Flowserve Type R User Manual

USER INSTRUCTIONS

R and RX

Centrifugal Rubber Lined Slurry Pump

PCN = 71569242 03-11(E) (incorporating 2162-EID)

Original instructions

Installation

Operation

Maintenance

These instructions must be read prior to installing,

operating, using, and maintaining this equipment.

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R and RX SLURRY Pump USER INSTRUCTIONS ENGLISH 71569242 03-11 (E)

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 Safety labels summary ..................................... 9

1.8 Specific machine performance ...................... 10

1 9 Noise level ..................................................... 10

2 TRANSPORT AND STORAGE ........................... 11

2.1 Consignment receipt and unpacking .............. 11

2.2 Handling ......................................................... 11

2.3 Lifting .............................................................. 11

2.4 Storage .......................................................... 11

2.5 Recycling and end of product life ................... 12

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

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

3.2 Name nomenclature ....................................... 12

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

3.4 Performance and operating limits .................. 13

3.5 Materials Of Construction .............................. 14

3.6 Tables of Engineering Data ........................... 15

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

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

4.2 Part assemblies .............................................. 19

4.3 Foundation ..................................................... 19

4.4 Baseplate installation ..................................... 19

4.5 Initial alignment .............................................. 20

4.6 Grouting ......................................................... 22

4.7 Piping ............................................................. 22

4.8 Final shaft alignment check ........................... 26

4.9 Electrical connections .................................... 26

4.10 Protection systems ....................................... 27

PAGE

6 MAINTENANCE ................................................... 32

6.1 General ........................................................... 32

6.2 Maintenance schedule .................................... 32

6.3 Spare parts ..................................................... 34

6.4 Recommended spares and consumable items34

6.5 Tools required ................................................. 34

6.6 Fastener torques ............................................ 35

6.7 Renewal clearances ....................................... 35

6.8 Disassembly ................................................... 35

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

6.10 Assembly ...................................................... 37

6.11 Impeller axial clearance adjustment ............. 44

6.12 Liner Mismatch ............................................. 46

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

8 PARTS LIST AND DRAWINGS ............................ 49

8.1 Frame 0 – 1.25R090 ....................................... 49

8.2 R Pump - Frames 1&2 .................................... 50

8.3 RX - Frames 1&2 ............................................ 51

8.4 R pump - Frame 3&4 ...................................... 52

8.6 General arrangement drawing ........................ 54

9 CERTIFICATION ................................................... 54

10 OTHER RELEVANT DOCUMENTATION AND

MANUALS ........................................................ 54

10.1 Supplementary User Instruction manuals .... 54

10.2 Change notes ............................................... 54

10.3 Additional sources of information ................. 54

5 COMMISSIONING, START-UP, OPERATION AND

SHUTDOWN .................................................... 27

5.1 Pre-commissioning procedure ....................... 27

5.2 Pump lubricants ............................................. 28

5.3 Direction of rotation ........................................ 29

5.4 Guarding ........................................................ 29

5.5 Priming and auxiliary supplies ....................... 29

5.6 Starting the pump ........................................... 29

5.7 Operating the pump ....................................... 30

5.8 Stopping and shutdown ................................. 31

5.9 Hydraulic, mechanical and electrical duty ...... 31

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R and RX SLURRY Pump USER INSTRUCTIONS ENGLISH 71569242 03-11 (E)

INDEX

PAGE

Alignment of shafting (see 4.5, 4.7 and 4.3) ............ 20

CE marking and approvals (1.2) ................................ 3

Clearances (see 6.7, Renewal clearances) ............. 34

Clearance setting (6.11) .......................................... 43

Commissioning and operation (see 5) ..................... 27

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

Direction of rotation (5.3) ......................................... 29

Dismantling (see 6.8, Disassembly) ........................ 35

Duty conditions (1.5) .................................................. 3

Electrical connections (4.8) ..................................... 15

Examination of parts (6.9)........................................ 25

Faults; causes and remedies ................................... 47

General assembly drawings (see 8) ........................ 49

Grouting (4.4) ........................................................... 21

Guarding (5.4) .......................................................... 29

Handling (2.2) ............................................................ 9

Hydraulic, mechanical and electrical duty (5.9) ....... 31

Lifting (2.3) ............................................................... 11

Location (4.1) ........................................................... 21

Lubrication schedule (see 5.2, Pump lubricants) .... 28

Maintenance schedule (6.2) .................................... 32

Piping (4.7) .............................................................. 22

Priming and auxiliary supplies (5.5) ......................... 29

Reassembly (see 6.10, Assembly) .......................... 37

Replacement parts (see 6.3 and 6.4) ...................... 32

Safety, electrical (see 4.9) ....................................... 26

Safety, protection systems (see 1.6) ......................... 5

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

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

Starting the pump (5.6) ............................................ 29

Stopping and shutdown (5.8) ................................... 31

Storage (2.4) .............................................................. 9

Supplementary manuals or information sources ..... 54

Tools required (6.5) ................................................. 34

Torques for fasteners (6.6) ...................................... 34

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R and RX SLURRY Pump USER INSTRUCTIONS ENGLISH 71569242 03-11 (E)

1 INTRODUCTION AND SAFETY

1.1 General

These instructions must always be kept close
to the product's operating location or directly with
the product.

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

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

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

These instructions must be read prior to

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

1.2 CE marking and approvals

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

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

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

Certification. (See section 9, Certification.)

1.3 Disclaimer

Information in these User Instructions is believed
to be complete and reliable. However, in spite of all
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
organizations. Genuine parts and accessories have been
designed, tested and incorporated into the products to
help ensure their continued product quality and
performance in use. As Flowserve cannot test parts and
accessories sourced from other vendors the incorrect
incorporation of such parts and accessories may
adversely affect the performance and safety features of
the products. The failure to properly select, install or use
authorized Flowserve parts and accessories is considered
to be misuse. Damage or failure caused by misuse is not
covered by the Flowserve warranty. In addition, any
modification of Flowserve products or removal of original
components may impair the safety of these products in
their use.

1.4 Copyright

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

1.5 Duty conditions

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

The product must not be operated beyond the

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

If the conditions of service on your purchase order are
going to be changed (for example liquid pumped,

Page 4 of 54

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R and RX SLURRY Pump USER INSTRUCTIONS ENGLISH 71569242 03-11 (E)

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
prevent injury to personnel and damage to the
environment and to equipment. For products used
in potentially explosive atmospheres section 1.6.4
also applies.

NEVER DO MAINTENANCE WORK

WHEN THE UNIT IS CONNECTED TO POWER

GUARDS MUST NOT BE REMOVED WHILE

THE PUMP IS OPERATIONAL

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

FLUORO-ELASTOMERS (When fitted.)
When a pump has experienced temperatures over
250 ºC (482 ºF), partial decomposition of fluoro­elastomers (example: Viton) will occur. In this condition
these are extremely dangerous and skin contact must
be avoided.

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

APPLYING HEAT TO REMOVE IMPELLER
There may be occasions when the impeller has either
been shrunk fit on to the pump shaft or has become
difficult to remove due to products of corrosion.

If you elect to use heat to remove the impeller, it must

be applied quickly to the impeller boss. TAKE GREAT
CARE!

Before applying heat ensure any residual hazardous
liquid trapped between the impeller and pump shaft is
thoroughly drained out through the impeller keyway to
prevent an explosion or emission of toxic vapour. This
must be carried out with the shaft in the vertical
position. On some pump sizes a cavity exists in the
impeller bore so on occasions a significant volume of
liquid may drain out.

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.

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R and RX SLURRY Pump USER INSTRUCTIONS ENGLISH 71569242 03-11 (E)

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 80 ºC (175 ºF) or
below -5 ºC (20 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.

Gland packing must not be used when pumping
hazardous liquids.

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, startup, operation and
shutdown.)

START THE PUMP WITH OUTLET
VALVE PARTLY OPENED
(Unless otherwise instructed at a specific point in the
User Instructions.)
This is recommended to minimize the risk of
overloading and damaging the pump motor at full or
zero flow. Pumps may be started with the valve further
open only on installations where this situation cannot
occur. The pump outlet control valve may need to be
adjusted to comply with the duty following the run-up

process. (See section 5, Commissioning start-up,
operation and shutdown.)

NEVER RUN THE PUMP DRY

INLET VALVES TO BE FULLY OPEN
WHEN PUMP IS RUNNING
Running the pump at zero flow or below the
recommended minimum flow continuously will cause
damage to the pump and mechanical 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.

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

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

1.6.4.2 Marking

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

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R and RX SLURRY Pump USER INSTRUCTIONS ENGLISH 71569242 03-11 (E)

II 2 GD c IIC 135 ºC (T4)

Equipment Group
I = Mining
II = Non-mining

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

Gas and/or dust
G = Gas
D = Dust

c = Constructional safety

(in accordance with EN13463-5)

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

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

1.6.4.3 Avoiding excessive surface temperatures

ENSURE THE EQUIPMENT TEMPERATURE

CLASS IS SUITABLE FOR THE HAZARD ZONE

Pumps have a temperature class as stated in the 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 that follows.

Temperature class

to EN13463-1

T6
T5
T4
T3
T2
T1

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

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

Maximum surface

temperature permitted

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

Temperature limit of

liquid handled *

Consult Flowserve
Consult Flowserve

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

The temperature rise at the seals and bearings 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 pump could be installed in
different hazarous atmospheres. In this case the user
is responsible for ensuring that the pump surface
temperature does not exceed that permitted in the
particular hazardous atmosphere.

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

Where there is any risk of the pump being run against a
closed valve generating high liquid and casing external
surface temperatures, 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, 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 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 fit an appropriate dry run protection device
(for example 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.

To avoid the potential hazard from random induced
current generating a spark, the baseplate must be
properly grounded.

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R and RX SLURRY Pump USER INSTRUCTIONS ENGLISH 71569242 03-11 (E)

Avoid electrostatic charge: do not rub non-metallic

surfaces with a dry cloth; ensure cloth is damp.

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

Additional requirement for metallic pumps on non­metallic baseplates
When metallic components are fitted on a non-metallic
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 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, 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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R and RX SLURRY Pump USER INSTRUCTIONS ENGLISH 71569242 03-11 (E)

1.7 Safety labels summary

1.7.1 Nameplate

For details of nameplate, see the Declaration of Conformity, or separate documentation included with these

User Instructions.

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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R and RX SLURRY Pump USER INSTRUCTIONS ENGLISH 71569242 03-11 (E)

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

R and RX Slurry

pump size

Noise Level dBA

(at 1 m (3 ft) reference 20 μPa)

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 assumed in the “pump and
motor” noise is that typically expected from standard and
high efficiency motors when on load directly 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 Flowserve 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 estimating sound power level L
add 17 dBA to the sound pressure value.

Pump speed

rpm

Sound Power

Level dBA

at 1 m (3.3

pA

(re 1pW) then

WA

1.25R090 74 2000 88

2.5 R091 75 2250 89
3 R091 75 2250 89
3 R111 77 2000 91
4 R122 80 1780 94
5 R142 80 1600 94
6 R163 81 1350 95
8 R193 82 1180 96

10R234 83 1000 97
12R264 83 880 97
18R416 86 1180 100

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R and RX SLURRY Pump USER INSTRUCTIONS ENGLISH 71569242 03-11 (E)

2 TRANSPORT AND STORAGE

2.1 Consignment receipt and unpacking

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

Check any crates, boxes and wrappings for any
accessories or spare parts which 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.

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

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
III) 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 than 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 impeller, wear plate and stuffing box.

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 III 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.

Pumps covered with plastic should

not be stored in a cool environment because
resulting condensation can cause rusting.

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R and RX SLURRY Pump USER INSTRUCTIONS ENGLISH 71569242 03-11 (E)

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 "R Slurry" pumps are single stage, end
suction centrifugal pumps specifically designed for
handling abrasive slurries typical of mining and mineral
process. The casing is radially split with the gland side
casing pedestal mounted. The discharge is tangential.
The casings are fitted with removable rubber liners.
The closed impeller with rear pump-out vanes is
capable of passing solids of various sizes. Sealing is
provided at the impeller to shaft fit to prevent corrosion
and thereby facilitate impeller removal. The rigid three
point thrust bearing housing support permits precision
bearing alignment. Since the casing is pedestal
mounted, back pull-out is not a normal feature.

The pump is sealed using non-asbestos packing in the
stuffing box. An optional hydrodynamic seal,
commonly referred to as an expeller is available and
various mechanical seal designs as specified by the
customer may be installed at the factory or retrofitted in
the field.

All pumps are carefully inspected and prepared for
shipment. All exterior machined surfaces are coated
with a rust preventative compound and openings are
provided with covers or plugs. Shaft packing, when
required, is shipped with the pump and should not be
installed until the pump is ready to run. Mechanical
seals, when provided, are factory installed and adjusted
prior to shipment. The axial impeller running clearance
is preset at the factory but should be checked prior to
final alignment in case of tampering.

These User Instructions also cover the RX and RS
configurations, check the nameplate against the
nomenclature.

3.2 Name nomenclature

The pump size will be engraved on the nameplate. The
following example explains how the pump name
identifies the construction features and options.

8R-193

Nominal discharge branch size.

Configuration – see below.

Nominal maximum impeller diameter.

Frame size

R is the basic pump type
X

is added for an expeller

3.3 Design of major parts

3.3.1 Pump casing

The pump casing is a semi-concentric volute type
casing and tangential discharge nozzle and is radially
split. The casing are cast iron and are pedestal
mounted therefore the discharge can be rotated to
meet a number of optional orientations. It is fitted with
replaceable rubber liners. The casing joints are self
sealed by the rubber liners however optional urethane
lined casing may require gaskets at some flange
connections. The casing flanges are also drilled and
tapped

3.3.2 Impeller

The impeller is a closed design as standard but may be
changed to open designs for mud, froth and viscous
applications. The impeller is thread mounted to the
shaft. All impellers are supplied with pump out vanes to
minimise wear and reduce pressure at the stuffing box.
The vanes are curved to optimize efficiency however,
the “S” configuration utilizes straight radial vanes to
reduce blockage. The impeller of the RS pump has
larger front clearances to reduce shear and improve
froth handling capabilities.

3.3.3 Shaft

The large diameter stiff shaft, mounted on bearings,
has a keyed drive end. The shaft extension at the
coupling is extended to cover multi-v-belt drives.

3.3.4 Pump bearings and lubrication

Ball bearings are fitted as standard and may be either
oil or grease lubricated.

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R and RX SLURRY Pump USER INSTRUCTIONS ENGLISH 71569242 03-11 (E)

Oil lubrication is only available where the pump shaft is
horizontal. The bearings on frame 6 pumps (18R416)
can not be grease lubricated.

3.3.5 Bearing housing

For oil lubricated bearings, a bulls eye level gauge is
supplied. Constant level oilers can also be fitted. Two
grease nipples enable grease lubricated bearings to be
replenished between major service intervals.

3.3.6 Stuffing box housing

The stuffing box is a loose design and has a spigot
(rabbet) fit with the pump casing. The design enables a
number of sealing options to be fitted as well a wide
range of materials options.

3.3.7 Shaft seal

The mechanical seal(s), attached to the pump shaft,
seals the pumped liquid from the environment. Gland
packing may be fitted as an option. The “X” model is
fitted with an optional dynamic or expeller seal for
certain applications.

3.3.8 Driver

The driver is normally an electric motor. Due to the
hardness of the impeller the norm is to use multi-v­belts. 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.
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

3.4.1.1 Temperature

Liner Materials

Maximum Operating

Temperature

Natural Rubber-soft 65ºC (150ºF)
Natural Rubber-Hard 80ºC (176ºF)
Nitrile 93ºC (200ºF)
Neoprene 100ºC (212ºF)

3.4.1.2 Pressure

The maximum working pressure will be 110 PSIG for all
sizes except for the 18R416 which will be 100 PSIG.
Vacuum service should be avoided due to potential of
rubber liner collapse.

3.4.2 Speed torque curves

To bring a centrifugal pump up to rated speed, the
driver must be capable of providing more torque at
each speed than required by the pump. 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. Normally, this is not a problem
with standard induction or synchronous motors
provided the proper voltage is supplied at the motor.

For pumps started at shut valve conditions, 100 percent
full speed torque can be calculated by using the
formula:

Torque (Nm) = 9545 Shutoff Power (kW)
r/min

Torque (ft.lb) = 5250 Shutoff 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) instead of percentage
torque to avoid confusion.

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3.5 Materials Of Construction

BASIC

CONSTRUCTION

Natural Rubber

Lined

Neoprene Lined Nitrile Lined

Casing – Suction and Gland Side ASTM A48 CL 35 (Cast iron)
Stuffing Box ASTM A48 CL35 (Cast iron) (2)
Suction Side liner, Gland side Liner Natural Rubber
Impeller Natural Rubber

Neoprene Nitrile
Neoprene Nitrile

Protector Plate HARD STEEL –360 BHN (2) (3)
Impeller Spacer HARD STEEL –360 BHN (2) (3)
Shaft Sleeve ASTM A743 CG3M (1)
Shaft AISI 1045
Gland Halves ASTM A743 CF8M (316)
Pipe Plugs (Stuffing Box) C.I. (2)
Gland Studs And Nuts AISI 316
Liner Studs & Nuts AISI 1018/1020 Steel
PACKING SYNTHETIC FIBRE
SEAL CAGE HALVES ASTM A743 CG8M
GASKETS-CASING SYNTHETIC FIBRE
GASKETS-SLEEVE TEFLON
O-RINGS BUNA-N (120o C MAX.)
MISC. FASTNERS,
PARTS

STEEL

(1) Nickel-Chrome-Boron Coated, except for units with mechanical seals.
(2) For acid kit construction 316 SS (standard) or Alloy C (optional) materials will be supplied.
(3) For severe abrasive applications Stellite 4 is available.

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R and RX SLURRY Pump USER INSTRUCTIONS ENGLISH 71569242 03-11 (E)

3.6 Tables of Engineering Data

Table of Engineering Data

3.6.1 (FRAMES 0, 1 & 2 - LIQUID END)

ENGINEERING DATA

PUMP DESIGN TYPE STD STD STD STD STD STD STD STD

SUCTION SIZE mm (in.) 38 (1.5) 64 (2.5) 76 (3) 64 (2.5) 76 (3) 102 (4) 127 (5) 152 (6)

DISCHARGE SIZE mm (in.) 32 (1.25) 64 (2.5) 76 (3) 64 (2.5) 76 (3) 76 (3) 102 (4) 127 (5)

MAX. SPHERE SIZE mm (in.) 10(0.38) 15 (0.6) 23 (0.9) 15 (0.6) 23 (0.9) 31 (1.2) 43 (1.7) 48 (1.9)

VVK²(wet) kg · m² (lb · ft²) 0.12 (2.8) 0.12 (2.8) 0.11 (2.6) 0.12 (2.8) 0.11 (2.6) 0.21 (4.9) 0.44 (11) 0.82 (19)

1 1/4R-090 2 1/2R-393 3R-090 2 1/2R-091 3R-091 3R-111 4R-122 5R-142

PUMP WEIGHT kg (Ibs)

IMPELLER CLEARANCE mm (in.)

O.D. SLEEVE mm (in.)

La STUFFING BOX mm (in.)

DEPTH OF BOX mm (in.)

PACKING SIZE mm (in.)

RECOMMENDED PACKING

ALTERNATIVE PACKING

195 (430) 218 (480) 241 (530) 241 (530) 264 (580) 286 (630) 391 (860) 486 (1 070)

0.38 (0.015)

50.8 (2.0) 76.2 (3.0)

69.85 (2.75) 101.6 (4.0)

71.4 (2.81) 93.5 (3.68)

9.5 (0.375) 12.7 (0.5)

L5 L5

2L3 2L3

0.38 (0.015)

50.8 (2.0)

69.85 (2.75)

71.4 (2.81)

9.5 (0.375)

L5

2L3

0.76 (0.030)

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R and RX SLURRY Pump USER INSTRUCTIONS ENGLISH 71569242 03-11 (E)

Table of Engineering Data

3.6.2 (FRAMES 0, 1 & 2 - FRAME DETAILS)

ENGINEERING DATA

SHAFT AND BEARING DATA

DIA. AT IMP ELL ER

DIA. UNDER SLEEVE

DIA. BETWEEN BEARINGS

DIA. AT COUPLING

LINE BEARING
THRUST BEARING

BEARING SPAN

NOM. IMPELLER
OVERHANG

L10 BEARING LIFE

BEARING SEALS

THRUST BEARING LIP SEAL

LINE BEARING LIP SEAL

1¼ R-090 2½ R-090 3 R-090 3 R-091 3 R-111

mm

(in.)
mm

(in.)

mm

(in.)
mm

(in.)

22.4

(0.88)

25.4

(1.00)

47.8

(1.88)

25.4

(1.00)

2½ R-091

28.58

(1.125)

41.27

(1.625)

63.5

(2.50)

41.27

(1.625)
6307 6311
3307 7309 BUA

mm

(in.)
mm

(in.)

168

(6.61)

(7.09)

193.8

(7.63)

207.8

(8.18)

MINIMUM 3 YEARS

C/R 12458

C/R 9998

C/R 16246

NAT. 473010

C / R 19832

NAT. 472492

4 R-122 5 R-142

34.93

(1.375)

66.68

(2.625)

91.9

(3.62)

63.5

(2.500)

6316

7314 BUA

279.4

(11.00)

204.7180
(8.06)

C/R 24982

NAT. 417449

NAT. 417350

THRUST BEARING O-RING

#240 #250

LINE BEARING O-RING N/A #246

#263

#259

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R and RX SLURRY Pump USER INSTRUCTIONS ENGLISH 71569242 03-11 (E)

3.6.3 (FRAME 3, 4 & 6 - LIQUID END)

Table of Engineering Data

ENGINEERING DATA

SUCTION SIZE

DISCHARGE SIZE

MAX.SPHERE SIZE

WK2 (wet)

PUMP WT.

IMPELLER CLEARANCE

O.D.SLEEVE

I.D.STUFFING BOX

STUFFNG BOX DEPTH

PACKING SIZE

RINGS OF PACKING 5 5 6

kgm

6 R-163 8 R-193

mm 203 254 305 356 508

(in.) (8) (10) (12) (14) (20)

mm 152 203 254 305 457

(in.) (6) (8) (10) (12) (18)

mm 53 71 91 81 50.8

(in.) (2.10) (2.80) (3.60) (3.20) (2.00)

2

1.81 3.62 8.83 12.6 86.79

lbft2

(lbs) (1830) (2220) (3480) (4620) (16000)

mm 1.14 1.5 1.8
(in.) (0.045) (0.06) (0.07)

mm 95.25 120.7 184.1
(in.) (3.75) (4.75) (7.250)

mm 127 152.4 222.3
(in.) (5.00) (6.00) (8.75)

mm 116.3 116.3 165
(in.) (4.58) (4.58) (6.5)

mm 15.9 x 15.9 15.9 x 15.9 19.1 x 19.1
(in.) (0.63 x 0.63) (0.63 x 0.63) (.75 x .75)

(43) (86) (209) (298) (2056)

kg 832 1009 1582 2100 7273

10 R-

234

12 R-

264

18 R-416

RECOMMENDED PACKING L5 L5 L6

ALTERNATIVE PACKING 2L3 2L3 2L4

Page 17 of 56 flowserve.com