

Supplementary manuals or info, contacts ................ 60

Tools required (6.4) .................................................. 43

Torques for fasteners (6.5) ....................................... 43

Trouble-shooting (see 7) .......................................... 51

Vibration (5.8.7) ........................................................ 38

Page 3 of 61

QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

1 INTRODUCTION AND SAFETY

1.1 General

These instructions must always be kept

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

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

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

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

These instructions must be read prior to

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

1.2 CE marking and approvals

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

Where applicable the Directives and any additional
Approvals cover important safety aspects relating to
machinery and equipment and the satisfactory provision

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

1.3 Disclaimer

Information in these User Instructions is believed to
be complete and reliable. However, in spite of all
the efforts of Flowserve Corporation to provide
comprehensive instructions, good engineering and
safety practice should always be used..

Flowserve manufactures products to exacting
International Quality Management System Standards as
certified and audited by external Quality Assurance
organizations. Genuine parts and accessories have
been designed, tested and incorporated into the
products to help ensure their continued product quality
and performance in use. As Flowserve cannot test
parts and accessories sourced from other vendors the
incorrect incorporation of such parts and accessories
may adversely affect the performance and safety
features of the products. The failure to properly select,
install or use authorized Flowserve parts and
accessories is considered to be misuse. Damage or
failure caused by misuse is not covered by the
Flowserve warranty. In addition, any modification of
Flowserve products or removal of original components
may impair the safety of these products in their use.

1.4 Copyright

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

1.5 Duty conditions

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

The product must not be operated beyond

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

If the conditions of service on your purchase order
are going to be changed (for example liquid pumped,
temperature or duty) it is requested that the user

Page 4 of 61

QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

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 spec ific safety m arkings 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 indica te s “ha zar do us an d to xic fluid ”
safety instructions where non-compliance would affect
personal safe ty 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 ins t ructi on i n t he as sem bly pr oce ss.

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 operatio ns 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.

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, d ue to in tern al pressure,
acts on the pump flange.

ENSURE CORRECT LUBRICATION
(See section 5, Commissioning, startup, operation
and shutdown.)

START THE PUMP WITH OUTLET
V ALVE PARTL Y 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
startup, 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 backpressure 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.

NEVER DO MAINTENANCE WORK

WHEN THE UNIT IS CONNECTED TO POWER

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

Page 5 of 61

QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

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 pump ing
hazardous liquids.

DRAIN THE PUMP AND ISOLATE PIPEWORK
BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be taken
where the pumped liquids are hazardo u s .

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.

GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS OPERATI ONAL
The unit must not be operated unless coupling guard
is in place. Failure to observe this warning could
result in injury to operating personnel.

THERMAL SHOCK
Rapid changes in the temperature of the liquid within
the pump can cause thermal shock that can result in
damage or breakage of components and should be
avoided.

APPL YING HEAT TO REMOVE IMPELLER
There may be occasions when the impeller has
become difficult to remove due to products that are
corrosive in nature.
If you elect to use heat to remove the impeller, it must
be applied with great care and before app lying heat,
ensure any residual hazardous liquid trapped
between the impeller and pump shaft is thoroughly
drained out through the impeller keyway to prevent
an explosion or emission of toxic vapor.
Impeller design varies and so are the heat, applying
location and the duration of heat application. Contact
nearest Flowserve Service Center for help.

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 m ust 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 °C (175 °F) or
below -5 °C (20 °F) in a restricted zone, or
exceeds local regulations, action as above shall
be taken.

1.6.4 Products used in potentially explosive
atmospheres

The following instructions for pumps and pump units
when installed in potentially explosive atmospheres
must be followed to help ensure explosion protection.
For ATEX both electrical and non-electrical
equipment must meet the requirements of European
Directive 94/9/EC. Always observe the regional legal
Ex requirements eg Ex electrical items outside the EU
may be required certified to other than ATEX eg IECEx,
UL.

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

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 ATEX 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 affects in the motor and the
ATEX Certification for the motor shall state that it
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 61

QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

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
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 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 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 to

EN13463-1

T6

T5
T4
T3
T2
T1

*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.

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

Consult Flowserve

Consult Flowserve

115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
400 °C (752 °F) *

The temperature rise at the seals and bearings due to
the minimum permitted flow rate is taken into account
in the temperatures stated.

The responsibility for compliance with the
specified maximum liqu id 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.

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, users shall fit an
external surface temperature protection device.

Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, temperature monitor or a
power monitor. Make routine vibration
measurements. In dirty or dusty environments,
regular checks shall be made and dirt removed 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 completely 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, user shall fit an appropriate dry run
protection device (eg. liquid detection or a power
monitor).

To avoid potential hazards from fugitive emissions of
vapor or gas to the atm osphere the surr ounding area
shall be well ventilated.

Page 7 of 61

QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

1.6.4.5 Preventing sparks

To prevent a potential hazard from mechanical
contact, the coupling guard must be non-sparking
and anti-static for Category 2.

To avoid the potential hazard from random induced
current generating a spark, the baseplate shall 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 and correct alignment must be
maintained.

1.6.4.6 Preventing leakage

The pump shall only be used to h andle 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 auxiliary systems.

Where there is the potential hazard of a loss of a seal
barrier fluid or external flush, the fluid shall be
monitored.

If leakage of liquid to atmosphere can result in a
hazard, users shall install a liquid detection device.

1.6.4.7 Maintenance to avoid the hazard

It is recommended that a maintenance plan and
schedule is adopted. See section 6.

1.7 Nameplate and safety labels

1.7.1 Nameplate

For details of nameplate, see the Declaration of
Conformity.

1.7.2 Safety labels

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.

Page 8 of 61

1.8 Specific machine performance

For performance parameters see section 1.5, Duty
conditions. Pump performance data are summarized

on pump data sheet which is included in proper
section of “Job User’s Instruct ion”.

QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

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 80 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 operating
conditions, pipework design and acoustic
characteristics of the building.

Typical sound pressure levels measured in dB and
A-weighted are shown in the table in section 1.9.1.
The figures are indicative only; they are subjected to
a +3 dB tolerance and cannot be guaranteed.

The dBA values are based on the noisiest ungeared
electric motors that are likely to be encountered. The
third column table shows 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 should be combined with the level for the driver
obtained from the supplier. Consult a Noise
Specialist for the combined calculation.

If the motor is driven by an inverter, it may show an
increase in noise level at some speeds.

1.9.1 Typical vertical motor noise data (Hollow
and solid shafts)

Motor

Frame

Size.

NEMA

180

210

250

280

320

360

400

440

449

5000

5800

6800

8000

RPM

3600 70.0 78.0
1800 60.0 68.0

1200 & slower 55.0 63.0

3600 70.0 78.2
1800 60.0 68.2

1200 & slower 55.0 63.2

3600 75.0 83.4
1800 70.0 78.4

1200 & slower 60.0 68.4

3600 75.0 83.8
1800 70.0 78.8

1200 & slower 60.0 68.8

3600 75.0 84.0
1800 65.0 74.0

1200 & slower 65.0 74.0

3600 75.0 84.2
1800 65.0 74.2

1200 & slower 65.0 74.2

3600 80.0 89.5
1800 70.0 79.5

1200 & slower 65.0 74.5

3600 80.0 90.0
1800 70.0 80.0

1200 & slower 70.0 80.0

1800 85.0 97.8

1200 & slower 80.0 92.8

3600 90.0 102.8
1800 85.0 97.8

1200 & slower 80.0 92.8

3600 90.0 103.7
1800 90.0 103.7

1200 & slower 80.0 93.7

1800 90.0 103.9

1200 & slower 85.0 98.8

1800 90.0 104.7

1200 & slower 85.0 99.7

Sound

Pressure

(dBA )

Sound
Power
(dBA )

 For units driven by equipment other than

electric motors or units contained within enclosures,
see the accompanying information sheets and
manuals.

Page 9 of 61

QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

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
sidewalls 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 forklift vehicles or slings dependent on their
size and construction.

2.3 Lifting

For pumps supplied with two piece head shaft or solid
shaft drivers, proceed with the lifting as explained in

2.3.1.
Flowserve will not supply eyebolts neither fixed nor

separately with the pump. It is the responsibility of the
installer to arrange appropriate hardware that can
handle the weights and results in safe and successfu l
installation.

2.3.1 Lifting of fabricated discharge heads with
or without the pump

If the pump is supplied with a fabricated discharge
head use the 4 points method of lifting as shown in the
details provided below or 2 points method using a
lifting beam. This method is applicable to the lifting of
the discharge head with or without the pump
assembled.

For pump supplied with motor stand already
assembled on the discharge head, the motor stand
lifting points shall not be used for lifting. Lift the pump
using a lifting beam and two of the four discharge
head lifting points.

Example: Lifting of discharge head

To avoid distortion, the pump unit
should be lifted by using lifting equipment certified to
local standards.

The pumps are generally very heavy
therefore, size/shape factors will have to be
considered before attempting to lift them. It is strongly
recommended to attempt lifting from a safe distance
to prevent any injury or loss of life. Consulting with
experts is recommended.

A crane must be used for all pump sets and
components in excess of 25 kg (55 lb.). Fully trained
personnel must carry out lifting, in accordance with
local regulations. If you are not sure about the driver
and pump weights contact Flowserve for information.

Pump heads may be shipped with the seal
housing installed. For ease of assembly and to
prevent damage, we recommend removing the
housing before putting the head on the pump.

For pumps supplied with hollow shaft drivers and
one-piece head shaft, attach head shaft to the
lineshaft with a coupling and tighten first.

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QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

2.3.2 Lifting of bowl assembly only

Clamp the bowl assembly and center the lifting hook
for lifting and lowering the assembly into the
sump/suction barrel.

a) Lower the bowl assembly until the clamp

extensions rest on the foundation (use
appropriate supports).

b) Build the very first section of the column piping,

and lower the entire assembly to assemble the
next column section.

c) Continue to build until it is ready for discharge

head assembly.
d) Install the discharge head.
e) Assemble the motor.

Example: Lifting of bowl assembly

2.3.3 Lifting of the motor stand only

Motor stand shall be lifted using the four lifting points
foreseen on the motor stand itself.

The four motor stand lifting points shall not be

used for the lift of the assembled pump.
Example: Lifting of motor stand

2.3.4 Lifting of suction barrel

Suction barrel (also referred as ‘Can’) is always
supplied separately and has to be installed into the
sump first. Install eyebolts on the flange of the suction
barrel and attach slings and straps to bring the
suction barrel to a vertical position. Move the barrel
for installation. Provide hand support to prevent the
suction barrel from swaying during movement.

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QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

Example: Lifting of suction barrel

SUCTION BARREL (CAN)

2.3.5 Lifting of fully assembled pumps

If the pump is fully assembled, it has to be adequately
strapped and supported at least two places before it
can be lifted from the shipping crate and moved to
the installation site. See details shown. Same rules
are applicable when the pump is pulled out from the
sump and moved to another locatio n.

Examples shown here are for
illustration only. See section 2.3 1~2.3.4 for specific
lifting instructions based on design variations. The
pumps vary in weight, length and physical
appearances from the types shown here. Therefore,
before lifting is attempted, exercise caution to pr event
any injuries or loss of life.

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 the pump at frequent intervals
(refer to section 2.4.1.2) to prevent brinelling of the
bearings and the seal faces, if fitted, from sticking.
Electric Motors (Pump Driver) should not be stored in
damp places without special protection (Refer to
Motor manufacturers instructions).

The pump may be stored as above for up to 6
months.

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QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

2.4.1 Long term storage

During extended periods of storage prior to
installation, precautions must be taken to protect the
pump from deterioration. The various parts of the
pump are protected prior to shipment by applying
varying grades of preservative to the parts. However,
during shipment and handling the preservatives are
subjected to conditions that can cause their removal.
Also, during extended periods of time the
preservatives may deteriorate. The listed procedures
(2.4.1.1 to 2.4.1.5) should be followed to prevent
deterioration of the pump during the extended
storage period. These procedures may also be
supplemented by the experience of the person(s)
performing the tasks.

2.4.1.1 Inspection upon arrival

When the pump is received it should be inspected for
damage or other signs of rough handling. If any
damage is found it should be reported to the carrier
immediately. Inspect the preservative coating on
various parts. If necessary, renew preservative in
areas where it has been rubbed or scraped.
Inspect all painted surfaces. If necessary, touch up
the areas where paint has been chipped or scraped.
Inspect all covers over pump openings and piping
connections. If covers or seals for the covers are
damaged or loose, they are to be removed, and a
visual inspection made of the accessible interior
areas for accumulation of foreign materials or water.
If necessary, clean and preserve the interior parts as
noted above to restore the parts to the "as shipped"
condition. Install or replace covers and fasten
securely.

2.4.1.2 Storage

component parts should be stored indoors where
they will be protected from the elements. In no case
should any pump element be subjected to exte nded
periods of submergence or wetting prior to start up. If
it is not possible to store the pump and its
components indoors, precautions must be taken to
protect them from the elements. Regardless of
whether storage is indoors or outside, the storage
area should be vibration free. All boxes marked for
indoor storage should be stored indoors. When
stored outdoors the pump and its components should
be protected from dirt, dust, rain, snow, or other
unfavorable conditions by heavy plastic sheets,
canvas, waterproof burlap or other suitable coverings.
All equipment must be placed upon skids or blocks to
prevent contact with the ground and surface
contaminants. Equipment must be adequately
supported to prevent distortion and bending.

If at all possible, the pump and its

The pump shaft should be rotated, in the direction of
rotation, at least 1 and 1/4 turn monthly during the
storage period and any other period s of s tandby.
When selecting a storage area the following should
be taken into consideration.

a) The deterioration of the equipment will be

proportionate to the class of stor age provided.

b) The expenses involved in restoring the

equipment at time of installation will be
proportionate to the class of stor age provided.

2.4.1.3 Inspection and maintenance

The stored equipment has to be placed on a periodic
inspection schedule by the purchaser.
The responsibility for setting up an inspection
schedule rests with the purchaser and will be
dependent upon the class of storage provided. It
would be expected initially, inspection would occur
weekly, then depending upon the inspection reports
being favorable or unfavorable, inspection would
continue weekly, monthly, or quarterly, as may be
determined.
Each inspection should consist of a general surface
inspection to assure that:

a) Pump supports are firmly in place.
b) Pump covers over openings are firmly in place.
c) Pump coverings, plastic or tarps are firmly in

place. Any holes or tears must be repaired to
prevent entrance of dirt or water.

d) Pump covers are periodically removed from

openings and interior accessible areas inspected.
If surface rusting has occurred, clean or coat with
preservative.

e) If rusting occurs on exterior surfaces clean and

repaint or coat with preservative.

f) Check individually wrapped parts for signs of

deterioration. If necessary, renew preservative
and wrapping.

Six months prior to the scheduled installation date, a
FLOWSERVE representative is to be employed to
conduct an inspection. This inspection may include,
not necessarily in its entirety and not limited to the
following:

a) An inspection of all periodic inspection records as

kept on file by the purchaser, and all inspection
reports that have been compiled during the
storage period.

b) An inspection of the storage area to determine

the "as stored" condition of the equipment prior to
any protection covers being removed.

c) An inspection of the equipment with protective

covers and flange covers removed.

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QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

d) Depending upon the length of time the equipment

was stored, the type of storage provided (i.e.
Indoor: heated, unheated, ground floor, concrete
floor. Outdoors: under roof, no roof, waterproof
coverings, on concrete, on ground) and as a
result of the inspection of (a),( b) & (c) above the
FLOWSERVE representative may require a
partial or complete dismantling of the equip m ent.

e) Dismantling may necessitate restoration of

painted or preserved surfaces, and, or
replacement of gaskets, "O" rings, packing and
bearings.

f) All costs involved during inspection, dismantling,

restoration, replacement of parts and reassembly
will have to the accounted to the purchaser. All
necessary labour, tools and cranes will be
supplied by the purchaser.

Upon completion of the inspection the FLOWSERVE
representative shall submit a report to the purchaser,
and to the Manager of Customer Service, stating in
detail the results of the inspection.
One month prior to installation of the equipment, a
FLOWSERVE representative is to be employed to
conduct a final inspection. This inspection will be
made to assure that the requirements of the six
months inspection report were satisfactorily
completed and that the equipment is ready for
installation.
Upon completion of this inspection the FLOWSERVE
representative shall submit a final report to the
purchaser, and to the Manager of Customer Service,
advising the results of the final inspection.
All costs involved in conducting the final inspection
will have to the accounted to the purchaser.
Prior to and during start up, any requireme nts for the
services of an FLOWSERVE representative will
revert back to the original contract agreement for
equipment purchased, with revised costing.

2.4.1.4 Delay in th e startup

Startup of the pumps, after installation on the plant,
should be executed within two months as a
maximum.
In case, for any reason, the period between
installation and startup should exceed the two
months, the following precautions must be taken:

a) If acid descaling are foreseen on the plant, the

pump must be by-passed during these
operations, or, otherwise, shall be fully
disassembled, washed with basic solution, dried
and reassembled. All these operations shall be
executed by Flowserve personnel or under
Flowserve supervision.

b) It is advisable, for a long term permanence on the

plant before startup, that blind flanges are
interposed between the pump nozzles and the
relevant pipe, to avoid the possibility that foreign
material can be introduced into the pump. In case
such flange s not installed, it is advisable that the
inner parts of the pumps is carefully inspected
(by disassembling, if necessary) to verify the
absence of foreign material before the startup.

c) During the period between installation and

startup the same maintenance checks described
in point 2.4.1.3 shall be carried out.

2.4.1.5 Painting and preservation

Paints and preservatives used are either
FLOWSERVE standard or 'special' as required by the
contract specification. Refer to FLOWSERVE for the
description of paints and preservatives used on this
order if needed.

2.4.1.6 Associated equipment

Motors, Turbines, Gears, etc., being supplied by
FLOWSERVE.
Generally rotors of associated equipment should be
blocked to relieve bearing loads. Storage should be
indoors and dry. See the specific manufacturers
storage requirements.

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 using an environmentally
acceptable method and in accordance with local
regulations. If the product contains substances which
are harmful to the environment, these should be
removed and disposed in accordance with current
local regulations. This also includes the liquids
and/or gases that may be used in the "seal system"
or other utilities.

Make sure that hazardous substances are

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

Page 14 of 61

QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

3 PUMP DESCRIPTION

Should questions arise concerning the pump,
Flowserve pump division will require the complete
serial number to be of assistance. The serial number
is stamped on a metal nameplate affixed to the
discharge head assembly. The driver will have a
separate nameplate attached to it. If you are
requesting information on the driver, please provide
both the driver serial number and the pump serial
number to Flowserve representative.

3.1 Configurations

QLQs, are engineered pumps as:
(a) Wet pit (sump) type
(b) Double casing (can) type pumps.
Most pumps are built with customer specific features
and for applications such as water pumpin g stations,
storm water service, industrial, O & G, power
applications. The pumps vary in size, impeller types
and length, whether it is an open shaft or enclosed
shaft designs and type of discharge head used.

3.1.1 Wet Pit (sump) Type QLQ

3.1.2 Suction barrel (Can) QLQC

3.2 Nomenclature

The pump size/ serial number will be engraved on the
nameplate typically as below: The nameplate is
attached to the discharge head assembly.

3.2.1 Bowl assembly nomenclature

12 QLQ 18 / 45 / 4

Nominal Bowl Discharge
flange inches

Bowl Model QLQ
First Stage Impeller

Nominal Dia. – inches
Additional Stages Model
Total Number of Stages

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QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

The typical nomenclature above is the general guide
to the QLQ configuration description. Identify the
actual pump size and serial number from the pump
nameplate. The driver will have a separate nameplate
attached it.

3.3 Design of major parts

3.3.1 Case assembly

Case assembly is designed to operate completely
submerged in the liquid. It consists of suction bells,
first and additional stages bowls, impellers and pump
shaft.
The suction bells serve as the input- ports to the first
stage impeller. Internal vanes support the housing of
the suction bell bearing.
The first stage casing is made of lower and upper
bell-mouth with bearing, double volute and discharge
branches with bearing. Twin volute is made efficiently
to convert to pressure the velocity added to the liquid
by the impeller.
Additional stage casings are diffuser type.

3.3.2 Impellers

QLQs are supplied with enclosed, double suction fist
stage impeller types, while additional stages impellers
are single suction. Impellers are low, medium and
high capacity type designed for maximum coverage
of all QLQ applications. Impellers are cast and
machined to match each order and to provide
required surface finish to achieve hydraulic
characteristics. Impellers are dynamically balanced
and held in position on the shaft by key and locking
nut.

3.3.3 Column assembly

The column assembly con sists of column pipe, which
connects the bowl assembly to the discharge head
and carries the pumped fluid to the discharge head.
Houses and supports the shaft and may contain
bearings. Typical column assemblies are flanged, with
integrated bearing support.

The column supports shaft assembly, that is either
a) Open lineshaft construction utilizing the fluid being

pumped to lubricate the lineshaft bearings.
or
b) Enclosed lineshaft construction has an enclosing

tube around the lineshaft and utilizes oil or other

clean fluid to lubricate the lineshaft bearings.
The shafts are key coupled with thrust stud design or

clamp ring design.

The column shaft is usually divided in more sections
to facilitate the assembly during installation and
maintenance.
See sectional drawings supplied with the pump for
exact column assembly details as per the order. The
size and configuration vary depending upon the
specific order requirements and application criteria

3.3.4 Suction strainers

Wet Pit (sump) QLQs can also be fitted with strainers
to prevent foreign particles from entering the pump.
The type of strainers and the mesh size depends on
the application. An example is shown below.
Strainers are usually fastened directly to the suction
bells .

3.3.5 Suction Can

Suction can is designed to allow the impeller to have
the proper level of NPSH to run properly, when the
available NPSH is insufficient at ground level.
It's connected with the Suction Head, and can be
directly installed on the foundations or through a
separate foundation plate,
According to the specification, it can be designed to
withstand the maximum Suction Pressure or to
withstand the Maximum Allowable Working Pressure.
Consult the dedicated pump document for more
details on it.

3.3.6 Discharge Head Assembly

The discharge head supports the driver and bowl
assembly as well as supplying a discharge connection
in most cases. A shaft sealing arrangement is located
in the discharge head to seal the shaft at its exit from
the liquid chamber. The shaft seal will usually be
either a mechanical seal assembly or packing seal
with an open lineshaft or a tube-packing box with an
enclosed lineshaft.

If the pump is required to have its own thrust bearing ,
it is installed in the discharge head has the pump
thrust bearing integrated.
The different types of discharge heads can be
summarized in two types.

Page 16 of 61

QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

3.3.6.1 Head for Wet pit (sump) pumps

The head has the suction nozzle and the thrust
bearing (if installed in the pump) integrated.
The head is fixed to the ground by means of a
foundation plate or by fou ndation beams on which the
head is placed.

3.3.6.2 Head for double casing (can) pumps

The head has the suction nozzle, the discharge
nozzle, the thrust bearing (if installed on the pump)
integrated. The head is connected to the suction
barrel (can) through a flange; the head can have
provisions to be fixed directly to the ground or to be
fixed on a separate foundation plate.
For special layouts the suction nozzle can be placed
below the mounting level (refer to the dedicated
General Arrangement drawing for reference).

3.3.7 Motor Stool

The motor stool is a fabricated steel structure
designed to maintain the proper alignment between
pump and electric motor.
It can be integrated with the pump head or it can be a
separate piece fixed upon the suction head.

3.3.8 Drivers

A variety of drivers may be used, however, electric
motors are most common. For the purposes of this
manual, all types of drivers can be grouped into two
categories.

a) Hollo w shaft drivers: where the head shaft extends
through a tube in the center of the rotor and is
connected to the driver by a clutch assembly at the top
of the driver.

b) Solid shaft drivers: where the rotor shaft is solid
and projects below the driver-mounting base. This type
driver requires an adjustable coupling for connecting to
the pump.

3.3.9 Stuffing box

QLQs are fitted with stuffing boxes which are
adequate for the pump working pressure. Stuffing
boxes may fit a mechanical or packing seal.

3.3.10 Mechanical shaft seal

QLQs can be fitted with single or double mechanical
seal. Depending on the services specified, the
mechanical seal has different plan to provide the
proper flushing to the faces trough appropriate piping
either installed on the pump or to be provided and
mounted when the pump is installed.

3.3.11 Thrust Bearing (if installed)

The pump shall be equipped with a thrust bearing
installed in the suction head (alternatively, the thrust
bearing of the driver can be designed to withstand the
thrusts of the pump).
The thrust bearing is designed to withstand the axial
loads (static weights of rotors and hydraulic loads)
occurring throughout the pump operating range.
The thrust bearings can be ball type, roller type or
tilting pad.
The bearings are housed in a fabricated steel support
directly mounted on the upper side of the discharge
head.
Lubrication of the thrust bearings is provided by oil
bath.
As standard option, an oil sight glass in installed
outside the bearing house to check oil level and
refilling.

3.3.12 Flexible coupling with spacer (if installed)

If the pump is equipped with thrust bearing, the pump
shaft is joined to the driver shaft with a flexible
coupling with spacer.
The flexible coupling allow the transmission of the
torque to the pump, but not the axial loads.

3.3.13 Rigid Coupling with spacer between
mechanical seal and bearing support (if installed)

If the pump is equipped with mechanical seal and
thrust bearing, a rigid coupling with spacer is placed
between the thrust bearing and the mechanical seal.
By the removal of the coupling hub and the spacer
only the removal of the mechanical seal is without the

Page 17 of 61

QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

need to dismantle the thrust bearing, simplifying the
maintenance operations.

3.3.14 Rigid coupling between motor and pump
(if installed)

If the pump is not equipped with the thrust bearing, a
rigid coupling provides the torque and the axial load
transmission between pum p and driver.

3.3.15 Accessories

Accessories (instrumentation, special flushing plans)
may be fitted when specified by the customer.

3.4 Performance and operating limits

This product has been selected to meet the
specifications of your purchase order, see section

1.5.
These pumps are furnished for a particular service

condition. Changes in the hydraulic system may
affect the pump's performance adversely. This is
especially true if the changes reduce the pressur e at
the suction flange or if the liquid temperature is
increased. In case of doubt, contact the nearest
FLOWSERVE office.

3.4.1 Operating limits

Pumped liquid temperature
limits*

Maximum ambient
temperature*

Maximum pump speed refer to the nameplate

-45 ºC (-50 ºF) to +205 ºC (400
ºF)

Up to +55 ºC (130 ºF)

*Subject to written agreement from Flowserve.
Special designs and materials may be available for
pumps operating above and below these specified
limits. Contact Flowserve for upgrade options
available for your specific application.

Page 18 of 61

QLQ, QLQC USER INSTRUCTIONS ENGLISH 87900027 – 06/14

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.

Six months prior to the scheduled installation date, a
Flowserve Pump Division representative is to be
employed to conduct an inspection of the equipment
and the facility. If any deterioration of equipment is
noticed, the Flowserve Pump Division representative
may require a partial or complete dismantling of the
equipment including restoration and replacement of
some components.

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.

4.1.1 General installation check-list

The following checks should be made before starting
actual installation.

a) Make sure that motor nameplate ratings and the

power supply system match correctly.

b) Check the sump depth and pump length match-

up.
c) Check the liquid level in the sump.
d) Check the installation equipment to be sure that

it will safely handle the pump weight and size.
e) Check all pump connections (bolts, nuts etc.) for

any shipping and handling related problems.

Apply thread lubricant sparingly to
male shaft threads only at the time of making up
shaft connection. Excess lubricant should be
avoided.

4.1.2 General installation instructions

As standard option the pumps are shipped with the
suction bowl, column and suction head fully
assembled and the suction barrel (if is supplied)
shipped separately.

4.1.2.1 Lifting

See lifting methods in section 2.3.

4.1.2.2 Equipment and tools required for
installation of a fully assembled pump

a) Mobile crane capable of hoisting and lowering the

entire weight of the pump and motor.

b)

Cable sling for attaching to the pump and motor
lifting eyes.

c)

Ordinary hand tools: Pipe wrenches, end
wrenches, socket set, screwdrivers, Allen
wrenches, wire brush, scraper and fine emery
cloth.

d)

Thread sealing compound designed for type of
connection and light machinery oil.

The single most common cause of pump
vibration is from a bent shaft. Shafting is straightened
to stringent tolerances prior to shipping and great
care must be exercised in its handling.

Always support shafting in at least three places when
lifting or installing.

Always support shafting in at least
three places when lifting or installing. No installation
should be attempted without adequate equipment
necessary for a successful installation.

 On hollow shaft drivers, check the clutch size

against the shaft size, which must go through the
clutch

 On solid shaft drivers, check the motor shaft size

against the coupling bore size

Page 19 of 61

Parts and accessories may be placed
inside shipping containers, or attached to skids in
individual packages.

Inspect all containers, crates and skids for attached
parts before discarding.

Lifting heavy objects is dangerous. Use of
appropriate tools and procedures is must.

4.1.2.3 Uncrating and cleaning of a fully
assembled pump

a) Clean the parts of all dirt, packing material and

other foreign matter.

b) Clean all machined surfaces. Remove any rust

spots found on the machined surfaces with fine
emery cloth.