Flowserve Twin Screw Rotary User Manual
USER INSTRUCTIONS
Twin Screw Rotary Pumps
External and Internal Bearing Design
PCN=71569243/71569244 – 07/10 (E)
Original Instructions
Installation
Operation
Maintenance
These instructions must be read prior to installing,
operating, using, and maintaining this equipment.
TWIN SCREW PUMPS. ORIGINAL USER INSTRUCTIONS. ENGLISH. 71569243 – 07/10
®
CONTENTS
PAGE
1 INTRODUCTION AND SAFETY ...........................1
1.1 General ...........................................................1
1.2 CE marking and approvals..............................1
1.3 Disclaimer .......................................................1
1.4 Copyright.........................................................1
1.5 Duty conditions................................................1
1.6 Safety ..............................................................2
1.7 Nameplate and warning labels........................6
1.8 Specific machine performance........................7
1.9 Noise level.......................................................7
2 TRANSPORT AND STORAGE.............................8
2.1 Consignment receipt and unpacking...............8
2.2 Handling.......................................................... 8
2.3 Lifting...............................................................8
2.4 Storage............................................................8
2.5 Recycling and end of product life.................... 9
3 PUMP DESCRIPTION........................................... 9
3.1 Configurations.................................................9
3.2 Name structure................................................9
NJHP...................9
3.3 Design of major parts......................................9
3.4 Performance and operating limits.................10
3.5 Table of Engineering Data.............................11
6.4 Tools required ............................................... 36
6.5 Torques for fasteners.................................... 36
6.6 Renewal clearances ..................................... 37
6.7 Disassembly.................................................. 37
6.8 Examination of parts..................................... 38
6.9 Assembly ...................................................... 38
6.10 New Rotating Elements.............................. 40
6.11 Free Movement........................................... 41
6.12 Timing Gear Replacement.......................... 41
7 FAULTS; CAUSES AND REMEDIES.................. 44
8 PARTS LIST AND DRA WI NGS........................... 46
8.1 Sectional Drawings-Typical............................46
8.2 General Arrangement Drawing..................... 51
9 CERTIFICATION................................................. 52
10 OTHER RELEVANT DOCUMENTATION AND
MANUALS ....................................................... 52
10.1 Supplementary User Instruction manuals... 52
10.2 Change notes ............................................. 52
10.3 Additional sources of information................ 52
11.0 OPTIONAL EQUIPMENT AND
ARRANGEMENTS .......................................... 52
11.1 Jacketed components................................. 52
11.2 Vertical mountings...................................... 52
4 INSTALLATION....................................................20
4.1 Location.........................................................20
4.2 Part assemblies.............................................20
4.3 Foundation....................................................20
4.4 Baseplate installation....................................20
4.5 Initial alignment.............................................21
4.6 Grouting ........................................................23
4.7 Piping............................................................23
4.8 Pressure gauges...........................................25
4.9 Final shaft alignment check ..........................25
4.10 Electrical connections ................................. 25
4.11 Protection systems......................................25
5 COMMISSIONING, START-UP, OPERA TION AND
SHUTDOWN....................................................26
5.1 Pre-commissioning procedure......................26
5.2 Lubricants.....................................................26
5.3 Direction of rotation.......................................28
5.4 Guarding .......................................................28
5.5 Priming and auxiliary supplies ......................28
5.6 Starting the pump..........................................28
5.7 High Temperature Startup..............................29
5.8 Post start-up..................................................29
5.9 Running the pump.........................................29
5.10 Stopping and shutdown...............................30
5.11 Hydraulic, mechanical and electrical duty...31
6 MAINTENANCE...................................................33
6.1 General .........................................................33
6.2 Maintenance schedule..................................33
6.3 Spare parts....................................................34
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TWIN SCREW PUMPS. ORIGINAL USER INSTRUCTIONS. ENGLISH. 71569243 – 07/10
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INDEX
PAGE
Alignment of shafting (see 4.5 and 4.9) .............21,25
CE marking and approvals (1.2)................................1
Clearances (see 6.6, Renewal clearances).............38
Commissioning and operation (see 5).....................27
Configurations (3.1)...................................................9
Direction of rotation (5.3).........................................29
Dismantling (see 6.7, Disassembly)........................38
Duty conditions (1.5)..................................................1
Electrical connections (4.10) ...................................25
Examination of parts (6.8)........................................39
Grouting (4.6)...........................................................23
Guarding (5.4)..........................................................29
Handling (2.2)............................................................8
Hydraulic, mechanical and electrical duty (5.11).....32
Lifting (2.3).................................................................8
Location (4.1)...........................................................20
Lubrication schedule (see 5.2, Pump lubricants) ....27
Maintenance schedule (6.2)....................................34
Piping (4.7) ..............................................................24
Priming and auxiliary supplies (5.5).........................29
Reassembly (see 6.9, Assembly)............................39
Replacement parts (see 6.3 and 6.4).................35,37
Safety, protection systems (see 1.6 and 4.11) ....2,26
Sound level (see 1.9, Noise level)............................. 7
Specific machine performance (1.8)..........................7
Starting the pump (5.6)............................................29
Stopping and shutdown (5.10).................................31
Storage (2.4)..............................................................8
Tools required (6.4) .................................................37
Torques for fasteners (6.5)......................................37
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TWIN SCREW PUMPS. ORIGINAL USER INSTRUCTIONS. ENGLISH. 71569243 – 07/10
®
1 INTRODUCTION AND SAFETY
1.1 General
These instructions must always be kept
close to the product's operating location or
directly with the product.
Flowserve's products are designed, developed and
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great care
and commitment to continuous quality control, utilising
sophisticated quality techniques, and safety
requirements.
We are committed to continuous quality improvement
and being at your service for any further information
about the product in its installation and operation or
about its support products, repair and diagnostic
services.
These instructions are intended to facilitate
familiarization with the product and its permitted use.
Operating the product in compliance with these
instructions is important to help ensure reliability in
service and avoid risks. The instructions may not take
into account local regulations; ensure such regulations
are observed by all, including those installing the
product. Always coordinate repair activity with
operations personnel, and follow all plant safety
requirements and applicable safety and health laws
and regulations.
These instructions should be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment must not be put into service until all
the conditions relating to safety noted in the
instructions, have been met.
1.2 CE marking and approvals
It is a legal requirement that machinery and
equipment put into service within certain regions of
the world shall conform with the applicable CE
Marking Directives covering Machinery and, where
applicable, Low Voltage Equipment, Electromagnetic
Compatibility (EMC), Pressure Equipment Directive
(PED) and Equipment for Potentially Explosive
Atmospheres (ATEX).
Where applicable, the Directives and any additional
Approvals, cover important safety aspects relating to
machinery and equipment and the satisfactory
provision of technical documents and safety
instructions. Where applicable this document
incorporates information relevant to these Directives.
To establish approvals and if the product itself is CE
marked, check the serial number plate and the
Certification (See section 9 Certification).
1.3 Disclaimer
Information in these User Instructions is believed
to be reliable. In spite of all the efforts of
Flowserve Corporation to provide sound and all
necessary information the content of this manual
may appear insufficient and is not guaranteed by
Flowserve as to its completeness or accuracy.
Flowserve manufactures products to exacting
International Quality Management System Standards
as certified and audited by external Quality Assurance
organisations. Genuine parts and accessories have
been designed, tested and incorporated into the
products to help ensure their continued product quality
and performance in use. As Flowserve cannot test
parts and accessories sourced from other vendors the
incorrect incorporation of such parts and accessories
may adversely affect the performance and safety
features of the products. The failure to properly
select, install or use authorised Flowserve parts and
accessories is considered to be misuse. Damage or
failure caused by misuse is not covered by
Flowserve's warranty. In addition, any modification of
Flowserve products or removal of original components
may impair the safety of these products in their use.
1.4 Copyright
All rights reserved. No part of these instructions may
be reproduced, stored in a retrieval system or
transmitted in any form or by any means without prior
permission of Flowserve Pump Division.
1.5 Duty conditions
This product has been selected to meet the
specifications of your purchaser order. The
acknowledgement of these conditions has been sent
separately to the Purchaser. A copy should be kept
with these instructions.
The product must not be operated beyond
the parameters specified for the application. If
there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice, quoting the serial number.
If the conditions of service on your purchase order are
going to be changed (for example liquid pumped,
temperature or duty) it is requested that you/the user
seek our written agreement before start up.
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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 would affect
personal safety.
This symbol indicates safety instructions where
non-compliance would affect personal safety.
This symbol indicates safety instructions where
non-compliance would affect protection of a safe life
environment.
This symbol indicates safety instructions
where non-compliance would affect the safe operation
or protection of the pump or pump unit.
This symbol indicates explosive atmosphere
zone marking according to ATEX. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
This sign is not a safety symbol but
indicates an important instruction in the assembly
process.
1.6.2 Personnel qualification and training
All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved. If the
personnel in question do not already possess the
necessary knowledge and skill, appropriate training
and instruction must be provided. If required the
operator may commission the manufacturer/supplier
to provide applicable training.
Always coordinate repair activity with operations and
health and safety personnel, and follow all plant safety
requirements and applicable safety and health laws
and regulations.
1.6.3 Safety action
This is a summary of conditions and actions to
prevent injury to personnel and damage to the
environment and to equipment. (For products
used in potentially explosive atmospheres section
1.6.4 also applies.)
PREVENT EXCESSIVE EXTERNAL
PIPE LOAD
Do not use pump as a support for piping. Do not
mount expansion joints, unless allowed by Flowserve
in writing, so that their force, due to internal pressure,
acts on the pump flange.
ENSURE CORRECT LUBRICATION
(See section 5 COMMISSIONING, START-UP,
OPERA TION AND SHUTDOWN.)
START THE PUMP WITH OUTLET
VALVE PART OPENED
(Unless otherwise instructed at a specific point in the
user instructions.)
This is recommended to minimize the risk of
overloading and damaging the pump motor at full or
zero flow. Pumps may be started with the valve
further open only on installations where this situation
cannot occur. The pump outlet control valve may
need to be adjusted to comply with the duty following
the run-up process. (See section 5 COMMISSIONING,
START-UP, OPERATION AND SHUTDOWN.)
NEVER RUN THE PUMP DRY
INLET VALVES TO BE FULLY OPEN
WHEN PUMP IS RUNNING
Running the pump at zero flow or below the
recommended minimum flow continuously will cause
damage to the seal.
DO NOT RUN THE PUMP AT
ABNORMALLY HIGH OR LOW FLOW RATES
Operating at a flow rate higher than normal or at a
flow rate with no back pressure on the pump may
overload the motor and cause cavitation. Low flow
rates may cause a reduction in pump/bearing life,
overheating of the pump, instability and cavitation/
vibration.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care
must be taken to avoid exposure to the liquid by
appropriate siting of the pump, limiting personnel
access and by operator training. If the liquid is
flammable and/or explosive, strict safety procedures
must be applied.
Gland packing must not be used when pumping
hazardous liquids.
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RELIEF VALVE PIPED BACK TO THE
SUCTION LINE REQUIRED
The Twin Screw Pumps are positive displacement
pumps and will build up considerable pressure if
discharge line is blocked.
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 (eg Viton) will occur. In this condition
these are extremely dangerous and skin contact must
be avoided.
HANDLING COMPONENTS
Many precision parts have sharp corners and the
wearing of appropriate safety gloves and equipment is
required when handling these components. To lift
heavy pieces above 25 kg (55 lb) use a crane
appropriate for the mass and in accordance with
current local regulations.
GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS OPERATIONAL
THERMAL SHOCK
Rapid changes in the temperature of the liquid within
the pump can cause thermal shock, which can result
in damage or breakage of components and should be
avoided.
NEVER APPLY HEAT TO REMOVE ROTOR
Trapped lubricant or vapour could cause an explosion.
HOT (and cold) PARTS
If hot or freezing components or auxiliary heating
supplies can present a danger to operators and
persons entering the immediate area action must be
taken to avoid accidental contact. If complete
protection is not possible, the machine access must
be limited to maintenance staff only, with clear visual
warnings and indicators to those entering the
immediate area. Note: bearing housings must not be
insulated and drive motors and bearings may be hot.
If the temperature is greater than 68 °C (175 °F) or
below 5 °C (20 °F) in a restricted zone, or exceeds
local regulations, action as above shall be taken.
1.6.4 Products used in potentially explosive
atmospheres
Measures are required to:
• Avoid excess temperature
• Prevent build up of explosive mixtures
• Prevent the generation of sparks
• Prevent leakages
• Maintain the pump to avoid hazard
The following instructions for pumps and pump units
when installed in potentially explosive atmospheres
must be followed to help ensure explosion protection.
Both electrical and non-electrical equipment must
meet the requirements of European Directive 94/9/EC.
1.6.4.1 Scope of compliance
Use equipment only in the zone for which it is
appropriate. Always check that the driver, drive
coupling assembly, seal and pump equipment are
suitably rated and/or certified for the classification of the
specific atmosphere in which they are to be installed.
Where Flowserve has supplied only the bare shaft
pump, the Ex rating applies only to the pump. The
party responsible for assembling the pump set shall
select the coupling, driver and any additional
equipment, with the necessary CE Certificate/
Declaration of Conformity establishing it is suitable for
the area in which it is to be installed.
The output from a variable frequency drive (VFD) can
cause additional heating effects in the motor and so,
for pumps sets with a VFD, the ATEX Certification for
the motor must state that it is covers the situation
where electrical supply is from the VFD. This
particular requirement still applies even if the VFD is
in a safe area.
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1.6.4.2 Marking
An example of ATEX equipment marking is shown
below. The actual classification of the pump will be
engraved on the nameplate.
II 2 GD c IIC 135 ºC (T4)
Equipment Group
I = Mining
II = Non-mining
Category
2 or M2 = High level protection
3 = normal level of protection
Gas and/or Dust
G = Gas; D= Dust
c = Constructional safety
(in accordance with EN13463-5)
Gas Group (Equipment Category 2 only)
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)
Maximum surface temperature (Temperature Class)
(See section 1.6.4.3.)
1.6.4.3 Avoiding excessive surface temperatures
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE
Pumps have a temperature class as stated in the
ATEX Ex rating on the nameplate. These are based
on a maximum ambient of 40 °C (104 °F); refer to
Flowserve for higher ambient temperatures.
The surface temperature on the pump is influenced by
the temperature of the liquid handled. The maximum
permissible liquid temperature depends on the
temperature class and must not exceed the values in
the table that follows.
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
EN 13463-1
T6
T5
T4
T3
T2
T1
Maximum
surface
temperature
permitted
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)
Temperature limit of liquid
handled (* depending on
material and construction
variant - check which is lower)
Consult Flowserve
Consult Flowserve
115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
400 °C (752 °F) *
The responsibility for compliance with the specified
maximum liquid temperature is with the plant
operator.
Temperature classification “Tx” is used when the liquid
temperature varies and when the pump is required to be
used in differently classified potentially explosive
atmospheres. In this case the user is responsible for
ensuring that the pump surface temperature does not
exceed that permitted in its a ctual inst alled l ocatio n.
If an explosive atmosphere exists during the
installation, do not attempt to check the direction of
rotation by starting the pump unfilled. Even a short
run time may give a high temperature resulting from
contact between rotating and stationary components.
Where there is any risk of the pump being run against a
closed valve generating high liquid and casing external
surface temperatures it is recommended that users fit
an external surface temperature protection device.
Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, temperature monitor or a
power monitor and make routine vibration monitoring
checks.
In dirty or dusty environments, regular checks must be
made and dirt removed from areas around close
clearances, 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.
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If the operation of the system cannot avoid this
condition the fitting of an appropriate dry run
protection device is recommended (eg liquid detection
or a power monitor).
To avoid potential hazards from fugitive emissions of
vapour or gas to atmosphere the surrounding area
must be well ventilated.
1.6.4.5 Preventing sparks
To prevent a potential hazard from mechanical
contact, the coupling guard must be non-sparking and
anti-static for Category 2.
To avoid the potential hazard from random induced
current generating a spark, the earth contact on the
baseplate must be used.
Avoid electrostatic charge: do not rub non-metallic
surfaces with a dry cloth; ensure cloth is damp.
The coupling must be selected to comply with 94/9/EC
and correct alignment must be maintained.
1.6.4.6 Preventing leakage
The pump must only be used to handle liquids
for which it has been approved to have the correct
corrosion resistance.
Avoid entrapment of liquid in the pump and associated
piping due to closing of suction and discharge valves,
which could cause dangerous excessive pressures to
occur if there is heat input to the liquid. This can occur
if the pump is stationary or running.
Bursting of liquid containing parts due to freezing must
be avoided by draining or protecting the pump and
ancillary systems.
Where there is the potential hazard of a loss of a seal
barrier fluid or external flush, the fluid must be
monitored.
If leakage of liquid to atmosphere can result in a
hazard, the installation of a liquid detection device is
recommended.
1.6.4.7 Maintenance to avoid the hazard
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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1.7 Nameplate and warning labels
1.7.1 Nameplate
For details of nameplate, see the Declaration of Conformity.
1.7.2 Safety labels
P/N 2113931-001 P/N 2113932-001
MECHANICAL SEAL WARNING ROTATION WARNING
GROUT WARNING LIFTING WARNING
P/N 2113934-001 P/N 9901701-001
LUBRICATION WARNING – QF-440-R01 (2124841)
Oil lubricated units only
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1.8 Specific machine performance
For performance parameters see section 1.5 Duty
conditions. When the contract requirement specifies
these to be incorporated into User Instructions these
are included here. Where performance data has been
supplied separately to the purchaser these should be
obtained and retained with these User Instructions if
required.
1.9 Noise level
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 expected from standard and
high efficiency motors when on load directly driving t he
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
ft) from the machine, for “free field conditions over a
reflecting plane”.
For units driven by equipment other than
electric motors or units contained within enclosures,
see the accompanying information sheets and
manuals.
TWIN SCREW pump size Sound Pressure Level
dbA @ 1 m (3.3 ft)
NA
77
NC 70 1750 84
ND 82 1750 96
NE 84 1750 98
NF 86 1750 100
NFX 86 1750 100
NG 86 1750 100
NH 87 1750 101
NI 87 1750 101
NII 87 1750 101
NIM 87 1750 101
NIJ 87 1750 101
NJ 88 1750 102
NL 88 1750 102
NLX 85 1150 99
NM 86 1150 100
NP18 87 1150 101
NP24 87 1150 101
Pump Speed
Sound Power Level
r/min
1750 91
at 1 m (3.3
pA
dBA re 1 pW
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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.
The pump should be lifted with suitably sized and
located slings. Do not use the shaft for lifting and take
special care to prevent the pump from rotating in the
slings due to unbalanced weight distribution.
2.3 Lifting
A crane must be used for all pump sets in excess
of 25 kg (55 lb). Fully trained personnel must carry out
lifting, in accordance with local regulations. The driver
and pump weights are recorded on their respective
nameplates or massplates.
2.4 Storage
2.4.1 Short-Term Storage
When it is necessary to store a pump for a short time
before it can be installed, place it in a dry, cool location.
Protect it thoroughly from moisture and condensation.
Protective flange covers should not be removed until
the pump is being installed.
Wrap the exposed portions of the shaft and coupling to
protect against sand, grit or other foreign matter. Oil
lubricated units should be lubricated (refer to section
5.1.3 Lubrication) to protect the bearings. Grease
lubricated units are lubricated at the factory during
assembly. Turn the rotor over by hand at least once a
week to maintain a protective film on the bearing
components.
2.4.2 Long-term storage
More thorough precautions are required if long-term
storage in excess of 90 days from factory shipment is
unavoidable.
The internal surfaces of the pump should be sprayed
with a rust preventative such as a water soluble oil or
other suitable alternative. Particular attention should
be given to the integral shafts, rotors and stuffing box.
Install gasketed metal flange covers on the suction and
discharge flanges (pipe plugs in the case of tapped
connections).
An optional method of protection is to suspend bags of
desiccant material inside casing and completely seal all
openings from the surrounding atmosphere. The
stuffing box should be packed with clean. dry rags.
Use of this method requires that the casing be initially
free of liquid. The desiccant material should be
checked at regular intervals to ensure that it has not
absorbed excessive water vapour. A warning
instruction, advising that the desiccant must be
removed prior to installation should be wired to the
pump.
A rust inhibitor should be added to the lubricating oil of
oil lubricated units to give additional protection without
destroying the lubricating properties of the oil. For
specific recommendations, consult your lubrication
dealer. Grease lubricated units, which can be identified
by the grease fitting at each bearing location, should be
well lubricated prior to placing in storage. Small
amounts of additional grease should be added at
regular intervals during storage. Refer to Section 5.1.3
Lubrication for additional information related to grease
lubrication.
Storage of pumps in areas of high ambient vibration
should be avoided to prevent bearing damage due to
brinelling. The risk of such damage can be reduced by
frequent rotation of the shaft.
The pump half coupling and key should be removed
from the shaft, coated with rust preventative and
wrapped to prevent metal-to-metal contact. Exposed
surfaces of the pump shaft should be protected with a
rust preventative. All dismantled parts should be
wrapped and tagged according to pump serial number
and a record kept of their location.
not be stored in a cool environment because
resulting condensation can cause rusting.
Pumps covered with plastic should
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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 in accordance with local regulations. If the
product contains substances that are harmful to the
environment, these should be removed and disposed of
in accordance with current local regulations. This also
includes the liquids and/or gases that may be used in
the "seal system" or other utilities.
Make sure that hazardous substances are
disposed of safely and that the correct personal
protective equipment is used. The safety specifications
must be in accordance with the current local
regulations at all times.
3 PUMP DESCRIPTION
3.1 Configurations
Flowserve Twin Screw Pumps are single stage,
positive displacement pumps especially designed for
the petroleum industries in the transfer of oils and other
liquids of varying viscosities. The flow of liquid through
the pump is accomplished by the progressive
movement of sealed cavities formed by the
intermeshing of matched pumping screws (one right
hand, one left hand) rotating in the precision ground
bores of the pump body. To balance the hydraulic
thrust created by the pumping action, two sets of
meshed screws are used, moving the liquid from both
ends of the body to the discharge port located at the
center of the body.
The key assembly of the screw pump is the rotating
element. Each rotating element consists of a drive
shaft and a driven shaft running on parallel axes at a
fixed center distance. Each shaft holds bearings, one
timing gear and two opposing pumping screws plus the
assorted hardware (locknuts, spacers) required for
mounting. On the pinned designs, the pumping screws
are mounted on the shafts and held in place by peened
taper pins. On the integral designs, the pumping
screws and the shaft are an integral piece machined
from a single steel bar. Precise clearances are
maintained between meshing screws to limit the
internal leakage (slip) in the pump. The timing gears
maintain these clearances, prevent contact between
the pumping screws and turn the driven shaft. Heavy
duty roller bearings eliminate radial contact between
the pumping screws and the body bores and support
the loading on the shafts produced by the pumping
action. Double row ball bearings position the shafts
axially and prevent contact between the flanks (sides)
of the meshing screws. Lubrication of the bearings is
provided by the liquid being pumped on Internal Pumps
and by oil contained in housings (sumps) on External
Pumps.
The bearing configurations of both Internal and
External Pumps provide a rear pull-out feature which
permits the quick removal of the entire rotating element
without disturbing the pump body or the drive. (Refer
to Section VIII). The use of a spacer type coupling
between the pump and driver is necessary to apply this
feature.
Standard shaft sealing is provided by packing which is
factory installed with the gland requiring only minor
adjustment prior to pump start-up. Mechanical seals
are optional equipment and when provided require no
adjustment prior to or during pump operation.
All pumps are shop performance tested to ensure
mechanical reliability and compliance with the specified
conditions of service. They are carefully inspected and
prepared for shipment. All exterior machined surfaces
are coated with rust preventative and all openings are
provided with covers or plugs.
3.2 Name structure
The pump size will be engraved on the nameplate. The
following example explains how the pump name
identifies the construction features and options.
NJHP
The first two letters indicate the “nominal pump size”
while the last two are an indication of the pump
configuration, in this case an external bearing pump
with integral shafts.
3.3 Design of major parts
3.3.1 Pump casing
The pump casing is a casting with side suction and top
discharge connections, although other configurations
are available. Refer to the General Arrangement
drawing for further details It is a one piece pressure
retaining casting with gasket connections to the seal
housings and the suction and discharge flanges.
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3.3.2 Pumping Rotors
The pumping rotors (screws) are single start and
mounted two to a shaft in opposing configuration i.e.
one left and one right hand rotor to each shaft. The
intermeshing rotors mounted on drive and driven shaft
create a positive displacement pumping action inside
the pump body.
3.3.3 Shaft
The drive shaft is mounted on bearings with the
pumping rotor and timing gear mounted to the shaft. It
has a keyed drive end. The driven shaft is also
mounted on bearings with the pumping rotor and timing
gear mounted to the shaft.
3.3.4 Timing Gears
The spur timing gears are mounted to the drive and
driven shafts with accurately located keys to maintain
the pumping rotors in mesh with no contact with each
other.
3.3.5 Pump bearings and lubrication
Antifriction radial and thrust bearings are mounted on
each shaft to support the induced loads. An oil bath is
provided at each end of the pump to lubricate the
bearings and timing gears.An oil site gage is supplied
in the bearing housings.
3.3.6 Stuffing box/seal housing
The stuffing box housing is doweled to both the pump
casing and the bearing housing to ensure proper
alignment. It can be supplied to fit standard packing or
different mechanical seals.
3.3.7 Shaft seal
The mechanical seals, attached to the pump shaft, seal
the pumped liquid from the environment. Gland packing
may be fitted as an option.
3.3.8 Driver
The driver is normally an electric motor. Different drive
configurations may be fitted such as internal
combustion engines, turbines, hydraulic motors etc
driving via couplings, belts, gearboxes, drive shafts etc.
3.3.9 Accessories
Accessories may be fitted when specified by the
customer.
3.4 Performance and operating limits
This product has been selected to meet the
specifications of your purchase order (See section 1.5
Duty conditions). The following data is included as
additional information to help with your installation. It is
typical, and factors such as temperature, materials, and
seal type may influence this data. If required, a
definitive statement for your particular application can
be obtained from Flowserve.
3.4.1 Operating limits
Pumped liquid temperature limits up to+177 ºC (300 ºF)
Maximum ambient temperature up to +50 ºC (122 ºF)
Maximum soft solids in suspension up to 1 % by volume
Maximum pump speed Refer to the nameplate
3.4.2 Speed torque curves
To bring a rotary pump up to rated speed, the driver
must be capable of providing more torque at each
speed than required by the pump. Normally, this is not
a problem with standard induction or synchronous
motors provided the proper voltage is supplied at the
motor.
The margin between the available and required torque
affects the time it takes the unit to reach full speed. If
the torque required by the pump exceeds the torque
capability of the drive at any run-up speed, the unit will
not accelerate to full speed.
For pumps started at set system resistance conditions,
100 percent full speed torque can be calculated by
using the formula:
Torque (Nm) = 9545 Power (kW)
r/min
Torque (lbfx ft) = 5250 Power (hp)
r/min
Torque required by the pump at any other speed during
start-up can be determined from the curve above. Note
that the driver manufacturer usually bases 100 percent
torque on the design power of the driver and
consequently the speed-torque curves should be
plotted in torque units (e.g. Nm or lbf× ft) instead of
percentage torque to avoid confusion.
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3.5 Table of Engineering Data
PUMP SIZE NA
MODEL INTERNAL BEARING EXTERNAL BEARING
SHAFT/SCREW DESIGN PINNED INTEGRAL PINNED INTEGRAL
SUCTION SIZE (STD) 2” NPT
DISCHARGE SIZE (STD) 1 ¼” NPT
CLEARANCES (STD) .08/.18 mm (.003/.007”)
WEIGHTS
KG(LBS)
PUMP 68 (150) 68 (150) 72.6 (160) 72.6 (160)
ROT ELEMENT 11.3 (25) 11.3 (25) 15.9 (35) 15.9 (35)
MOMENT OF INERTIA (LBS/IN2) 6 6 6 6
SHAFT DIA @ COUPLING
19.84 mm
(.7813”)
19.84 mm (.7813”) 18.7 mm (.7350) 23.8 mm (.9375)
SHAFT DIA @ ST BOX 20.6 mm (.812”) 20.6 mm (.812”) 23.8 mm (.937”) 28.6 mm (1.1 25”)
STUFFING
BOX
BORE 33.3 mm (1.312”) 33.3 mm (1.312”) 36.5 mm (1.437”) 41.3 mm (1.625”)
DEPTH 38.1 mm (1.500”) 38.1 mm (1.500”) 38.1 mm (1.500”) 38.1 mm (1.500”)
NO OF STUFF BOXES 1 1 4 4
PACKING
SIZE 6.4 MM (1/4”) sq 6.4 MM (1/4”) sq 6.4 MM (1/4”) sq 6.4 MM (1/4”) sq
NO OF RINGS 6 6 24 24
APPROX.
OIL FILL
TIMING GEAR HSG N/A N/A 0.5 L 0.5 L
BEARING HSG SEE
NOTE 1
N/A N/A 0.12 L 0.12 L
PUMP SIZE NC
MODEL INTERNAL BEARING EXTERNAL BEARING
SHAFT/SCREW DESIGN PINNED INTEGRAL PINNED
INTEGRAL
(RTG)
SUCTION SIZE (STD) 3” 150# FLANGED
DISCHARGE SIZE (STD) 2” 150# FLANGED
CLEARANCES (STD) .13/.28 mm (.005/.011”)
WEIGHTS
KG(LBS)
PUMP 113.4 (250) 113.4 (250) 163 (360) 163 (360)
ROT ELEMENT 20.4 (45) 20.4 (45) 27.2 (60) 27.2 (60)
MOMENT OF INERTIA (LBS/IN2) 35 35 41 41
SHAFT DIA @ COUPLING 22.2 mm (.875”) 22.2 mm (.875”) 25.4 mm (1.000”) 28.6 mm (1.125”)
SHAFT DIA @ ST BOX 22.2 mm (.875”) 22.2 mm (.875”) 31.8 mm (1.250”) 38.1 mm (1.500”)
STUFFING
BOX
BORE 34.9 mm (1.375”) 34.9 mm (1.375”) 44.5 mm (1.750”) 54 mm (2.125”)
DEPTH 50.8 mm (2.000”) 50.8 mm (2.000”) 57.2 mm (2.250”) 57.2 mm (2.250”)
NO OF STUFF BOXES 1 1 4 4
SIZE 6.4 MM (1/4”) sq 6.4 MM (1/4”) sq 6.4 MM (1/4”) sq 7.9 mm (5/16”) sq
PACKING
NO OF RINGS 8 8 28 28
APPROX.
OIL FILL
TIMING GEAR HSG N/A N/A 1.0 L 1.0 L
BEARING HSG SEE
NOTE 1
N/A N/A 0.12 L 0.12 L
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PUMP SIZE ND
MODEL INTERNAL BEARING EXTERNAL BEARING
SHAFT/SCREW DESIGN PINNED INTEGRAL PINNED INTEGRAL
SUCTION SIZE (STD) 3” 150# FLANGED
DISCHARGE SIZE (STD) 2 ½” 150# FLANGED
CLEARANCES (STD) 13/.28 mm (.005/.011”)
WEIGHTS
KG(LBS)
PUMP 125 (275) 125 (275) 204 (450) 204 (450)
ROT ELEMENT 24.9 (55) 24.9 (55) 34 (75) 34 (75)
MOMENT OF INERTIA (LBS/IN2) 51 51 60 60
SHAFT DIA @ COUPLING 27 mm (1.0625”) 27 mm (1.0625”) 27 mm (1.0625”) 30.2 mm (1.1875”)
SHAFT DIA @ ST BOX 28.6 mm (1.125”) 28.6 mm (1.125”) 31.8 mm (1.250”) 44.5 mm (1.750”)
STUFFING
BOX
BORE 41.3 mm (1.625”) 41.3 mm (1.625”) 44.5 mm (1.750”) 57.2 mm (2.250”)
DEPTH 57.2 mm (2.250”) 57.2 mm (2.250”) 63.5 mm (2.500”) 63.5 mm (2.500”)
NO OF STUFF BOXES 1 1 4 4
SIZE 6.4 MM (1/4”) sq 6.4 MM (1/4”) sq 6.4 MM (1/4”) sq 6.4 MM (1/4”) sq
PACKING
NO OF RINGS 9 9 36 36
APPROX.
OIL FILL
TIMING GEAR HSG N/A N/A 1.25 L 1.25 L
BEARING HSG SEE
NOTE 1
N/A N/A 0.12 L 0.12 L
PUMP SIZE NE
MODEL INTERNAL BEARING EXTERNAL BEARING
SHAFT/SCREW DESIGN PINNED INTEGRAL PINNED INTEGRAL
SUCTION SIZE (STD) 4” 150# FLANGED
DISCHARGE SIZE (STD) 3” 300# FLANGED
CLEARANCES (STD) .15/.30 mm (.006/.012”)
WEIGHTS
KG(LBS)
PUMP 227 (500) 227 (500) 272 (600) 272 (600)
ROT ELEMENT 38.5 (85) 38.5 (85) 45.4 (100) 45.4 (100)
MOMENT OF INERTIA (LBS/IN2) 100 100 110 110
SHAFT DIA @ COUPLING 30.2 mm (1.1875) 41.3 mm (1.625) 30.2 mm (1.1875) 36.5 mm (1.4375)
SHAFT DIA @ ST BOX 31.2 mm (1.250) 41.3 mm (1.625) 37.3 mm (1.469) 50.8 mm (2.000)
STUFFING
BOX
BORE 44.5 mm (1.750) 54 mm (2.125) 50 mm (1.969) 54 mm (2.125)
DEPTH 57.2 mm (2.250) 57.2 mm (2.250) 57.2 mm (2.250) 57.2 mm (2.250)
NO OF STUFF BOXES 1 1 4 4
SIZE 6.4 MM (1/4”) sq 6.4 MM (1/4”) sq 6.4 MM (1/4”) sq 6.4 MM (1/4”) sq
PACKING
NO OF RINGS 9 7 24 24
APPROX.
OIL FILL
TIMING GEAR HSG N/A N/A 1.5 L 1.5 L
BEARING HSG SEE
NOTE 1
N/A N/A 0.25 L 0.25 L
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PUMP SIZE NF
MODEL INTERNAL BEARING EXTERNAL BEARING
SHAFT/SCREW DESIGN PINNED INTEGRAL PINNED INTEGRAL (RTG)
SUCTION SIZE (STD) 5” 150# FLANGED
DISCHARGE SIZE (STD) 4” 300# FLANGED
CLEARANCES (STD) .15/.30 mm (.006/.012”)
WEIGHTS
KG(LBS)
PUMP 318 (700) 318 (700) 408 (900) 408 (900)
ROT ELEMENT 64 (140) 64 (140) 75 (165) 75 (165)
MOMENT OF INERTIA (LBS/IN2) 225 225 245 245
SHAFT DIA @ COUPLING 41.3 mm (1.625”) 44.5 mm (1.750”) 41.3 mm (1.625”) 41.3 mm (1.625”)
SHAFT DIA @ ST BOX 44.5 mm (1.750”) 44.5 mm (1.750”) 47.6 mm (1.875”) 60.3 mm (2.375”)
STUFFING
BOX
BORE 66.7 mm (2.625”) 66.7 mm (2.625”) 66.7 mm (2.625”) 79.4 mm (3.125”)
DEPTH 66.7 mm (2.625”) 66.7 mm (2.625”) 60.3 mm (2.375”) 60.3 mm (2.375”)
NO OF STUFF BOXES 1 1 4 4
PACKING
SIZE
11.1 mm (7/16)
sq
11.1 mm (7/16) sq 9.5 mm (3/8”) sq 9.5 mm (3/8”) sq
NO OF RINGS 6 6 24 24
APPROX.
OIL FILL
TIMING GEAR HSG N/A N/A 2.5 L 2.5 L
BEARING HSG SEE
NOTE 1
N/A N/A 0.5 L 0.5 L
PUMP SIZE NFX
MODEL INTERNAL BEARING EXTERNAL BEARING
SHAFT/SCREW DESIGN PINNED INTEGRAL PINNED INTEGRAL
SUCTION SIZE (STD) 5” 150# FLANGED
DISCHARGE SIZE (STD) 4” 300# FLANGED
CLEARANCES (STD) .15/.30 mm (.006/.012”)
WEIGHTS
KG(LBS)
PUMP 324 (714) 324 (714) 416 (917) 416 (917)
ROT ELEMENT 69.9 (154) 69.9 (154) 82.6 (182) 82.6 (182)
MOMENT OF INERTIA (LBS/IN2) 247 247 270 270
SHAFT DIA @ COUPLING 41.3 mm (1.625”) 44.5 mm (1.750”) 41.3 mm (1.625”) 41.3 mm (1.625”)
SHAFT DIA @ ST BOX 44.5 mm (1.750”) 44.5 mm (1.750”) 47.6 mm (1.875”) 60.3 mm (2.375”)
STUFFING
BOX
BORE 66.7 mm (2.625”) 66.7 mm (2.625”) 66.7 mm (2.625”) 79.4 mm (3.125”)
DEPTH 66.7 mm (2.625”) 66.7 mm (2.625”) 60.3 mm (2.375”) 60.3 mm (2.375”)
NO OF STUFF BOXES 1 1 4 4
PACKING
SIZE
11.1 mm (7/16)
sq
11.1 mm (7/16) sq 9.5 mm (3/8”) sq 9.5 mm (3/8”) sq
NO OF RINGS 6 6 24 24
APPROX.
OIL FILL
TIMING GEAR HSG N/A N/A 2.5 L 2.5 L
BEARING HSG SEE
NOTE 1
N/A N/A 0.5 L 0.5 L
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PUMP SIZE NG
MODEL INTERNAL BEARING EXTERNAL BEARING
SHAFT/SCREW DESIGN PINNED INTEGRAL PINNED INTEGRAL
SUCTION SIZE (STD) 5” 150# FLANGED
DISCHARGE SIZE (STD) 4” 300# FLANGED
CLEARANCES (STD) .15/.30 mm (.006/.012”)
WEIGHTS
KG(LBS)
PUMP 324 (714) 324 (714)
ROT ELEMENT 69.9 (154) 69.9 (154)
MOMENT OF INERTIA (LBS/IN2) 247 247
SHAFT DIA @ COUPLING 42.8 mm (1.687) 42.8 mm (1.687)
SHAFT DIA @ ST BOX 44.5 mm (1.750) 44.5 mm (1.750)
STUFFING
BOX
BORE 63.5 mm (2.500) 63.5 mm (2.500)
DEPTH 69.9 mm (2.750) 69.9 mm (2.750)
NO OF STUFF BOXES 1 1
SIZE 9.5 mm (3/8”) sq 9.5 mm (3/8”) sq
PACKING
NO OF RINGS 7 7
APPROX.
OIL FILL
TIMING GEAR HSG N/A N/A 2.5L 2.5 L
BEARING HSG SEE
NOTE 1
N/A N/A 0.5 L 0.5 L
PUMP SIZE NH
MODEL INTERNAL BEARING EXTERNAL BEARING
SHAFT/SCREW DESIGN PINNED INTEGRAL PINNED INTEGRAL (RTG)
SUCTION SIZE (STD) 6” 150# FLANGED
DISCHARGE SIZE (STD) 4” 300# FLANGED
CLEARANCES (STD) .25/.41 mm (.010/.016”)
WEIGHTS
KG(LBS)
PUMP 454 (1000) 454 (1000) 544 (1200) 544 (1200)
ROT ELEMENT 107 (235) 107 (235) 136 (300) 136 (300)
MOMENT OF INERTIA (LBS/IN2) 565 565 635 635
SHAFT DIA @ COUPLING 44.5 mm (1.750”) 44.5 mm (1.750”) 44.5 mm (1.750”) 44.5 mm (1.750”)
SHAFT DIA @ ST BOX 44.5 mm (1.750”) 44.5 mm (1.750”) 63.5 mm (2.500”) 73 mm (2.875”)
STUFFING
BOX
BORE 63.5 mm (2.500”) 63.5 mm (2.500”) 82.6 mm (3.250”) 92.1 mm (3.625”)
DEPTH 92.1 mm (3.625”) 92.1 mm (3.625”) 88.9 mm (3.500”) 88.9 mm (3.500”)
NO OF STUFF BOXES 1 1 4 4
SIZE 9.5 mm (3/8”) sq 9.5 mm (3/8”) sq 9.5 mm (3/8”) sq 9.5 mm (3/8”) sq
PACKING
NO OF RINGS 9 9 32 32
APPROX.
OIL FILL
TIMING GEAR HSG N/A N/A 3.8 L 3.8 L
BEARING HSG SEE
NOTE 1
N/A N/A 0.25 L 0.25 L
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