Flowserve T-series User Manual

USER INSTRUCTIONS

T-series Thrust Bearing Pot

Installation

Operation

Thrust bearing pots for vertical wet pit pumps

PCN=26999907 01-2013 (E). Original instructions.

Maintenance

These instructions must be read prior to installing,

operating, using and maintaining this equipment.

USER INSTRUCTIONS T-SERIES THRUST BEARING POT ENGLISH 26999907 01-2013

CONTENTS

Page

1 INTRODUCTION AND SAFETY ....................... 3

1.1 General ....................................................... 3

1.2 CE marking and approvals ........................... 3

1.3 Disclaimer ................................................... 3

1.4 Copyright ..................................................... 3

1.5 Duty conditions ............................................ 3

1.6 Safety .......................................................... 4

2 TRANSPORT AND STORAGE ......................... 6

2.1 Consignment receipt and unpacking ............ 7

2.2 Handling ...................................................... 7

2.3 Lifting .......................................................... 7

2.4 Storage ....................................................... 7

2.5 Recycling and end of product life ................. 7

3 DESCRIPTION ................................................. 7

3.1 Configurations ............................................. 7

3.2 Name nomenclature .................................... 7

3.3 Design of major parts ................................... 7

3.4 Performance and operating limits ................. 8

4 INSTALLATION .............................................. 10

4.1 Thrust bearing pot installation .................... 10

4.2 Optional Bearing Gard™ installation .......... 10

4.3 Optional Lifeseal™ installation ................... 11

4.4 Thrust bearing pot installation with optional

Bearing Gard™/Lifeseal™ sealing ............. 11

4.5 Pump vertical axial play adjustment ........... 12

4.6 Lubrication and cooling requirements ......... 12

4.7 Motor stand and flexible coupling ............... 12

6 MAINTENANCE ............................................. 13

6.1 General ..................................................... 13

6.2 Maintenance schedule ............................... 14

6.3 Spare parts ................................................ 14

6.4 Tools required ............................................ 15

6.5 Fastener torques ....................................... 15

6.6 Disassembly .............................................. 15

6.7 Examination of parts .................................. 15

6.8 Assembly ................................................... 15

7 FAULTS; CAUSES AND REMEDIES .............. 18

8 PARTS LISTS AND DRAWINGS ..................... 19

8.1 7000s series .............................................. 19

8.2 7000s + 6000s series ................................. 20

8.3 29000s + 22000s series ............................. 21

8.4 7000s + 6000s series with Bearing Gard™

seal and Lifeseal™ .................................... 22

8.5 General arrangement drawing .................... 23

9 CERTIFICATION ............................................ 23

10 OTHER RELEVANT DOCUMENTATION AND

MANUALS ...................................................... 23

10.1 Supplementary User Instruction manuals ... 23

10.2 Change notes ............................................ 23

10.3 Additional sources of information ............... 23

Page

5 COMMISSIONING, START-UP, OPERATION

AND SHUTDOWN .......................................... 12

5.1 Pre-commissioning procedure ................... 12

5.2 Lubrication ................................................. 13

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USER INSTRUCTIONS T-SERIES THRUST BEARING POT ENGLISH 26999907 01-2013

1 INTRODUCTION AND SAFETY

1.1 General

These Instructions must always be kept

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

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

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

These instructions are intended to facilitate
familiarization with the product and its permitted
use. Operating the product in compliance with
these instructions is important to help ensure
reliability in service and avoid risks. The
instructions may not take into account local

regulations; ensure such regulations are observed

by all, including those installing the product.
Always coordinate repair activity with operations
personnel, and follow all plant safety requirements
and applicable safety and health laws and
regulations.

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

1.2 CE marking and approvals

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

Where applicable, the Directives and any additional
Approvals, cover important safety aspects relating to
machinery and equipment and the satisfactory
provision of technical documents and safety
instructions. Where applicable this document
incorporates information relevant to these Directives
and Approvals.

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

1.3 Disclaimer

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

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

1.4 Copyright

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

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

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product for the application intended, contact
Flowserve for advice, quoting the serial

number.

If the conditions of service on your purchase order are
going to be changed (for example liquid pumped,
temperature or duty) it is requested that the user
seeks the written agreement of Flowserve before start
up.

1.6 Safety

1.6.1 Summary of safety markings

These User Instructions contain specific safety
markings where non-observance of an instruction
would cause hazards. The specific safety markings
are:

This symbol indicates electrical

safety instructions where non-compliance will

involve a high risk to personal safety or the loss of

life.

This symbol indicates safety instructions

where non-compliance would affect personal safety
and could result in loss of life.

This symbol indicates “hazardous and toxic
fluid” safety instructions where non-compliance

would affect personal safety and could result in loss

of life.

This symbol indicates safety

instructions where non-compliance will involve some

risk to safe operation and personal safety and would

damage the equipment or property.

This symbol indicates explosive atmosphere
zone marking according to ATEX. It is used in
safety instructions where non-compliance in the
hazardous area would cause the risk of an
explosion.

This symbol is used in safety instructions to

remind not to rub non-metallic surfaces with a dry
cloth; ensure the cloth is damp. It is used in safety
instructions where non-compliance in the

hazardous area would cause the risk of an

explosion.

This sign is not a safety symbol but

indicates an important instruction in the assembly

process.

1.6.2 Personnel qualification and training

All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved. If the

personnel in question do not already possess the
necessary knowledge and skill, appropriate training
and instruction must be provided. If required the
operator may commission the
manufacturer/supplier to provide applicable

training.

Always coordinate repair activity with operations
and health and safety personnel, and follow all
plant safety requirements and applicable safety and
health laws and regulations.

1.6.3 Safety action

This is a summary of conditions and actions to
help prevent injury to personnel and damage to
the environment and to equipment. For
products used in potentially explosive

atmospheres section 1.6.4 also applies.

NEVER DO MAINTENANCE WORK

WHEN THE UNIT IS CONNECTED TO POWER

GUARDS MUST NOT BE REMOVED WHILE

THE UNIT IS OPERATIONAL

DRAIN THE UNIT AND ISOLATE

PIPEWORK BEFORE DISMANTLING THE UNIT

The appropriate safety precautions should be taken

where the pumped liquids are hazardous.

FLUORO-ELASTOMERS (When fitted.)

When a unit has experienced temperatures over

250 ºC (482 ºF), partial decomposition of fluoro-

elastomers (example: Viton) will occur. In this
condition these are extremely dangerous and skin

contact must be avoided.

HANDLING COMPONENTS

Many precision parts have sharp corners and the
wearing of appropriate safety gloves and
equipment is required when handling these
components. To lift heavy pieces above 25 kg (55
lb) use a crane appropriate for the mass and in

accordance with current local regulations.

THERMAL SHOCK

Rapid changes in the temperature of the liquid
within the unit can cause thermal shock, which can
result in damage or breakage of components and

should be avoided.

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

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be limited to maintenance staff only, with clear
visual warnings and indicators to those entering the
immediate area. Note: bearing housings must not
be insulated and drive motors and bearings may be
hot.

If the temperature is greater than 80 ºC (175 ºF)
or below -5 ºC (23 ºF) in a restricted zone, or
exceeds local regulations, action as above shall
be taken.

HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care
must be taken to avoid exposure to the liquid by
appropriate siting of the pump, limiting personnel
access and by operator training. If the liquid is
flammable and/or explosive, strict safety procedures
must be applied.

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

1.6.4 Products used in potentially explosive

atmospheres

Measures are required to:

• Avoid excess temperature

• Prevent build up of explosive mixtures

• Prevent the generation of sparks

• Prevent leakages

• Maintain the unit to avoid hazard

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

1.6.4.1 Scope of compliance

Use equipment only in the zone for which it is
appropriate. Always check that the driver, drive
coupling assembly, seal and pump equipment are
suitably rated and/or certified for the classification of
the specific atmosphere in which they are to be
installed.

Where Flowserve has supplied only the bare shaft
pump unit, the Ex rating applies only to the pump

unit. The party responsible for assembling the ATEX
pump set shall select the coupling, driver and any
additional equipment, with the necessary CE
Certificate/ Declaration of Conformity establishing it
is suitable for the area in which it is to be installed.

The output from a variable frequency drive (VFD) can
cause additional heating affects in the motor and so,
for pumps sets with a VFD, the ATEX Certification for
the motor must state that it is covers the situation
where electrical supply is from the VFD. This particular
requirement still applies even if the VFD is in a safe
area.

1.6.4.2 Marking

An example of ATEX equipment marking is shown
below. The actual classification of the pump unit
will be engraved on the nameplate.

II 2 GD c IIC 135 ºC (T4)

Equipment Group
I = Mining
II = Non-mining

Category
2 or M2 = high level protection
3 = normal level of protection

Gas and/or dust
G = Gas
D = Dust

c = Constructional safety

(in accordance with EN13463-5)

Gas Group
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)

Maximum surface temperature (Temperature
Class)
(see section 1.6.4.3.)

1.6.4.3 Avoiding excessive surface
temperatures

ENSURE THE EQUIPMENT
TEMPERATURE CLASS IS SUITABLE FOR THE
HAZARD ZONE

Units 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 unit is influenced
by the temperature of the liquid handled. The

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Temperature class

maximum permissible liquid temperature depends
on the temperature class and must not exceed the
values in the table that follows.

to EN13463-1

T6
T5
T4
T3
T2
T1

* The table only takes the ATEX temperature class into consideration.

Unit design or material, as well as component design or material,
may further limit the maximum working temperature of the liquid.

Maximum surface

temperature permitted

85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)

Temperature limit of

liquid handled *

65 °C (149 °F) *
80 °C (176 °F) *
115 °C (239 °F)
180 °C (356 °F)

275 °C (527 °F)
400 °C (752 °F)

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

The responsibility for compliance with the
specified maximum liquid temperature is with
the plant operator.

Temperature classification “Tx” is used when the
liquid temperature varies and the unit could be
installed in different hazarous atmospheres. In this
case the user is responsible for ensuring that the
unit surface temperature does not exceed that
permitted in the particular hazardous atmosphere.

If an explosive atmosphere exists during the
installation, do not attempt to check the direction of
rotation by starting the unit unfilled. Even a short
run time may give a high temperature resulting
from contact between rotating and stationary
components.

Avoid mechanical, hydraulic or electrical overload
by using motor overload trips, temperature monitor
or a power monitor and make routine vibration
monitoring checks.

In dirty or dusty environments, make regular
checks and remove dirt from areas around close
clearances, bearing housings and motors.

1.6.4.4 Preventing the build up of explosive
mixtures

ENSURE THE UNIT IS PROPERLY FILLED
AND VENTED AND DOES NOT RUN DRY
It is essential to make sure that seal chambers,
auxiliary shaft seal systems and any heating and
cooling systems are properly filled.

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 baseplate must be

properly grounded.

Avoid electrostatic charge: do not rub non-

metallic surfaces with a dry cloth; ensure cloth is
damp.

For ATEX applications the coupling must be selected
to comply with 94/9/EC. Correct coupling alignment

must be maintained.

Additional requirement for metallic pumps on
non-metallic baseplates

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

1.6.4.6 Preventing leakage

Bursting of liquid containing parts due to freezing
must be avoided by draining or protecting the unit
and ancillary systems.

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

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

1.6.4.7 Maintenance to avoid the hazard

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

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

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

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

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2 TRANSPORT AND STORAGE

2.1 Consignment receipt and
unpacking

Immediately after receipt of the equipment it must
be checked against the delivery/shipping
documents for its completeness and that there has
been no damage in transportation. Any shortage
and/or damage must be reported immediately to
Flowserve Pump Division and must be received in
writing within one month of receipt of the
equipment. Later claims cannot be accepted.

Check any crate, boxes or wrappings for any
accessories or spare parts that may be packed
separately with the equipment or attached to side
walls of the box or equipment.

Each product has a unique serial number. Check
that this number corresponds with that advised and
always quote this number in correspondence as
well as when ordering spare parts or further
accessories.

2.2 Handling

Boxes, crates, pallets or cartons may be unloaded
using fork lift vehicles or slings dependent on their
size and construction.

2.3 Lifting

A crane must be used for all pump sets and
components in excess of 25 kg (55 lb.). Fully
trained personnel must carry out lifting, in
accordance with local regulations.

Before lifting the driver alone, refer to the
manufacturer’s instructions.

2.4 Storage

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

The unit may be stored as above for up to 6
months. Consult Flowserve for preservative
actions when a longer storage period is needed.

2.5 Recycling and end of product life

At the end of the service life of the product or its
parts, the relevant materials and parts should be

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

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

3 DESCRIPTION

3.1 Configurations

These instructions cover only rolling element type
bearing thrust pots, without fan cooling, with
different rolling element bearing sizes available as
shown in the drawings. (See section 8.)

Thrust bearing pots are designed for vertical
centrifugal pumps driven by solid shaft electric
motor which have very limited capacity for taking
the pump vertical thrusts without a thrust bearing
pot fitted to the pump.

Installation is between the pump discharge head
and the motor/pump coupling. Sufficient room
should be provided between the pump discharge
head and the driver, normally by a driver stool, to
allow the necessary span for the installation of the
thrust bearing pot and the pump/motor coupling.

Pump hydraulic thrusts, producing energy, are not
transmitted to the pump foundation but are
converted into heat that is absorbed by the
lubrication oil for the bearings.

3.2 Name nomenclature

The thrust bearing pot size will be on the General
Arrangement drawing for the pump.

3.3 Design of major parts

3.3.1 Bearing housing

The bearing housing [3200] allows the installation
in the pump and takes the bearings themselves. It
acts as the sump for the lubrication oil for the
bearings and the larger sizes incorporate an
integral water cooling jacket that must be used to
allow adequate cooling of the bearings lubrication
oil where fitted with a cooling jacket. The bearing
housing incorporates ports to allow the internal

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Load capacity

Max. torque

Dynamic (C)

Static (C

0

)

kN

(lbf (x1 000))

rpm mm (in.)

kNm (

lbf•ft (x

1 000))

kN

recirculation of the oil lubrication and includes an oil
level gage to check the lubricant oil level.

3.3.2 Bearings

The bearings [3010 and 3011] are hydrodynamic
rolling element type ball or roller bearings sized to
absorb the pump vertical thrust and pump rotor
weight from the centering sleeve [2470].

The thrust bearing [3010] absorbs the pump
hydraulic down thrust and the pump rotor weight.

The line bearing [3011] guides the rotating
components and absorbs the pump up-thrust
produced at start-up in most vertical pumps.

3.3.3 Centering sleeve

The centering sleeve [2470] connects mechanically
with an axial setting adjusting nut [2909], the pump
rotor and the bearings.

3.4 Performance and operating limits

3.4.1 Load capacity

Size Description

3.3.4 Bearing cover

The Bearing cover [3260] and upper bearing
housing [3210] provide sealing to the bearing
housing [3200] against the atmosphere.
It incorporates the oil filling connection and holds
the line bearing [3011] in position.

3.3.5 Thrust axial setting adjusting nut

The axial setting control adjusting nut [2909]
connects mechanically with the centering sleeve
[2470], the pump rotor and the bearings. This
allows control of the pump rotor axial regulation
play.

3.3.6 Accessories

Accessories may be fitted when specified.
Fan cooling is not available for these designs of

thrust bearing pot as a default; available designs
for special requirements or applications must be
consulted with Flowserve representative.

Max. speed Max. shaft dia

(11 – 13 % Cr. Shaft)

7211B
7218B 106 (23.8) 73.5 (16.5) 4 000 57.2 (2.25) 3.48 (2.57)
7318B 156 (35.1) 114 (25.6) 3 570 57.2 (2.25) 3.48 (2.57)

7322B 225 (50.6) 193 (43.4) 2 850 69.9 (2.75) 6.90 (5.09)
7211B + 6013
7218B + 6020 106 (23.8) 73.5 (16.5) 4 000 57.2 (2.25) 3.48 (2.57)
7318B + 6022 156 (35.1) 114 (25.6) 3 570 57.2 (2.25) 3.48 (2.57)
7322B + 6028 225 (50.6) 193 (43.4) 2 850 69.9 (2.75) 6.90 (5.09)

29417 + 22217
29420 + 22220 863 (194) 1 250 (281) 1 600 69.9 (2.75) 6.90 (5.09)
29424 + 22224 1 170 (263) 1 760 (395) 1 300 76.2 (3.0) 9.60 (7.08)

Single row angular

contact bearing

Single row angular

contact and radial

ball bearing

Spherical thrust

and spherical
roller bearing

46.2 (10.4) 28.5 (6.4) 6 450 31.8 (1.25) 0.29 (0.21)

46.2 (10.4) 28.5 (6.4) 6 060 31.8 (1.25) 0.29 (0.21)

633 (142) 900 (202) 1 900 57.2 (2.25) 3.48 (2.57)

3.4.2 Maximum down thrust

Max. instant

Size

7211B
7218B 12.4 (2.8) 13.2 (2.9) 15.6 (3.5) 16.6 (3.7) 17.9 (4) 19.7 (4.4) 40 (88)
7318B 18.2 (4.1) 19.4 (4.3) 23.0 (5.2) 24.4 (5.5) 26.3 (5.9) 29 (6.5) 48 (106)

7322B 28.0 (6.3) 33.2 (7.4) 35.2 (7.9) 38 (8.5) 41.8 (9.4) 50 (132)
7211B + 6013
7218B + 6020 12.4 (2.8) 13.2 (2.9) 15.6 (3.5) 16.6 (3.7) 17.9 (4) 19.7 (4.4) 58 (128)
7318B + 6022 18.2 (4.1) 19.4 (4.3) 23.0 (5.2) 24.4 (5.5) 26.3 (5.9) 29 (6.5) 67 (148)
7322B + 6028

29417 + 22217
29420 + 22220
29424 + 22224

up-thrust

(lbf ( x1000))

N/A

13.5 (3.0)

37.4 (8.4)

3 500 2 900 1 750 1 460 1 170 880 kg (lb)

5.4 (1.2) 5.7 (1.3) 6.8 (1.5) 7.2 (1.6) 7.8 (1.8) 8.6 (1.9) 20 (44)

5.4 (1.2) 5.7 (1.3) 6.8 (1.5) 7.2 (1.6) 7.8 (1.8) 8.6 (1.9) 22 (49)

Max down thrust for L

kN (lbf (x1 000)) @ rpm

28.0 (6.3) 33.2 (7.4) 35.2 (7.9) 38 (8.5) 41.8 (9.4) 110 (243)
68 (15) 72 (16) 77 (17) 84 (19) 86 (190)

= 16 000 hours

10h

98 (22) 105 (23) 114 (26) 276 (608)

142 (32) 155 (35) 276 (608)

Nett

weight

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