Flowserve VF User Manual

Page 1
VF centrifugal pump
USER INSTRUCTIONS
Installation
Operation
Vertical, multi-stage, shaft driven type centrifugal pump
PCN=71561233 – 11/09 (E) Original instructions.
Maintenance
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
CONTENTS
1 INTRODUCTION AND SAFETY ...........................4
1.1 General............................................................4
1.2 CE marking and approvals..............................4
1.3 Disclaimer........................................................4
1.4 Copyright .........................................................4
1.5 Duty conditions................................................4
1.6 Safety ..............................................................5
1.7 Nameplate and safety labels...........................8
1.8 Specific machine performance........................8
1.9 Noise level......................................................9
2 TRANSPORT AND STORAGE ...........................10
2.1 Consignment receipt and unpacking.............10
2.2 Handling ........................................................10
2.3 Lifting.............................................................11
2.4 Storage..........................................................11
2.5 Recycling and end of product life..................11
3 PUMP DESCRIPTION.........................................12
3.1 Configurations ...............................................12
3.2 Nomenclature................................................13
3.3 Coverage charts ............................................13
4 INSTALLATION ...................................................14
4.1 Location.........................................................14
4.2 Foundation.....................................................14
4.3 Grouting.........................................................16
4.4 Initial alignment .............................................16
4.5 Piping.............................................................17
4.6 Electrical connections....................................18
4.7 Protection systems ........................................19
5 COMMISSIONING START-UP, OPERATION AND
SHUTDOWN...................................................19
5.1 Direction of rotation .......................................19
5.2 Guarding........................................................19
5.3 Priming and auxiliary supplies.......................19
5.4 Starting the pump..........................................20
5.5 Running the pump.........................................20
5.6 Stopping and shutdown.................................21
5.7 Hydraulic, mechanical and electrical duty.....22
5.8 Pumps for Food Use or Potable Water .........22
PAGE
6 MAINTENANCE...................................................22
6.1 General..........................................................22
6.2 Maintenance schedule...................................23
6.3 Spare parts....................................................26
6.4 Recommended spares ..................................26
6.5 Disassembly ..................................................26
7 FAULTS; CAUSES AND REMEDIES ..................27
8 PARTS LIST AND DRAWINGS ...........................28
8.1 Sectional drawings ........................................28
8.2 Sectional drawings part list............................30
8.3 General arrangement drawing.......................30
9 CERTIFICATION .................................................31
10 OTHER RELEVANT DOCUMENTATION AND
MANUALS.......................................................31
10.1 Supplementary User Instructions ................31
10.2 Change notes ..............................................31
10.3 Additional sources of information ................31
PAGE
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
INDEX
Additional sources (10.3).......................................31
Alignment of shafting (see 4.2, 4.4 and 4.7)
ATEX marking (1.6.4.2) ...........................................6
CE marking and approvals (1.2)..............................4
Certification (9) ......................................................31
Change notes (10.2)..............................................31
Cleaning prior to operation (5.8.1) ........................22
Commissioning, start-up, operation (5) .................19
Compliance, ATEX (1.6.4.1)....................................6
Configurations (3.1) ...............................................12
Copyright (1.4).........................................................4
Direction of rotation (5.1) .......................................19
Disassembly (6.5)..................................................26
Discharge piping (4.5.1) .......................................17
Disclaimer (1.3)........................................................4
Dismantling (see 6.5, Disassembly)......................26
Drawings (8.1) .......................................................28
Duty conditions (1.5)................................................4
Electrical connections (4.6) ...................................18
End of product life (2.5) .........................................11
Faults; causes and remedies (7) ...........................27
Final checks (4.5.3) ..............................................18
First pump start up (5.4.2) ....................................20
Foundation (4.2) ....................................................14
Forces and moments (see 4.5.1)...........................17
General arrangement drawing (8.3) ......................30
Gland packing (6.2.5) ............................................25
Grouting (4.3).........................................................16
Guarding (5.2)........................................................19
Handling (2.2) ........................................................10
Hydraulic, mechanical and electrical duty (5.7).....22
Inspection (6.2.2 and 6.2.3)...................................24
Installation (4) ........................................................14
Internal coating (6.2.6)...........................................26
Lifting (2.3).............................................................11
Location (4.1).........................................................14
Maintenance (6).....................................................22
Maintenance schedule (6.2) ..................................23
Mechanical seal (6.2.4) .........................................25
Nomenclature (3.2)................................................13
Nameplate (1.7.1)....................................................8
Operating limits (see 3.1) ......................................12
Ordering spare parts (6.3.1) ..................................26
Parts lists (8.2).......................................................30
Piping (4.5) ............................................................17
Protection systems (4.7)........................................19
Pump masses (2.2.2) ............................................11
Receipt and unpacking (2.1)..................................10
Recommended fill quantities (see 6.2.1)...............23
Recommended grease lubricants (see 6.2.1) .......23
Recommended spares (6.4) ..................................26
Recycling (2.5).......................................................11
Replacement parts (see 6.3 and 6.4)....................26
Running the pump (5.5).........................................20
Safety action (1.6.3).................................................5
Safety labels (1.7.2).................................................8
Safety markings (1.6.1) ...........................................5
Safety, protection systems (see 1.6 and 4.7)
PAGE
PAGE
Sectional drawings (8.1) ........................................28
Sound level (see 1.9, Noise level)...........................9
Sources, additional information (10.3)...................31
Spare parts (6.3)....................................................26
Specific machine performance (1.8)........................8
Standard maintenance (6.2.1) ..............................23
Starting the pump (5.4)..........................................19
Stop/start frequency (5.5.5) ...................................21
Stopping and shutdown (5.6).................................21
Storage, pump (2.4)...............................................11
Storage, spare parts (6.3.2)...................................26
Supplementary manuals or information sources ...31
Thermal expansion (4.4.1) ....................................16
Transport and storage (2) .....................................10
Trouble-shooting (see 7)........................................27
Vibration (5.5.4) .....................................................21
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
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, 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 reliable. In spite of all the efforts of Flowserve Pump Division 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 organizations. Genuine parts and accessories have been designed, tested and incorporated into the products to help ensure their continued product quality and performance in use. As Flowserve cannot test parts and accessories sourced from other vendors the incorrect incorporation of such parts and accessories may adversely affect the performance and safety features of the products. The failure to properly select, install or use authorized Flowserve parts and accessories is considered to be misuse. Damage or failure caused by misuse is not covered by the Flowserve warranty. In addition, any modification of Flowserve products or removal of original components may impair the safety of these products in their use.
1.4 Copyright
All rights reserved. No part of these instructions may be reproduced, stored in a retrieval system or transmitted in any form or by any means without prior permission of Flowserve.
1.5 Duty conditions
This product has been selected to meet the specifications of your purchaser order. The acknowledgement of these conditions has been sent separately to the Purchaser. A copy should be kept with these instructions.
The product must not be operated beyond
the parameters specified for the application. If there is any doubt as to the suitability of the product for the application intended, contact Flowserve for advice, quoting the serial number.
If the conditions of service on your purchase order are going to be changed (for example liquid pumped, temperature or duty) it is requested that the user seeks the written agreement of Flowserve before start up.
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
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:
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.
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 substances and toxic fluid” safety instructions where non­compliance 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 cloth is damp. It is used where non­compliance 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.
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.
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 IMPELLER 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 (155 °F) or below -5 °C (23 °F) in a restricted zone, or exceeds local regulations, action as above shall be taken.
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
HAZARDOUS LIQUIDS When the pump is handling hazardous liquids care must be taken to avoid exposure to the liquid by appropriate sitting 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 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. Pump outlet valve shall 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
Where applicable, both electrical and non-electrical equipment must meet the requirements 94/9/EC.
Even if the installation is in a region where ATEX is not the applicable regulation, the general measures described shall be followed to ensure safe operation.
The measures are explained under the headings of: Avoiding excessive surface temperature. Preventing build up of explosive mixtures. Preventing the generation of sparks. Preventing leakages. Maintaining the pump to avoid hazard.
1.6.4.1 Scope of compliance
Use equipment only in the zone for 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 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.
DO NOT RUN THE PUMP AT ABNORMALLY HIGH OR LOW FLOW RATES Operating at a flow rate higher than normal or at a flow rate with no backpressure on the pump may overload the motor and cause cavitations. Low flow rates may cause a reduction in pump/bearing life, overheating of the pump, instability and cavitations/vibration.
1.6.4 Products used in potentially explosive atmospheres
The following instructions for pumps and pump units when installed in potentially explosive atmospheres must be followed to help ensure explosion protection.
The terminology and procedures ensure that the installed pump is in compliance with the European Directive 94/9/EC, known as the ATEX Directive, which is mandatory in Europe and may also be specified in other countries.
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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)
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
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, bearings and due to the minimum permitted flow rate is taken into account in the temperatures stated.
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) *
Temperature
class to
prEN 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)
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 hazardous 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. Furthermore, confinement of liquid in the pump and pipes must be avoided (valve closed). If the liquid heats up this may cause excessive pressure and lead to bursting of pump 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 PUMP IS PROPERLY FILLED AND
VENTED AND DOES NOT RUN DRY. Ensure pump and relevant suction and discharge
pipeline system is totally filled with liquid at all times during the pump operation, so that an explosive atmosphere is prevented. In addition it is essential to make sure that seal chambers, auxiliary shaft seal systems and any heating and cooling systems are properly filled.
If the operation of the system cannot avoid this condition the fitting of an appropriate dry run protection device is recommended (eg liquid detection or 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 ground contact on the baseplate must be used.
Avoid electrostatic charge: do not rub non­metallic surfaces with a dry cloth, ensure cloth is damp.
Where applicable the coupling must be selected to comply with 94/9/EC and correct alignment must be maintained.
Additional requirements for metallic pumps on non-metallic baseplates.
When metallic components are fitted on a non­metallic baseplate they must be individually earthed (grounded).
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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 the discharge valve, 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.)
1.7 Nameplate and safety labels
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
Oil lubricated units only:
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.
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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 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 LpA at 1 m (3.3 ft) from the machine, for “free field conditions over a reflecting plane”.
For estimating sound power level LWA (re 1 pW) then add 17 dBA to the sound pressure value.
1 The noise level of machines in this range will most likely be of values which require noise exposure control, but typical values are inappropriate.
Note: for 1 180 and 960 r/min reduce 1 450 r/min values by 2 dBA. For 880 and 720 r/min reduce 1 450 r/min values by 3 dBA.
Motor size
and speed
kW (hp)
<0.55(<0.75) 72 72 64 65 62 64 62 64
0.75 (1) 72 72 64 66 62 64 62 64
1.1 (1.5) 74 74 66 67 64 64 62 63
1.5 (2) 74 74 66 71 64 64 62 63
2.2 (3) 75 76 68 72 65 66 63 64 3 (4) 75 76 70 73 65 66 63 64 4 (5) 75 76 71 73 65 66 63 64
5.5 (7.5) 76 77 72 75 66 67 64 65
7.5 (10) 76 77 72 75 66 67 64 65 11(15) 80 81 76 78 70 71 68 69
15 (20) 80 81 76 78 70 71 68 69
18.5 (25) 81 81 77 78 71 71 69 71 22 (30) 81 81 77 79 71 71 69 71 30 (40) 83 83 79 81 73 73 71 73 37 (50) 83 83 79 81 73 73 71 73 45 (60) 86 86 82 84 76 76 74 76 55 (75) 86 86 82 84 76 76 74 76
75 (100) 87 87 83 85 77 77 75 77
90 (120) 87 88 83 85 77 78 75 78 110 (150) 89 90 85 87 79 80 77 80 150 (200) 89 90 85 87 79 80 77 80 200 (270) 300 (400) 87 90 85 86
Typical sound pressure level LpA at 1 m reference 20 µPa, dBA
3 550 r/min 2 900 r/min 1 750 r/min 1 450 r/min
Pump
only
1 1 1 1
Pump and
motor
Pump
only
Pump and
motor
Pump
only
85 87 83 85
Pump and
motor
Pump
only
Pump and
motor
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In areas where the staff has to intervene, remember that when the level of the sound pressure is:
below 70 dBA: it is not necessary to take special precautions.
above 70 dBA: people working continuously in the machine room must be supplied with protective devices against noise.
below 85 dBA: no particular measures need to be taken for casual visitors staying in the room during a limited period.
above 85 dBA: the room must be considered as a dangerous area because of the noise and a warning sign must be fixed at each entry warning the people coming into the room, even for a short period, that they must wear hearing protection.
above 105 dBA: special hearing protection adapted to this noise level and to the spectral noise components must be installed and a warning sign to this effect erected at each entry. The staff in the room must wear ear protection.
Make sure that the noise, which travels through the walls and windows, does not generate too high noise levels in the machine room's surroundings.
2 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be checked against the delivery and shipping documents for its completeness and that there has been no damage in transportation.
Any shortage and or damage must be reported immediately to Flowserve Pump Division and received in writing within one month of receipt of the equipment. Later claims cannot be accepted.
Check any crate, boxes and wrappings for any accessories or spare parts that may be packed separately with the equipment or attached to sidewalls of the box or equipment.
Each product has a unique serial number. Check that this number corresponds with that advised and always quote this number in correspondence as well as when ordering spare parts or further accessories.
2.2 Handling
2.2.1 General instructions concerning handling
Boxes, crates, pallets or cartons may be unloaded using forklift vehicles or slings dependent on their size and construction. See 2.3.1 for positioning of slings.
To lift heavy pieces above 25 kg (55 lb), use a winch adapted to the mass and in accordance with the current local regulations.
To lift machines or pieces with one or several suspension rings, only use hooks and chains in compliance with the local regulations concerning safety. Never put cables, chains or ropes directly on or in the suspension rings. Cables, chains or lifting ropes must never present excessive bending.
Never bend the lifting hooks, suspension rings, chains, etc., which should only be made to endure stresses within, calculated limits. Remember that the capacity of a lifting device decreases when the direction of the lifting force direction makes an angle with the device axis.
To increase the safety and the efficiency of the lifting device, all the lifting elements must be as perpendicular as possible. If necessary a lifting beam can be placed between the winch and the load.
When heavy pieces are lifted up, never stay or work under the load or in the area, which could be in the path of the load if it were to swing or fall away. Never leave a load hanging from a winch. The acceleration or the slowing-down of lifting equipment must stay in the safety limits for the staff.
A winch must be positioned in such a way that the load will be raised perpendicularly. Where possible necessary precautions must be taken to avoid the swing of the load, using for example two winches making approximately the same angle, below 30°, with the vertical.
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
2.2.2 Pump masses
The pump masses vary according to the number of stages. Please see the overall drawing or the description plate to get this mass.
All motors (for masses see the motor
description plate) must be handled with a winch.
For masses above 25 kg (55 lb), manual
handling is forbidden
2.3 Lifting
2.3.1 Slinging of motor pumps units
Use handling means in accordance with motor pump unit mass mentioned on the CE plate. For the masses of the pumps bare end of shaft see table §
2.2.2 and nameplate.
To avoid distortion, the pump unit
should be lifted as shown.
A crane must be used for all pump sets in excess of 25kg (55 Ib). Fully trained personnel must carry out lifting, in accordance with local regulations. Motor pump unit
Components weighing less than 25 kg can be handled manually following the correct actions and using the correct posture.
When handling always wear gloves, safety boots and an industrial safety helmet.
For masses above 25 kg (55 lb), manual handling is forbidden
2.4 Storage
Store the pump in a clean, dry location sheltered from dust, bad weather, vibration, and mechanical damage (blows, impacts...). Leave piping connection covers in place to keep dirt and other foreign material out of pump casing. Turn pump once a week to prevent brinelling of the bearings and the seal faces, from sticking.
Do not store pumps starting on the fan guard. The pump may be stored as above for up to 6
months. Consult FLOWSERVE for preservative actions when a longer storage period is needed.
2.5 Recycling and end of product life
At the end of the service life of the product or its parts, the relevant materials and parts should be recycled or disposed of using an environmentally acceptable method and local regulations. If the product contains substances which are harmful to the environment, these should be removed and disposed of in accordance with current regulations. This also includes the liquids and or gases in the "seal system" or other utilities.
fluids are disposed of safely and that the correct personal protective equipment is used. The safety specifications must be in accordance with the current regulations at all times.
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Make sure that hazardous substances or toxic
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
3 PUMP DESCRIPTION
3.1 Configurations
The centrifugal motor pump is designed for the pumping of cold water or all clear liquids which are not solid and liquid mixtures, non-corrosive, non­abrasive when in contact with the pump motor unit and its working parts (Important: for other liquids consult FLOWSERVE for beforehand advice).
The VF type is a vertical multistage centrifugal shaft driven pump. A thrust bearing bracket carrying the bearing housing and driver, the delivery connection being located above or below the mounting plate.
The pump must be stored in a non explosive, ventilated location, sheltered from bad weather, dust and vibrations.
The reliability of the delivered machine can only be ensured if it is used according to the conditions given in this manual. The maximum values specified in this manual must never be exceeded:
Maximum pumped fluid temperature
................................................................. 45 °C
Minimum pumped fluid temperature
.................................................................- 10 °C
Density................................................. 1
Viscosity .............................................. 1 mm²/s
Content of sand.............................≤ 1 g/l sand
.......................................... 3 g/l dry particules
non abrasive nature
The maximum speed is shown on the
pump nameplate.
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3.2 Nomenclature
Characteristics shown on the nameplate fixed on the pump are as shown below: Each pump is supplied with the following nameplate:
Speed of rotation
Radial/thrust bearing
Year of construction + Manufacture number
Pump type
Flow rate
Head
Mass Maximum admissible
Pressure at 20 °C Maximum / minimum
temperature
Each pump unit is supplied with the following nameplate:
Mass of the set
3.3 Coverage charts
3.3.1 1450 min-1 (50 Hz): coverage charts (Q, H)
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3.3.2 730 and 970 min-1: coverage charts (Q, H)
4 INSTALLATION
Equipment operated in hazardous locations must comply with the relevant explosion protection regulations. See section 1.6.4, Products used in
potentially explosive atmospheres.
The condition of minimum submergence must be respected. Level control shall be fitted in the sump to prevent liquid level dropping below minimum acceptable.
All equipment must be grounded.
4.1 Location
The pump should be located to allow room for access, ventilation, maintenance and inspection with ample headroom for lifting.
4.2 Foundation
There are many methods of installing pump units to their foundations. The correct method depends on the size of the pump unit, its location and noise vibration limitations. Non-compliance with the provision of correct foundation and installation may lead to failure of the pump and as such would be outside the terms of the warranty.
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
NF E 27 811
If the pump is set on a tank, make sure that the connection flange is perfectly flat and horizontal. If the assembling is on a concrete stone or a metallic structure, be sure of the flatness and rigidity of the unit.
If the pump is mounted on a recently sunk well, the soil round the well may not be stabilized. After some times, check perpendicularity and level, and if needed, adjust before definitive anchoring.
The anchoring frame will then be fixed provisionally. Anchor bolts must be appropriate for the foot bolt holes. Use anchor bolts of accepted standards and sufficient length so that they may be clamped safely in the grout.
Provide sufficient space in the foundation to accommodate the anchor bolts. If necessary, provide concrete gullets.
4.2.1 Installation of the pump
4.2.1.1 Erection of hydraulic unit
a) Install the pump in the position defined in
figure 1.
b) The last body, fitted with its wear ring and its
bearing liner, shall be help upside down on the shims in AA.
c) Protect the shaft on the entire bearing area
which subsequently receives the jacket, into the body. Wedge in B so as to place the shaft in its final position in the body.
d) Engage the shaft, fitted with its last jacket, into
the body. Wedge in B so as to place the shaft in its final position in the body.
FIGURE I
e) As assembly proceeds, coat the assembly
faces with a sealing product.
f) All impellers and jackets (and wells) shall be
locked onto the shaft by means of the nut and
its lock-crew provided for this purpose. g) Tighten the assembly. h) Attach then the suction ear. i) Place the pump in vertical position, resting
onto its ear, and complete the assembly by
attaching the discharge cuff. j) Install the intermediate bearing with its liner,
coated with sealing compound. It shall be
fastened only at connection of the pump to the
discharge line.
4.2.1.2 Installation of the hydraulic unit and discharge stack
(see figure 2)
a) Install collar C on the pump, lift the assembly
and allow it to rest vertically onto the
installation plane via the collar. b) On ground level and in horizontal position,
engage an intermediate shaft into a riser tube
by leaving it to protrude by about 250 mm. c) Fasten collar C2 to the shaft and to the pipe.
Wedge the shaft at its output from the other
end of the pipe. Coat the assembly faces of
the intermediate bearing and of the bottom
tube with sealing compound.
Collar C1
Collar C2
Collar C
d) Insert the intermediate bearing, fitted with its
liner, into the bottom shaft fitted with the jacket
below the liner and the coupling cotter key;
install in place. e) Fasten collar C1 below the opposite flange of
the upper pipe; collar C1 shall be used to lift
the assembly and position it vertically with the
shafts aligned.
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
f) Couple both shafts: engage the 2 coupling
stop half-rings, then fasten the 2 coupling half­shells (thrust them against the jacket below the liner).
g) Remove collar C. Apply a sealing compound
onto the flange and fasten it onto collar C1 mounted on the pipe.
h) Successively install the following driveshaft
elements under the same conditions, the last pipe to be installed being that which carries the last bearing.
i) As the pipes are being fastened, do not forget
to install the auxiliary spraying pipes for the liners.
4.2.1.3 Drive head installation
a) Coat the assembly faces of the last
intermediate bearing and of the discharge elbow with sealing compound.
b) Insert the intermediate bearing onto the
bottom shaft and put it in place.
c) Install the sleeve, the jacket under the packing,
with its o-ring, onto the driveshaft.
d) Sling it up vertically and couple it to the bottom
shaft.
e) Coat the assembly faces of the upper flange of
the connection cuff and the support cage with sealing compound.
f) Assemble these parts and perform the
following operations:
1) Position the support, insert it onto the driveshaft and fasten it to the discharge elbow or the last tube.
2) Lift the assembly by slinging the support, remove collar C1 below the last tube. Allow the support to rest onto the rests provided for this purpose.
g) Lift the stop box assembly. h) Axial adjustment of the rotor, while operating
the axial adjusting nut of the rotor [2915] located at the top of the thrust bearing :
1) Move the rotor until the contact with the casing
2) To measure the position of the shaft end compared to the cover of the thrust bearing.
3) Then reassemble the rotor until the contact with the casing and again measure the position of the shaft end.
4) Move again the rotor of half of the difference of the measured dimensions.
5) Mount the fastening screws of the nut and mount the coupling of the pump.
i) Install the motor, fitted with its coupling half-
sleeve. Check the alignment pump-motor according to the procedure § 4.4.
j) Connect the liner spraying lines and the stack
filling lines.
l) Check the rotation direction of
the motor before the coupling operation which completes the erection procedure.
4.3 Grouting
If anchor bolts have been pre-cast in the foundation slightly tighten the anchor bolts. Otherwise let them hang in the foundation holes.
a) Use grouting products with anti-shrinking
components.
b) To grout up to the required level. Polish
surfaces. Take necessary precautions to avoid air bubbles.
c) Lay-down the barrier, break external angles,
polish the different surfaces.
d) After grout starts to cure, definitively tighten
anchor bolts.
e) Control the alignment such as described
below.
4.4 Initial alignment
Before connecting the couplings
verify the motor rotation direction.
4.4.1 Thermal expansion
The pump and motor will normally have to be aligned at ambient temperature and should be corrected to allow for thermal expansion at operating temperature. In pump installations involving high liquid temperatures, the unit should be run at the actual operating temperature, shut down and the alignment checked immediately.
k) Check that the rotor is free to
rotate manually.
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
4.4.2 Alignment methods
Ensure pump and driver are isolated electrically and the half couplings are disconnected. Ensure that the pump pipe work, suction and discharge, is disconnected.
The alignment MUST be checked.
Although the pump will have been aligned at the factory it is most likely that this alignment will have been disturbed during transportation or handling. If necessary, align the motor to the pump, not the pump to the motor.
Alignment Parallelism and concentricity check
with a rule
with a comparator
If the motor stool is fitted with a screw adjustment, take 3 or 4 measurements at different places.
Admissible margin for a motor with roller bearings = 0.15 mm parallel checking
Otherwise: there are no coupling checks regarding parallelism or concentricity. Owing to the design of the machine the set is self-aligning.
4.5 Piping
The user must verify that the equipment is
isolated from any external sources of vibration.
Do not mount expansion joints in such a way that their force, due to internal pressure, may act on the pump flange.
Maximum forces and moments allowed on the pump flanges vary with the pump size and type. Greater forces or moments may cause misalignment, hot bearings, worn couplings, vibrations and the possible failure of the pump casing.
When designing the pipes (§ 4.5.2) take necessary precautions in order not to exceed the maximum allowed forces.
Forces and moments applied to the pump flanges must never exceed the values shown in the table below:
For pumps in steel or alloy steel:
DN 250 300 400 500 600 700
Fx
445 535 720 900 1080 1260
Fy
405 485 650 810 970 1130
Fz
500 600 800 1000 1200 1400
ΣΣΣΣ F 785 940 1250 1560 1880 2195
Mx
220 300 480 710 1000 1320
My
270 360 580 870 1210 1550
Mz
190 260 420 610 860 1120
Discharge above the mounting plate
ΣΣΣΣ M 390 530 860 1280 1800 2320
Fx
149 179 230 299 359 419
Fy
135 161 215 269 323 377
Fz
167 200 266 332 398 464
ΣΣΣΣ F 261 313 417 521 625 729
Mx
73 99 159 236 332 434
Protective covers are fitted to the
My
pipe connections to prevent foreign bodies entering during transportation and installation. Ensure that these covers are removed from the pump before connecting any pipes.
4.5.1 Discharge pipework
The dimensions of the pipes do not directly depend on discharge diameter of the pump. First, choose a flow speed about 3 m/s at discharge.
Discharge below the mounting plate
F = Force in daN M = Moment in m.daN FR = Resultant force Mr = Moment resultant
89 121 194 289 404 528
Mz
63 86 138 205 288 376
ΣΣΣΣ M 131 178 286 426 598 782
For cast iron pumps: these values are to
Never use pump as a support for
be divided by 2.
piping.
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
Discharge pipe above the mounting plate
Discharge pipe below the mounting plate
4.5.2 Design of a discharge line
a) If discharge line is provided with a divergent,
its total angle will be between 7° and 12°.
b) Install the discharge valve after the non-return
valve downstream.
c) The non-return valve will be set in the
discharge pipe to protect the pump from any excessive pressure surge and from reverse rotation.
If necessary, a control manometer can be connected on the pipework.
Do not tighten flanges before the final check (see § 4.5.3).
4.5.3 Final checks
a) Check the tightening of anchor bolts. Tighten
them if necessary.
b) Check that protective covers on suction and
discharge flanges are removed.
c) Check that holes of pipe work flanges are
parallel and correspond to those of the pump.
d) Tighten discharge flange. e) Check by hand that the pump turns freely. A
binding indicates a distortion of the pump, which is due to excessive pipes strains. If necessary the pipework design must be re­examined.
f) If it provided, connect auxiliary pipe systems
(hydraulic, pneumatic, sealing system).
g) Control tightness and functionality of auxiliary
pipings.
4.6 Electrical connections
4.6.1 Safety conditions about electrical connections
Ensure piping and fittings are
flushed before use.
Ensure piping for hazardous liquids is arranged to allow pump flushing before removal of the pump
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Electric connections must be carried out by a qualified electrician, following the local rules and regulations in force.
It is important to be aware of the EUROPEAN DIRECTIVE on potentially explosive areas where compliance with IEC60079-14 is an additional requirement for making electrical connections.
Avoid mechanical, hydraulic or electrical overload by using motor overload trips or a power monitor and make routine vibration monitoring.
It is important to be aware of the EUROPEAN DIRECTIVE on electromagnetic compatibility when wiring up and installing equipment on site. Attention must be paid to ensure that the techniques used during wiring/installation do not increase electromagnetic emissions or decrease the electromagnetic immunity of the equipment, wiring or any connected devices. If in doubt, contact Flowserve for advice.
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
The motor must be wired up in accordance with the motor manufacturer's instructions (normally supplied within the terminal box) including any temperature, earth leakage, current and other protective devices as appropriate. The identification nameplate should be checked to ensure the power supply is appropriate.
A device to provide emergency stopping shall be fitted.
Carry out the ground connections according to the current local regulations.
To avoid any risk of jamming, the direction of rotation will be checked after priming of the pump (§ 5.4.1) and before the first start (§
5.4.2).
4.7 Protection systems
The following protection systems are recommended particularly if the pump is installed in a potentially explosive area or is handling a hazardous liquid. If in doubt consult Flowserve.
If there is any possibility of the system allowing the pump to run against a closed valve or below minimum continuous safe flow a protection device should be installed to ensure the temperature of the liquid does not rise to an unsafe level.
If there are any circumstances in which the system can allow the pump to run dry, or start up empty, a power monitor should be fitted to stop the pump or prevent it from being started. This is particularly relevant if the pump is handling a flammable liquid.
If leakage of product from the pump can cause a hazard it is recommended that an appropriate leakage detection system is installed.
To prevent excessive surface temperatures at bearings it is recommended that temperature or vibration monitoring are carried out. See sections
5.5.3 and 5.5.4. Except when explicitly required by the customer in
the specifications, when a possibility of reverse rotation exists the customer must install a reverse rotation protection device.
The customer must install all equipment required to avoid water hammer.
5 COMMISSIONING START-UP, OPERATION AND SHUTDOWN
These operations must only be carried
out by qualified personnel.
5.1 Direction of rotation
Starting or operating pumps with the wrong direction of rotation can be harmful to the pumps. Ensure that the pump rotation is the same as the arrow on the pump casing. It is preferable to check the direction of rotation before installing the coupling. If not, the pump must be filled in with the liquid before start-up.
If maintenance work has been carried out to the site's electricity supply, the direction of rotation should be re-checked as above in case the supply phasing has been altered.
5.2 Guarding
Guarding is supplied fitted to the pump set.
If this has been removed or disturbed ensure that all the protective guards around the pump coupling and exposed parts of the shaft are securely fixed.
5.3 Priming and auxiliary supplies
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.
Ensure all electrical, hydraulic, pneumatic, sealant and lubrication systems (as applicable) are connected and operational.
Ensure the inlet pipe and pump casing are completely full of liquid before starting continuous duty operation.
These operations must be carried out by personnel with approved qualifications.
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5.4 Starting the pump
5.4.1 Bring controls and preparation before the first starting and after each service call
Necessarily:
a) Check the tightening of the different plugs. b) Check that the gland lightly tightens the
packing rings.
c) Risk of seal ring overheating.
d) Install all protection systems
and more particularly the shield grid of the gland packing [9610.01] and the coupling guard [9610.02].
e) Check that the liner spraying and filling lines
are effectively connected to the clean water
distribution network. f) Close the valve at discharge. g) Check the direction of rotation of the motor.
Refer to the rotation arrow of the pump. h) Check that the motor bearings are correctly
greased. i) Make sure that the ventilating grate is not
obstructed or too near to a wall or an obstacle.
5.4.2 First pump start-up
a) Before starting, the flushing valves of the seals
(if existing) must be opened. b) The flushing valves of the bearing liner must
be opened. c) Start motor and check outlet pressure. d) If pressure is satisfactory, slowly OPEN the
outlet valve.
e) Do not run the pump with the
outlet valve closed for a period longer than 30
seconds. f) If NO pressure, or LOW pressure, STOP the
pump. Refer to fault finding chart for fault
diagnosis. The pump should run smoothly and without
abnormal vibration (see page 21) The pump must never run at a capacity of less
than 40% of that at the best efficiency.
Never remove a plug when the pump is
running. When the unit is normally running, note the
maximum intensities absorbed on each phase. Adjust definitively the circuit breaker for a slightly greater current to the maximum noticed current, which must never be superior to the currents, indicated on the motor description plate. Check that the voltage between phases in the motor terminals is correct.
A well adjusted and maintained circuit breaker efficiently protects the pump unit. Any disjunction means that the unit is badly running (voltage loss, cut phase, misadjustment, foreign matter in the pump, jamming, etc...).
5.5 Running the pump
5.5.1 Venting the pump
Vent the pump to enable all trapped air to escape taking due care with hot or hazardous liquids. Under normal operating conditions, after the pump has been fully primed and vented, it should be unnecessary to re-vent the pump.
5.5.2 Pump fitted with a stuffing box
If the pump has a packed gland there must be some leakage from the gland. Gland nuts should initially be finger-tight only. Leakage should take place soon after the stuffing box is pressurized. If no leakage takes place the packing will begin to overheat. If overheating takes place the pump should be stopped and allowed to cool before being re-started. When the pump is re-started it should be checked to ensure leakage is taking place at the packed gland.
When adjusting an operating stuffing box (shield grids removed for this operation), the operator must be very careful. Safety gloves are compulsory and loose clothes are not allowed (above all to the arms) to avoid being caught by the pump shaft.
The pump should be run for ten minutes with steady leakage and the gland nuts tightened by 10 degrees at a time until leakage is reduced to an acceptable level. The temperature of the gland should be checked after each round of tightening. If the temperature starts to climb rapidly then back off the gland nuts until the temperature drops down. Wait for the temperature to stabilize before tightening again. The leakage must not be reduced below a rate of 20 drops per minute. Bedding in of the packing may take several hours.
Shield grids being removed during installation of the gland packing, it must be ensured that they are replaced as soon as this operation is completed.
SAFETY INSTRUCTIONS WHEN THE PUMP IS RUNNING:
If hot or freezing components of the machine can present a danger to operators, they must be shielded to avoid accidental contact. If a 100 % protection is not possible, the machine access must be confined to the maintenance staff only.
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The adjusting lines, the stuffing box, the lines under pressure or the mechanical seal cooling lines must be protected against external knocks.
It is strictly forbidden to open switch cupboards, switch boxes, or all other live electric equipment. If it is necessary to open them in order to take readings, to carry out tests or adjustments for example, only a skilled technician may do them with adapted tools. Make sure that physical protection against electrical risks are used.
5.5.3 Bearings
If the pumps are working in a potentially explosive atmosphere, temperature or vibration monitoring at the bearings is recommended. If bearing temperatures are to be monitored it is essential that a benchmark temperature is recorded at the commissioning stage and after the bearing temperature has stabilized.
Record the bearing temperature (t) and the
ambient temperature (ta)
Estimate the likely maximum ambient
temperature (tb)
Set the alarm at (t+tb-ta+5) °C [(t+tb-ta+10) °F]
and the trip at 100 °C (212 °F) for oil lubrication and 105 °C (220 °F) for grease
lubrication It is important, particularly with grease lubrication, to keep a check on bearing temperatures. After start up the temperature rise should be gradual, reaching a maximum after approximately 1.5 to 2 hours. This temperature rise should then remain constant or marginally reduce with time.
5.5.4 Normal vibration levels, alarm and trip
For guidance, pumps generally fall under a classification for rigid support machines within the International rotating machinery standards and the recommended maximum levels below are based on those standards.
Alarm and trip values for installed pumps should be based on the actual measurements (N) taken on site on the bearing housings of the pump in the fully commissioned as new condition. The example (N) value is given for the preferred operating flow region (typically this may extend to 70 to 120 % of the pump best efficiency point); outside the preferred flow region the actual vibration experienced may be multiplied by up to 2.
These standard values can vary with the rotational speed and the power absorbed by the pump. For any special case, do not hesitate to consult us. Measuring vibration at regular intervals will then show any deterioration in pump or system operating conditions.
Vibration Velocity - unfiltered
Normal N Alarm N x 1.25 Shutdown Trip N x 2.0
Vertical Configuration
mm/s (in./s) r.m.s.
7.1 (0.28) 9.0 (0.35)
14.2 (0.56)
5.5.5 Stop/start frequency
Pump sets are normally suitable for the number of equally spaced stop/starts per hour shown in the table below. Check actual capability of the driver and control/starting system before commissioning.
Motor rating kW (hp)
Up to 15 (20) 15
Between 15 (20) and 90 (120) 10
90 (120) to 150 (200) 6
Above 150 (200) Refer
Maximum stop/starts
per hour
Where duty and standby pumps are installed it is recommended that they are run alternately every week.
5.6 Stopping and shutdown
5.6.1 Stopping and restarting in continuous running
According to hydraulic conditions of the installation and its automation degree, stop and restart procedures can have different forms. Nevertheless all of them must respect imperatively the following rules:
Stopping: a) Avoid that the unit turns in the opposite
direction to the normal running.
b) Avoid a continuous running below the
authorized flow rate (see § 5.4.2).
Restart: a) Ensure a continuous supply with a sufficient
available NPSH.
b) Ensure a back pressure so that the motor
power is not in excess.
c) Respect the starting frequency
imposed by the motor manufacturer.
d) Protect the pump against water hammer
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when stopping or starting.
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
Shutdown:
Close the outlet valve and stop the
motor.
For prolonged shut-downs and especially when ambient temperatures are likely to drop below freezing point, the pump must be drained or otherwise protected.
Switch off flushing and/or cooling/ heating liquid supplies at a time appropriate to the process.
5.7 Hydraulic, mechanical and electrical duty
This product has been supplied to meet the performance specifications of your purchase order, however it is understood that during the life of the product these may change. The following notes may help the user decide how to evaluate the implications of any change. If in doubt contact your nearest Flowserve office.
5.7.1 Specific gravity (SG)
Pump capacity and total head in meters (feet) do not change with SG, however pressure displayed on a pressure gauge is directly proportional to SG. Power absorbed is also directly proportional to SG. It is therefore important to check that any change in SG will not overload the pump driver or over­pressurize the pump.
5.7.2 Viscosity
For a given flow rate the total head reduces with increased viscosity and increases with reduced viscosity. Also for a given flow rate the power absorbed increases with increased viscosity, and reduces with reduced viscosity. It is important that checks are made with your nearest Flowserve office if changes in viscosity are planned.
5.7.3 Pump speed
Changing pump speed effects flow, total head, power absorbed, NPSHR, noise and vibration. Flow varies in direct proportion to pump speed, head varies as speed ratio squared and power varies as speed ratio cubed. The new duty, however, will also be dependent on the system curve. If increasing the speed, it is important therefore to ensure the maximum pump working pressure is not exceeded, the driver is not overloaded, NPSHA > NPSHR, and that noise and vibration are within local requirements and regulations.
5.7.4 Net positive suction head (NPSHA)
NPSH available (NPSHA) is the head available at the impeller inlet, above the vapour pressure of the pumped liquid. NPSH required (NPSHR) is the minimum head required at the impeller inlet, above the vapour pressure of the pumped liquid, to avoid excessive cavitation and extreme performance degradation. It is important that NPSHA > NPSHR. The margin between NPSHA > NPSHR should be as large as possible.
If any change in NPSHA is proposed, ensure these margins are not significantly eroded. Refer to the pump performance curve to determine exact requirements particularly if flow has changed.
If in doubt please consult your nearest Flowserve office for advice and details of the minimum allowable margin for your application.
5.7.5 Pumped flow
Flow must not fall outside the minimum and maximum continuous safe flow shown on the pump performance curve and or data sheet.
5.8 Pumps for Food Use or Potable Water
If the pump has not been specifically ordered for a food or drinking water application it must not be used for these types of applications. If it has been ordered for this type of application the following recommendations are to be followed.
5.8.1 Cleaning prior to operation
Pumps that are to be used for a food or drinking water application should be cleaned before being put into initial operation and after the installation of spare parts that are in contact with the liquid.
Cleaning once the pump has been commissioned will depend on the application and operating conditions. The user must ensure that the cleaning procedures are suitable for the application and operating conditions, and local regulations.
6 MAINTENANCE
6.1 General
If a belt drive is used, the assembly and tension of the belts must be verified during regular maintenance procedure.
In dirty or dusty environments, regular checks must be made and dirt removed from areas around close clearances, bearing housings and motors.
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6.2 Maintenance schedule
It is the plant operator's responsibility to ensure that all maintenance, inspection and assembly work is carried out by authorized and qualified personnel who have adequately familiarized themselves with the subject matter by studying this manual in detail (see also section
1.6.2). Any work on the machine must be performed when it is at a standstill. It is imperative that the procedure for shutting down the machine is followed, as described in section 5.6.
On completion of work all guards and safety devices must be re-installed and made operative again.
Before restarting the machine, the relevant instructions listed in section 5, Commissioning, start up, operation and shut down must be observed.
An oil, grease or liquid leakage may make the ground slippery. The maintenance of a machine must always begin and finish by cleaning the ground and the exterior of the machine.
If platforms, stairs and guardrails are required for maintenance, they must be placed for easy access to areas where maintenance and inspection are to be carried out. The positioning of these accessories must not limit access or hinder the lifting of the part to be serviced.
When air or compressed inert gas are used to clean the machines, the operator and those people in the vicinity must be careful and have appropriate gas-protection, wearing at least eye protectors. DO NOT SPRAY air or compressed inert gaz on skin. DO NOT DIRECT an air or gas jet towards other people. Never use air or compressed inert gas to clean clothes.
Before working on the pump, take measures to prevent an uncontrolled start. Put a warning board on the starting device with the words: "Machine under repair: do not start". With electric drive equipment, lock the main switch open and withdraw any fuses. Put a warning board on the fuse box or main switch with the words:
"Machine under repair: do not connect".
Never clean pieces with inflammable solvents or carbon tetrachloride. Protect yourself against toxic fumes when cleaning pieces with cleaning agents.
It is recommended that a maintenance plan and schedule is adopted, in line with these User Instructions. It should include the following: a) The pump must be completely vented and
drained and rendered inert before any disassembly operation.
b) Any auxiliary systems installed must be
monitored, if necessary, to ensure they function correctly.
c) During cleaning of the pump ensure the
compatibility between the cleaning products
and the gaskets. d) Verify the condition of the gaskets e) Gland packings must be adjusted correctly to
give visible leakage and concentric alignment
of the gland follower to prevent excessive
temperature of the packing or follower.
Mechanical seals should present no leakage. f) Check for any leaks from gaskets and seals.
The correct functioning of the shaft seal must
be checked regularly. g) Check bearing lubricant level, and if the hours
run show a lubricant change is required. h) Check that the duty condition is in the safe
operating range for the pump. i) Check vibration, noise level and surface
temperature at the bearings to confirm
satisfactory operation. j) Check the tightness of the connections. k) Check dirt and dust is removed from areas
around close clearances, bearing housings
and motors. l) Check coupling alignment and re-align if
necessary. m) Verify the correct operation of the system.
The equipment used for maintenance and disassembly in an ATEX zone must be in conformity with the requirements zone.
Our specialist service personnel can help with preventative maintenance records and provide condition monitoring for temperature and vibration to identify the onset of potential problems.
If any problems are found the following sequence of actions should take place: a) Refer to section 7, Faults; causes and
remedies, for fault diagnosis. b) Ensure equipment complies with the
recommendations in this manual. c) Contact Flowserve if the problem persists.
6.2.1 Standard maintenance
Roller bearing
The bearings fitted are prepacked with grease at the factory. When the regreasing period is reached it is necessary to remove as much of the old grease as possible with a clean lint free cloth and repack the bearings with fresh grease.
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Page 24
VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
Gr
ease nipple
Pump type
VF 40-20
3 stages
VF 40-20
> 3 stages
VF 60-18
3 stages
VF 60-18
> 3 stages
VF 78-37 8000 100
VF 95-27 8000 100
VF 180-27 8000 8000 100
VF 190-19 8000 100
VF 185-35
1 stage
VF 185-35
> 1 stage
VF 250-43
1 stage
VF 250-43
>1 stage
VF 240-51
1 stage
VF 240-51
> 1 stage
VF 300-37 7500 180
Lubrification frequency in hours*
730 min-1 970 min
8000 35
8000 100
8000 35
8000 100
8000 100
7500 180
8000 100
7500 180
8000 100
7500 180
-1
1450 min
-1
Quantity
(gr)
6.2.2 Routine inspection (daily / weekly)
The following checks should be made and the appropriate action taken to remedy any deviations:
a) Check the behaviour of the pump while
running: noise level, vibrations, bearings temperature, flow rate and pressure.
b) Check that there are no abnormal fluid or
lubricant leaks (static and dynamic seals) and that any sealant systems (if fitted) are full and operating normally.
c) Check the level and condition of oil lubricant.
On grease lubricated pumps, check running hours since last recharge of grease or complete grease change.
6.2.3 Periodic inspection (6 monthly)
VF 310-25 7500 180
VF 460-31 8000 7500 180
VF 550-29
1 stage
VF 550-29
>1 stage
8000 180
3500 60
* At least once a year The grease used in factory for first filling is: SHELL ALVANIA R2 Its equivalents: MOBIL : Mobilux EP 2,
TOTAL : Multis 2, ELF : ELF MULTI
a) Check foundation bolts for b) Check pump running records for hourly usage
c) The coupling should be checked for correct
motor pump unit, the user must:
a)
b) Ensure that your equipment corresponds to c) Contact FLOWSERVE after-sales Department
Page 24 de 32
security of attachment and corrosion. to determine if bearing lubricant requires
changing. alignment and worn driving elements.
If a check shows a bad running of the
Refer to the "fault finding chart"
chapter 7 of this leaflet to apply the recommended solutions.
the arrangements of this leaflet. if the problem persists.
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
6.2.4 Mechanical seals
The current maintenance is limited to seal control. It is necessary to detect any small leakage which announces the beginning of the deterioration of friction faces or secondary seal elements (rings, bellows, synthetic membranes). It is advisable to stop the pump as soon as possible. Have an approved seal vendor replace or repair the seal.
6.2.5 Gland packing
6.2.5.1 Pump fitted with a packed gland
A well run in and correctly adjusted packing gland requires little maintenance. If, after some time, the leakage becomes too great, the gland should be tightened again in order to return these to a normal level.
If re-tightening is not possible, new packing must be installed.
6.2.5.2 Gland packing inspection and removal
a) Remove the shield guards b) Slide back the gland. c) Remove the packing rings with an extractor
designed for this purpose (including the lantern ring if it exists; note its position and its direction of rotation).
d) Inspect the state of the sleeve surface; the
presence of many marked grooves will indicate that it must be replaced.
e) Carefully clean the different pieces of the
packing gland.
6.2.5.3 Gland packing fitting
If the packing is supplied as cord the packing must be cut so that the external diameter is lightly tightened and there is an initial gap between the sleeve and the packing ring.
For that purpose, wind the packing helically around the shaft sleeve or a chuck of the same diameter. (Take precautions to avoid damaging sleeve).
Example of straight cut Example of bevel cut
Ensure a tightening on the stuffing
box housing and not on the sleeve.
SETTING OF PACKING
Follow the instructions: a) Assembly of the packing in S. b) Staggering by about 90° between two
packings.
c) Assemble packing after packing.
After setting the last packing, fix the gland on the packings and screw up the nut by hand.
After this screwing phase, the shaft should turn by hand as easily as before the setting of the packings.
PUMP TYPE
VF 40-20 3 stages VF 40-20
3 < stages 6 VF 40-20 > 7 stages
VF 60-18 3 stages VF 60-18
3 < stages 6 VF 60-18 > 7 stages
VF 78-37 6 12 x 12 230 VF 95-27 2 stages VF 95-27 > 2 stages VF 180-27 1 stage VF 180-27 > 1 stage 6 12 x 12 230 VF 190-19 1 stage VF 190-19 > 1 stage 6 12 x 12 230 VF 185-35 1 stage VF 185-35 > 1 stage 6 14 x 14 315 VF 250-43 1 stage VF 250-43 >1 stage 6 14 x 14 315 VF 240-51 1 stage VF 240-51> 1 stage 6 14 x 14 315 VF 300-37 6 14 x 14 315 VF 310-25 6 14 x 14 315 VF 460-31 6 14 x 14 315 VF 550-29 1 stage VF 550-29 > 1 stage 6 16 x 16 396
Quantity
6 10 x 10 160 6 10 x 10 175 6 12 x 12 230
6 10 x 10 160 6 10 x 10 175 6 12 x 12 230
6 10 x 10 175 6 12 x 12 230 6 10 x 10 175
6 10 x 10 175
6 12 x 12 230
6 12 x 12 230
6 12 x 12 230
6 14 x 14 315
PACKING

(in mm)
Length (in
mm)
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
6.2.6 Internal coating
If the pump has an internal coating, this coating must be inspected periodically. Any wear or cracks of the coating found must be immediately repaired. Failure to do this may lead to accelerated wear of the coating during operation and corrosion of the exposed base metal, depending on the material and pumped liquid. Special attention must be paid to the coating edges. Any loss of coating material is considered to be normal wear and tear on the pump and is not considered as warranty. Flowserve has applied the coatings according to the supplier's instructions but will not be held responsible for coating wear or cracks that may develop over time
.
6.3 Spare parts
6.3.1 Ordering of spares Flowserve keeps records of all pumps that have
been supplied. When ordering spares the following information should be quoted.
1) Pump serial number.
2) Pump size.
3) Part name
4) Part number
The pump size and serial number are shown on the pump nameplate.
To ensure continued satisfactory operation, replacement parts to the original design specification should be obtained from Flowserve. Any change to the original design specification (modification or use of a non-standard part) will invalidate the pumps safety certification.
6.3.2 Storage of spares
Spares should be stored in a clean dry area away from vibration. Inspection and re-treatment of metallic surfaces (if necessary) with preservative is recommended at 6 monthly intervals.
6.4 Recommended spares
1500, 2110, 2130, 2261, 2450, 2461, 2472, 3011, 3400, 4130, 4134, 4610, 9302
a) Destroy all the gaskets after dismantling,
replace them when reassembling.
b) IT IS RECOMMENDED THAT
BEARINGS ARE NOT REUSED AFTER ANY REMOVAL FROM THE SHAFT.
c) After serving during two years, replace the
gland packing.
6.5 Disassembly
Refer to section 1.6, Safety, and section 6
Maintenance, before dismantling the pump.
Before dismantling the pump for
overhaul, ensure genuine Flowserve replacement parts are available. Refer to sectional drawings for part numbers and identification.
REPAIR OF THE PUMP
If the pump presents abnormalities or a
persistent malfunction, contact immediately:
FLOWSERVE
After-sales Service Tel.: 02 43 40 57 57
(33) 2 43 40 57 57
Fax.: 02 43 40 58 17
(33) 2 43 40 58 17
According to the After-sales Service instructions, disassembly will be limited to the dismantling of the pump.
a) DISCONNECT THE UNIT
FROM POWER.
b) Close the inlet valve (if fitted) and outlet valve. c) Wait for the moment when the pump casing is
cooled and at ambient temperature.
d) DRAIN PUMP. e) Dismantle inlet and outlet pipeworks as well
as all pipeworks.
f) REMOVE PUMP TAKING INTO
ACCOUNT SAFETY (§ 1) AND HANDLING (§ 2.2) PROCEDURES.
ANY DISASSEMBLY, REPAIR OR REASSEMBLY WILL BE CARRIED OUT UNDER FLOWSERVE' RESPONSABILITY, EITHER DIRECTLY BY THE AFTER-SALES SERVICE OR BY OTHER FLOWSERVE-AGENTS WHO WILL GET THE REQUIRED INSTRUCTIONS AND APPROVALS. THIS IS THE CASE OF AUTHORIZED REPAIRERS WHOSE ADDRESSES AND TELEPHONE NUMBERS WILL BE GIVEN ON REQUEST.
Page 26 de 32
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
7 FAULTS; CAUSES AND REMEDIES
 


  




The motor is running on 2 phases only - Check and control the motor electrical power supply
Motor running too low - Check the connection in the terminal box according to the

Worn wear-ring surfaces - Foresee pump mending: CONSULT FLOWSERVE
   
   

   

Insufficient flow rate Irregular pump running Driver overloaded Mechanical seal leak Equipment vibration Excessive pump casing temperature
POSSIBLE CAUSES SOLUTIONS

Air bubbles in pipes - Check and deaerate the pipes
 
Suction level too low - Check the available NPSH > the required NPSH
- Check valves and strainers
- Check the immersion head of the suction valve

Wrong rotation - Reverse 2 phases on motor terminal boxes
voltage

Total manometric head system higher than pump
differential head

Total manometric head system lower than pump
differential head
 
Pipes (valves, filter...) - Control, dismantle and clean
 
Insufficient flow rate - Check the discharge pipe (valves, back pressure)
Seizure, jamming - CONSULT FLOWSERVE Excessive strains on flanges - Check the flange connections and eliminate strains (pipe
Defective gland packing on the shaft - Check and replace all the gland packings parts
Defective motor bearings - CONSULT FLOWSERVE

Specific gravity or viscosity of liquid too high - Consult our local agent to analyse the problem

Misalignment - Check the alignment of the pump and of its driver

Foundations not sufficiently rigid - Check the setting of baseplates: tightening, bad
- Check the discharge head
- Check the head losses in discharge pipes (partly closed valve, foreign particles, back pressure too high)
- Modify the installation or change the pump set
-Throttle at discharge valve or trim the impeller (contact our local agent)
positionning or elastic sleeves mounting)
- Mechanical seal: CONSULT FLOWSERVE
adjustment, seal
Insufficient pressure Pump looses prime after starting
POSSIBLE CAUSES SOLUTIONS

Rotation speed too low (check the driver) - Check the connection in the terminal box according to the

Mechanical defects - CONSULT FLOWSERVE

Suction level too low - Check the available NPSH > the required NPSH

Defective gasket - CONSULT FLOWSERVE
voltage
- Reduce geometrical suction lift (diameter increase and appropriate fitting positions)
- Check valves and strainers
- Check the immersion head of the suction valve
Page 27 de 32
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
8 PARTS LIST AND DRAWINGS
8.1 Sectional drawings
DISCHARGE ABOVE THE MOUNTING PLATE
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Page 29
VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
DISCHARGE BELOW THE MOUNTING PLATE
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Page 30
VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
8.2 Sectional drawings part list
ITEMS DESIGNATION
ITEMS DESIGNATION
6700
Key
1170
1310
1340
1371
1500
2110
2130
2261
2450
2461
2472
2540
2915
3011
3160
3244
3250
3261
3400
3712
3853
3863
4110
4130
4131
4134
4610
Pump bowl
Bellmouth
Adaptor
Discharge elbow
Wear ring
Pump shaft
Top shaft
Mixed flow impeller, shroudred
Shaft sleeve
Spacer sleeve for bearing
Inner race centring sleeve with collar
Thrower
Shaft adjusting nut
Radial ball bearing
Motor stool
Bearing carrier for anti-friction bearing
Bearing spider
Bearing cover, drive side
Bearing bush
Bearing nut
Grease nipple
Grease regulator
Stuffing box housing
Gland packing
Follower
Lantern ring
Round section joint ring
7120
7415
9302
9311
9320
9402
9453
9620
9621
9623
9626
9638
9690
9923
9929
9930
9940
9941
9944
9951
Muff coupling, split
Coupling ring, split
Shell bearing
Grease nipple cap
Stopping device
Gland flange
Evacuation pipe of stuffing box leakage
Various pipe
Screwed plug
Union T
Union joint
Purger
Special shackle pin
Hexagon nut
Self-braked nut
Slotted round nut for book-spanner
Special ring
Plain washer
Curved spring washer
Stud
8.3 General arrangement drawing
The typical general arrangement drawing and any specific drawings required by the contract will be sent to the Purchaser separately unless the contract specifically calls for these to be included into the User Instructions. If required, copies of other drawings sent separately to the Purchaser should be obtained from the Purchaser and retained with these User Instructions.
6531
6541
Suction strainer
Lockwasher
Page 30 de 32
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VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
9 CERTIFICATION
Certificates determined from the Contract requirements are provided with these instructions where applicable. Examples are certificates for CE marking, ATEX marking etc. If required, copies of other certificates sent separately to the Purchaser should be obtained from the Purchaser for retention with these User Instructions.
10 OTHER RELEVANT DOCUMENTATION AND MANUALS
10.1 Supplementary User Instructions
Supplementary instructions such as for a driver, instrumentation, controller, seals, sealant system etc are provided as separate documents in their original format. If further copies of these are required they should be obtained from the supplier for retention with these User Instructions.
10.2 Change notes
If any changes, agreed with Flowserve Pump Division, are made to the product after its supply, a record of the details should be maintained with these User Instructions.
10.3 Additional sources of information
Reference 1:
NPSH for Rotor dynamic Pumps: a reference guide, Euro pump Guide No. 1, Euro pump & World Pumps, Elsevier Science, United Kingdom,
1999.
Reference 2:
Pumping Manual, 9th edition, T.C. Dickenson, Elsevier Advanced Technology, United Kingdom,
1995.
Reference 3:
Pump Handbook, 2nd edition, Igor J. Karassik et al, McGraw-Hill Inc., New York, 1993.
Reference 4:
ANSI/HI 1.1-1.5, Centrifugal Pumps ­Nomenclature, Definitions, Application and Operation.
Reference 5:
ANSI B31.3 - Process Piping.
Page 31 de 32
Page 32
VF USER INSTRUCTIONS ENGLISH 71561233 - 11/09
Local Flowserve factory representatives:
Repair & Service Fax:
+33 2 43
40 58 17
Your Flowserve factory contacts:
Flowserve Pompes Route d'Angers - 72234 ARNAGE BP 305, 72001 LE MANS Cedex, France
Telephone (24 hours): +33 2 43 40 58 47 Sales & Admin: +33 2 43 40 57 57
North America: Flowserve 5310 Taneytown Pike, PO Box 91 Taneytown, MD 21787-0091, USA
Telephone: +1 (410) 756 2602 Customer Service FAX: +1 (410) 756 2615 Parts inquiry/Order PH: +1 (800) 526 3569
South America: Flowserve do Brasil Ltda Av. Don Helder Camara, 5451 20771-001 Rio de Janerio
Tel: +55-21-2108-4000 Fax: +55-21-2108-4184
To find your local Flowserve representative please use the Sales Support Locator System found at www.flowserve.com
FLOWSERVE REGIONAL SALES OFFICES:
USA and Canada
Flowserve Corporation 5215 North O’Connor Blvd., Suite 2300 Irving, Texas 75039-5421 USA Telephone 1 972 443 6500 Fax 1 972 443 6800
Europe, Middle East, Africa
Worthing S.P.A. Flowserve Corporation Via Rossini 90/92 20033 Desio (Milan) Italy Telephone 39 0362 6121 Fax 39 0362 303396
Latin America and Caribbean
Flowserve Corporation 6840 Wynnwood Lane Houston, Texas 77008 USA Telephone 1 713 803 4434 Fax 1 713 803 4497
Asia Pacific
Flowserve Pte. Ltd 10 Tuas Loop Singapore 637345 Telephone 65 6771 0600 Fax 65 6779 4607
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