Flowserve S-series User Manual

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USER INSTRUCTIONS

PolyChem S-series pumps

ISO and ANSI

Horizontal, end suction, single stage, centrifugal, chemical process pumps

PCN=71569207 11-08 (E) (Based on P-30-502-E.) Original instructions.

Installation

Operation

Maintenance

These instructions must be read prior to installing,

operating, using and maintaining this equipment.

USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

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.......................................................... 11

2.5 Recycling and end of product life.................. 11

3 DESCRIPTION....................................................12

3.1 Configurations...............................................12

3.2 Nomenclature................................................ 12

3.3 Design of major parts....................................12

3.4 Performance and operation limits.................13

4 INSTALLATION....................................................14

4.1 Location.........................................................14

4.2 Part assemblies.............................................14

4.3 Foundation....................................................14

4.4 Grouting ........................................................16

4.5 Initial alignment.............................................17

4.6 Piping............................................................ 18

4.7 Electrical connections ...................................23

4.8 Final shaft alignment check ..........................23

4.9 Protection systems........................................ 23

6 MAINTENANCE.................................................. 30

6.1 General......................................................... 30

6.2 Maintenance schedule.................................. 31

6.3 Spare parts ................................................... 31

6.4 Recommended spares

and consumable items ............................... 31

6.5 Tools required............................................... 32

6.6 Fastener torques........................................... 32

6.7 Setting impeller clearance and impeller

replacement................................................32

6.8 Pump removal and disassembly................... 35

6.9 Examination of parts..................................... 37

6.10 Assembly of pump and seal........................ 41

7 FAULTS; CAUSES AND REMEDIES.................. 47

8 PARTS LISTS AND DRAWINGS ........................ 49

8.1 PolyChem S-series....................................... 49

9 CERTIFICATION................................................. 50

10 OTHER RELEVANT DOCUMENTATION

AND MANUALS............................................... 50

10.1 Supplementary User Instructions ............... 50

10.2 Change notes ............................................. 50

10.3 Additional sources of information................ 50

Page

5 COMMISSIONING, STARTUP, 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.......................................26

5.5 Guarding .......................................................27

5.6 Priming and auxiliary supplies ......................28

5.7 Starting the pump..........................................28

5.8 Running or operation ....................................28

5.9 Stopping and shutdown.................................29

5.10 Hydraulic, mechanical and electrical duty...30

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

INDEX

Page

Additional sources of information (10.3).................50

Assembly of pump and seal (6.10).........................41

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

Certification (9) ....................................................... 50

Change notes (10.2)...............................................50

Configurations (3.1)................................................ 12

Consignment receipt and unpacking (2.1).............. 10

Design of major parts (3.3)..................................... 12

Direction of rotation (5.4)........................................ 26

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

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

Electrical connections (4.7) .................................... 23

Examination of parts (6.9) ...................................... 37

Fastener torques (6.6)............................................ 32

Final shaft alignment check (4.8)............................ 23

Foundation (4.3) .....................................................14

Grouting (4.4).......................................................... 16

Guarding (5.5)......................................................... 27

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

Hydraulic, mechanical and electrical duty (5.10).... 30

Impeller clearance (5.3)..........................................26

Initial alignment (4.5) ..............................................17

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

Location (4.1)..........................................................14

Maintenance schedule (6.2)................................... 30

Nameplate and safety labels (1.7)............................8

Noise level (1.9)........................................................9

Nomenclature (3.2).................................................12

Part assemblies (4.2).............................................. 14

Parts list (8)............................................................. 49

Performance and operation limits (3.4) ..................13

Piping (4.6) ............................................................. 18

Pre-commissioning procedure (5.1) ....................... 24

Priming and auxiliary supplies (5.6)........................ 28

Protection systems (4.9).........................................23

Pump lubricants (5.2) ............................................. 24

Pump removal and disassembly (6.8).................... 35

Recommended spares

and consumable items (6.4).............................. 31

Recycling and end of product life (2.5)...................11

Running or operation (5.8)...................................... 28

Safety (1.6)............................................................... 5

Setting impeller clearance

and impeller replacement (6.7).......................... 32

Spare parts (6.3)..................................................... 31

Specific machine performance (1.8)......................... 9

Starting the pump (5.7)...........................................28

Stopping and shutdown (5.9).................................. 29

Storage (2.4)...........................................................11

Supplementary user instructions (10.1).................. 50

Tools required (6.5) ................................................32

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

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 certai n regions of t he world shall conform with the applicable CE Marking Directive s covering Machinery and, where appli cable, Low V oltage 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 App rovals.

To confirm the Approvals applying and if the product is CE marked, check the serial number plate markings and the Certification. (See section 9, Certificatio n.)

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 fr om other vendo rs 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 Flow serve parts an d accessories is considered to be misuse. Damage or failure caused by misuse is not covere d 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

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 ex ample li quid pum ped, temperature or duty) it is requested that the user seeks the written agreement of Flowserve before start up.

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

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 af fect personal safety and co uld result in loss of life.

This symbol indicates “hazardous and toxic fluid” safety instructions where non-compliance would af fect personal safety and could result in loss of life.

This symbol indi cates safet y inst ruct ions where non-compliance will involve some risk to safe operation and personal safety and would dam age 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 expl osion.

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.

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 prod ucts used in potentially explosive atmosphere s section 1.6.4 also applies.

NEVER DO MAINTENANCE WORK

WHEN THE UNIT IS CONNECTED TO POWER

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 OPERATE THE PUMP WITHOUT THE COUPLING GUARD AND ALL OTHER SAFETY DEVICES CORRECTLY INSTALLED

This sign is not a safety symbol but indicates

an important instructio n in the assembly pro cess.

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 involv ed. If the perso nnel in question do not already possess the necessary knowledge and skill, appropriate training and inst ruction must be provided. If required the operator may commission the manufactur er/sup plier t o 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.

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GUARDS MUST NOT BE REMOVED WHILE THE PUMP IS OPERATIONAL

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 ºC (175 ºF) or below 5 ºC (20 ºF) in a restricted zone, or exceeds local regulations, action as above shall be taken.

NEVER APPLY HEAT TO REMOVE IMPELLER This could damage the liner plus trapped lubricant or vapor could cause an explosion.

USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

1.6.4 Products used in potentially explosive

THERMAL SHOCK

atmospheres

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.

The following instructions for pumps and pump units when installed in potentially explosive atmospheres must be followed to help ensure explosion protection. The terminology and

HAZARDOUS LIQUIDS When the pump is handling hazardous liquids care must be taken to avoid exposur e to the l iquid by approp riate 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.

procedures ensure that the installed pump is in compliance with the European Directive 94/9/EC, known as the ATEX Directive, which is mandatory in Europe and may also be specified in other countries. Where applicable, both electrical and non-electrical equipment must meet the requirements 94/9/EC. Even if the installation is in a region where ATEX is

PREVENT EXCESSIVE EXTERNA L PIPE LOAD Do not use pump as a support for piping. Do not mount expansion joints, u nless all owed by Fl owserve i n writin g, so that their force, due to internal p ressure, act s on t he 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.)

not the applicable regulation, the general measures described shall be followed to ensure safe operation.

The measures are explained under the headings of:

• Avoiding excessive surface temperature

• Preventing build up of explosive mixtures

• Preventing the generation of sparks

• Preventing leakages

• Maintaining the pump to avoid hazard

1.6.4.1 Scope of compliance

Use equipment only in the zone for whi ch it is appropriate. Always check that the driver , drive coupling assembly, seal and pump equipment are suitably rated and/or certifie d for the classi fication of the specific atmosphere in which they are to be inst alled.

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/

NEVER RUN THE PUMP DRY OR

WITHOUT PROPER PRIME (Casing flooded)

Declaration of Conformity establishing it is suitable for the area in which it is to be installed.

NEVER OPERATE THE PUMP WITH THE SUCTION VALVE CLOSED It should be fully opened when the pump is running.

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

NEVER OPERATE THE PUMP AT ZERO FLOW OR FOR EXTENDED PERIODS BELOW THE MINIMUM CONTINUOUS FLOW

where electrical supply is from the VFD. This particular requirement still applies even if the VFD is in a safe area.

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 spa cer and starting the pump. Incorrect rotation of the pump for even a short period can unscrew the impeller, which can cause significant damage.

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

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

Pump liquid temperature

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 temperature class and must not exceed the values in the table applicable below. 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

EN13463-1

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 when the pump is requir ed 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 installe d location.

Do not attempt to check the direction of rotation with the coupling element/pins fitted due to the risk of sev ere contact between rotating and stationary compo nents.

Where there is any risk of the pump being run against a closed valve generating high liqui d and casing exte rnal surface temperatures it is recommended that users fit an external surface temperature protectio n device.

Avoid mechanical, hydraulic or electrical overlo ad by using motor overload trips, temperature monitor or a power monitor and perform rout ine vibrat ion monito ring.

In dirty or dusty environments, regular checks must 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 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 the fitting of an appropriate dry run protection device is recommended (for example liquid detection or a power monitor).

To avoid potential hazards from fugitive emissions of vapor or gas to atmosphere the surrounding area must be well ventilated.

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

1.6.4.5 Preventing sparks

To prevent a potential hazard from mechanical

contact, the coupling guard must be non-sparking. To avoid the potential hazard from random induced

current generating a spark, the earth contact on the baseplate must be used.

Avoid electrostatic charge: do not rub no n-metallic

surfaces with a dry cloth; en sure cloth is dam p. When applicable the coupling must be selected to

comply with 94/9/EC and correct alignment must be maintained.

Additional requirement for metallic pumps on non-metallic baseplates

When metallic components are fitted on a nonmetallic baseplate they must be individually earthed.

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 a nd associat ed piping due to closing of su ction an d discharg e valves, which could cause dangerous excessiv e pressures to occur if there is heat input t o the liqu id. This ca n 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 lo ss of a seal barrier fluid or external flush, the f luid must be monit ored.

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 of the centrifugal pump to avoid a hazard

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

The responsibility for compliance of maintenance and compliance during mainten ance with the specified product 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) only:

THIS DEVICE IS NOT A CONTAINMENT SYSTEM NOR A SEAL BACKUP SYSTEM IT IS A LIMITED PROTECTION DEVICE. IT WILL REDUCE BUT NOT ELIMINATE THE PROBABILITY OF INJURY.

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

1.8 Specific machine performance

For performance parameters see section 1.5, Dut y conditions. Where performance data has been supplied

separately to the purchaser these should be obtained and retained with these User Inst ructions if re quired.

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 a ssumed in t he “pump and motor” noise is that typically exp ected f rom stand ard and high efficiency motors when on load dire ctly 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 Flowserv e 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 L

at 1 m

(3.3 ft) from the machine, for “free field conditions over a reflecting plane”.

For estimating sound power level L

(re 1 pW) then

add 14 dBA to the sound pressure value.

Motor size and speed

kW (hp)

<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) 300 (400) – 87 90 85 86

1 The noise level of machine s in this range will most likely be of valu es which req uire no ise exposure control, but ty pical values are inappropr iate.

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.

3 550 r/min 2 900 r/min 1 750 r/min 1 450 r/min

Pump

only

Pump and

Typical sound pressure level LpA at 1 m reference 20 µPa, dBA

motor

1 1

Pump

only

Pump and

motor

Pump

only

85 87 83 85

Pump and

motor

Pump

only

Pump and

motor

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

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 and must be received in writing within thirty (30) calendar days 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

Pumps and motors often have integral lifting lugs or eye bolts. These are intended for use in only lifting the individual piece of equipment.

2.3.1.3 Bearing housing [3200]

Group A and 1 lower support ribs between the housing barrel an d the casing attachment flange. Use a choker hitch when slinging. (Make sure there are no sharp edges on the bottom side of the ribs that could cut the sling.)

Group B, C and 2 through the lifting lug located on the top of the housing.

2.3.1.4 Power end

Same as bearing housing.

2.3.1.5 Bare pump

Horizontal pumps nozzle and around the outboar d end of th e bearing housing with separate slings. Choker hitches must be used at both attachment points and pulled tight. Make sure the completion of the choker hitch on the discharge nozzle is toward the coupling end of the pump shaft as shown in Figure 2-1. The sling lengths should be adjusted to balance th e load bef ore att achi ng the lift ing hook. Pump models with non standard flanges can not accommodate a sling around the discharge nozzle; when lifting these pumps an in dividual trai ned in properly lifting equipment must be consulted.

Figure 2-1

: insert a sling between the upper and

: insert either a sling or hook

: sling around the pump discharge

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 shown.

Care must be taken to lift components or assemblies above the center of gr avity to prev ent the unit from flipping. This is especially t rue with In -Line pumps.

2.3.1 Lifting pump components

2.3.1.1 Casing [1100]

Use a choker hitch pulled tight around the discharge nozzle.

2.3.1.2 Rear cover [1220]

Insert an eye hook in the drilled and tapped hole on the face of the cover. Use either a sling or hook through the eye bolt.

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

2.3.2 Lifting pump, motor and baseplate assembly

If the baseplate has lifting holes cut in the sides at the end (Type D and Type E base s) insert lifti ng S hook s at the four corners and use slings or chains to connect to the lifting eye. (Figure 2-1.) Do not use slings through the lifting holes.

For other baseplates, sling around the pump discharge nozzle, and around the outboard end of the motor frame using choker hitches pulled tight. Pump models with non standard flanges can not accommodate a sling around the discharge nozzle; when lifting these pumps an individual trained in properly lifting equipment must be consulted. (Figure 2-1.)

The sling should be positioned so the weight is not carried through the motor fan housing. Make sure the completion of the choker hitch on the discharge nozzle is toward the coupling end of the pump shaft as shown in Figure 2-1.

2.4 Storage

Store th e pump in a clea n, dry locati on away from vibration. Leave piping connectio n covers in place to keep dirt and other foreign material out of pump casing. T urn pump at int erv als to pr event brinel ling 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.

2.4.1 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:

• All loose unmounted items are packaged in a

water proof plastic bag and placed under the coupling guard

• Inner surfaces of the bearing housing, shaft (area

through bearing housing) and bearings are coated with Cortec VCI-329 rust inhibitor, or equal.

2.4.2 Long term storage and packaging

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 unit s are to be idle fo r extende d periods after addition of lubricants, in hibitor oils a nd greases should be used. Every three months, the pump shaft should be rotated approximately 10 revolution s.

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.

Bearing housings are not filled with oil

prior to shipment

• Regreasable bearings are packed with grease (MOBIL POLYREX EM)

• Exposed shafts are taped with Polywrap

• Flange covers are secured to both the suction

and discharge flanges

• In some cases with assemblies ordered wit h external piping, components may be disassembled for shipment

• The pump must be stored in a covered, dry location

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

3 DESCRIPTION

3.1 Configurations

PolyChem S-series chemical process pumps are horizontal, end suction, single stage, centrifugal pumps. The ISO version of this pump conforms dimensionally to ISO 2858/5199 while the ANSI model agrees dimensionally with ASME B73.1. Both have centerline discharge.

3.2 Nomenclature

The pump size will be engraved on the nameplate typically as below:

PS 40 – 200 / 190CL (ISO) PS 2 x 1 - 10 / 8.25CL (ANSI)

P = PolyChem pump line S = Sealed

Power end:

Mark 3A – Standard ANSI 3A – Optional (lifetime guarantee)

ISO pump:

“40” = Nominal discharge port size (mm) “200” = Nominal (max.) impeller diameter (mm) “190” =Actual impeller diameter (mm)

ANSI pump:

“2” = Nominal suction port size (in.) “1” = Nominal discharge port size (in.) “10” = Nominal (max) impeller diameter (in.) “8.25” = Actual impeller diameter (in.)

Impeller style (ISO or ANSI):

CL = closed vane impeller OP = Open impeller

Pump design variation (ANSI only):

HD = Heavy duty shaft which is available on all Group 2

pump models. The shaft increases from

47.63 mm (1.875 in.) to 53.98 mm (2.125 in.).

An example of the nameplate used on the PolyChem pump is shown in Figure 3-1. This nameplate is always mounted on the bearing housing.

Figure 3-1: Nameplate mounted to housing

Serial No.

Equipment No.

Purchase Order

Model

Material

Date DD/MMM/YY

Size

PS 2 X 1 - 10 / 8.25CL

MDP

3.3 Design of major parts

3.3.1 Pump casing

Removal of the casing is not required when performing maintenance of the rotating element. The rotating element is easily removed (back pull out).

3.3.2 Impeller

Depending on the pump size, the impeller is either closed vane or open.

3.3.3 Shaft/sleeve

Solid and sleeved shafts are available, supported on bearings, threaded impeller end and 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

Large oil bath reservoir.

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.

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 et c drivin g via couplings, belts, gearboxes, drive shafts etc.

3.3.9 Accessories

Accessories may be fitted when specified by the customer.

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

3.4 Performance and operation limits

This product has been selected t o meet th e specification of your purchase order. See section 1.5.

The following data is included as additional information

3.4.2 Pressure-temperature ratings

PN 16 flanges are standard for the ISO model pump while Class 150 flanges are standard for the ANSI model. Refer to Figure 3-3A and 3-3B for each pump’s pressure-temperature (P-T) ratings.

to help with your installation. It is typical, and factors such as liquid being pumped, temperature, material of construction, and seal type may influence this data. If required, a definitive statement fo r your appli cation can be obtained from Flowserve.

3.4.1 Material cross reference chart

Figure 3-2 is the material cross-reference chart for all PolyChem S-series pumps.

The maximum discharge pressure must be less than or equal to the P-T rating. Discharge pressure may be approximated by adding the suction pressure to the differential pressure developed by the pump.

3.4.3 Suction pressure limits

The suction pressure limits for PolyChem S-series pumps are limited by the P-T rating.

Figure 3-2: Material cross-reference chart

Flowserve

material code

Z0L48 PFA lined Ductile iron (cast) DIPA None Note 1 1.0 E2025 Ductile Iron Casting 7043 None EN1563, Gr. JS 1025 1.0 E3020 Ductile Iron Casting DCI None A395, Gr. 60-40-18 1.0

D0005 Carbon Steel SR None N/A D2044 Quenched and Tempered Steel CK45 None EN 10083-1 N/A D3013 1018 Carbon Steel Z None N/A D3058 304 Stainless Steel 304 None A276, Type 304 N/A D3277 Carbon Steel BB 1144 UNS G11440 N/A E2008 Ductile Iron Casting 7040 None EN1563, Gr. JS 1030 N/A E3006 Cast Iron Casting CI None A48, Gr. 25A N/A E3035 Ductile Iron Casting DCI2 None A536, Gr. 65-45-12 N/A E4034 Ductile Iron Casting DCI4 None Note 2 N/A

I3011 Titanium TIW B348, Gr. 3 N/A

J0020 Sintered silicon carbide SC3 None None N/A K3019 Hastelloy C276 C276 C276 UNS N10276 N/A K4008 Chlorimet 3 DC3 Hastelloy® C A494, Gr. CW6M N/A L0009 Carbon Filled Teflon TFEC None N/A L1010 Ethylene Propylene Diene Monomer EPDM None N/A L1011 Viton VA None N/A L1017 Nitrile Butadiene Rubber NBR None N/A L1049 Kalrez 4079 KAL None N/A

L1103 Pollyulphone PS None N/A M1001 ISO 3506 Grade A2 Class 70 A270 None N/A M1006 ISO898 QT 12.9 None N/A M1013 ISO 898/1 Class 8.8 88 None N/A

Z0067 Protective Plated Carbon Steel SRCD None N/A

Z0L49 PFA lined carbon steel (wrought) SRPA None N/A

Z0L52 Carbon filled fluoropolymer CFTM None N/A

Z0L53 Carbon fiber reinforced PFA CRPA None N/A

Z0L59 1018 (SR) welded to 316 (SS) ZH None N/A

Z0L60 1018 (SR) welded to C20 (Alloy 20) ZC20 None N/A

Z0L61 304 (SS) welded to B2 (B2) EHB None N/A

Z0L62 304 (SS) welded to C276 (C276) EHC None N/A

Z0L64 Teflon lined A193, Gr. B7 B7TF None N/A

Z0L65 Teflon lined A194, Gr. 2H SRTF None N/A

Z0L72 Teflon – Silicon Rubber – Carbon Steel TSSR None N/A Z0M21 PFA lined stainless steel (cast) D4PA None N/A Z0M22 Viton – Carbon Steel VSR None N/A Z0M35 Carbon fiber reinforced fluoropolymer CRTM None N/A

®Hastelloy is a registered trademark of Haynes International, Inc. Note 1. The casting used for ISO pumps is E2025 and for ANSI pumps is E3020 Note 2. Dual Spec. EN1563 Gr. JS1030 & A536 Gr. 65-45-12

Designation

Durco

legacy

codes

Equivalent

wrought

designation

EN/ASTM

specifications

Nozzle load

material group

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

Figure 3-3A: Pressure-temperature rating

(ISO pump with PN 16 flanges – Material Group No. 1.0)

Temperature

°C ( °F)

Bar (psi)

-29

(-20)

(232)

-18 (0)

(232)

(100)

(232)

(200)

(232)

121

(250)

(232)

149

(300)

15.5

(225)

Figure 3-3B: Pressure–temperature rating

(ANSI pump with Class 150 flanges – Material Group No. 1.0)

Temperature

°C ( °F)

Bar

(psi)

-29

(-20)

17.2

(250)

-18 (0)

17.2

(250)

(100)

17.2

(250)

(200)

16.2

(235)

149

(300)

14.8

(215)

3.4.4 Minimum continuous flow

The minimum continuous flow (MCF) is based on a percentage of the best efficiency point (BEP). Figure 3-4 identifies the MCF for all PolyChe m S-serie s pump s.

Figure 3-4: Minimum continuous flow

n/a

MCF % of BEP

1 750/1 450

r/min

10 % 10 %

20 % 10 %

40 % 10 %

1 180/960

r/min

Pump size

PS3x2-6 20 % 10 % 10 % PS3x2-10

PS50-250 PS4x3-10

PS65-250 PS3x2-13

PS50-315 PS4x3-13

PS65-315 PS6x4-13HD

PS100-315 All other sizes

3 500/2 900

r/min

30 % 10 % 10 %

10 % 10 % 10 %

4 INSTALLATION

Equipment operated in hazardous locations must comply with the relevant explosion protection regulatiuons. See section 1.6.4, Products used in potentially explosive atmospheres.

4.1 Location

The pump should be located to allow room for acce ss, ventilation, maintenance, and inspe ction with ample headroom for lifting and should be as close as practicable to the supply of liquid to be pumped.

Refer to the general arrangement drawing for the pump set.

4.2 Part assemblies

The supply of motors and baseplates are 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 section 4.5 and 4.8.

4.3 Foundation

4.3.1 Protection of openings and threads

When the pump is shipped, all threads and all openings are covered. This protection/covering should not be removed until installation. If, for any reason, the pump is removed from service, this protection should be reinstalled.

4.3.2 Rigid baseplates - overview

The function of a baseplate is to provide a rigid foundation under a pump and its driver that maintains alignment between the two. Baseplates may be generally classified into two types:

• Foundation-mounted, grouted de sign. (Figure 4-1. )

• Stilt mounted, or free standing. (Figure 4-2.)

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.

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

Experience indicates that a baseplate with 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 a nd drive r to within th eir 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 confir m 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 alig nment wh en the installer puts the baseplate assembly into its original, top levelled, unstressed conditi on.

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 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 [2] above the stilt bolt head

[1] to the desired height.

d) Assemble lock washer [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 [3] and nut [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 [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 [3] first then tighten the other nuts.

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.

Figure 4-3

1. Stilt bolt

2. Nuts

3. Lock washer

4. Floor cup

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 [4] above the stilt bolt head [1].

This allows for 51 mm (2 in.) upwa rd movement f or the final height adjustment o f the suctio n/discha rge flange.

c) Assemble the lock washer [6] flat washer [5] and

bottom spring/cup assembly [2] down over the stilt bolt [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 [3] down over

stilt bolt.

f) Assemble flat washer [5], lock washer [6] and

nuts [4] on the stilt bolt.

g) Tighten down top nuts, compressing the top

spring approximately 13 mm (0.5 in.). Additional compression may be required to stabilize the baseplate.

h) After all four stilts have been assembled, position

the baseplate in place, over the floor cups [7] under each stilt location, and lower the baseplate down to the floor.

i) Level and make final height adjustments to the

suction and discharge pipe by first loosening the top nuts, and turning the bottom nuts to raise or lower the baseplate.

j) Recompress the top spring to the compression

established in step g) and lock the nuts.

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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.

Figure 4-4

1 in. (25 mm) approx. i nitial heigh

1 . Sti l t bo l t

2. Bott om spring [ 3¼ in. (83 mm ) O/D x 4 in.

(102 mm) floor cups]

3. Top spring [2 in. (51 m m) O/D x 4 in.

(102 mm) floor cups]

4. Nuts

5. Flat washer

6. Loc k was her

7. Floor cup

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 levelled. a) Level the baseplate by using the stilt adjusters.

(Shims are not needed as with grouted baseplates.)

b) After the base is level, it is locked in place by

locking the stilt adjusters.

c) 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.

d) 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.

e) 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. f) Lock the stilt adjusters. 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.

b) 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.

c) Recommended mass of a concrete foundation

should be three times that of the pump, motor and base. Refer to Figure 4-5.

Foundation bolts are imbedded in the concrete inside a sleeve to allow some movement of the bolt.

Figure 4-5

d) Level the pump baseplate assembly. If the

baseplate has machined coplanar mounti ng surfaces, these machined surfaces are to be referenced when leveling the baseplate. This may require that the pump and motor b e remove d 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 p roper surfa ces to reference when leveling the pump baseplate assembly are the pump suction and discharge flanges. DO NOT stress the baseplate.

e) Do not bolt the suction or discharge flanges of the

pump to the piping until the ba seplate f oundati on 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 levelne ss 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 i s more than

1.5 m (5 ft.) long. Do not rely on th e bottom of t he baseplate to be flat. Standard baseplate bottoms are not machined, and it is not likely that the field mounting surface is flat.

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f) 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.

g) 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.

h) Continue adjusting the jackscrews or shims and

tightening the anchor bolts until the baseplate is level.

i) Check initial alignment. If the pump and motor

were removed from the baseplate proceed with step j) 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 descri bed above, pumps are given a preliminary alignment at t he fact ory. Thi s 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 hol es 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 shoul d 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 m oving the pump for horizontal alignment.

j) 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.

k) 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

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.

b) The baseplate is levelled as necessary. Levelling

is accomplished by placing shims under the rails of the base at the appropriate anchor bolt hole locations. Levelness is checked in both the longitudinal and lateral directions.

c) The motor and appropriate motor mounting

hardware is placed on the baseplate and the motor is checked for any planar soft-foot condition. If any is present it is eliminated by shimming.

d) The motor feet holes are centered on the motor

mounting fasteners. This is done by using a centering nut as shown in Figure 4-6.

Figure 4-6

e) The motor is fastened in place by tightening the

nuts on two diagonal motor mounting studs.

f) The pump is put onto the baseplate and levelled.

The foot piece under the bearing housing is adjustable. It is used to level the pump, if necessary. If an adjustment is necessary, add or remove shims [3126.1] between the foot piece and the bearing housing.

g) The spacer coupling gap is verified.

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h) The parallel and angular vertical alignment is

made by shimming under the motor.

i) The motor feet holes are again centered on the

motor mounting studs using the centering nut. At this point the centering nut is removed and replaced with a standard nut. This gives maximum potential mobility for the motor to be horizontally moved during final, field alignment. All four motor feet are tightened down.

j) The pump and motor shafts are then aligned

horizontally, both parallel and angular, by moving the pump to the fixed motor. The pump feet are tightened down.

k) Both horizontal and vertical alignment is again

final checked as is the coupling spacer gap.

l) See section 4.8, Final shaft alignment.

4.6 Piping

Protective covers are fitted to both the suction and discharge flanges of the casing and must be removed prior to connecting the pump to any pipes.

4.6.1 Suction and discharge piping

All piping must be independently supported, accurately aligned and preferably connected to the pump by a short length of flexible piping. The pump should not have to support the weight o f the pip e or compen sate for misalignment. It should be possible to inst all sucti on and discharge bolts through mating flanges without pulling or prying either of the flanges. All piping must be tight. Pumps may air-bind if air is allowed to leak into the piping. If the pump flange(s) h ave tapped holes, select flange fasteners with thread engagement at least equal to the fastener diameter but that do not bottom out in the tapped holes before th e joint is t ight.

The following is the recommended proce dure for attaching piping to the PolyChem S -series pump. (See section 6.6 for torque values.) a) Check the surface of both flanges (pump/pipe) to

ensure they are clean, flat, and without def ects. b) Lubricate the fasteners. c) Hand tighten all of the fasteners in a crisscross

pattern. d) The fasteners should be torqued in increments –

based a crisscross pattern.

 The first increment should be at 75% of the

full torque

 The second increment should be at the full

torque

 Verify that the torque value of the first

fastener is still at the full torque value

e) Retorque all fasteners afte r 24 hours or after the

first thermal cycle.

f) Retorque all fasteners at least annually

4.6.2 Suction piping

To avoid NPSH and suction problems, suction piping must be at least as large as the pump suction connection. Never use pipe or fittings on the suction that are smaller in diameter than the pump suction size.

Figure 4-7 illustrates the ideal piping con figuration with a minimum of 10 pipe diameters between the source and the pump suction. In most cases, horizontal reducers should be eccentric and mounted with the flat side up as shown in Figure 4-8 with a maximum of one pipe size reduction. Never mount eccentric reducers with the flat side down. Horizontally mounted concentric reducers should not be used if there is any possibility of entrained air in the process fluid. Vertically mounted concentric reducers are acceptable. In applications where the fluid is completely de-aerated and free of any vapor or suspended solids, concentric reducers are preferable to eccentric reducers.

Figure 4-7 Figure 4-8

Avoid the use of throttling valves and st rainer s in the suction line. Start up strainers must be removed shortly before start up. When the pump is installed bel ow the source of supply, a valve should be installed in the suction line to isolate the pump and permit pump inspection and maintenance. However, never place a valve directly on the suction nozzle of the pump.

Refer to the Durco Pump Engineering Manual and the Centrifugal Pump IOM Section of the Hydraulic Institute Standards for additional recommendations on suction piping. (See section 10.)

Refer to section 3.4 for performance and operating limits.

4.6.3 Discharge piping

Install a valve in the discharge line. This valve is required for regulating flow and/or to isolate the pump for inspection and maintenance.

When fluid velocity in the pipe is high, for example, 3 m/s (10 ft/sec) or higher, a rapidly closing discharge valve can cause a damaging pressure surge. A dampening arrangement should be provided in the piping.

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4.6.4 Allowable nozzle loads

4.6.4.1 Introduction

Never use the pump as a support for

piping. Maximum forces and moments allowed on pump flanges

vary based on the pump size. When these forces and moments are minimized, there is a corresponding reduction in misalignment, hot bearings, worn couplings, vibration and possible failure of the pump casing. The following points should be strictly followed:

• Prevent excessive external pipe load

• Never draw piping into place by applying force to

pump flange connections

• Do not mount expansion joints so that their force, due to internal pressure, acts on the pipe flange

The PolyChem product line is designed to meet the requirements of ANSI/HI 9.6.2. Allowable nozzle loads for ISO pumps may be calculated using ANSI/HI 9.6.2 by selecting a comparable pump size.

Figure 4-9: Casing material correction factors – Material Group No. 1.0

Temperature ˚C ( ˚F)

Correction factors 0.89 0.89 0.83 0.78

-29

(-20)

(100)

(200)

150

(300)

Figure 4-10: Baseplate correction factors

Base type Grouted Bolted

Type A 1.0 0.7 0.65 Type B - Polybase 1.0 n/a 0.95 Type C n/a 1.0 1.0 Type D 1.0 0.8 0.75 Type E - PIP 1.0 0.95 n/a Polyshield -

baseplate/foundation

1.0 n/a n/a

Stilt

mounted

4.6.4.2 PolyChem S-series pumps

The following steps are based upon ANSI/HI 9.6.2. All information necessary to complete the evaluation is given below. For complete details please review the standard. a) PolyChem S-series pumps are only manufactured

from Ductile Iron. For reference the “Material Group No.” for this material is 1.0.

b) Find the “Casing Materi al Correction Fact or” in

Figure 4-9 based upon the operating temperature. Interpolation may be used to determine the correction factor for a specific t emperat ure.

c) Find the “Baseplate Correction Factor” in Figure

4-10. The correction factor depends upon how the baseplate is to be installe d.

d) Locate the pump model bei ng evaluat ed in Figure

4-14 and multiply each load rating by the casi ng correction factor. Record the adj usted Fi gure 4 -14 loads.

e) Locate the pump model being evaluated in

Figures 4-15 and 4-16 and multiply each load rating by the baseplate correction factor. Record the adjusted Figure 4-15 and 4-16 loads.

f) Compare the adjusted Figure 4-14 values (step

D) to the values shown in Figure 4-13. The lower of these two values should be used as the adjusted Figure 4-13 values. (The HI standard

also asks that Figure 4-13 loads be reduced if Figure 4-15 or 4-16 values are lower. Flowserve does not follow this step.)

g) Calculate the applied loads at the casing flanges

according to the coordinate system found in Figure 4-11. The 12 forces and moments possible are Fxs, Fys, Fzs, Mxs, Mys, Mzs, Fxd, Fyd, Fzd, Mxd, Myd and Mzd. For example, Fxd designates force in the “x” direction on the discharge flange. Mys designates the moment about the “y”-axis on the suction flange.

h) Figure 4-12 gives the acceptance criteria

equations. For long coupled pumps, equation sets 1 through 5 must be satisfied. For C-Face pumps (Ultralign), only equation sets 1 and 2 must be satisfied.

i) Equation set 1.

Each applied load is divided by the corresponding adjusted Figure 4-13 value. The absolute value of each ratio must be less than or equal to one.

j) Equation set 2.

The summation of the absolute values of each ratio must be less than or equal to two. The ratios are the applied load divided by the adjusted Figure 4-14 values.

k) Equation sets 3 and 4.

These equations are checking for coupling misalignment due to nozzle loading in each axis. Each applied load is divided by the corresponding adjusted load from Figure 4-15 and 4-16. The result of each equation must be between one and negative one.

l) Equation set 5.

This equation calculate s the total

shaft movement from the results of equations 3 and

4. The result must be less than or equal to one.

Page 19 of 52 flowserve.com

USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

Figure 4-11: Coordinate system

Figure 4-12: Acceptance criteria equations

Set Equations Figure Remarks

adjxs

adjxd

adjxs

adjxd

adjys

adjyd

adjys

adjyd

adjzs

adjzd

adjzs

adjzd

adjxs

adjxd

adjxs

adjxd

adjys

adjyd

adjys

adjyd

++++++

______

adjzs

≤+++++

______

adjzd

______

adjzs

______

0.2

,0.1,0.1,0.1,0.1,0.1,0.1

≤≤≤≤≤≤

adjzd

Adjusted

4-13

0.1,0.1,0.1,0.1,0.1,0.1

≤≤≤≤≤≤

Adjusted

4-14

Maximum individual

Nozzle stress,

bolt stress,

pump slippage

Note. All of the above equations are found by dividing the applied piping loads by the adjusted figure values.

adjys

adjyd

adjxs

adjxd

adjxs

adjxd

0.10.1 ≤≤− A

adjzs

adjyd

0.10.1 ≤≤− B

0.122≤+ BA

adjys

+++

adjyd

adjxs

adjzd

adjxd

++++=

adjzs

____

adjzd

____

adjyd

+++++=

adjzs

_____

+++++

adjzd

______

adjys

Adjusted

4-15

Adjusted

4-16

y-axis

movement

z-axis

movement

Combined

axis

movement

Page 20 of 52 flowserve.com

USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

Figure 4-13: Maximum individual loading

Suction Discharge

Pump size

PS 1.5x1-6 PS32-160

PS 3x1.5-6 PS 3x2-6

PS65-160 PS 1.5x1-8

PS40-200 PS 2x1-10 & 10HD

PS32-250 PS 3x2-10 & 10HD

PS50-250 PS 4x3-10 &

10HDPS65-250 PS 3x2-13 & 13HD

PS50-315 PS 4x3-13 & 13HD

PS65-315 PS 6x4-13HD

PS100-315

Forces N (lbf) Moments Nm (lbf•ft) Forces N (lbf) Moments Nm (lbf•ft)

Fxs Fys Fzs Mxs Mys Mzs Fxd Fyd Fzd Mxd Myd Mzd

4 670

(1 050)

4 670

(1 050)

4 670

(1 050)

4 670

(1 050) 10 408

(2 340) 12 010

(2 700) 10 230

(2 300)

8 540

(1 920) 12 010

(2 700) 12 010

(2 700)

3 336 (750)

5 516

(1 240)

4 670

(1 050)

5 382

(1 210)

4 270 (960)

6 005

(1 350)

6 005

(1 350)

5 471

(1 230)

6 005

(1 350)

6 005

(1 350)

3 336

(750)

5 560

(1 250)

4 670

(1 050)

5 382

(1 210)

4 270

(960)

6 583

(1 480)

6 672

(1 500)

5 471

(1 230)

6 672

(1 500)

6 672

(1 500)

976

(720)

1 220

(900)

1 220

(900)

976

(720)

1 722

(1 270)

1 763

(1 300)

1 763

(1 300)

1 763

(1 300)

1 763

(1 300)

1 763

(1 300)

231

(170)

664

(490)

298

(220)

258

(190)

298

(220)

420

(310)

420

(310)

475

(350)

542

(400)

1 763

(1 300)

231

(170)

664

(490)

298

(220)

258

(190)

298

(220)

420

(310)

420

(310)

475

(350)

542

(400) 1 492

(1 100)

3 558 (800)

6 227

(1 400)

6 227

(1 400)

6 227

(1 400)

6 227

(1 400)

6 227

(1 400)

6 227

(1 400)

6 005

(1 350)

6 005

(1 350)

6 005

(1 350)

6 005

(1 350)

6 005

(1 350)

6 005

(1 350)

6 005

(1 350)

6 005

(1 350)

6 005

(1 350)

6 005

(1 350)

13 344 (3 000)

14 456 (3 250)

14 456 (3 250) 14 456 (3 250)

14 456 (3 250)

556

(410)

678

(500)

678

(500)

488

(360)

895

(660)

759

(560)

1 627

(1 200)

1 627

(1 200)

1 627

(1 200)

1 627

(1 200)

556

(410)

746

(550) 1 356

(1 000)

488

(360)

895

(660)

759

(560) 1 980

(1 460)

1 722

(1 270)

2 034

(1 500)

2 034

(1 500)

556

(410)

692

(510)

692

(510)

488

(360)

895

(660)

759

(560)

936

(690)

936

(690)

936

(690)

936

(690)

Figure 4-14: Maximum combined loading

Suction Discharge

Pump size

PS 1.5x1-6 PS32-160

PS 3x1.5-6 PS65-250

PS 3x2-6 PS 1.5x1-8

PS40-200 PS 2x1-10 & 10HD

PS32-250 PS 3x2-10 & 10HD

PS50-250 PS 4x3-10 & 10HD

PS65-250 PS 3x2-13 & 13HD

PS32-315 PS 4x3-13 & 13HD

PS65-315 PS 6x4-13HD

PS100-315

Forces N (lbf) Moments Nm (lbf•ft) Forces N (lbf) Moments Nm (lbf•ft)

Fxs Fys Fzs Mxs Mys Mzs Fxd Fyd Fzd Mxd Myd Mzd

8 985

(2 020)

8 985

(2 020)

8 985

(2 020)

8 985

(2 020) 10 408

(2 340) 12 010

(2 700) 10 230

(2 300)

8 540

(1 920) 12 010

(2 700) 12 010

(2 700)

3 336

(750)

5 516

(1 240)

4 670

(1 050)

5 382

(1 210)

4 270

(960)

6 005

(1 350)

6 005

(1 350)

5 471

(1 230)

6 005

(1 350)

6 005

(1 350)

3 336

(750)

9 385

(2 110)

4 670

(1 050)

5 382

(1 210)

4 270

(960)

6 583

(1 480)

7 295

(1 640)

5 471

(1 230) 10 631

(2 390) 27 756

(6 240)

2 481

(1 830)

3 105

(2 290)

3 105

(2 290)

2 481

(1 830)

4 936

(3 640)

5 058

(3 730)

5 058

(3 730)

5 058

(3 730)

5 058

(3 730)

5 058

(3 730)

231

(170)

664

(490)

298

(220)

258

(190)

298

(220)

420

(310)

420

(310)

475

(350)

542

(400)

6 753

(4 980)

231

(170)

664

(490)

298

(220)

258

(190)

298

(220)

420

(310)

420

(310)

475

(350)

542

(400) 1 492

(1100)

8 985

(2 020)

8 985

(2 020)

8 985

(2 020)

8 985

(2 020)

8 985

(2 020)

8 985

(2 020)

8 985

(2 020)

8 985

(2 020)

8 985

(2 020)

8 985

(2 020)

6 005

(1 350)

6 005

(1 350)

6 005

(1 350)

6 005

(1 350)

6 005

(1 350)

6 005

(1 350)

6 005

(1 350)

6 005

(1 350)

6 005

(1 350)

6 005

(1 350)

27 756 (6 240)

27 756 (6 240) 27 756 (6 240)

27 756 (6 240)

556

(410)

746

(550)

1 397

(1 030)

488

(360)

895

(660)

759

(560)

1 980

(1 460)

1 980

(1 460)

2 346

(1 730)

2 915

(2 150)

556

(410)

746 (550) 1 397

(1 030)

488 (360)

895 (660)

759 (560)

1 980

(1 460)

1 980

(1 460)

2 346

(1 730)

2 915

(2 150)

556

(410)

692

(510)

692

(510)

488

(360)

895

(660)

759

(560)

936

(690)

936

(690)

936

(690)

936

(690)

Figure 4-15: Maximum Y-axis loading for shaft deflection

Suction Discharge

Pump size

Grupo 1 & A -

Grupo 2, B & C -

Forces N (lbf) Moments Nm (lbf•ft) Forces N (lbf) Moments Nm (lbf•ft)

Fxs Fys Fzs Mxs Mys Mzs Fxd Fyd Fzd Mxd Myd Mzd

-8 896

(-2 000)

-15 568 (-3 500)

1 220.4

(900)

1 762.8

(1 300)

1 627.2 (1 200)

1 762.8 (1 300)

1 695

(1 250)

4 068

(3 000)

6 672

(1 500) 11 120

(2 500)

-678

(-500)

-1 627

(-1 200)

2 034

(1 500)

2 034

(1 500)

1 695

(1 250)

4 068

(3 000)

Page 21 of 52 flowserve.com

USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

Figure 4-16: Maximum Z-axis loading for shaft deflection

Suction Discharge

Pump size

Grupo 1 & A

Grupo 2, B & C

Forces N (lbf) Moments Nm (lbf•ft) Forces N (lbf) Moments Nm (lbf•ft)

Fxs Fys Fzs Mxs Mys Mzs Fxd Fyd Fzd Mxd Myd Mzd

4 670

(1 050) 15 568

(3 500)

-5 560

(-1 250)

-6 672

(-1 500)

2 034

(1 500)

2 034

(1 500)

1 627

(1 200)

1 763

(1 300)

-3 390

(-2 500)

-4 746

(-3 500)

3 558

(800)

6 227

(1 400)

8 896

(2 000) 11 120

(2 500)

-13 344

(-3 000)

-14 456

(-3 250)

-2 034

(-1 500)

-2 034

(-1 500)

1 356

(1 000)

2 915

(2 150)

-3 390

(-2 500)

-4 746

(-3 500)

4.6.5 Pump and shaft alignment check

After connecting the piping, rotate the pump drive shaft clockwise (viewed from motor end) by hand several complete revolutions to be sure there is no binding and that all parts are free. Recheck shaft alignment. (See section 4.5.) If piping caused unit to be out of alignment, correct piping to relieve strain on the pump.

4.6.6 Auxiliary piping

4.6.6.1 Mechanical seal

When the pump is intended to be equipped with a mechanical seal, it is Flowserve standard practice to install the mechanical seal in the pump prior to shipment. Specific order requirements may specify

4.6.6.4 Piping connection - oil mist lubrication system

The piping connections for an oil mist lubrication system are shown below.

Figure 4-18: Oil mist ready housing wet sump

Figure 4-17

that the seal be shipped separately, or none be supplied. It is the pump installer’s responsibility to determine if a seal was installed. If a seal was supplied but not installed, the seal and installation instructions will be shipped with the pump.

Failure to ensure that a seal is instal led

may result in serious leakage of the pumped fluid. Seal and seal support system must be installed and

operational as specified by the seal manufacturer. The seal chamber/gland may have ports that have

been temporarily plugged at the factory to keep out foreign matter. It is the installer’s responsibility to determine if these plugs should be removed and external piping connected. Refer to the seal drawings and or the local Flowserve representative for the proper connections.

4.6.6.2 Piping connection – seal support system

If the pump has a seal support system it is mandatory that this system be fully installed and operational before the pump is started.

4.6.6.3 Piping connection - bearing housing cooling system

Make connections as shown below. Liquid at less than 32 °C (90 °F) should be supplied at a regulated flow rate of at least 0.06 l/s (1 US gpm).

Figure 4-19: Oil mist ready housing dry sump

Page 22 of 52 flowserve.com

USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

4.7 Electrical connections

Electrical connections must be made by a qualified Electrician in accordance with relevant local national and international regulations.

A device to provide emergency stopping must be fitted. If not supplied pre-wired to the pump unit, the controller/starter electrical details will also be supplied within the controller/starter. For electrical details on pump sets with controllers see the separate wiring diagram.

It is important to be aware of the EUROPEAN DIRECTIVE on potentially explosive areas where compliance with IEC60079-14 is an additional requirement for making electrical connections.

It is important to be aware of the EUROPEAN DIRECTIVE on electromagnetic compatibility when wiring up and installing equipment on site. Attention must be paid to ensure that the techniques used during wiring/installation do not increase electromagnetic emissions or decrease the electromagnetic immunity of the equipment, wiring or any connected devices. If in any doubt contact Flowserve for advice.

The motor must be wired up in accordance with the motor manufacturer's instructions (normally supplied within the terminal box) including any temperature, earth leakage, current and other protective devices as appropriate. The identification nameplate should be checked to ensure the power supply is appropriate.

See section 5.4, Direction of rotation,

before connecting the motor to the electrical supply.

4.8 Final shaft alignment check

a) Level baseplate if appropriate. b) Mount and level pump if appropriate. Level the

pump by putting a level on the discharge flange. If not level, adjust the footpiece by adding or removing shims [3126.1] between the footpiece and the bearing housing.

c) Check initial alignment. If pump and driver have

been remounted or the specifications given below are not met, perform an initial alignment as described in section 4.5. This ensures there will be sufficient clearance between the motor hold down bolts and motor foot holes to move the motor into final alignment. The pump and driver should be within 0.38 mm (0.015 in.) FIM (full indicator movement) parallel, and 0.0025 mm/mm (0.0025 in./in.) FIM angular.

Stilt mounted baseplates

If initial alignment cannot be achieved with the motor fasteners centered, the baseplate may be twisted. Slightly adjust (one turn of the adjusting nut) the stilts at the driver end of the baseplate and check for alignment to the above tolerances. Repeat as necessary while maintaining a level condition as measured from the pump discharge flange.

d) Run piping to the suction and discharge to the

pump. There should be no piping loads transmitted to the pump after connection is made. Recheck the alignment to verify that there are no significant changes.

e) Perform final alignment. Check for soft-foot under

the driver. An indicator placed on the coupling, reading in the vertical direction, should not indicate more than 0.05 mm (0.002 in.) movement when any driver fastener is loosened. Align the driver first in the vertical direction by shimming underneath its feet.

f) When satisfactory alignment is obtained the

number of shims in the pack should be minimized. It is recommended that no more than five shims be used under any foot. Final horizontal alignment is made by moving the driver. Maximum pump reliability is obtained by having near perfect alignment. Flowserve recommends no more than

0.05 mm (0.002 in.) parallel, and 0.0005 mm/mm (0.0005 in./in.) angular misalignment. (See section 6.8.4.7.)

g) Operate the pump for at least an hour or until it

reaches final operating temperature. Shut the pump down and recheck alignment while the pum p is hot. Piping thermal expansion may change the alignment. Realign pump as necessary.

4.9 Protection systems

The following protection systems are recommended particularly if the pump is installed in a potentially explosive area or is handling a hazardous liquid. If in any doubt consult Flowserve.

If there is any possibility of the system allowing the pump to run against a closed valve or below minimum continuous safe flow a protection device should be installed to ensure the temperature of the liquid does not rise to an unsafe level.

If there are any circumstances in which the system can allow the pump to run dry, or start up empty, a power monitor should be fitted to stop the pump or prevent it from being started. This is particularly relevant if the pump is handling a flammable liquid.

Page 23 of 52 flowserve.com

USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

If leakage of product from the pump or its associated sealing system can cause a hazard it is recommended that an appropriate leakage detection system is installed.

To prevent excessive surface temperatures at bearings it is recommended that temperature or vibration monitoring are carried out.

5 COMMISSIONING, STARTUP, OPERATION AND SHUTDOWN

These operations must be carried

out by fully qualified personnel.

5.1 Pre-commissioning procedure

5.1.1 Pre start-up checks

Prior to starting the pump it is essential that the following checks be made. These checks are all described in detail in the Maintenance section of this manual.

• Pump and motor properly secured to the baseplate

• All fasteners tightened to the correct torque

• Coupling guard in place and not rubbing

• Rotation check, see section 5.4.

This is absolutely essential

• Impeller clearance setting

• Shaft seal properly installed

• Seal support system operational

• Bearing lubrication

• Bearing housing cooling system operational

• Pump instrumentation is operational

• Pump is primed

• Rotation of shaft by hand

As a final step in preparation for operation, it is important to rotate the shaft by hand to be certain that all rotating parts move freely, and that there are no foreign objects in the pump casing.

5.2 Pump lubricants

5.2.1 Oil bath

The standard bearing housing bearings are oil bath lubricated and are not lubricated by Flowserve. Before operating the pump, fill the bearing housing to the center of the oil sight glass with the proper type oil. (See Figure 5-1 for approximate amount of oil required - do not overfill.)

An optional oil slinger is available. The oil slinger is not necessary; however, if used, it provides an advantage by allowing a larger tolerance in acceptable oil level. Without an oil slinger, the oil level in the bearing housing must be maintained at

±3 mm (±

/8 in.) from the center of the sight glass. The sight glass has a 6 mm (¼ in.) hole in the center of its reflector. The bearing housing oil level must be within the circumference of the center hole to ensure adequate lubrication of the bearings.

See Figure 5-2 for a general description of the lubri cants to be used and Figure 5-7 for recommended lubricants. DO NOT USE DETERGENT OILS. The oil must be free of water, sediment, resin, soaps, acid and fillers of any kind. It should contain rust and oxidat ion inhibi tors. The proper oil viscosity is determined by the bearing housing operating temperature as given in Figure 5-3.

To add oil to the housing, clean and then rem ove the vent plug [6521] at the top of the bearing housing, pour in oil until it is visually half way up in the sight glass [3855]. Fill the constant level oiler bottle, i f used, and return it to its position. The correct oil level is obtained with the constant level oiler in its lowest posit ion, which results in the oil level being at the top of the oil inlet pipe nipple, or half way up in the sight glass window. Oil must be visible in the bottle at a ll times.

Note that on ANSI 3A™ power ends there is no constant level oiler. As stated above, proper oil level is the center of the “bull’s eye” sight glass [3856].

In many pumping applications l ubricatin g oil b ecomes contaminated before it loses its lubric ating qualitie s or breaks down. For this reason it is recommended that the first oil change take plac e after approxi mately 16 0 hours of operation, at which time, the used oil should be examined carefully for contaminant s. Duri ng the initi al operating period monitor the bearing hous ing operati ng temperature. Record the external bearing hou sing temperature. See Figure 5-4 for maximum acceptabl e temperatures. The normal oil change interval i s based on temperature and is shown in Figure 5-5.

Figure 5-1: Amount of oil required

Pump Mark 3A and ANSI 3A

Group A 458 ml (15.5 fl. oz.) Group 1 251 ml (8.5 fl. oz.) Group B 946 ml (32 fl. oz.) Group 2 946 ml (32 fl. oz.) Group C 793 ml (26.8 fl. oz.)

Figure 5-2: Recommended lubricants

Mineral oil

Synthetic

Grease

Quality mineral oil with rust and oxidation inhibitors. Mobil DTE heavy/medium (or equivalent)

Royal Purple or Conoco SYNCON (or equivalent). Some synthetic lubricants require Viton O-rings.

MOBIL POLYREX EM (or compatible)

Page 24 of 52 flowserve.com

USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

Figure 5-3: Oil viscosity grades

Maximum oil temperature

Up to 60 °C (140 °F) 32 95 Up to 71 °C (160 °F) 46 95 Up to 80 °C (175 °F) 68 95 Up to 94 °C (200 °F) 100 95

ISO viscosity

grade

Minimum

viscosity index

Figure 5-4: Maximum external housing temperatures

Lubrication Temperature

Oil bath 82 °C (180 °F) Oil mist 82 °C (180 °F) Grease 94 °C (200 °F)

The maximum temperature that the bearing can be exposed to is 105 °C (220 °F). Bearing temperatures may be up to 16 °C (30 °F) higher than the housing temperature.

Figure 5-5: Lubrication intervals*

Lubricant

Under 71 °C (160 °F)

Grease 6 months 3 months 1.5 months Mineral oil 6 months 3 months 1.5 months

Synthetic oil** 18 months 18 months 18 months * Assuming good maintenance and operation practices, and no contamination. ** May be increased to 36 months with ANSI 3A™ power end.

71-80 °C (160-175 °F)

80-94 °C (175-200 °F)

Figure 5.7: Recommended oil lubricants

Oil Splash lubrication Oil mist lubrication

Viscosity

mm²/s 40 ºC

32 68 46

Temp. max. ºC (ºF) 65 (149) 80 (176) -

lubrication

Centrifugal pump

DIN51502 ISO VG

Designation according to

DEA

Elf

BP Energol HL32

BP Energol HLP32

HL/HLP 32

Anstron HL32

Anstron HLP32

OLNA 32

HYDRELEF 32

TURBELF 32

ELFOLNA DS32

Esso

Mobil

TERESSO 32

NUTO H32

Mobil DTE oil light

Mobil DTE13 Mobil DTE24

Q8 Verdi 32

Q8 Haydn 32

Shell Tellus 32 Shell Tellus 37

Rando Oil HD 32

Rando Oil HD-AZ-32

Wiolan HN32 Wiolan HS32

Oil companies and lubricants

Shell

Texaco

Wintershall

(BASF Group)

Figure 5-6: Grease lubrication amounts

Group Bearing Initial lube Relubrication

Inboard Until grease comes out plug

Outboard standard

Outboard duplex

Until grease comes out plug

(2.1 in3)

34 cm

Inboard Until grease comes out plug

Outboard standard

Outboard duplex

Inboard Outboard -

standard Inboard Outboard -

standard Outboard -

duplex Inboard Outboard -

standard

Until grease comes out plug

(2.1 in3)

34 cm Until grease comes out plug 12 cm Until grease comes out plug 20 cm Until grease comes out plug 17 cm Until grease comes out plug 28 cm

(4.1 in3)

68 cm Until grease comes out plug 12 cm Until grease comes out plug 20 cm

Note: if new bearings are not lubricated, they should be packed

prior to installation.

7 cm 12 cm

17 cm 7 cm 12 cm

17 cm

34 cm

(0.4 in3)

(0.7 in3)

(1.0 in3)

(0.4 in3)

(0.7 in3)

(1.0 in3)

(0.7 in3)

(1.2 in3)

(1.0 in3)

(1.7 in3)

(2.1 in3)

(0.7 in3)

(1.2 in3)

HL/HLP 68

BP Energol HL68

BP Energol HLP68

Anstron HL68

Anstron HLP68

TURBELF SA68

ELFOLNA DS68

TERESSO 68

NUTO H68

Mobil DTE oil heavy medium

Mobil DTE26

Q8 Verdi 68

Q8 Haydn 68

Shell Tellus 01 C 68

Shell Tellus 01 68

Rando Oil 68

Rando Oil HD C-68

Wiolan HN68 Wiolan HS68

BP Energol HL46

BP Energol HLP46

Mobil DTE oil medium

Shell Tellus 01 C 46

Shell Tellus 01 46

Rando Oil HD B-46

HL/HLP 46

Anstron HL46

Anstron HLP46

TURBELF SA46 ELFOLNA DS46

TERESSO 46

NUTO H46

Mobil DTE15M

Mobil DTE25

Q8 Verdi 46

Q8 Haydn 46

Rando Oil 46

Wiolan HN46 Wiolan HS46

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

5.2.2 Grease

5.2.2.1 Regreasable single shielded bearings

When the grease lubrication option is specified, single shielded bearings, grease fittings and vent pipe plugs are installed inboard and outboard.

Figure 5-8: Pump shield orientation

The bearings are packed with MOBIL POLYREX EM grease prior to assembly. The grease reservoir should be packed prior to operating the pump in accorda nce with the relubrication instruct ions. Fo r relubri cation, a grease with the same type base (polyurea) and oil (mineral) should be used. To regrease, remove the pipe plug from both the inboard and outboard bearing location. (See Figure 5-9.) Add grea se thro ugh ea ch fitting until either grease is expelled out the purge hole or until the required volume of grease has been added. (See Figure 5-6.) After relubricating the bearings three times, it is typically recommended that the bearing housing is cleaned out.

To regrease bearings under coupling guard, stop pump, lock the motor, remove coupling guard, and then regrease the bearings.

Figure 5-9: Regreasable configuration

5.2.2.2 Grease for life - double shielded or double sealed bearings

These bearings are packed with grease by the bearing manufacturer and should not be relubricated. The replacement interval for these bearings is greatly affected by their operating temperature and speed. Shielded bearings typically operate cooler.

5.2.3 Oil mist

The inlet port for all horizontal pumps is the plugged ½ in. NPT located at the top of the bearing hou sing. A vent fitting has been supplied on the bearing carrier as well as a plugged ¼ in. NPT bottom drain on the bearing housing. See section 4.6.6.4, Pi ping connection - Oil mist lubrication system. Do not allow oil level to remain above the center of the bearing housing sight glass window with purge mist (wet sump) systems.

The optional oil slinger must not be used with an oil mist system.

5.3 Impeller clearance

The impeller clearance was set at the factory. For open impellers the clearance is based on the application temperature at the time the pump was purchased. (See Figure 5-10.) If the process temperature changes the impeller clearance must be reset. All open style impellers are set to the casing. The preferred setting for a closed style impeller is midway between the casing and the cover. See section 6.6 for impeller adjustment instructions.

Figure 5-10: Open impeller clearance settings

Temperature °C (°F) Clearance mm (in.)

< 38 (100) 0.58 ± 0.08 (0.023 ± 0.003) 38 to 65 (101 to 150) 0.71 (0.028) 66 to 93 (151 to 200) 0.84 (0.033)

94 to 121 (201 to 250) 0.97 (0.038)

122 to 149 (251 to 300) 1.09 (0.043)

Notes.

1. Rotation of bearing carrier from center of one lug to center of next results in axial shaft movement of 0.1 mm (0.004 in.).

2. Open impellers are set to casing.

5.4 Direction of rotation

5.4.1 Rotation check

It is absolutely essential that the

rotation of the motor be checked before connecting

Do not fill the housing with oil when greased bearings are used. The oil will leach the grease out of the bearings and the life of the bearings may be drastically reduced.

the shaft coupling. Incorrect rotation of the pump, for even a short time, can dislodge and damage the impeller, casing, shaft and shaft seal. All PolyChem S-series pumps turn clockwise as viewed from the motor end. A direction arrow is cast on the front of the casing as shown in Figure 5-11. Make sure the motor rotates in the same direction.

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

If maintenance work has been carried out to the sites electrical supply, the direction of rotation should be re-checked as above in case the supply phasing has been altered.

Figure 5-12

The coupling guard shown in Figure 5-12 conforms to the USA standard ASME B15.1, “Safety standard for mechanical power transmission apparatus.” Flowserve manufacturing facilities worldwide conform to local coupling guard regulations.

5.5.2 ClearGuard™ - optional

Figure 5-11

5.4.2 Coupling installation

The coupling should be installed as advised by the coupling manufacturer. Pumps are shipped without the spacer installed. If the spacer has been installed to facilitate alignment, then it must be removed prior to checking rotation. Remove all

Flowserve offers as an option a ClearGuard™, which allows you to see the condition of the coupling. (See Figure 5-13.) This guard can be used in place of the existing clamshell guard described above. Disassembly of the ClearGuard™ is accomplished by removing the fasteners that hold the two guard halves together followed by removing the foot bolts and rotating the support leg out of the slot on the guard.

protective material from the coupling and shaft before installing the coupling.

5.5 Guarding

Power must never be applied to the driver when the coupling guard is not installed.

Flowserve coupling guards are safety devices inten ded to protect workers from inherent dangers of the rotating pump shaft, motor shaft and coupling. It is intended to prevent entry of hands, fingers or other body parts into a point of hazard by reaching through, over, under or around the guard. No st andard coupling guard provides complete protection from a disinteg rating coupling. Flowserve cannot guarantee thei r guard s will completely contain an exploding coupling.

5.5.1 Clam shell guard - standard

The standard coupling guard for all PolyChem S-series pumps is the “clam shell” design and is shown in Figure 5-12. It is hinged at the top and it can be removed by loosening one of the foot bolts and sl iding t he suppo rt leg out from under the cap screw (note th at the fo ot is slotted). The leg can then be rotated upward and half of the guard can be disengaged (unhin ged) from the ot her. Only one side of the guard needs to be removed. To reassemble simply reverse the above procedu re.

Figure 5-13

5.5.3 Trimming instructions

In order to correctly fit the pump/motor configuration, each guard must be trimmed to a specific length. This trimming is done on the motor end of the guard. a) Measure minimum distance from the center of

mounting hole in the baseplate to the motor. (If clam shell guard proceed to step c.)

b) Locate a reference center in the slot of the

ClearGuard™ coupling guard flange, see figure 5-14. Transfer the length mea surement t o the guard using this reference center.

c) Trim the motor end of the guard according to the

above measurement. Trimming is best done with a band saw, but most other types of manual or power saws give acceptable results. Care must be taken to ensure that there is no gap larger than 6 mm (0.24 in.) between the motor and the coupling guard.

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

5.7 Starting the pump

a) Open the suction valve to full open position. It is

very important to leave the suction v alve o pen while the pump is operating. Any throttling or adjusting of flow must be done through the discharge valve. Partially closing the suction valve can create serious NPSH and pump performance problems.

Figure 5-14

diameter, trim guard so that it extends over the end of the motor as far as possible.

e) Deburr the trimmed end with a file or a sharp

knife if ClearGuard™. Care must be taken to eliminate all sharp edges.

5.5.4 Assembly instructions

5.5.4.1 Clam shell guard

a) Mount support leg to each clam shell, figure 5-12. b) Attach one half of the guard to the baseplate. c) Engage the tabs of guard halves together. d) Attach the second support leg to the baseplate.

5.5.4.2 ClearGuard™

a) Place the bottom and top halves of the guard

around the coupling.

b) Install the support legs by inserting and then

rotating the tab on the leg through the slot in the guard until it comes through and locks the top and bottom halves of the guard together.

c) Attach the support legs to the baseplate using the

fasteners and washers provided.

d) Install fasteners in the holes provided to secure

the guard flanges together.

If motor diameter is smaller than guard

5.6 Priming and auxiliary supplies

The PolyChem S-series centrifug al pump will not mov e liquid unless the pump is p rimed. A pu mp is sai d to be “primed” when the casing and the suction piping are completely filled with liquid. Open discharge valves a slight amount. This will allow any entrapped air to escape and will normally allow the pump to prime, if the suction source is above the pump. When a condition exists where the suction pressure may drop below the pump’s capability, it is advisable to add a low-pressure control device to shut the pump down when the pressure drops below a predetermined minimu m.

suction and discharge valves closed. This could

cause an explosion. c) Ensure the pump is primed. (See section 5.6.) d) All cooling, heating, and flush lines must be

started and regulated. e) Start the driver (typically, the electric motor). f) Slowly open t he discharge valve until the desired

flow is reached, keeping in mind the minimum

continuous flow listed in section 3.4.4. g)

be opened within a short interval after starting the

driver. Failure to do this could cause a dangerous

build up of heat, and possibly an explosion.

Never operate pump with both the

It is important that the discharge valve

5.8 Running or operation

5.8.1 Minimum continuous flow

Minimum continuous stable flow is the lowest flow at which the pump can operate and still meet the bearing life, shaft deflection and bearing housing vibration limits documented in the latest version of ASME B73.1. Pumps may be operated at lower flows, but it must be recognized that the pump may exceed one or mo re of these limits. For example, vibration may exceed the limit set by the ASME standard. The size of the pump, the energy absorbed, and the liq uid pump ed are so me of the considerations in determining the minimum continuous flow (MCF).

The minimum continuous flow (capacity) is established as a percentage of the best efficiency point (BEP). (See section 3.4.4.)

5.8.2 Minimum thermal flow

All PolyChem S-series pumps also have a minimum thermal flow. This is defined as the minimum flow

that will not cause an excessive temperature rise. Minimum thermal flow is application dependent.

Do not operate the pump below minimum thermal flow, as this could cause an excessive temperature rise. Contact a Fl owserve sale s engine er for determination of minimum thermal flow.

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

Avoid running a centrifugal pump at dra stically reduced capacities or with discharge valve closed for extended periods of time. This can cause severe t emperat ure rise and the liquid in the pump may reach its boiling point. If this occurs, the mechanical seal will be exposed to vapor, with no lubrication, and may score o r seize to the stationary parts. Continu ed runnin g under these conditions when the suction valve is also closed can create an explosive condition due to the confined vapor at high pressure and temperature.

Thermostats may be used to safeguard against over heating by shutting down the pump at a predetermi ned temperature.

Safeguards should also be taken against possible operation with a closed discharge valve, such as installing a bypass back to the suction source. The size of the bypass line and the required bypass flow rate is a function of the input horsepower and the allowable temperature rise.

5.8.3 Reduced head

Note that when discharge head drops, the pump’s flow rate usually increases rapidly. Check motor for temperature rise as this may cause overload. If overloading occurs, throttle the discharge.

5.8.4 Surging condition

A rapidly closing discharge valve can cause a damaging pressure surge. A dampening arrangement should be provided in the piping.

5.8.5 Operation in sub-freezing conditions

When using the pump in sub-freezing conditions where the pump is periodically idle, the pump should be properly drained or protected with thermal devices which will keep the liquid in the pump from freezing.

5.8.6 Bearing monitoring

If the pumps are operating in a potentially explosive atmosphere temperature or vibration monitoring of the bearings is recommended.

If bearing temperatures are to be monitored it is essential that a benchmark temperature is recorded at the commissioning stage and after the bearing temperature has stabilized.

• Record the bearing temperature (t) and the

ambient temperature (ta)

• Estimate the likely maximum ambient

temperature (tb)

• Set the alarm at (t+tb-ta+5) ºC ((t+tb-ta+10) ºF)

and the trip at 100 ºC (212 ºF) for oil lubrication and 105 ºC (220 ºF) for grease lubrication.

It is important, particularly with grease lubrication, to keep a check on bearing temperatures. After start up the temperature rise should be gradual, reaching a maximum after approximately 1.5 to 2 hours. This temperature rise should then remain constant or marginally reduce with time.

5.8.6.1 Normal vibration levels, alarm and trip

For guidance, pumps generally fall under a classification for rigid support machines within the International rotating machinery standards and the recommended maximum levels below are based on those standards.

Alarm and trip values for installed pumps should be based on the actual measurements (N) taken on site on the bearing housings of the pump in the fully commissioned as new condition.

The example (N) value is given for the preferred operating flow region (typically this may extend to 70 to 120 % of the pump best efficiency point); outside the preferred flow region the actual vibration experienced may be multiplied by up to 2.

These standard values can vary with the rotational speed and the power absorbed by the pump. For any special case, do not hesitate to consult us.

Measuring vibration at regular intervals will then show any deterioration in pump or system operating conditions.

Vibration velocity – unfiltered

Normal N Alarm N x 1.25 Shutdown trip N x 2.0

Horizontal pumps

≤ 15 kW (20 hp)

mm/s (in./sec) r.m.s.

≤ 3.0 (0.12) ≤ 4.5 (0.18) ≤ 3.8 (0.15) ≤ 5.6 (0.22) ≤ 6.0 (0.24) ≤ 9.0 (0.35)

> 15 kW (20 hp) mm/s (in./sec) r.m.s.

5.9 Stopping and shutdown

5.9.1 Shutdown considerations

Pump sets are normally suitable for the number of equally spaced stop/starts per ho ur shown in the table below. Check the capability of the driver and control/starting system before commissioning.

Motor rating kW (hp)

Between 15 and 90 (20 and 120) 10

Up to 15 (20) 15

Above 90 (120) 6

Where duty and standby pumps are installed it is recommended that they are run alternately every week.

Maximum start ups

per hour

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

5.10 Hydraulic, mechanical and electrical duty

This product has been supplied to meet the performance specifications of your purchase order, however it is understood that during the life of the product these may change. The following notes will help the user decide how to evaluate the implications of any change. If in doubt contact your nearest Flowserve office.

5.10.1 Specific gravity (SG)

Pump capacity and total head in metres (feet) do not change with SG, however pressure displayed on a pressure gauge is directly proportional to SG. Power absorbed is also directly proportional to SG. It is therefore important to check that any change in SG will not overload the pump driver or over-pressurize the pump.

5.10.2 Viscosity

For a given flow rate the total head reduces with increased viscosity and increases with reduced viscosity. Also for a given flow rate the power absorbed increases with increased viscosity, and reduces with reduced viscosity. It is important that checks are made with your nearest Flowserve office if changes in viscosity are planned.

5.10.3 Pump speed

Changing pump speed effects flow, total head, power absorbed, NPSH direct proportion to pump speed. Head varie s as speed ratio squared and power varies as speed ratio cubed. The new duty, however, will also be dependent on the system curve. If increasing the spee d, it is impo rtant therefore to ensure the maximum pu mp working pressure is not exceeded, the driver is not overloaded, NPSH

>NPSHR, and that noise and vibration a re withi n

local requirements and regulations.

5.10.4 Net positive suction head (NPSH

NPSH available (NPSH available in the pumped liquid, above its vapor pressure, at the pump suction branch.

NPSH required (NPSH required in the pumped liquid, above its vapor pressure, to prevent the pump from cavitating. It is important that NPSH NPSH

>NPSHR should be at large as possible.

If any change in NPSH margins are not significantly eroded. Refer to the pump performance curve to determine exact requirements particularly if flow has changed.

, noise and vibration. Flow varies in

)

) is a measure of the head

>NPSHR. The margin between

is proposed, ensure these

If in doubt please consult your nearest Flowserve office for advice and details of the minimum allowable margin for your application.

5.10.5 Pumped flow

Flow must not fall outside the minimum and maximum continuous safe flow shown on the pump performance curve and or data sheet.

6 MAINTENANCE

6.1 General

It is the plant operator's responsibility to ensure that all maintenance, inspection and assembly work is carried out by authorized and qualified personnel who have adequately familiarized themselves with the subject matter by studying this manual in detail. (See also section 1.6.2.)

Any work on the machine must be performed when it is at a standstill. It is imperative that the procedure for shutting down the machine is followed, as described in section 5.9.

On completion of work all guards and safety devices must be re-installed and made operative again.

Before restarting the machine, the relevant instructions listed in section 5, Commissioning, start up, operation and shut down must be observed.

Oil and grease leaks may make the ground slippery. Machine maintenance must always begin and finish by cleaning the ground and the exterior of the machine.

If platforms, stairs and guard rails are required for maintenance, they must be placed for easy access to areas where maintenance and inspection are to be carried out. The positioning of these accessories must not limit access or hinder the lifting of the part to be serviced.

When air or compressed inert gas is used in the maintenance process, the operator and anyone in the vicinity must be careful and have the appropriate protection.

Do not spray air or compressed inert gas on skin. Do not direct an air or gas jet towards other people.

Never use air or compressed inert gas to clean cloth es.

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Before working on the pump, take measures to prevent an uncontrolled start. Put a warning board on the starting device with the words: "Machine under repair: do not start".

With electric drive equipment, lock the main switch open and withdraw any fuses. Put a warning board on the fuse box or main switch with the words: "Machine under repair: do not connect".

Never clean equipment with inflammable solvents or carbon tetrachloride. Protect yourself against toxic fumes when using cleaning agents.

Refer to the parts list shown in section 8 for item number references used throughout this section.

6.2 Maintenance schedule

It is recommended that a maintenance plan and schedule be implemented, in accordance with these User Instructions, to include the following: a) Any auxiliary systems installed must be monitored,

if necessary, to ensure they function correctly.

b) Check for any leaks from gaskets and seals. The

correct functioning of the shaft seal must be checked regularly.

c) Check bearing lubricant level, and the remaining

hours before a lubricant change is required.

d) Check that the duty condition is in the safe

operating range for the pump.

e) Check vibration, noise level and surface

temperature at the bearings to confirm satisfactory operation.

f) Check dirt and dust is removed from areas around

close clearances, bearing housings and motors.

g) Check coupling alignment and re-align if

necessary.

6.2.1 Preventive maintenance

The following sections of this manual give instructions on how to perform a complete maintenance overhaul. However, it is also important to periodically repeat the Pre start-up checks listed in section 5.1. These checks will help extend pump life as well as the length of time between major overhauls.

6.2.2 Need for maintenance records

A procedure for keeping accurate maintenance records is a critical part of any program to improve pump reliability. There are many variables that can contribute to pump failures. Often long term and repetitive problems can only be solved by analyzing these variables through pump maintenance records.

6.2.3 Cleanliness

One of the major causes of pump failure is the presence of contaminants in the bearing housing. This contamination can be in the form of moisture, dust, dirt and other solid particles such as metal chips. Contamination can also be harmful to the mechanical seal (especially the seal faces) as well as other parts of the pump. For example, dirt in the impeller threads could cause the impeller to not be seated properly against the shaft. This, in turn, could cause a series of other problems. For these reasons, it is very important that proper cleanliness be maintained. Some guidelines are listed below:

• After draining the oil from the bearing housing, periodically send it out for analysis. If it is contaminated, determine the cause and correct.

• The work area should be clean and free from

dust, dirt, oil, grease etc.

• Hands and gloves should be clean.

• Only clean towels, rags and tools should be used.

6.3 Spare parts

The decision on what spare parts to stock varie s greatly depending on many factors such as the criticality of the application, the time required to buy and receive new spares, the erosive/corrosive nature of the application, and the cost of the spare part. Section 8 identifies all of the components that make up each pump addressed in this manual. Please refer to the Flowserve Durco Pump Parts Catalog for more information. A copy of this book can be obtained from your l ocal Fl owserv e sale s engineer or distributor/re present ative.

6.3.1 Ordering of spare parts

Flowserve keeps records of all pumps that have been supplied. Spare parts can be ordered from your local Flowserve sales engineer or from a Flowserve distributor or representative. When ordering spare parts the following information should be supplied:

1) Pump serial number

2) Pump size and type

3) Part name – see section 8

4) Part item number – see section 8

5) Material of construction (alloy)

6) Number of parts required

The pump size and serial number can be found on the nameplate located on the bearing housing. See Figure 3-1.

6.4 Recommended spares and

consumable items

Mechanical process fluid seals, bearing housing lip seals, bearings, shafting, impeller, and gaskets.

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6.5 Tools required

A typical range of tools that will be required to maintain these pumps is listed below.

Standard hand tools

• Hand wrenches (Metric and SAE)

• Socket wrenches (Metric and SAE)

• Allen wrenches (Metric and SAE)

• Soft mallet

• Screwdrivers

Specialized equipment

• Bearing pullers

• Bearing induction heaters

• Dial indicators

• Spanner wrench

• Flowserve impeller tool kit (ISO and ANSI)

To simplify maintenance, it is recommended that the Flowserve impeller tool kit (shown in Figure 6-1) is used. This tool kit includes an impeller wrench, which simplifies installation and removal of the i mpeller. It also contains “nose cones” which protect shaft threads and mechanical seal O-rings during maintena nce.

This tool kit can be ordered from your local Flowserve sales engineer or from a Flowserve distributor or representative.

Figure 6-3: Recommended flange fastener torques - SI (US)

ISO pump with PN16 flanges

Flange size

mm (in.)

32 (1.3) 4 16 (0.63) 91 (67) 40 (1.6) 4 16 (0.63) 99 (73) 50 (2.0) 4 16 (0.63) 124 (91) 65 (2.6) 4 16 (0.63) 153 (112)

80 (3.1) 8 16 (0.63) 110 (81) 100 (3.9) 8 16 (0.63) 135 (99) 125 (4.9) 8 16 (0.63) 185 (137)

Number

of bolts

Bolt diam.

mm (in.)

Bolt torque

Nm (lbf•ft)

ANSI pump with Class 150 flanges

Flange size

in. (mm)

1 (25.4) 4 0.50 (12) 34 (25)

1 ½ (38.1) 4 0.50 (12) 75 (55)

2 (50.8) 4 0.63 (16) 102 (75)

3 (76.2) 4 0.63 (16) 149 (110) 4 (101.6) 8 0.63 (16) 129 (95) 6 (152.4) 8 0.75 (19) 169 (125)

Number

of bolts

Bolt diam.

in. (mm)

Bolt torque

Nm (lbf•ft)

6.7 Setting impeller clearance and impeller replacement

A new impeller O-ring [4610.8] must be installed whenever the impeller has been removed from the shaft. Impeller clearance settings for open style impellers may be found in section 5.3. Impeller balancing instructions may be found in section 6.8.

6.7.1 Installation and clearance setting for closed vane impellers

Install the impeller [2200] by screwing it onto the shaft (use heavy gloves) until it firmly seats against the shaft/sleeve face.

The impeller could have sharp edges,

which could cause an injury. It is very important to

Figure 6-1

wear heavy gloves.

6.6 Fastener torques

Non-metallic gaskets incur creep relaxation – before commissioning the pump, check and retighten fasteners to tightening torques stated.

with the seal set. Doing so may result in seal leakage and/or damage.

Do not adjust the impeller clearance

Figure 6-2: Recommended pump fastener torques - SI (US)

Item Comment

6570.2 3/8 in. - 27 (20) 10 mm - 27 (20) 3/8 in. - 27 (20) 10 mm - 27 (20) 10 mm - 27 (20)

6570.3 3/8 in. - 16 (12) 3/8 in. - 16 (12) 1/2 in. - 41 (30) 12 mm - 41 (30) 12 mm - 41 (30)

6570.4 1/2 in. - 54 (40) 12 mm - 54 (40) 3/4 in. - 217 (160) 16 mm - 108 (80) 16 mm - 108 (80)

6570.5 N/A N/A 1/2 in. - 54 (40) 12 mm - 54 (40) 12 mm - 54 (40)

6570.12 #10 - 5 (4) #10 - 5 (4) #10 - 5 (4) N/A N/A

6580.1 1/2 in. - 34 (25) 12 mm - 34 (25) 5/8 in. - 61 (45) 16 mm - 61 (45) 16 mm - 61 (45)

6580.2 3/8 in. - 14 (10) 10 mm - 14 (10) 1/2 in. - 34 (25) 12 mm - 34 (25) 12 mm - 34 (25)

Note: for non-lubricated threads, increase the value by 25 %.

Group 1 Group A Group 2 Group B Group C

Size – Lubricated torque Nm (lbf•ft)

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Tighten the impeller with the impeller wrench from the Flowserve impeller tool kit. To do this, grasp the impeller in both hands and, with the impeller wrench handle to the left (viewed from the impeller end of the shaft - Figure 6-4) spin the impeller forcefully in a clockwise direction to impact the impeller wrench handle on the work surface to the right. (Figure 6-5.)

Do not attempt to tighten the impeller on the shaft by hitting the impeller with a hammer or any other object or by inserting a pry bar between the impeller vanes. Serious damage to the impeller may result from such actions.

Indicator

pattern

Rotate the bearing carrier counter-clockwise the required amount to get the desired clearance.

Rotation equivalent to 0.1 mm (0.004 in.) axial movement

Figure 6-6

Lastly, uniformly tighten the set screws [6570.3] in incremental steps up to the final torque value to lock the bearing carrier in place.

An alternate approach for setting the impeller is to set it off the rear cover. Turn the bearing carrier counterclockwise until the impeller comes into light rubbing contact with the rear cover. Rotating the shaft at the

Figure 6-4

same time will accurately determine this zero setting. Using a felt tip pen place a reference mark on both the bearing housing and the carrier. The desired clearance setting is 2.5 mm (0.10 in.). Rotate the bearing carrier clockwise 25 indicator patterns to get the desired clearance.

Figure 6-5

The preferred impeller setting l ocatio n is midw ay between the casing and the rear cover. This is accomplished by loosening the set screws [6570.3] and rotating the bearing carrier [3240]. Turn the bearing carrier counter-clockwise until the impeller comes into light rubbing contact with the rear cove r. Rotating the shaft at the same time will accurately determine this zero setting. Using a felt tip pen place a reference mark on both the bearing housing and the carrier.

Now, rotate the bearing carrier clockwise while counting the number of indicator patterns (Figure 6-6) until you come into light rubbing contact with the casing. As before, rotating the shaft will help in establishing when contact is made. Rotating the bearing carrie r the width of one of the indicator patterns cast into the bearing carrier moves the impeller axially 0.1 mm (0.004 in.).

Generally speaking the total axially clearance will be approximately 5.0 mm (0.20 in.). Once you know the total axial clearance, that number should be split in half and then divided by 0.10 mm (0.004 in.) to determine the number of indicator patterns that the bearing carrier should be rotated.

Lastly, uniformly tighten the set screws [6570.3] in incremental steps up to the final torque value to lock the bearing carrier in place.

Tightening the set screws [6570.3] will cause the impeller to move 0.05 mm (0.002 in.) closer to the rear cover because of the internal looseness in the bearing carrier threads. This change is considered insignificant to the impeller clearance setting a nd need not be accounted for when setting a closed vane impeller.

Example.

The impeller of a pump has been replaced and as a result the impeller setting must be reset. Since the preferred approach is t o locate t he impe ller mi dway between the casing and the cover the first step i s to determine the amount of axial clearan ce that is available. Turn the bearing carrier counter-clockwise until the impeller comes into light rubbi ng contact with the rear cover. Flowserve suggests that a felt tip pen be used to mark an initial reference point on the bearing housing and the bearing carrier. Rotate the bearing carrier clockwise until the impeller comes into light contact with the casing keeping track of the number of indicator patterns moved, which i n this exam ple is 46. This number of indicator patterns correspo nds to a total axial clearance of 4.6 mm (0.18 in.).

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Place a second mark with the felt tip pen on the bearing carrier and then rotate 23 indicator patterns counter-clockwise from this second mark. Uniformly tighten the set screws [6570.3] in incremental steps to lock the bearing carrier in place. The impeller is now set 2.3 mm (0.09 in.) off of the casing.

6.7.2 Installation and clearance setting for front vane open style impellers

Install the impeller [2200] by screwing it onto the shaft (use heavy gloves) until it firmly seats against the shaft shoulder.

The impeller could have sharp edges, which could cause an injury. It is very important to wear heavy gloves.

Tighten the impeller with the impeller wrench from the Flowserve impeller tool kit. To do this, grasp the impeller in both hands and, with the impeller wrench handle to the left (viewed from the impeller end of the shaft - Figure 6-4), spin the impeller forcefully in a clockwise direction to impact the impeller wrench handle on the work surface to the right. (Figure 6-5.)

Like all front vane open style impellers, the Flowserve open impeller clearance must be set off the casing. The casing must be installed to accurately set the impeller clearance.

Attach the power end/rear cover plate assembly to the casing. Loosen the set screws [6570.3] and rotating the bearing carrier [3240] clockwise until the impeller comes into light rubbing contact with the casing. Rotating the shaft at the same time will accurately determine this zero setting. Using a felt tip pen place a reference mark on both the bearing housing and the carrier.

Now rotate the bearing carrier counter-clockwise to get the proper clearance. Refer to Figure 5-10 for the proper impeller clearance settings. Rotating the bearing carrier the width of one of the indicator pattern moves the impeller axially 0.1 mm (0.004 in.). (See Figure 6-6.) To determine how far to rotate the bearing carrier divide the desired impeller clearance by 0.1 mm (0.004 in.) (one indicator pattern). Tightening the set screws [6570.3] will cause the impeller to move 0.05 mm (0.002 in.) away from the casing because of the internal looseness in the

bearing carrier threads. This must be considered when setting the impeller clearance. Rotate the bearing carrier counter-clockwise the required amount to get the desired clearance to the casing.

Lastly, uniformly tighten the set screws [6570.3] in incremental steps up to the final torque value to lock the bearing carrier in place.

See section 5.3 for impeller clearance settings.

Example.

The impeller of a pump is to be placed in a service based an operating temperat ure of 65 °C (150 °F) therefore the impeller setting would be

0.71 mm (0.028 in.) off the casing. This value however needs to be adjusted by 0.05 mm (0.002 in.) to compensate for the movement associate d with tightening the set screws on the bearing carrier. This is accomplished by subtracting 0.05 mm (0.002 in. ) from the desired impeller setting value of 0.71 mm (0.028 in.). As a result, the bearing carrier would need to be moved axially 0.64 mm (0.025 in.). First, turn t he beari ng carrier clockwise until the impeller comes into light rubbing contact with the casing. To determine the number of indicator patterns that you will need to rotate the carrier, divide 0.10 (0.004) into the d esired setti ng;

0.71 ⎟ 0.10 = 7.1 (.028 ⎟ 0.004 = 7). Rotate the bearing carrier counter-clockwise 7 indicator patterns which will give a clearance of 0.70 mm (0.028 in.). Flowserve suggests that a felt tip pen be used to mark an initial reference point on the bearing housing and the bearing carrier. A second mark should also be placed on the bearing carrier 7 indicato r patterns cl ockwise fro m the initial reference point. Rotate the bearing carrier counter-clockwise until the second mark on the bearing carrier lines up with the initial reference point mark on the bearing housing. Uniformly tighten the set screws [6570.3] to lock the bearing carrier in place. The impeller is now set.

The above procedure is fairly straightforward when doing the final setting of the impel ler. Ho wever, it ca n be quite laborious when doing the preliminary setti ng in order to establish the location of th e mechan ical se al. For this reason, the following practice is recommended. Before the pump is taken out of service, adjust th e impeller until it touches the casing and then rot ate the bearing carrier until the desired impell er clearance is obtained. Identify this location o n the bea ring carri er and then rotate the bearing carrier until the impelle r contacts the rear cover. Record the di stan ce from th e desired impeller clearance setting to when the impelle r contacts the rear cover. The pump is now removed from the casing and taken to the shop for maintenance. When it is time to set the seal, the impeller is simply set off the rear cover by the same distance recorded earlier.

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

c) If a cartridge type mechanical seal [4200] is used,

The above technique is only applicable if all of the original pump components are reinstalled. If the casing, cover, impeller or shaft is replaced this method must not be used.

the spacing clips or tabs should be installed prior to loosening the set screws which attaches the seal to the shaft or removing it from the cover. This will ensure that the proper seal compression is maintained.

6.8 Pump removal and disassembly

6.8.1 Pump removal

a) Before performing any maintenance, disconnect the

driver from its power supply and lock it off line.

Lock out power to driver to prevent

personal injury.

b) Close the discharge and suction valves, and

drain all liquid from the pump.

c) Close all valves on auxiliary equipment and

piping, then disconnect all auxiliary piping.

d) Decontaminate the pump as necessary.

If Flowserve PolyChem S-series pumps contain dangerous chemicals it is important to follow plant safety guidelines to avoid personal injury or death.

e) Remove the coupling guard. (See section 5.5.) f) Remove the spacer from t he coupling. g) Remove casing fasteners [6580.1]. h) Remove the fasteners holding the bearing

housing foot to the baseplate.

i) Move the power end, rear cover, and seal chamb er

assembly away from the casing.

The power end and rear cover assembly is heavy. It is important to follow plant safety guidelines when lifting it.

j) Transport the assembly to the maintenance shop.

6.8.2 Pump disassembly

a) Remove coupling hub from the pump shaft [2100].

Do not apply heat to the impeller. This could damage the liner plus if liqu id is entrapped in the hub, an explosion c ould occur.

b) Using the shaft key [6700], mount the impeller

wrench from the Flowserve impeller tool kit (Figure 6-1) to the end of the shaft. With the wrench handle pointing to the left when viewed from the impeller end, grasp the impeller [2200] fi rmly wit h both hands (wear heavy gloves). By turning the impeller in the clockwise direction move the wrench ha ndle to the 11 o’clock position and then spin the impeller quickly in a counter-clockwise directio n so that the wrench makes a sudden impact with a hard surface on the bench. After several sharp raps, the impeller should be free. Unscrew the impelle r and rem ove from the shaft. Discard the impeller O-ring [4610.8].

on the PolyChem S-series pump. The style of sleeve depends on the pump model/impeller.

Pump Impeller

1.5X1-6

1.5X1-8 Closed X 3X1.5-6

3X2-6

2X1-10 Closed X 3X2-10

3X2-10HD

4X3-10

4X3-10HD

3X2-13 Open X

3X2-13HD Open X

4X3-13 Open X 4X3-13HD Open X 6X4-13HD Open X

Pump Impeller

PS32-160 Closed X PS65-160 Closed X PS40-200 Closed X PS32-250 Closed X PS50-250 Closed X PS65-250 Closed X PS50-315 Open X PS65-315 Open X

PS100-315 Open X

Design 1 standard is silicon carbide although metallic versions of the sleeve are available. Depending on the seal design, if set screws are utilized to attach the rotary unit and they fall onto the sleeve you must replace the standard sleeve (silicon carbide) with a metal sleeve or convert to a solid shaft.

Design 2 standard is a metallic hook sleeve.

Three sleeve designs are utilized

ANSI

Sleeve design

Closed X

Open X X

Closed X

Open X X

Closed X

Open X X

Closed X

Open X X

Closed X

Open X X

Closed X

Open X X

Closed X

X X

Open

1 2 3

ISO

Sleeve design

1 2 3

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

Design 3 standard is a carbon filled fluoropolymer sleeve. Depending on the seal design, if set screws are utilized to attach the rotary unit and they fall onto the sleeve, damage may occur. You may wish to convert to Design 2.

Sleeve design 1 and 2

d) Remove the seal gland nuts [6580.2] if so

equipped.

e) Remove the two cap screws [6570.2] which

attach the rear cover [1220] to the adapter. Carefully remove this part.

f) If a component type inside mechanical seal [4200]

is used, loosen the set screws on the rotating unit and remove it from the shaft. Then pull the gland [4120] and the stationary seat off the shaft. Remove the stationary seat from the gland.

g) If a component type outside mechanical seal is

used, remove the gland [4120] and the stationary seat. Remove the stationary seat from the gland. Loosen the set screws in the rotating unit and

remove it from the shaft. h) Discard all O-rings and gaskets. i) If the pump has a sleeve [2400] it can now be

removed. The unit now appears as shown in

Figure 6-7. Proceed to step j).

f) Remove the seal gland nuts [6580.2]. Proceed to

step j).

j) If the power end is oil lubricated, remove the

drain plug [6569.1] and drain the oil from the bearing housing [3200].

k) If the pump has lip seals, a deflector [2540] will

be present. Remove it.

l) Loosen the three set screws [6570.3] on the

bearing carrier [3240]. The bearing carri er must be completely unscrewed from the bearing housing.

Do not pry against the shaft.

ISO Group A and ANSI pumps:

The face of the bearing carrier has three square lugs that protrude from the surface. The b earing carrier is turned by using an open end wrench on one of the square lugs as shown in Figure 6-9.

ISO Group B and C pumps:

The bearing carrier is turned by using a strap wrench, with the strap located around th e outside diameter of the carrier face.

Figure 6-7

Sleeve design 3

d) Remove the sleeve [2400]. The use of a gear

puller may be necessary since the sleeve is

mounted on tolerance rings. (See Figure 6-8.)

Discard tolerance rings.

Figure 6-8

e) Remove the two cap screws [6570.2] which

attach the rear cover [1220] to the adapter.

Carefully remove this part.

Figure 6-9

m) Because the O-rings [4610.2] will cause some

resistance in removing the bearing carrier assembly from the housing, hold the bearing carrier flange firmly and with slight rotation, pull it out of the bearing housing. The bearing carrier assembly with the shaft and bearings should come free. This unit will appear as shown in Figure 6-10. Further disassembly is not required unless the bearings are to be replaced.

Figure 6-10

n) Remove the snap ring [2530]. (See Figure 6-11.)

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

Figure 6-11

ISO Group A and the ANSI pump models when equipped with duplex angular contact bearings use a bearing retainer [2530.1] instead of a snap ring. Remove the carrier from the bearing.

o) The bearing locknut [3712] and lock washer

[6541.1] may now be removed from the shaft [2100]. Discard the lock washer.

p) An arbor or hydraulic press may be used to

remove the bearings [3011 and 3013] from the shaft. It is extremely important to apply even pressure to the inner bearing race only. Never apply pressure to the outer race as this exerts excess load on the balls and causes damage.

Applying pressure to the outer

race could permanently damage the bearings.

q) The ISO Group A and the ANSI pump models

has an optional oil slinger [2541] located between the bearings. If present, inspect it for damage or looseness. Remove if it needs to be replaced.

r) On ISO Group B and C pumps and ANSI Group 2

pumps, the bearing housing [3200] must be separated from the bearing housing adapter [1340]. The adapter O-ring [4610.2] should be discarded. This is accomplished by removing the cap screws [6570.5], which thread into the bearing housing.

s) If lip seals [4310.1] and [4310.2] are used, they

should be removed from the bearing carrier and adapter and discarded.

t) If the bearing isolators are removed from either

the bearing carrier or adapter they must not be reused, discard appropriately.

u) If magnetic seals are used, maintain the seals as

specified by the manufacturer.

v) Mark 3A design.

gauge [3855] and oil level tag (Figure 6-1 2) from the bearing housing.

ANSI 3A design:

and oil level tag (Figure 6-12) from the beari ng housing.

Remove the Trico oil er/si ght

Remove the sight gauge [3856]

Save these parts for reuse.

6.9 Examination of parts

6.9.1 Cleaning/inspection

All parts should be thoroughly cleaned and inspected. New bearings, O-rings, gaskets, and lip seals should be used. Any parts that show wear or corrosion should be replaced with new genuine Flowserve parts.

It is important that only non-flammable, non-contaminated cleaning fluids are used. These fluids must comply with plant safety and environmental guidelines.

6.9.2 Critical measurements and tolerances

To maximize reliability of pumps, it is important that certain parameters and dimensions are measured and maintained within specified tolerances. It is important that all parts be checked. Any parts that do not conform to the specifications should be replaced with new Flowserve parts.

6.9.3 Parameters that should be checked by users

Flowserve recommends that the user check the measurements and tolerances in Figure 6-13 whenever pump maintenance is performed. Each of these measurements is described in more detail on the following pages.

6.9.4 Additional parameters checked by Flowserve

The parameters listed below are somewhat more difficult to measure and/or may require specialized equipment. For this reason, they are not typically checked by our customers, although they are monitored by Flowserve during the manufacturing and/or design process.

6.9.4.1 Shaft and sleeve (if fitted)

Replace the sleeve if grooved, pitted or worn. Prior to mounting bearings or installing the shaft into the bearing housing, check the following parameters.

Figure 6-12

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

Diameter/tolerance, under bearings:

In order to ensure proper fit between the shaft and bearings, verify that both the inboard (IB) and outboard (OB) shaft diameter is consistently within the minimum/maximum values shown in Figure 6-14. A micrometer should be used to check these outside diameter (OD) dimensions on the shaft.

Figure 6-13

Suggested by major seal vendors mm (in.)

See note 1

0.03 (0.001)

0.05 (0.002)

0.076 (0.003)

0.05 (0.002)

0.03 (0.001)

0.13 (0.005)

0.05 (0.002)

ASME

Topic

Shaft

Diameter tolerance, under bearings

Impeller

Balance

Bearing housing

Diameter (ID) tolerance at bearings

Power end assembly

Shaft runout Shaft sleeve runout Radial deflection - static Shaft endplay

Seal chamber

Face squareness to shaft Register concentricity

Complete pump

Shaft movement caused by pipe strain Alignment Vibration at bearing housing

n/s = not specified.

1. The maximum values of acceptable unbalance are: 1 500 r/min: 40 g 2 900 r/min: 20 g Flowserve performs a single plane spin balance on most impellers. Balancing is performed to the ISO 1940 Grade 6.3 tolerance criteria.

2. ASME B73.1 does not specify a recommended level of alignment. Flowserve recommends that the motor be aligned to the pump within 0.05 mm (0.002 in.) parallel Full Indicator Movement (FIM) and 0.0005 mm/mm (0.0005 in./in.) angular FIM. Closer alignment will extend MTBPM. For detail discussion of this subject see Section 5,

3. See ASME B73.1, paragraph 5.1.4.

B73.1 standard mm (in.)

n/s

0.05 (0.002)

0.05 (0.002) n/s n/s

0.08 (0.003)

n/s n/s

See note 3

·mm/kg (1 800 r/min: 0.021 oz-in./lb) of mass.

·mm/kg (3 600 r/min: 0.011 oz-in./lb) of mass.

Installation, of this manual.

Suggested and/or provided by Flowserve mm (in.)

0.005 (0.0002)

0.013 (0.0005)

0.05 (0.002)

0.08 (0.003)

0.13 (0.005)

0.05 (0.002) See note 2 See note 3

6.9.4.2 Bearings

It is recommended that bearings not be re-used after removal from the shaft. Prior to mounting bearings, check the following parameters.

Diameter/tolerance, inside diameter:

In order to ensure proper fit between bearings and the shaft, verify that the inside diameter (ID) of both the IB and OB bearing are consistently within the minimum/maximum values shown in Figure 6-14. An inside caliper should be used to check these ID diameters on the bearings.

Diameter/tolerance, outside diamete r:

In order to ensure proper fit between bearings and the bearing housing, verify that the OD on both the IB and OB bearings are consistently within the minimum/ maximum values shown in Figure 6-15. A micrometer should be used to check these OD dimensions on the bearings.

Figure 6-14a: ISO pumps

Group A Group B Group C

OB bearing/ shaft mm (in)

IB bearing/ shaft mm (in)

Bearing Shaft Fit Bearing Shaft Fit

30.000/29.990

(1.1811/1.1807)

30.013/30.002

(1.1816/1.1812)

0.023T/0.002T

(0.0009T/0.0001T)

35.000/34.988

(1.3780/1.3775)

35.014/35.004

(1.3785/1.3781)

0.025T/0.004T

(0.0010T/0.0001T)

45.000/44.988

(1.7717/1.7712)

45.014/45.004

(1.7722/1.7718)

0.026T/0.004T

(0.0010T/0.0001T)

45.000/44.988

(1.7717/1.7712)

45.014/45.004

(1.7722/1.7718)

0.026T/0.004T

(0.0010T/0.0001T)

55.000/54.985

(2.1654/2.1648)

55.016/55.004

(2.1660/2.1655)

0.031T/0.004T

(0.0012T/0.0001T)

55.000/54.985

(2.1654/2.1648)

55.016/55.004

(2.1660/2.1655)

0.030T/0.004T

(0.0012T/0.0001T)

Figure 6-14b: ANSI pumps

Group 1 Group 2 Group 2 HD

OB bearing/ shaft mm (in)

IB bearing/ shaft mm (in)

Bearing Shaft Fit Bearing Shaft Fit

30.000/29.990

(1.1811/1.1807)

30.013/30.002

(1.1816/1.1812)

0.023T/0.002T

(0.0009T/0.0001T)

35.000/34.988

(1.3780/1.3775)

35.014/35.004

(1.3785/1.3781)

0.026T/0.004T

(0.0010T/0.0001T)

50.000/49.988

(1.9685/1.9680)

50.013/50.002

(1.9690/1.9686)

0.025T/0.003T

(0.0010T/0.0001T)

50.000/49.988

(1.9685/1.9680)

50.013/50.002

(1.9690/1.9686)

0.025T/0.002T

(0.0010T/0.0001T)

50.000/49.988

(1.9685/1.9680)

50.013/50.002

(1.9690/1.9686)

0.025T/0.002T

(0.0010T/0.0001T)

60.000/59.985

(2.3622/2.3616)

60.015/60.002

(2.3628/2.3623)

0.030T/0.002T

(0.0012T/0.0001T)

Figure 6-15a: ISO pumps

OB bearing/ carrier mm (in)

IB bearing/ housing mm (in)

Bearing

Carrier

Fit

Bearing

Housing

Fit

Group A Group B Group C

72.000/71.987

(2.8346/2.8341)

72.017/71.999

(2.8353/2.8346)

0.030L/0.000L

(0.0012L/0.0000L)

72.000/71.987

(2.8346/2.8341)

72.017/71.999

(2.8353/2.8346)

0.030L/0.000L

(0.0012L/0.0000L)

100.000/99.985 (3.9370/3.9364)

100.023/100.002 (3.9379/3.9371)

0.038L/0.002L (0.0015/0.0001L)

100.000/99.985 (3.9370/3.9364)

100.018/100.002 (3.9377/3.9371)

0.033L/0.002L

(0.0013L/0.0001L)

120.000/119.985 (4.7244/4.7238)

120.023/120.002 (4.7253/4.7245)

0.028L/0.002L

(0.0015L/0.0001L)

120.000/119.985 (4.7244/4.7238)

120.018/120.002 (4.7251/4.7245)

0.033L/0.002L

(0.0013L/0.0001L)

Figure 6-15b: ANSI pumps

Group 1 Group 2 Group 2 HD

OB bearing/ carrier mm (in)

IB bearing/ housing mm (in)

Bearing

Carrier

Fit

Bearing

Housing

Fit

72.000/71.987

(2.8346/2.8341)

72.017/71.999

(2.8353/2.8346)

0.030L/0.000L

(0.0012L/0.0000L)

72.000/71.986

(2.8346/2.8341)

72.017/71.999

(2.8353/2.8346)

0.031L/0.000L

(0.0012L/0.0000L)

110.000/109.985 (4.3307/4.3301)

110.023/110.007 (4.3316/4.3310)

0.038L/0.007L

(0.0015/0.0003L)

110.000/109.985 (4.3307/4.3301)

110.023/110.007 (4.3316/4.3310)

0.038L/0.007L

(0.0015L/0.0003L)

110.000/109.985 (4.3307/4.3301)

110.023/110.007 (4.3316/4.3310)

0.038L/0.007L

(0.0015/0.0003L)

110.000/109.985 (4.3307/4.3301)

110.023/110.007 (4.3316/4.3310)

0.038L/0.007L

(0.0015/0.0003L)

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

6.9.4.3 Impeller balancing

Shaft whip is deflection where the centerli ne of the impeller is moving around the true axis of the pump. It is not caused by hydraulic force but rather by an imbalance with the rotating element. Shaft whip is very hard on the mechanical seal becau se the f aces must flex with each revolution in order to maintain contact. To minimize shaft whip it is imperative that the impeller is balanced. All open impellers manufactured by Flowserve are balanced aft er they are trim med. If for any reason a customer trims an impeller, it must be rebalanced. See note 1 under Figure 6-13 regarding acceptance criteria.

6.9.4.4 Bearing housing/carrier

Prior to installing the shaft into the bearing housing, check the following parameters.

Diameter/tolerance, at bearing surface

In order to ensure proper fit between the bearing

Radial deflection - static

Radial movement of the shaft can be caused by a loose fit between the shaft and the bearing and/or the bearing and the housing. This movement is mea sured by attempting to displace the shaft ve rtically by a pplying an upward force of approximately 4.5 kg (10 lb) to the impeller end of the shaft. While applying this force, the movement of an indicator is observed as shown in the following diagram. The movement should be che cked at a point as near as possible to t he lo cation of the se al faces. A movement of more than 0.05 mm (0.002 in.) is not acceptable.

Runout

housing/carrier and the bearings, verify that the ID of both the IB and OB bearing surfaces are consistently within the minimum/maximum values shown in Figure 6-15. An inside caliper should be used to check these ID dimensions in the bearing housing.

6.9.4.5 Power end

Assembled bearing housing, carrier, bearings, and shaft.

Shaft/shaft sleeve run-out

Shaft run-out is the amount the shaft is “out of true” when rotated in the pump. It is measured by attaching a dial indicator to a stationary part of the pump so that its contact point indicates the radial movement of the shaft surface as the shaft is rotated slowly. If a shaft sleeve is used then shaft sleeve run-out must be checked. It is analogous to shaft run-out. Measurement of shaft run-out/shaft sleeve run-out will disclose any out of roundness of the shaft, any eccentricity between the shaft and the

Shaft endplay

The maximum amount of axial shaft movement, or endplay, on a Durco pump should be 0.03 mm (0.001 in.) and is measured as shown below. Observe indicator movement while tapping the shaft from each end in turn with a soft mallet. Shaft endplay can cause several problems. It can cause fretting or wear at the point of contact between the shaft and the secondary sealing element. It can also cause seal overloading or underloading and possi bly chipping of the seal faces. It can also cause the faces to separate if significant axial vibration occurs.

Deflection

sleeve, any permanent bend in the shaft, and/or any eccentricity in the way the shaft or bearings are mounted in the bearing housing.

Shaft run-out can shorten the life of the bearings and the mechanical seal. The following diagram shows how to measure shaft/shaft sleeve run-out. Note that both ends need to be checked. The run-out should be 0.025 mm (0.001 in.) FIM or less.

6.9.4.6 Seal chamber

Endplay

Assembled power end and rear cover.

Face squareness to shaft

Also referred to as “Seal chamber face run-out.” This run-out occurs when the seal chamber face is not perpendicular to the shaft axis.

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

This will cause the gland to cock, which causes the stationary seat to be cocked, which causes the seal to wobble. This run-out should be less than 0.08 mm (0.003 in.) and should be measured as shown below:

Face squareness

An eccentric seal chamber bore or gland register can interfere with the piloting and ce ntering of the seal components and alter the hydrauli c loading of th e seal faces, resulting in reduction of seal life and performance. The seal chamber register concentricity should be less than 0.13 mm (0.005 in.). The diagram below shows how to measure this concentricity.

6.9.4.7 Installed pump

Complete pump installed.

Shaft movement caused by pipe strain

Pipe strain is any force put on the pump casing by the piping. Pipe strain should be measured as shown below. Install the indicators as shown before attaching the piping to the pump. The suction and discharge flanges should now be bolted to the piping separately while continuously observing the indicators. Indicator movement should not exceed

0.05 mm (0.002 in.).

Concentricity

Pipe strain movement

Alignment

Misalignment of the pump and motor shafts can cause the following problems:

• Failure of the mechanical seal

• Failure of the motor and/or pump bearings

• Failure of the coupling

• Excessive vibration/noise

The schematics below show the technique for a typical rim and face alignment using a dial indicator. It is important that this alignment be done after the flanges are loaded, and at typical operating temperatures. If proper alignment cannot be maintained a C-flange motor adapter and/or stilt/spring mounting should be considered.

Many companies today are using laser alignment which is a more sophisticated and accurate technique. With this method a laser and sensor measure misalignment. This is fed to a computer with a graphic display that shows the required adjustment for each of the motor feet.

See section 4.8 for recommended final shaft alignment limits.

Vibration analysis

Vibration analysis is a type of condition monitoring where a pump’s vibration “signature” is monitored on a regular, periodic basis. The primary goal of vibration analysis is extension on MTBPM. By using this tool Flowserve can often determine not only the existence of a problem before it becomes serious, but also the root cause and possible solution.

Modern vibration analysis equipment not only detects if a vibration problem exists, but can also suggest the cause of the problem. On a centrifugal pump, these causes can include the following: unbalance, misalignment, defective bearings, resonance, hydraulic forces, cavitation and recirculation. Once identified, the problem can be corrected, leading to increased MTBPM for the pump.

Flowserve does not make vibration analysis equipment, however Flowserve strongly urges customers to work with an equipment supplier or consultant to establish an on-going vibration analysis program. See note 3 under Figure 6-13 regarding acceptance criteria.

Alignment

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

6.10 Assembly of pump and seal

It is important that all pipe threads be sealed properly. PTFE tape provides a very reliable seal over a wide range of fluids, but it has a serious shortcoming if not installed properly. If, during application to the threads, the tape is wrapped over the end of the male thread, strings of the tape will be formed when threaded into the female fitting. These strings can then tear away and lodge in the piping system. If this occurs in the seal flush system, small orifices can become blocked effectively shutting off flow. For this reason, Flowserve does not recommend the use of PTFE tape as a thread sealant.

Flowserve has investigated and tested alternate sealants and has identified two that provide an effective seal, have the same chemical resistance as the tape, and will not plug flush systems. These are La-co Slic-Tite and Bakerseal. Both products contain finely ground PTFE particles in an oil based carrier. They are supplied in a paste form which is brushed onto the male pipe threads. Flowserve recommends using one of these paste sealants.

Full thread length engagement is required for all fasteners.

Refer to Figure 6-2 for recommended bolt

torques.

6.10.1 Power end assembly

The Mark 3A design has an optional oil slinger. If the slinger was removed during disassembly, install a new slinger [2541]. (See Figure 6-16.)

Figure 6-16

6.10.1.1 Bearing installation

Mounting of bearings on shafts must be done in a clean environment. Bearing and power end life can be drastically reduced if even very small foreign particles work their way into the bearings. Wear clean gloves.

Bearings should be removed from their protective packaging only immediately before assembly to limit exposure to possible contamination. After removing the packaging they should only come in contact with clean hands, fixtures, tools and work surfaces.

The chart shown in Figure 6-19 gives the SKF part numbers for bearings in Flowserve PolyChem pumps.

The term “inboard bearing” refers to the bearing nearest to the casing. “Outboard bearing” refers to the bearing nearest to the motor. (See Figure 6-16.)

Both bearings have a slight interference fit which requires that they be pre ssed on t he shaft wit h an arbor or hydraulic press. Figure 6-14 identifies the bearing fits. Even force should be applied to only the inner race. Never press on the outer race, as the force will damage the balls and races.

An alternate method of installing bearings is to heat the bearings to 93 °C (200 °F) by means of an oven or induction heater. With this approach the bearing must be quickly positioned on the shaft.

Never heat the bearings above 110 °C (230 °F). To do so will likely cause the bearing fits to permanently change, leading to early failure. a) Install the inboard bearing [3011] on the shaft

[2100] the bearing must be positioned again st the shoulder as shown in Figure 6-16. (If the power end is equipped with single shielded regreasable bearings, see Figure 5-8 for proper orientation of the shields.)

b) Install the outboard bearing retaining device onto

the shaft. Double row bearings. onto the outboard end of the shaft and slide down to the inboard bearing. (Note: the p roper orient ation of the snap ring must be assured in this step. The flat side of the snap ring mu st face away fro m the inboard bearing.) Duplex angular contact bearings. retainer [2530.1] onto the outboard end of the shaft and slide down to the inboard bearin g. Note: the proper orientation of the bearing retainer must be assured in this step. The small side of the retai ner must face away from the inboard bearing.

c) Install the outboard bearing.

Double row bearings

[3013] firmly against the shoulder as shown in Figure 6-16. If hot bearin g mount ing tech nique s are used, steps must be taken to ensure the outboard bearing is firmly positioned against the shaft shoulder. The outboard bearing, while still hot, is to be positioned against the shaft shoulder.

Duplex angular contact bearings

contact bearings must be mounted back-to-back with the wider thrust sides of the outer races in contact with each other as shown in Figure 6-17. Only bearings designed for universal mounting should be used. SKF’s designation is “BECB”. NTN’s designation is “G”. (Note: a special shaft is required when using duplex angular contact bearings.)

Place the snap ring [2530]

Place the bearing

. Install the outboard bearing

. Duplex angular

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

Install the outboard seal in the bore of the bearing

It must be understood that fixtures and equipment used to p ress t he bea ring mu st be designed so no load is ever transmitted through the bearing balls. This would damage the bearing.

carrier. There are no orientation issues since this is a multiport design seal.

Magnetic seals.

Follow the installation instructions

provided by the manufacturer.

6.10.1.3 Bearing carrier/power end assembly

a) Install new O-ring s [4610.2] ont o the bearing ca rrier.

Figure 6-17

d) After the bearing has cooled below 38 °C (100 °F)

the bearing should be pressed against the shaft shoulder. Figure 6-18 identifies the approximate force needed to seat the bearing against the shaft shoulder. If a press is not available the locknut [3712] should be installed immedi ately after the bearing is placed on the shaft and ti ghten ed to ensure the bearing remains in contact with the shaft shoulder. The locknut should then be retightened repeatedly during the time the bearing is cooling. Once cool the locknut should be removed.

Figure 6-18

Pump

Group A/1 5 780 (1 300) 27 +4/-0 (20 +5/-0)

Group 2 11 100 (2 500) 54 +7/-0 (40 +5/-0) Group B 9 600 (2 200) 46 +7/-0 (34 +5/-0) Group C 12 000 (2 700) 63 +7/-0 (47 +5/-0)

Press force

N (lbf)

Locknut torque

Nm (lbf▪ft)

e) Install lock washer [6541.1] and locknut [3712].

The locknut should be torqu ed to t he valu e show n in Figure 6-18. One tang on the lock washer m ust be bent into a corresponding groove on the locknut.

6.10.1.2 Bearing housing seals

Lip seals.

If lip seals were used, install new lip seals

in the bearing carrier [3240] and the housing [3200 Group A and 1] or the adapter [1340 - Group B, C and 2]. The lip seals [4310.1 and 4310.2] are double lip style, the cavity between these two lips should be

/2 to 2/3 filled with grease. When installing this part, the large metal face on the lip seal must face away from the bearings.

Labyrinth seals.

The following are general installation

instructions regarding the VBXX Inpro seal. Follow the instructions provided wit h the seal by the ma nufactu rer. The elastomer O-ring located on the O D of the se al has been sized to overfill the groove in which it is located. When installing the seal into its corresponding housing, in addition to compressing th e O-rin g a cert ain amou nt of material may shear off. This sheared material should be removed. An arbor press should be used to inst all the seal. Install the inboard seal i n the bore of the bearing housing (Group A and 1) or adapter (Group B, C and 2) with the single expulsion port positioned at the

b) Slide the bearing carrier [3240] over the outboard

bearing [3013].

c) Install the outboard bearing retaining device.

Double row bearings on Group A, B, C, 1 and 2 pumps. Slide the snap ring [2530] in place with

its flat side against the outboard bearing and snap it into its groove in the bearing carrier.

Duplex angular contact bearings on Group A, 1 and 2 pumps. Slide the bearing retainer [2530.1]

against the outboard bearing and install and tighten the socket head cap screws [6570.12]. (See Figure 6-2 for correct torque values.)

Never compress the snap ring unless it is positioned around the shaft and between the bearings. In this configuration, it is contained therefore if it should slip off the compression tool it is unlikely to cause serious injury.

d) The shaft, bearings, and bearing carrier

assembly (Figure 6-10) can now be installed into the bearing housing [3200]. The bearing carrier [3240] should be lubricated with oil on the O-rings and threads before installing the assembly into the bearing housing. Thread the bearing carrier into the bearing housing by turning it clockwise to engage the threads. Thread the carrier onto the housing until the carrier flange is approximately 3 mm (

/8 in.) from the housing. Install the set

screws [6570.3] loosely.

e) Reinstall any tags, plugs, site gauges and oiler.

Mark 3A design.

Install the following items onto the bearing housing; oil level tag (Figure 6-12) and combination Trico oiler/sight gauge [3855], vent/ breather [6521] and drain plug [6569.1].

ANSI 3A design.

Install the following items onto

the bearing housing; oil level tag (Figure 6-12) and sight gauge [3855], plug [6521] and magnetic drain plug [6521.1].

f) On Group B, C and 2 pumps, assemble the

bearing housing adapter [1340] to the bearing housing [3200]. Be sure to install a new O-ring [4610.2]. Thread the cap screws [6570.5] through the adapter and into the tapped holes in the bearing housing.

g) If the pump has lip seals, install the deflector [2540].

6 o’clock position.

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

Figure 6-19: Flowserve PolyChem S-series bearings

Group

2“HD”

Notes:

1. These bearings are open on both sides. They are lubricated by oil bath or oil mist.

2. These bearings are pre-greased by Flowserve. Replacement bearings will generally not be pre-greased, so grease must be applied by

3. These bearings are shielded on both sides. They come pre-greased by the bearing manufacturer. The user does not need to regrease

4. These bearings are sealed on both sides. They come pre-greased by the bearing manufacturer. The user does not need to regrease

5. The codes shown are SKF codes. Inboard and outboard bearings have the C3, greater than “Normal” clearance. These clearances

6. Regreasable - single shielded bearings are not available in the duplex configuration; however, open oil bath-type bearings can be used

7. Not available.

8. All bearing configurations are supplied only with steel cages.

9. SKF - the 5300 and 3300 bearing series are identical and therefore can be used interchangeably.

Type of bearing

Oil bath/mist - open 1 6207-C3 5306-AC3 or 3306-AC3 7306-BECBY Regreasable - single shielded 2 6207-ZC3 5306-AZC3 or 3306-AZC3 N/A 6

1/A

Greased for life - double shielded 3 6207-2ZC3 5306-A2ZC3 or 3306-A2ZC3 N/A 7 Sealed for life - double sealed 4 6207-2RS1C3 5306-A2RSC3 or 3306-A2RS1C3 N/A 7 Oil bath/mist - open 1 6310-C3 5310-AC3 (AHC3) or 3310-AC3 7310-BECBY Regreasable - single shielded 2 6310-ZC3 5310-AZC3 or 3310-AZC3 N/A 6

Greased for life - double shielded 3 6310-2ZC3 5310-A2ZC3 or 3310-A2ZC3 N/A 7 Sealed for life - double sealed 4 6310-2RS1C3 5310-A2RSC3 or 3310-A2RS1C3 N/A7 Oil bath/mist - open 1 6212-C3 5310-AC3 (AHC3) or 3310-AC3 7310-BECBY Regreasable - single shielded 2 6212-ZC3 5310-AZC3 or 3310-AZC3 N/A 6 Greased for life - double shielded 3 6212-2ZC3 5310-A2ZC3 or 3310-A2ZC3 N/A 7 Sealed for life - double sealed 4 6212-2RS1C3 5310-A2RSC3 or 3310-A2RS1C3 N/A 7 Oil bath/mist - open 1 6309-C3 5309-AC3 (AHC3) or 3309-AC3 N/A Regreasable - single shielded 2 6309-ZC3 5309-AZC3 or 3309-AZC3 N/A

Greased for life - double shielded 3 6309-2ZC3 5309-A2ZC3 or 3309-A2ZC3 N/A Sealed for life - double sealed 4 6309-2RS1C3 5309-A2RSC3 or 3309-A2RS1C3 N/A Oil bath/mist - open 1 6311-C3 5311-AC3 (AHC3) or 3311-AC3 N/A Regreasable - single shielded 2 6311-ZC3 5311-AZC3 or 3311-AZC3 N/A

Greased for life - double shielded 3 6311-2ZC3 5311-A2ZC3 or 3311-A2ZC3 N/A Sealed for life - double sealed 4 6311-2RS1C3 5311-A2RSC3 or 3311-A2RS1C3 N/A

the user. They have a single shield, which is located on the side next to the grease buffer, or reservoir. The bearings draw grease from the reservoir as it is needed. The shield protects the bearing from getting too much grease, which would generate heat. The grease reservoir is initially filled with grease by Flowserve. Lubrication fittings are provided, to allow the customer to periodically replenish the grease, as recommended by the bearing and/or grease manufacturer.

these bearings. The shields do not actually contact the bearing race, so no heat is generated. these bearings. The seals physically contact and rub against the bearing race, which generates heat. These bearings are not

recommended at speeds above 1 750 rpm. are recommended by SKF to maximize bearing life. for the regreasable configuration. These bearings must be pre-greased during assembly. Lubrication fittings are provided, to allow the

user to periodically replenish the grease, as recommended by the bearing and/or grease manufacturer.

Inboard single row, deep groove

6.10.2 Wet end assembly

Outboard double row, angular contact, deep groove

5 & 9

To ensure proper sealing between the rear cover [1220]

Optional outboard duplex angular contact 5

7 7 7 7 7 7 7 7

and the gland all PolyChem S-series pumps utilizes a

Three sleeve designs are utilized on the PolyChem S-series pump. The style of sleeve depends on the pump model/impeller. See section

6.7.2, Pump disassembly, for description. See Figure 6-20 for seal sizes.

Figure 6-20

Pump model

Group A 35 1.378 Group B 43 1.693 Group C 53 2.087 Group 1 34.93 1.375 Group 2 47.63 1.875

Group 2 “HD” 53.98 2.125

mm in.

Seal size

combination of Belleville wa shers [65 41.5] an d flat washers [6541.4] to create a spring load. Care must be taken to ensure that the concave d side of the Bellev ille washer faces toward the rear cover. (Figure 6-21.)

Figure 6-21

Stud [6572.2] Washer [6541.4] Nut [6580.2]

Belleville washer [6541.5

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

6.10.2.1 Cartridge mechanical seals

Sleeve design 1 and 2

Review the seal assembly instructions and drawings provided by the seal manufacturer. a) If the pump is equipped with a sleev e [2400], slip it

into place over the impeller end of the shaft [2100].

b) Install a nose cone on the end of the shaft and

then slide the cartridge seal [4200] onto the shaft until it lightly touches the bearing housing [3200] or adapter [1340].

c) Install the rear cover plate [1220] to the bearing

housing (Group A and 1) or the bearing housing adapter (Group B, C and 2) by using the cap screws [6570.2].

d) Install the cartridge seal gland to the rear cover

plate [1220] using studs [6572.2] and nuts [658 0.2]. e) Install the impeller [2200] as instructed in section 6.7. f) Tighten set screws on the seal to lock the rotating

unit to the shaft. Finally, remove centering clips

from the seal.

Sleeve design 3

Review the seal assembly instructions and drawings provided by the seal manufacturer. a) Loosely attach the cartridge seal gland to the rear

cover plate [1220] using studs [6572.2] and nuts

[6580.2]. b) Install the rear cover plate [1220] to the bearing

housing (Group 1) or the bearing housing adapter

(Group 2) by using the cap screws [6570.2]. c) Install new tolerance rings into each end of the

sleeve [2400]. (See Figure 6-22.)

f) Install the impeller [2200] as instructed in section 6.7. g) Tighten the nuts [6580.2] used to attach the

gland to the cover plate [1220].

h) Tighten set screws on the seal to lock the rotating

unit to the shaft. Finally, remove centering clips from the seal.

6.10.2.2 Component type mechanical seal sleeve design 1 and 2

Review the seal assembly instructions and drawings (seal set dimension) provided by the seal manufacturer. In order to properly set a component seal it is necessary to first locate the shaft in its final axial position. This is accomplished in the following manner: a) Install the rear cover plate [1220] to the bearing

housing (Group A and 1) or the bearing housing adapter (Group B, C and 2) by using the cap screws [6570.2].

b) Install and set the impelle r [2200] clearance as

outlined in section 6.6. Put bluing on the shaft/ sleeve in the area near the face of the seal chamber [rear cover 1220]. Scribe a mark on the

Figure 6-24

shaft at the face of the seal chamber. (Figure 6-25.)

c) Remove the impeller and seal chamber (rear cover)

following the instructions given in se ction 6.8 and install a nose cone onto the end of the shaft.

Figure 6-22

d) Install sleeve assembly onto shaft [2100] utilizing

the nose cone to ensure the end of the sleeve

remains flush with the end of the shaft. (See

Figure 23.)

Figure 6-25

Single internal seal installation

d) Place the gland [4120], gland gasket [4590.3],

stationary seat and a second gland gasket [4590.3] onto the shaft until it lightly touches the

Figure 6-23

e) Install O-ring onto flange portion of the sleeve.

bearing housing (Group A and 1) or adapter (Group B, C and 2).

(See Figure 6-24.)

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

e) Locate the rotary seal un it onto the shaft (or sleev e)

according to the set dimensio n provide d by the se al

manufacturer. Tighten set screws on the sea l to

lock the rotating unit to the shaft/sleeve. f) Install the rear cover plate [1220] to the bearing

housing (Group A and 1) or the bearing housing

adapter (Group B, C, and 2) by using the cap

screws [6570.2]. g) Inset the pilot diameter of the stationary seat into

the seal chamber bore of the rear cover [1220]. h) Pilot the gland onto the seat using studs [6572.2]

and nuts [6580.2].

Single external seal installation

Carry out steps a) to c), above. d) Locate the rotary seal unit onto the shaft/sleeve

according to the set dimension provided by the

seal manufacturer. Tighten set screws on the

seal to lock the rotating unit to the shaft/sleeve. e) Install the gland gasket [4590.3], stationary seat

and a second gland gasket [4590.3] followed by

the gland [4120] onto the rear cover plate [1220]. f) Assemble using studs [6572.2] and nuts [6580.2]. g) Install the rear cover plate [1220] to the bearing

housing (Group A and 1) or the bearing housing

adapter (Group B, C, and 2) by using the cap

screws [6570.2].

Double seal installation

The PolyChem S-series pump line only has one rear cover plate [1220] design (FML) therefore a canister [1220.2] must be utilized to create a seal chamber in which the inside stationary seat can be located.

Carry out steps a) to c), above. d) Install the inboard stationary seat into the canister

[1220.2]. (See Figure 6-26.)

g) Install a gland gasket [4590.3] into the gland. h) Locate the rotary seal un it onto the shaft/sleeve

according to the set dimension provided by the seal manufacturer. Tighten set screws on the seal to

lock the rotating unit to the shaft/sleev e. Install a stationary seat into the rear cover plate [1220].

i) Install the rear cover plate [1220] to the bearing

housing (Group A and 1) or the bearing housing adapter (Group B, C and 2) by using the cap screws [6570.2].

j) Attach the gland/seat to the rear cover plate

[1220] using studs [6572.2] and nuts [6580.2].

6.10.3 Impeller assembly

The impeller [2200] can now be installed as instructed in section 6.7. Remember that the impeller clearance is already set. It cannot be changed at this point without resetting the seal.

If a new impeller of maximum diameter has been acquired and needs trimming or if the existing impeller needs trimming this is accomplished by turning (machining). It is recommen ded that thi s trimmin g operation be performed by a Flowserve representativ e. However, if this cannot be accommodated the following guidelines should be followed.

Figure 6-27

Closed vane impellers are fully trimable with the exception of the below noted pump model. Open vane impellers are manufactured using numerous component cores. See the chart below for minimum trim ranges.

a) Obtain a machining arbor from a Flowserve

representative or use the pump shaft.

b) Carefully mount the arbor or shaft into a lathe.

Take care to minimize the runo ut of the m achinin g

Figure 6-26

e) Place a gland gasket [4590.3] onto the canister

[1220.2] and install this assembly into the rear cover plate [1220]. (See Figure 6-27.)

arbor/shaft. c) Install the impeller. d) All impellers trims are machined straight (parallel

to the pump shaft).

f) Install the outboard stationary seat into t he gland

[4120] and place it onto the shaft until it lightly touches the bearing housing (Group 1) or adapter (Group 2 and 3).

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

Pump models PS50-315, PS65-315, PS100-315, PS3x2-13, PS4x3-13 and PS6x4-13HD

The first five digits and letter located on the stem identifies the pump model while the next two or three digits represent the trim diameter of the component core. Figure 6-30 identifies the minimum impeller trim based on the component core size.

Figure 6-28

6.10.3.1 Closed impeller vane exception

PS1.5x1-6 <114.3 mm (4.5 in.) Trim impeller vane (Figure 6-28) below 114.3 mm (4.5 in.) with a staggered cut to avoid contacting the component core.

6.10.3.2 Open impeller vane minimum trim restriction

The minimum diameter to which an impeller can be

Figure 6-30

Impeller stem code

116 304.8 12.00 106 279.4 11.00

96 254.0 10.00 86 228.6 9.00

Minimum trim

mm in.

trimmed is based on the size of the component core. The metal portion of the impeller has been etched and or stamped with a code to aid in identifying the size of the component core.

Pump models PS1.5x1-6OP, PS3x1.5-6OP, PS3x2-6OP, PS3x2-10OP and PS4x3-10OP

Five digits are etched on those impellers without a stem and stamped on those impellers with a stem. The digits correspond to the impeller part number which in turn corresponds to the minimum trim to which the impeller can be machined. Figure 6-29 identifies the minimum impeller trim based on these numbers.

Figure 6-29

Pump model

PS1.5x1-6OP

PS3x1.5-6OP

PS3x2-6OP

PS3x2-10OP

PS4x3-10OP

Impeller

code

51998 152.4 6.00 49989 139.7 5.50 50009 127.0 5.00 50012 114.3 4.50 50015 101.6 4.00 49926 152.4 6.00 49966 139.7 5.50 49969 127.0 5.00 49707 228.6 9.00 50125 203.2 8.00 50128 177.8 7.00 50131 152.4 6.00 50204 228.6 9.00 20207 203.2 8.00 50210 177.8 7.00

Minimum trim

mm in.

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

7 FAULTS; CAUSES AND REMEDIES

The following is a guide to troubleshooting problems with Flowserve PolyChem pumps. Common problems are analyzed and solutions offered. Obviously, it is impossible to cover every possible scenario. If a problem exists that is not covered by one of the examples, then refer to one of the books listed in section 10, Additional sources of information, or contact a Flowserve sales engineer or distributor/representative for assistance.

FAULT SYMPTOM

Pump not reaching design flow rate

Pump not reaching design head (TDH)

⇓

No discharge or flow with pump running

⇓

z z z z

z z z

z z Entrained gas from process. Process generated gases may require larger pumps. z z Speed too low. Check motor speed against design speed.

z z z

z z

z z Impeller clearance too large. Reset impeller clearance.

z z z

z z

z z Damaged pump shaft, impeller. Replace damaged parts.

Pump operates for short period, then loses prime

⇓

Excessive noise from wet end

⇓

Excessive noise from power end

⇓

PROBABLE CAUSES POSSIBLE REMEDIES

⇓

Insufficient NPSH. (Noise may not be present.)

System head greater than anticipated.

Entrained air. Air leak from atmosphere on suction side.

Direction of rotation wrong.

Impeller too small.

Plugged impeller, suction line or casing which may be due to a product or large solids.

Wet end parts (casing cover, impeller) worn, corroded or missing.

Not properly primed.

Impeller rubbing.

Abnormal fluid rotation due to complex suction piping.

Bearing contamination appearing on the raceways as scoring, pitting, scratching or rusting caused by adverse environment and entrance of abrasive contaminants from atmosphere.

Recalculate NPSH available. It must be greater t han the NPSH required by pump at desired flow. If not, redesign suction piping, holding number of elbows and number of planes to a minimum to avoid adverse flow rotation as it approaches the impeller.

Reduce system head by increasing pipe size and/or reducing number of fittings. Increase impeller diameter. (nb: Increasing impeller diameter may require use of a larger motor.)

1. Check suction line gaskets and threads for tightness.

2. If vortex formation is observed in suction tank, install vortex breaker.

3. Check for minimum submergence

After confirming wrong rotation, reverse any two of three leads on a three phase motor. The pump should be disassembled and inspected before it is restarted.

Replace with proper diameter impeller. (NOTE: Increasing impeller diameter may require use of a larger motor.)

1. Reduce length of fiber when possible.

2. Reduce solids in the process fluid when possible.

3. Consider larger pump. Replace part or parts. Repeat priming operation, recheck instructions. If pump has run

dry, disassemble and inspect the pump before operation.

1. Check and reset impeller clearance.

2. Check outboard bearing assembly for axial end play.

Redesign suction piping, holding the number of elbows and planes to a minimum to avoid adverse fluid rotation as it approaches the impeller.

1. Work with clean tools in clean surroundings.

2. Remove all outside dirt from housing before exposing bearings.

3. Handle with clean dry hands.

4. Treat a used bearing as carefully as a new one.

5. Use clean solvent and flushing oil.

6. Protect disassembled bearing from dirt and moisture.

7. Keep bearings wrapped in paper or clean cloth while not in use.

8. Clean inside of housing before replacing bearings.

9. Check oil seals and replace as required.

10. Check all plugs and tapped openings to make sure that they are tight.

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

Pump not reaching design flow rate

Pump not reaching design head (TDH)

⇓

No discharge or flow with pump running

⇓

Pump operates for short period, then loses prime

⇓

Excessive noise from wet end

⇓

Excessive noise from power end

⇓

PROBABLE CAUSES POSSIBLE REMEDIES

⇓

Brinelling of bearing identified by indentation on the ball races, usually caused by incorrectly applied forces in assembling the bearing or by shock loading such as hitting the bearing or drive shaft with a hammer.

False brinelling of bearing identified again by either axial or circumferential indentations usually caused by vibration of the balls between the races in a stationary bearing.

Thrust overload on bearing identified by flaking ball path on one side of the outer race or in the case of maximum capacity bearings, may appear as a spalling of the races in the vicinity of the loading slot. (Please note: maximum capacity bearings are not recommended) These thrust failures are caused by improper mounting of the bearing or excessive thrust loads.

Misalignment identified by fracture of ball retainer or a wide ball path on the inner race and a narrower cocked ball path on the outer race. Misalignment is caused by poor mounting practices or defective drive shaft. For example, bearing not square with the centerline or possibly a bent shaft due to improper handling.

Bearing damaged by electric arcing identified as electro- etching of both inner and outer ring as a pitting or cratering. Electrical arcing is caused by a static electrical charge emanating from belt drives, electrical leakage or short circuiting.

Bearing damage due to improper lubrication, identified by one or more of the following:

1. Abnormal bearing temperature rise.

2. A stiff cracked grease appearance.

3. A brown or bluish discoloration of the bearing races.

When mounting the bearing on the drive shaft use a proper size ring and apply the pressure against the inner ring only. Be sure when mounting a bearing to apply the mounting pressure slowly and evenly.

1. Correct the source of vibration.

2. Where bearings are oil lubricated and employed in units that may be out of service for extended periods, the drive shaft should be turned over periodically to relubricate all bearing surfaces at intervals of one to three months.

Follow correct mounting procedures for bearings.

Handle parts carefully and follow recommended mounting procedures. Check all parts for proper fit and alignment.

1. Where current shunting through the bearing cannot be corrected, a shunt in the form of a slip ring assembly should be incorporated.

2. Check all wiring, insulation and rotor windings to be sure that they are sound and all connections are properly made.

3. Where pumps are belt driven, consider the elimination of static charges by proper grounding or consider belt material that is less generative.

1. Be sure the lubricant is clean.

2. Be sure proper amount of lubricant is used. The constant level oiler supplied with Flowserve pumps will maintain the proper oil level if it is installed and operating properly. In the case of greased lubricated bearings, be sure that there is space adjacent to the bearing into which it can rid itself of excessive lubricant, otherwise the bearing may overheat and fail prematurely.

3. Be sure the proper grade of lubricant is used.

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

8 PARTS LISTS AND DRAWINGS

8.1 PolyChem S-series

Item Description

1100 Casing 1220 Cover

1220.2 Canister 1340 Adapter 2100 Shaft 2200 Impeller 2400 Sleeve 2530 Retainer ring, snap

2530.1 Retainer ring, ring 2540 Deflector 2541 Oil slinger 3011 Radial ball bearing, I.B. 3013 Thrust ball bearing, O.B.

3126.1 Shim, foot 3134 Support foot 3200 Bearing housing 3240 Bearing carrier 3712 Bearing lock nut 3855 Constant level oiler 3856 Sight oil gauge 4120 Gland 4200 Mechanical seal

4310.1 Lip seal, I.B.

4310.2 Lip seal, O.B.

4590.3 Gasket, Gland

4610.1 O-ring, adapter

4610.2 O-ring, carrier

4610.8 O-ring, impeller 6521 Vent plug

6541.1 Lock washer, bearing

6541.4 Lock washer, flat

6541.5 Lock washer, Belleville

6569.1 Plug, bearing housing

6570.2 Screw, cover

6570.3 Screw, carrier

6570.4 Screw, foot

6570.5 Screw, adapter

6570.12 Screw, duplex

6572.1 Stud, casing

6572.2 Stud, gland

6580.1 Nut, casing

6580.2 Nut, gland 6700 Key, shaft Tag - oil level

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9 CERTIFICATION

Certificates, determined from the cont ract req uirement s are provided with these instructions where applicable. Examples are certificates for CE marking and ATEX marking etc. If required, copie s of other certifi cates sent separately to the Purchaser should be obtai ned from Purchaser for retention with these User Instructions.

10 OTHER RELEVANT DOCUMENTATION AND MANUALS

10.1 Supplementary User Instructions

Supplementary instructions such as for a driver, instrumentation, controller, seals, sealant systems etc are provided as separate documents in their original format. If further copies of these are required they should be obtained from the supplier for retention with these User Instructions.

10.2 Change notes

If any changes, agreed with Flowserve, are made to the product after it is supplied, a record of the details should be maintained with these User Instructions.

10.3 Additional sources of information

The following are excellent sources for additional information on Flowserve PolyChem S-series pumps, and centrifugal pumps in general.

Pump Engineering Manual R.E. Syska, J.R. Birk, Flowserve Corporation, Dayton, Ohio, 1980.

Specification for Horizontal End Suction Centrifugal Pumps for Chemical Process, ASME B73.1

The American Society of Mechanical Engineers, New York, NY.

End-suction centrifugal pumps (rating 16 bar) – Designation, nominal duty point and dimensions, ISO 2858

International Organization for Standardization.

American National Standard for Centrifugal Pumps for Nomenclature, Definitions, Design and Application (ANSI/HI 1.1-1.3)

Hydraulic Institute, 9 Sylvan Way, Parsippany, New Jersey 07054-3802.

Technical specification for centrifugal pumps – Class II, ISO 5199

International Organization for Standardization

American National Standard for Centrifugal Pumps for Installation, Operation, and Maintenance (ANSI/HI 1.4)

Hydraulic Institute, 9 Sylvan Way, Parsippany, New Jersey 07054-3802.

Flowserve PolyChem Sales Bulletin PS-10-17. RESP73H Application of ASME B73.1-1991,

Specification for Horizontal End Suction Centrifugal Pumps for Chemical Process, Process Industries Practices

Construction Industry Institute, The University of Texas at Austin, 3208 Red River Street, Suite 300, Austin, Texas 78705.

Pump Handbook 2nd edition, Igor J. Karassik et al, McGraw-Hill, Inc., New York, NY, 1986.

Centrifugal Pump Sourcebook John W. Dufour and William E. Nelson, McGraw-Hill, Inc., New York, NY, 1993.

Pumping Manual, 9th edition T.C. Dickenson, Elsevier Advanced Technology, Kidlington, United Kingdom, 1995.

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Notes:

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USER INSTRUCTIONS POLYCHEM S-SERIES ENGLISH 71569207 11-08

Your Flowserve factory contact:

Flowserve Pump Division 3900 Cook Boulevard Chesapeake VA 23323-1626 USA

Telephone +1 757 485 8000 Fax +1 757 485 8149

Flowserve Pumps Flowserve GB Limited PO Box 17, Lowfield Works Newark, Notts NG24 3EN United Kingdom

Telephone (24 hours) +44 1636 494 600 Sales & Admin Fax +44 1636 705 991 Repair & Service Fax +44 1636 494 833 E.mail newarksales@flowserve.com

Your local Flowserve representative:

To find your local Flowserve representative please use the Sales Support Locator System found at www.flowserve.com

FLOWSERVE REGIONAL SALES OFFICES:

USA and Canada

Flowserve Corporation 5215 North O’Connor Blvd., Suite 2300 Irving, Texas 75039-5421, USA Telephone +1 972 443 6500 Fax +1 972 443 6800

Europe, Middle East, Africa

Worthing S.P.A. Flowserve Corporation Via Rossini 90/92 20033 Desio (Milan), Italy Telephone +39 0362 6121 Fax +39 0362 303 396

Latin America and Caribbean

Flowserve Corporation 6840 Wynnwood Lane Houston, Texas 77008, USA Telephone +1 713 803 4434 Fax +1 713 803 4497

Asia Pacific

Flowserve Pte. Ltd 200 Pandan Loop #06-03/04 Pantech 21 Singapore 128388 Telephone +65 6775 3003 Fax +65 6779 4607

Flowserve S-series User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual