Flowserve WDX User Manual

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Pump Division

Type: WDX CENTRIFUGAL PUMPS

USER INSTRUCTIONS: INSTALLATION, OPERATION, MAINTENANCE

PCN=71576322 06-05 (E)

These instructions must be read prior to installing,

operating, using and maintaining this equipment.

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

CONTENTS

PAGE

1 INTRODUCTIONAND SAFETY..........................4

PAGE

6 MAINTENANCE................................................28

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.................................8

1.8 Specific machine performance......................8

1.9 Noiselevel..................................................9

2 TRANSPORT AND STORAGE..........................10

2.1 Consignment receipt and unpacking...........10

2.2 Handling...................................................10

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

2.4 Storage.....................................................12

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

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

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

3.2 Nomenclature............................................13

3.3 Design of major parts.................................13

3.4 Materials of construction............................14

3.5 Performance and operating limits................14

3.6 Coverage charts........................................15

4 INSTALLATION.................................................16

4.1 Location....................................................16

4.2 Cleaning priorto installation.......................16

4.3 Foundation................................................16

4.4 Grouting....................................................17

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

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

4.7 Final shaft alignment check........................21

4.8 Electrical connections................................21

4.9 Protection systems ....................................22

6.1 General.....................................................28

6.2 Maintenance schedule...............................28

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

6.4 Recommended spares and consumable..........

items..............................................................32

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

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

6.7 Renewal clearances..................................32

6.8 Disassembly..............................................32

6.9 Inspection of components...........................36

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

7 FAULTS; CAUSES AND REMEDIES..................38

8 PARTS LISTS AND DRAWINGS........................40

8.1 Sectional drawings, WDXR grease lubricated

uncooled........................................................40

8.2 Sectional drawings, variants.......................41

8.3 Sectional drawings, otherdetails................42

8.4 Sectional drawingspart list.........................43

8.5 General arrangement drawing....................45

9 CERTIFICATION..............................................45

10 OTHER RELEVANT DOCUMENTATION AND

MANUALS....................................................45

10.1 Supplementary User Instructions..............45

10.2 Change notes..........................................45

10.3 Additional sources of information..............45

5 COMMISSIONING, START-UP, OPERATIONAND

SHUTDOWN................................................22

5.1 Pre-commissioning procedure....................22

5.2 Pump lubricants.........................................23

5.3 Direction of rotation....................................24

5.4 Guarding...................................................24

5.5 Priming and auxiliary supplies....................24

5.6 Starting the pump......................................25

5.7 Running the pump.....................................25

5.8 Stopping and shutdown..............................27

5.9 Hydraulic, mechanical and electrical duty....27

5.10 Pumpsfor Food Use or Potable Water......27

Page 2 of 46

INDEX

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

PAGE

Additional sources (10.3)......................................45

Alignment of shafting (see 4.3,4.5 and 4.7)

Assembly (6.10)...................................................37

ATEX marking (1.6.4.2)..........................................7

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

Certification (9)....................................................45

Change notes(10.2)............................................45

Clearances(see 6.7, Renewal clearances)............32

Commissioning, start-up, operation (5)..................22

Compliance, ATEX (1.6.4.1)...................................6

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

Coverage charts(3.6)..........................................15

Design ofmajorparts(3.3)...................................13

Direction of rotation (5.3)......................................24

Disassembly (6.8)................................................32

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

Dismantling (see 6.8, Disassembly)......................32

Drawings (8)........................................................40

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

Electrical connections(4.8)...................................21

End of product life (2.5)........................................12

Inspection of components (6.9).............................36

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

Faults; causesand remedies (7)...........................38

Foundation (4.3)..................................................16

Forces and moments (4.6.3).................................20

General arrangement drawing (8.5).......................45

Grouting (4.4)......................................................17

Guarding (5.4).....................................................24

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

Hydraulic, mechanical and electrical duty (5.9)......27

Inspection (6.2.1 and 6.2.2)..................................29

Installation (4)......................................................16

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

Location (4.1)......................................................16

Lubrication (see 5.1.1, 5.2 and6.2.3)

Lubrication schedule (5.2.4)..................................24

Maintenance (6)...................................................28

Maintenance schedule (6.2)..................................28

Nomenclature (3.2)..............................................13

Nameplate (1.7.1)..................................................8

Operating limits(3.5.1).........................................14

Ordering spare parts (6.3.1)..................................31

Partslists (8.4)....................................................43

Performance (3.5)................................................14

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

Pre-commissioning (5.1).......................................22

Protection systems(4.9).......................................22

Pumpmasses(2.2.2)...........................................11

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

Receipt and unpacking (2.1).................................10

Recommended fill quantities(see 5.2.3)................23

Recommended grease lubricants (5.2.2)...............23

Recommended oil lubricants (5.2.1)......................23

Recommended spares (6.4).................................32

Recycling (2.5)....................................................12

Replacement parts (see 6.3 and 6.4).....................31

Running the pump (5.7)........................................25

Safety action (1.6.3)...............................................5

Safetymarkings(1.6.1)..........................................5

Safety,protection systems (see 1.6 and 4.9)

Sectional drawings (8.1).......................................40

Sound level (see 1.9, Noise level)...........................9

Sources, additional information (10.3)...................45

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

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

Starting the pump (5.6).........................................25

Stop/start frequency (5.7.6)..................................26

Stopping and shutdown (5.8)................................27

Storage, pump (2.4).............................................12

Storage, spareparts (6.3.2)..................................32

Supplementarymanualsor information sources.....45

Thermal expansion (4.5.1)....................................17

Toolsrequired (6.5)..............................................32

Torques for fasteners (6.6)...................................32

Transport (2).......................................................10

Trouble-shooting (see 7)......................................38

Vibration (5.7.5)...................................................26

Warninglabels (1.7.2)............................................8

Page 3 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

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 productsare designed,developed and manufactured with state-of-the-art technologies in

modern facilities. The unit isproduced with greatcare and commitment to continuous quality control, utilizing

sophisticated quality techniques, and safety requirements.

Flowserve iscommitted to continuous quality improvement and being atservice for any further

information about the product in its installation and operation or aboutits 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

instructionsis importantto help ensure reliability in service and avoid risks. The instructions maynot take

intoaccount local regulations; ensure such regulations are observed byall, including those installing the

product.Always coordinate repair activity with operations personnel, and followall plant safety

requirementsand applicable safetyand healthlaws and regulations.

These instructions must be readprior to

installing, operating, using andmaintaining 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 beenmet.

1.2 CEmarking and approvals

It isa 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, whereapplicable, Low

Voltage Equipment, Electromagnetic Compatibility (EMC), Pressure Equipment Directive (PED) and

Equipment for Potentially Explosive Atmospheres (ATEX).

To confirm the Approvalsapplying andif the productis CEmarked, check the serial numberplate markings and

the Certification.(See section9, Certification.)

1.3 Disclaimer

Information in these User Instructions is believed to be reliable. In spite of all theefforts of Flowserve

Pump Divisionto provide sound andall necessary information the content ofthis manual may appear

insufficientand is notguaranteed by Flowserve as to its completeness or accuracy.

Flowservemanufacturesproductstoexacting International QualityManagement System Standards as

certifiedandaudited byexternal Quality Assurance organizations. Genuine parts andaccessorieshave been

designed, testedandincorporatedinto theproducts to helpensuretheircontinuedproduct quality and

performancein use.AsFlowserve cannottest parts and accessories sourced from other vendorstheincorrect

incorporation of such partsand accessoriesmay adversely affect the performanceand safety features of

theproducts. The failure to properly select,install oruse authorized Flowserve parts andaccessoriesis

considered to bemisuse. Damageor failure caused by misuse is notcoveredby the Flowserve warranty. In

addition, any modification of Flowserveproducts or removal of original components mayimpair the safetyof

these productsin theiruse.

1.4 Copyright

All rightsreserved. No part of these instructionsmay be reproduced, stored in a retrieval system or

transmittedin any form or byany meanswithout prior permission of Flowserve Pump Division.

1.5 Duty conditions

This product has been selected to meet the specifications of your purchaser order. The

acknowledgement of these conditionshas been sent separately to the Purchaser. Acopy should be kept

with these instructions.

The product must not be operated beyond

the parameters specified for theapplication. If there is any doubt as to the suitability of the

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

Where applicablethe Directivesand any additional Approvals coverimportant safety aspects relating to

machineryand equipment andthe satisfactoryprovision of technical documentsand safetyinstructions. Where

applicablethisdocument incorporatesinformation relevant to these Directivesand Approvals.

Page 4 of 46

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

temperature or duty) itis requested that the user seeks the written agreementof Flowserve before start up.

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

1.6 Safety

1.6.1 Summary of safetymarkings

These User Instructionscontain specificsafetymarkings where non-observance of aninstruction would cause

hazards.The specific safetymarkings are:

This symbol indicateselectrical safety instructionswhere non-compliance will involve a high risk to personal safety orthe lossof life.

This symbol indicatessafety instructions where

non-compliance would affect personal safety and could result in lossof life.

This symbol indicates “hazardous substances and

toxic fluid” safety instructions where non-compliance

would affect personal safetyand could result in lossof life.

This symbol indicatessafety instructions

where non-compliance will involve some riskto safe operation and personal safetyand woulddamage the

equipment orproperty.

1.6.3 Safety action

This is a summary of conditionsand actions to prevent injury to personnel and damage to the

environment and to equipment. For products used in potentially explosive atmospheres section1.6.4

also applies.

NEVER DOMAINTENANCE WORK

WHEN THE UNIT IS CONNECTEDTO POWER

GUARDS MUST NOT BE REMOVED WHILE

THE PUMP IS OPERATIONAL

DRAIN THE PUMP AND ISOLATE PIPEWORK

BEFORE DISMANTLINGTHE PUMP The appropriate safety precautions should be taken

where the pumped liquids are hazardous.

FLUORO-ELASTOMERS (When fitted.)

When a pump has experienced temperaturesover 250 ºC (482 ºF), partial decomposition offluoro-elastomers

(example: Viton) will occur. In this condition these are extremely dangerousand skin contact must be

avoided.

This symbol indicatesexplosive atmosphere

zone marking according to ATEX. Itisused in safety instructionswhere non-compliance in the hazardous

area would cause the riskof an explosion.

This symbol is used in safety instructions to remind not to rub non-metallic surfaceswith a dry cloth; ensure cloth is damp.It isused where non-

compliance in the hazardousarea would cause the risk of an explosion.

This signis not a safety symbol butindicates

animportant instruction inthe assembly process.

1.6.2 Personnel qualification and training

All personnel involvedin the operation, installation, inspection and maintenance ofthe unit must be

qualified to carry out the work involved. If the personnel in questiondo not already possessthe

necessary knowledge and skill, appropriate training and instruction must be provided. If required the

operatormay commission themanufacturer/supplier to provide applicable training.

Always coordinate repair activity with operationsand health and safety personnel,and follow all plant safety

requirementsand applicable safetyand healthlaws and regulations.

HANDLING COMPONENTS

Many precision partshave sharp corners and the wearing ofappropriate safetygloves and equipmentis

required when handling these components. To lift heavy piecesabove 25 kg (55 lb) use a crane

appropriate for the massand in accordance with current local regulations.

THERMAL SHOCK

Rapid changes in the temperature of theliquid within the pump can cause thermal shock, which can result in

damageor breakage of componentsand should be avoided.

NEVERAPPLY HEAT TO REMOVE IMPELLER

Trappedlubricant or vapourcould cause an explosion.

HOT (and cold) PARTS

If hot orfreezing componentsor auxiliary heating supplies can present a danger to operatorsand

persons entering the immediate area actionmust be taken to avoid accidental contact. If complete

protection is notpossible, the machine accessmust be limited to maintenance staff only,with clear visual

warningsandindicatorsto those entering the immediate area.Note: bearing housingsmust not be

insulated and drive motors and bearings maybe hot.

If the temperature is greater than 68 °C (175 °F) or below 5 °C (20 °F) in a restricted zone, or exceeds

local regulations, action as above shall be taken.

Page 5 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

HAZARDOUS LIQUIDS

Whenthe pump ishandling hazardousliquidscare must be taken to avoid exposure to the liquid by appropriate

sitting ofthe pump,limiting personnel accessand by operatortraining. If theliquid isflammable and/or

explosive, strict safety proceduresmust be applied.

Gland packing must not be used when pumping hazardous liquids.

PREVENT EXCESSIVE EXTERNAL

PIPE LOAD Do not use pump asa support for piping. Do not mount

expansion joints, unlessallowed by Flowservein writing, so that their force, due tointernal pressure,

acts on the pump flange.

ENSURE CORRECT LUBRICATION

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

START THE PUMPWITHOUTLET

VALVE PART OPENED (Unless otherwiseinstructed at a specific point in the

User Instructions.) This is recommended to minimize the riskof

overloading and damaging the pump motor at full or zero flow. Pumpsmay be started with the valve further

open only oninstallations where this situation cannot occur. Pumpoutlet 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 RUNTHE PUMP DRY

1.6.4 Products used in potentially explosive atmospheres

Measures are required to:

 Avoid excess temperature.  Prevent build up of explosive mixtures.  Prevent thegeneration of sparks.  Preventleakages.  Maintain the pump to avoid hazard.

The following instructions forpumpsandpump units wheninstalledinpotentially explosive atmospheres

must be followed tohelp ensure explosion protection. Both electrical andnon-electrical equipment mustmeet

the requirementsofEuropean Directive 94/9/EC.

1.6.4.1 Scope of compliance

Use equipmentonlyin the zone for whichitis

appropriate. Always check thatthe driver, drivecoupling assembly, seal andpump equipmentare suitably rated

and/or certifiedfor the classificationof the specific atmospherein which theyare tobeinstalled.

Where Flowserve hassupplied only the bare shaft pump, the Ex rating applies only to thepump. The party

responsibleforassembling the pump set shall selectthe coupling,driverandany additional equipment, with the

necessary CE Declarationof Conformity establishing it issuitable for the area in which itis to be installed.

The output from a variable frequency drive (VFD)can cause additional heating affectsin themotorand so, for

pumpssetswith a VFD, the ATEX Certification for the motormust statethatitis coversthe situation where

electrical supplyis from the VFD.This particular requirement still applies evenif the VFDis in a safearea.

INLET VALVES TO BE FULLYOPEN

WHEN PUMP IS RUNNING Running the pump at zero flow orbelow the

recommended minimum flow continuously will cause damage to the seal.

DO NOT RUN THE PUMPAT

ABNORMALLY HIGH ORLOW 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/bearinglife, overheating of the pump,instability and cavitations/vibration.

Page 6 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

1.6.4.2 Marking

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

engraved on the nameplate.

II 2 GD c IIC135 ºC (T4)

Equipment Group I =Mining

II = Non-mining Category

2 orM2 = Highlevel protection 3 = normallevel of protection

Gas and/or Dust G = Gas; D= Dust

c = Constructional safety

(in accordance with prEn13463-5)

Gas Group (Equipment Category2 only) IIA –Propane (typical)

IIB –Ethylene (typical) IIC –Hydrogen (typical)

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

1.6.4.3 Avoiding excessive surface temperatures

ENSURE THE EQUIPMENT TEMPERATURE

CLASS IS SUITABLE FORTHE HAZARD ZONE Pumpshave a temperatureclassas stated in the

ATEX Exrating on the nameplate. These are based on a maximum ambient of 40 °C (104 °F); refer to

Flowserve forhigher ambient temperatures. The surface temperature on thepump is influenced by

the temperature of theliquid handled. The maximum permissible liquid temperature depends on the

temperature classand must notexceed the values in the table that follows.

The temperature rise at the seals, bearingsand due to the minimum permitted flow rate is taken into account

in the temperatures stated.

Temperaturelimit of liquid

handled (* depending on

materialandconstruction

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 variesand the pump could be installed in differenthazardous atmospheres. In thiscase the user

isresponsible for ensuring that the pump surface temperature doesnot exceed that permitted in the

particular hazardous atmosphere. If an explosive atmosphere exists during the

installation, do notattempt to check the direction of rotation by starting the pump unfilled. Even a short run

time maygive a high temperature resulting from contact between rotating and stationary components.

Where thereis any riskof thepump being run against a closed valve generating high liquid and casing external

surface temperaturesit is recommended that users fit an external surface temperature protectiondevice.

Avoid mechanical, hydraulic or electrical overload by using motor overload trips, temperaturemonitor or a

powermonitor 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 housingsand 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 istotally filled with liquid at all times during the pump operation, so that an explosive

atmosphere is prevented. In addition itis 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 emissionsof vapour or gasto atmospherethe surroundingarea

must be well ventilated.

Page 7 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

1.6.4.5 Preventingsparks

To prevent a potential hazardfrom mechanical contact, the coupling guard must be non-sparking. To avoid the potential hazardfrom random induced

current generating a sparkthe ground contacton the baseplatemust be used.

Avoid electrostatic charge: do not rub nonmetallic surfaceswith a dry cloth, ensure cloth is damp.

The couplingmust 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 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.

Where there is a riskfrom such tools or materials; maintenancemust be conducted in a safe area.It is

recommended that a maintenance plan and schedule isadopted. (See section 6, Maintenance.)

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 Warning labels

Avoidentrapmentofliquid in the pumpand associated piping dueto closing of suctionand discharge valves,

which couldcause dangerousexcessive pressuresto occurif there isheatinput to the liquid.Thiscanoccurif

thepump is stationaryor running. Bursting of liquid containing partsdue to freezing must

be avoided by draining or protecting the pump and ancillary systems.

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

monitored. If leakage ofliquid to atmosphere can resultin a

hazard, the installationof a liquid detection device is recommended.

1.6.4.7 Maintenance to avoid the hazard

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

The responsibility forcompliance withmaintenance instructions is with the plant operator.

Oil lubricated units only:

1.8 Specific machine performance

For performance parameterssee section 1.5, Duty conditions. When the contract requirement specifies

these to beincorporated into User Instructions these are included here. Where performance data hasbeen

supplied separately to the purchaser these should be obtained and retained with these User Instructions if

required.

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.

Page 8 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

1.9 Noise level

When pump noise level exceeds 85dBA attentionmust be given to prevailing Health and Safety Legislation, to

limit the exposure of plantoperating personnel to the noise. The usual approach is to control exposure time

to the noise or to enclose the machine to reduce emitted sound. Youmay have already specified a

limitingnoise level when the equipment was ordered, however if no noise requirements were defined then

machines above a certain power level will exceed 85 dB(A). In such situations consideration must be given

to the fitting of an acoustic enclosure to meetlocal regulations.

Pumpnoise level isdependent on a numberof factors

- the type of motor fitted, theoperating capacity, pipeworkdesign and acoustic characteristics of the

building. Typical sound pressure levelsmeasured in dB and A-weighted are shown in the table below.

The figures are indicative only, theyare subject to a +3 dB tolerance, and cannot be guaranteed.

The values are based on the noisiest ungeared electric motorswhich are likely to be encountered.Theyare

LpAsound pressure levels at 1m (3.3ft) from the directly driven pump, for "free field over a reflecting

plane". For estimating LwAsound powerlevel (re 1 pW) add 14 dB(A) to the sound pressure value.

If a pump only hasbeen purchased, for fitting with your own driver, then the "pump only" noise levelsfrom the

table should be combined with thelevel forthe driver obtained from the supplier. If the motor is driven by an

inverter, it may showan increase in noise level at some speeds. Consult a Noise Specialist for this

calculation

 For units driven by equipmentother than

electric motors or unitscontained within enclosures, see the accompanying information sheetsand

manuals.

Typicalsoundpressure level, dBA,LpA at 1 m reference 20 μPa (LwAsound power1 pWwhere LpA>85 dBA)

and speed

kW (hp)

5.5 (7.5)

7.5 (10) 11 (15)

15(20)

18.5(25) 22(30) 30(40)

37(50) 45(60) 55(75)

75(100) 90(120)

110 (150) 150 (200)

200 (270) * * * * * 83 * 80 300 (400) - - - - * 84 * 81 500 (670) - - - - *

* Motors inthis rangeare generallyjobspecific and noiselevelsshould be calculated based onactual equipmentinstalled.

For 960 rpmreduce 1450rpm values by 5 dBA.

3550 r/min 2900 r/min 1750 r/min 1450 r/minMotor size

Pump and

motor

dBA

90(99) 90(99)

91(100) 92(101)

92(101) 92(101)

100 (109) 85(94) 93(102) 100 (109) 86(95) 93(102)

100 (109) 87(96) 93(102) 100 (109) 88(97) 95(104)

100 (109) 90(99) 95(104) 86(95) 88(97) 100 (109) 90(99) 95(104) 86(95) 90(99) 100 (109) 91(100) 95(104) 87(96) 91(100)

101 (110) 92(101) 96(105) 88(97) 91(100)

Pump

only

dBA

77 83 73 76 73 72 71 78 83 74 77 74 73 72 80 84 76 78 76 74 73

83 83 83

Pump and

motor

dBA

85(94) 85(94) 85(94)

Pump

only

dBA

79 80 79 76 75 79 80 79 76 75 79 81 79 77 75 81 84 80 80 76

82 84 80 80 76 83 84 80 80 76 84

Pump and

motor

dBA

86(95)

Pump

only

dBA

81 82 77 81 83 78

81 83

85(94)

Pump and

motor

dBA

85(94) 86(95)

86(95)

* 83

Pump

only

dBA

78 79

Page 9 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

In areas where the staff hasto intervene, remember that when the level of the sound pressure is:

Below 70dBA :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 85dBA :No particular measuresneed to be

taken for casual visitorsstaying in the room during a limitedperiod.

Above 85 dBA :The room must be considered as a

dangerousarea because of the noiseand 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 componentsmust

beinstalled and a warning sign to this effect erected at each entry.

The staff in the room must wear

ear protection.

Each product has a unique serial number. Checkthat this number corresponds with that advised and

always quote this numberin correspondence aswell as when ordering spare parts or furtheraccessories.

2.2 Handling

2.2.1 General instructions concerning handling

Boxes, crates, pallets or cartons maybe unloaded using fork-lift vehiclesor slings dependent on their

size and construction. See 2.3.1 for positioning of slings.

To lift heavy piecesabove 55 lb (25 kg), use a crane corresponding to the massand in accordance with

the current local regulations. To lift machines or pieces with one or several lifting

rings, only use hooksand chainsin compliance with the local regulations concerning safety. Never put

cables, chainsor ropesdirectly on orin the lifting rings. Cables, chains orlifting ropes must never

present excessive bending. Never bend thelifting hooks, lifting rings, chains,

etc...They are only made to endurestresses 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.

Make sure that the noise, which travels through the wallsand windows, does notgenerate 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 completenessand thatthere has been no damagein transportation.

Any shortage and ordamage must be reported immediately to Flowserve Pump Division and

received in writing within one month ofreceipt of the equipment. Later claims cannot be accepted.

Check any crate, boxesand wrappingsfor any accessories or spare parts thatmay be packed

separately with the equipmentor attached to side wallsof the boxor equipment.

To increase the safety and efficiency of the lifting device, all the lifting elementsmust be as

perpendicular as possible. If necessary a lifting beam can be placed between the crane and theload.

When heavy piecesare lifted up, never stay or work under theload 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 crane. The acceleration

or the deceleration of lifting equipment must stay in the safetylimits for the staff.

A crane 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. For example use two winches

making approximately the same angle,lessthan 30°, with the vertical.

Page 10 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

2.2.2 Pump masses

All masses, in the table below,are for 3 stages, in construction M2.

PUMP

SIZE

1.5WDX

2WDX

3WDX

4WDX

MET PUMP MASS

WDXR/C WDXE WDXS

lb kg lb kg lb kg lb kg

Non

298 135 271 123 243 110 23

cooled

Cooled

309 140 295 134 267 121 23

Non

355 161 315 143 302 137 31

cooled

Cooled

386 175 342 155 328 149 31

Non

483 219 450 204 421 191 46 21

cooled

Cooled

516 234 478 217 450 204 46 21

Non

661 300 606 275 562 255 60 27

cooled

Cooled

694 315 628 285 606 275 60 27

MASS

PER

STAGE

All masses, in the table below,are for 3 stages, in construction M3,M4, M5, M6, M7.

To avoid distortion, the pump unit

should belifted asshown.

Motor pump unit

10.5

PUMP

SIZE

MET PUMP MASS

WDXR/C WDXE WDXS

MASS

PER

STAGE

lb kg lb kg lb kg lb kg

Non

324 147 298 135 260 118 25

1.5WDX

cooled

Cooled

335 152 322 146 293 133 25

Non

375 170 335 152 322 146 34

cooled

2WDX

Cooled

406 184 362 164 348 158 34

Non

527 239 494 224 465 211 51 23

3WDX

4WDX

cooled

Cooled

560 254 522 237 494 224 51 23

Non

710 322 650 295 602 273 66 30

cooled

Cooled

743 317 672 305 694 315 66 30

2.3 Lifting

2.3.1 Slinging of motor pumps units

Use handlingmeans in accordance with motor

pump unit massmentionedon the CE plate.For the massesof the pumps bare end of shaft see table §

2.2.2 and nameplate.

11.5

15.5

When handling always wear gloves, safety

shoes and an industrial safety helmet.

For massesabove 55 lb (25 kg), manual

handling is forbidden.

Page 11 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

2.4 Storage

Store the pump in a clean, dry location

away from vibration. Leave piping connection covers in place to keep dirtand other foreignmaterial out of

pump casing.Turn pump at intervalsto prevent brinelling of the bearings and the seal faces, if fitted,

from sticking. Do not store pumps starting on the fanguard. The pump maybe stored asabove forup to 6

months. Consult Flowserve forpreservative 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 orits parts, the relevant materials and partsshouldbe

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 currentregulations. This also includes the liquidsand or gases in the

"seal system" or otherutilities.

Make sure that hazardous substances or toxic

fluid are disposed of safely and that the correct personal protective equipment isused. The safety

specifications must be in accordance with the current regulations at all times.

Horizontal

WDXR

Radial suction Driveend on dischargeside- CW Thrustbearing ondriveside

Radial bearing onsuction side 2shaftseals

WDXC

Horizontal Radial suction Driveend on suction side- CCW Thrustbearing onsuctionsi de Radial bearing ondischargeside

2shaftseals

3 PUMP DESCRIPTION

3.1 Configurations

The WDX type pump isa horizontal,multistage, radial split case, vaned diffuser type centrifugal pump

equipped with a special suctionimpeller for low NPSH. It can be used with motor, steam turbine and

gasoline ordiesel engine drives. The WDX pumpsare of modular construction with

identical stages being stacked axially to achieve the desired pressure output. Four high strength external

tie rods connecting the two end casingshold them together. A variety of optimal features and materials

allow it to fit a wide range of applications such as boiler feed or reverse osmosis.

Various orientationsfor the radial suction and discharge nozzles are allowed every 90°except

towardsthe bottom. The WDX can have the following configurations:

Horizontal

WDXE

End suction Driveend on dischargeside- CW Thrustbearing ondriveside Sleeve bearing on suctionside 1shaftseal

WDXS

Horizontal Radial suction Driveend on dischargeside- CW Thrustbearing ondriveside

Sleeve bearing on suctionside 1shaftseal

Page 12 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

Year of construction +

Maximumadmi

ssible

Maximum/ minimum

3.2 Nomenclature

Characteristics shown on the nameplate fixed on the pump are as shown below: Each pump issupplied with the following nameplate:

Speed ofrotation

Pump type

Flowrate

Head

Radial/thrust bearing

Manufacturenumber

Each pump unitis supplied with the following nameplate:

Mass

Pressure at 20°C

temperature

Mass of the set

The pump size will be engraved on the nameplate typicallyas below:

4 WDX E 6 D

Nominal discharge branch size. Seriesname Configuration (see 3.1 above) Number of stages Hydraulic type

The typical nomenclatureabove is the general guide to the WDX configuration description. Identify the

actual pump size and serial numberfrom the pump nameplate. Checkthat this agrees with the applicable

certification provided.

3.3 Design of major parts

3.3.1 Pump casing

The pump casings(suction, discharge and stage) are

sealed with o’rings and designed to contain the

pressures generated by the pump at the various possible design pressures and temperatures.

3.3.2 Impeller

Theimpeller is fully shrouded and may be fitted with optional wear rings.

The suction impelleris specifically designed to have a low NPSH requirement.

3.3.3 Diffuser

The diffusersare fully machined to optimise performance.

3.3.4 Shaft

The shaft mounted on bearings with a keyed drive end.

Page 13 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

3.3.5 Pump bearings andlubrication

WDX pumpsare designed so the antifriction bearings may be either oil orgrease lubricated.

WDXE and WDXS have product lubricated line bearingswith sleeve andbushing made of silicon

carbide. Bearingisolators or stationarylabyrinths maybe fitted

as an optionin the bearing coversto protect the bearings.

3.3.6 Bearing housing

Grease nipplesenable grease lubricated bearings to be replenished between major service intervals. For

oil-lubricated bearings, a constant level oilerisfitted.

3.3.7 Stuffing box housing

The stuffing box housing hasa spigot (rabbet) fit between the pump casing and bearing housing for

optimum concentricity. The design enablesa number of sealing optionsto be fitted.

3.3.8 Shaft seal

Themechanical seal(s) attached to the pump shaft sealsthe pumped liquid fromthe environment.

Stuffing boxeshave been designed for component or cartridge seals. Glandpackingmay be fitted as an

option.

3.3.9 Driver

The driver isnormallyan electricmotor.Differentdrive configurationsmaybe fitted such asinternal combustion

engines, turbines, hydraulicmotorsetcdriving via couplings,belts,gearboxes,drive shaftsetc.

3.3.10 Accessories

Accessories may be fitted when specified by the customer.

3.4 Materials of construction

Material

column

M2 Castiron Cast iron Chrome steel M3 Carbonsteel Castiron Chrome steel

M4 Carbonsteel M5 Chrome steel M6 M7 Stainless steel

Casing Impeller Shaft

Duplex

stainless steel

Stainless

steel

Stainless

steel

Stainless

steel

Stainless

steel

Chrome steel Chrome steel

stainless steel stainless steel

Duplex Duplex

3.5 Performance and operating limits

This product has been selected to meet the specifications of your purchase order.See the

nameplate and section 1.5.

Themaximumallowable speed forcast iron

impellersis3600RPMand for steel impellersis4000 RPM.

3.5.1Minimal flow

20 % of BEP up to 280° F (140 °C) 25 % of BEP between 280 °F (140 °C) and 410 °F

(210 °C)

3.5.2 Clearance data

Nominal

Interstage

clearance

min/max

mm(inch)

0.170/0.259

(0.0067/0.0102)

0.170/0.259

(0.0067/0.0102)

0.170/0.259

(0.0067/0.0102)

0.170/0.259

(0.0067/0.0102)

0.200/0.303

(0.0079/0.0119)

0.200/0.303

(0.0079/0.0119)

0.200/0.303

(0.0079/0.0119)

0.200/0.303

(0.0079/0.0119)

Size

Mat

M2M30.170/0.259

1.5

M4 toM70.320/0.409

1.5

M2M30.170/0.259

M4 toM70.330/0.419

M2M30.200/0.303

M4 toM70.360/0.463

M2M30.200/0.303

M4 toM70.410/0.513

Nominalwear

ringclearance

min/max

mm(inch)

(0.0067/0.0102)

(0.0126/0.0161)

(0.0067/0.0102)

(0.0130/0.0165)

(0.0079/0.0119)

(0.0142/0.0182)

(0.0079/0.0119)

(0.0161/0.0202)

3.5.3 Sleeve bearing clearance (WDXE/S)

Pump size

1.5 WDX

2WDX

3WDX

4WDX

Diametral clearance

min/max

mm(inch)

0.007 - 0.041

(0.0003- 0.0016)

0.007 - 0.041

(0.0003- 0.0016)

0.007 - 0.041

(0.0003- 0.0016)

0.007 - 0.041

(0.0003- 0.0016)

3.5.4 Bearing bushings

Interstage bearing bushings can bemounted on the pump. Their numberand location depend on the

material chosen and the number of stagesof the pump. For furtherinformation, see general

arrangement drawing ofthepump.

Nominal

Balancedrum

clearance

min/max

mm(inch)

0.150/0.226

(0.0059/0.0089)

0.300/0.376

(0.0118/0.0148)

0.170/0.259

(0.0067/0.0102)

0.470/0.559

(0.0185/0.0220)

0.170/0.259

(0.0067/0.0102)

0.480/0.569

(0.0189/0.0224)

0.180/0.269

(0.0071/0.0106)

0.500/0.603

(0.0197/0.0237)

Page 14 of 46

3.6 Coverage charts

3.3.1 2970 min-1(50 Hz): coverage charts (Q, H)

3.3.2 3550 min-1(60 Hz): coverage charts (Q, H)

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

4 INSTALLATION

Equipment operated in hazardous locations

must comply with the relevant explosion protection regulations. See section 1.6.4, Products usedin

potentially explosive atmospheres.

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 forlifting and should beasclose as practicable to the supplyof liquid to bepumped.

The pump should be located above the floodlevel. The pipework should be such that thereis an

adequate NPSH at the pump centreline.The foundation should provide enough support so that the

pump is not supported by the pipework. Refer to the general arrangementdrawing for the

pump set.

4.2 Cleaning prior to installation

Remove glue and dirt from suction and discharge flanges. Check motors to make sure no foreign

objects haveentered through fan and cooling openings. Remove any compounds on exposed

areasof pump shaft. Cleanpump and motor nameplate.

A unit mounted on steel workor structural members should bemounted over oradjacent to girdersor

wallsso that no misalignment will occur from yielding or sagging of the structure.

Anchor boltsmust be in accordance with the foot bolt holes. Use anchor bolts of accepted standards and

sufficient to ensure seave fitting in the foundation. Particularly, thisapplies to individual plateswhere the

anchor boltshave to withstand the driving torque. Provide sufficient space in the foundation to

accommodate the anchorbolts. Ifnecessary, provide concrete risers.

4.3.2 Positioning on foundation

Pumpsare generallyshipped mounted, andit is usuallyunnecessary with unitsof moderate size to

remove the pump or driver from its baseplate when levelling.

Ensure the following are met: a) Clean the foundation thoroughly.

b) The baseplate should be mounted onto a firm

foundation, either an appropriate thicknessof quality concrete or sturdy steel framework

capable of absorbing all normal vibrations. (It should NOT be distorted or pulled down onto the

surface of the foundation, butshould be supported to maintain the original alignment).

c) Install the baseplate onto packing pieces evenly

spaced and adjacent to foundation bolts.

4.3 Foundation

Therearemanymethodsof installing

pump units to their foundations. The correct method dependson the size of the pump unit, itslocation and

noise vibrationlimitations. Non-compliance with the provision of correct foundation and installationmay

lead to failure of the pump and, assuch, would be outside the terms of the warranty.

4.3.1 General recommendations

Foundation bolts should belocated or embedded in the concrete by lay-out ortemplate in relation to the

suction and discharge piping. Foundation bolts of the specified size maybe enclosed in a pipe sleeve two

or three diameterslarger than the boltsto compensate forminor variationin alignment.

Standard accessory steel baseplates furnished with these pumps and motors10 HP (7.5 kW) and under

may be bolted to machine or equipment structures, either rigidly or,if flexible piping is used, with properly

designed vibration isolators.

d) Level with shims, about 25 mm (1”), between

baseplate and packing pieces.

e) Checkthe horizontal position by meansof a

precision level placed upon an adequate reference (discharge flange, machined surfaces

of casings etc...).Tolerances within 0.5 mm per m (0.006in per ft).

f) The pumpanddriver havebeenaligned before

dispatchhowever thealignmentofpump and motor half couplingmustbe checked. Ifthisisincorrect,it

indicates that the baseplate hasbecome twisted and should be corrected by re-shimming.

Page 16 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

barriers

g) If anchorboltshave been embeddedin the

foundation, slightly tighten the anchor bolts. Otherwise let them hang in the foundation holes.

h) If not supplied, guarding shall be fitted as necessary

to meet the requirementsofEN292and EN953 and orany applicable local safety regulations.

4.4 Grouting

Where applicable, groutin the foundation bolts. Grouting provides solid contact between the pump

unit and foundation prevents lateral movement of running equipment and dampens resonant vibrations.

Prepare the site forgrouting.Beforegrouting clean the foundation surface thoroughly. Provide external

barriers asshown:

4.5.1 Thermal expansion

The pump and motor will normally have to be aligned at ambient temperatureand should be corrected to allow for thermal expansion at

operating temperature. In pump installationsinvolving high liquid temperatures, the unit should be run atthe

actual operating temperature, shut down and the alignment checked immediately.

4.5.2 Alignment methods

Ensure pump and driver areisolated electrically and the half couplings are disconnected. Ensure that the pump pipework, suction and

discharge,is disconnected.

The alignment MUST be checked.

Although the pump will havebeen aligned at the factoryit is most likely that this alignment will have

been disturbed during transportation or handling. If necessary, align themotor to the pump, not the pump

to the motor.

Prepare grouting product (concrete, resin) in accordance withmanufacturers' instructions.

(Use anti-shrink products) To grout up to the required level. Polish surfaces.

Take necessary precautions to avoid air bubbles. Lay-down the barrier, break external angles and

polish the different surfaces. Foundation bolts should only be fully tightened when

the grout hascured.

4.5 Initial alignment

Pump-Driver unit supplied assembled on their baseplate:

Themachines have originally been aligned in the work-shop.

Pump and Driver supplied on separate baseplates:

Themachines have originally been mounted on their respective baseplate in the workshop. The pumpis to

be installed first and should be considered as the fixedpoint.The alignment is then performedon the

driveralone. Before aligning verify that the pump is horizontal by

using a flange surface or otherhorizontal surface. Adjust if necessary by adjusting the height of the

wobble foot. Tighten any nuts that have been loosened.

Alignmentisachieved by adding or removing shims under themotor feet and also moving the motor

horizontally as required. In some cases where the alignment cannot be achieved it will be necessary to

move the pump before recommencing the above procedure.

Before connecting the couplings verify

the motor rotation direction.

For couplings with narrow flangesuse a dial indicator as shown below to check both parallel and angular

alignment.

Page 17 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

Parallel

Angular

Maximum permissible misalignment at working temperature:

Parallel 0.2 mm (0.008 in.)TIR Angular 0.1 mm (0.004 in.) TIR

When checking parallel alignment, the total indicator read-out (TIR) shown is twice the value of the actual

shaft displacement. Alignin thevertical plane first, then horizontally by

movingmotor.When performing final alignment,check for soft-foot under the driver. A TIR indicatorplacedon

the coupling, readingin the vertical direction, should not indicate more than 0.05mm (0.002 in.)movement when

anydriverfoot fastenerisloosened. Whilethe pumpiscapable of operating with the

maximum misalignment shownabove, maximum pump reliabilityis obtained by nearperfect alignment of 0.05

to 0.10 mm (0.002 to0.004in.)TIRparallel and

0.05mm (0.002in.)per100mm (4in.) of coupling flange diameter asTIR angular misalignment.This

coversthefull series of couplings available. Pumpswith thick flanged non-spacer couplings can

be alignedby using a straight-edge across the outsidediametersof the coupling hubsand

measuring the gap between the machined faces using feeler gauges, measuring wedge or calipers.

When the electric motor has sleeve bearings it is necessary to ensure that themotor isaligned to run

on its magnetic centreline.

 Refer to themotor manual for details.

A button (screwed into one of the shaft ends)is normally fitted between the motorand pump shaft

ends to fix the axial position.

If the motor does not run in its

magneticcentre the resultantadditional axial force may overload the pump thrust bearing.

Complete piping asbelow and see sections4.7,

Final shaft alignment check up to and including section 5, Commissioning, startup, operation and

shutdown before connecting driver and checking actual rotation.

4.6 Piping

The user must verify that the equipment is

isolated from any external sources of vibration.

Protective coversare fitted to the pipe connectionsto prevent foreign bodies entering during transportation andinstallation. Ensure that these

coversare removed from the pump before connecting anypipes.

4.6.1 Suction and discharge pipework

In order to minimize friction losses and hydraulic noise in the pipeworkit is good practice to choose

pipeworkthatisone or two sizes larger than the pump suction and discharge.Typicallymain pipework

velocitiesshould not exceed 2 m/s (6 ft/sec) suction and 3 m/s (9 ft/sec) on the discharge.

Takeinto account the available NPSH must be higher than the required NPSH of the pump. When

determining the NPSH available the vapour pressure at the operating temperature must be taken into

account.

Never use the pump as a support for piping.

Maximum forces and moments allowed on the pump flangesvary with the pump size and type.To

minimize these forcesandmoments thatmay,if excessive, cause misalignment, hot bearings, worn

couplings, vibration and the possible failure of the pump casing, the following points should be strictly

followed:

 Prevent excessive external pipe load  Never drawpiping into place by applying forceto

pump flange connections.

 Do not mount expansionjoints so that their force,

due to internal pressure, acts on the pump flange. It isrecommended that expansion jointsuse

threaded rod to limit any forcesof thistype.

 Thermal expansions must be compensatedin

such a way that no additional forces act on the pump flanges.

 Make sure that piping flanges are square and

concentric to the pump flanges.

Page 18 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

The table in 4.6.3 summarizes the maximum forces and moments allowed on WDX pump casings. Refer

to Flowserve forother configurations.

Ensure piping and fittings are flushed

before use.

Ensure piping for hazardous liquids is arranged

to allow pump flushing before removal ofthe pump.

Excessive external strains(forces, moments)

may causemisalignment, general vibrations, hot bearingsor excessive wear on couplingsand seals.

In extreme cases, leakage may result with potential lossof life with hot or corrosive liquids.

4.6.2 Suction piping

Refer to the diagrams below for typical designs of suction piping for both flooded suction and suction lift.

a) Theinlet pipe should be one or two sizes larger

than the pump inlet boreand pipe bends should be as large a radius aspossible.

b) Pipeworkreducers should be conical and have a

maximum total angle of divergenceof 15 degrees.

c) Pipeworkshould be arranged to avoidair pockets. d) If high pointscannot beavoided on the suctionline

equip them with air relief cocks.

e) On suction lift the piping should be inclined up

towardsthe pumpinlet with eccentric reducers incorporated to prevent air locks.

f) On positive suction, the inlet piping must have a

constant fall towards the pump.

g) Flow should enterthe pump suction with uniform

flow, to minimize noise and wear. Thisis particularly important on large or high-speed

pumpswhich should have a minimum of five diameters of straight pipe on the pump suction

between the elbow and inlet flange. See section

10.3, Reference 1, for more detail.

h) Inlet strainers, when used, should have a net `free

area' of at least three times the inlet pipe area.

i) Do notinstall elbowsat an angle other than

perpendicular to the shaft axis. Elbowsparallel to the shaft axis will cause uneven flow.

j) Except in unusual circumstancesstrainersare

not recommended in inlet piping. If considerable foreign matter is expected a screen installed at

the entrance to the wet well is preferable.

k) Fitting anisolation valve will allow easier

maintenance.

l) If an inlet valve is necessary, choose a model

with full bore so as to limitlosses. Valve stem should bein a vertical position. There should be

a minimum of five pipe diametersbetween the pump and the valve.

m) Never throttle pump on suction side and never

place a valve directly on the pump inlet nozzle.

n) Do not tighten flanges before the final check.

Typical design –flooded suction

Note:

Ideallyreducers should be limited toone pipediameter change, ie 150 mm (6 in.) to 200 mm (8 in.). Must have a maximumtotal angleof divergence of15 degrees.

Typical design –suction lift

Notes:

1. S = Minimum submergence >3E.

2. Ideallyreducers to be limitedto one pipediameter change,

ie 150 mm (6 in.) to 200 mm (8 in.). Must have a maximumtotal angleof divergence of 15 degrees.

Page 19 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

4.6.3Maximum forces and momentsallowed on WDX pump flanges

Direction of forces Fx = horizontal parallel to pump axis

Fy = horizontal perpendicular to pump axis Fz = vertical perpendicular to pump axis

Direction of moments Mx = around a horizontal axis parallel to pump axis

My = around a horizontal axis nozzle axis Mz = around a horizontal axis perpendicular to pump axis

PIPE

CONFIGURATION

Vertical pipework 50 mm

perpendicular 3in

totheshaft 80 mm

Horizontal pipework 3 in

perpendicular 80 mm

totheshaft 4 in

Horizontal 4in within the pump axis 100 mm

FLANGE FORCES MOMENTS

Diameter Fy Fz Fx F My Mz Mx M

1.5 in

40 mm

2in

4in

100 mm

6in

150 mm

1.5 in

40 mm

2in

50 mm

100 mm

6in

150 mm

3in

80 mm

6in

150 mm

130 lbf 200 lbf 160 lbf 290 lbf 170 ft-lbf 260 ft-lbf 340 ft-lbf 460 ft-lbf 58 daN 89 daN 71 daN 128 daN 23 daN.m 35 daN.m 46 daN.m 62 daN.m 130 lbf 200 lbf 160 lbf 290 lbf 170 ft-lbf 260 ft-lbf 340 ft-lbf 460 ft-lbf 58 daN 89 daN 71 daN 128 daN 23 daN.m 35 daN.m 46 daN.m 62 daN.m 200 lbf 300 lbf 240 lbf 430 lbf 350 ft-lbf 530 ft-lbf 700 ft-lbf 950 ft-lbf 89 daN 133 daN 107 daN 193 daN 47 daN.m 72 daN.m 95 daN.m 128 daN.m 260 lbf 400 lbf 320 lbf 570 lbf 500 ft-lbf 740 ft-lbf 980 ft-lbf 1330ft-lbf 116 daN 178 daN 142 daN 256 daN 68 daN.m 100 daN.m 133 daN.m 180 daN.m 460 lbf 700 lbf 560 lbf 1010 lbf 870 ft-lbf 1300 ft-lbf 1700ft-lbf 2310ft-lbf 205 daN 311 daN 249 daN 448 daN 118 daN.m 176 daN 230 daN.m 313 daN.m 130 lbf 200 lbf 160 lbf 290 lbf 170 ft-lbf 260 ft-lbf 340 ft-lbf 460 ft-lbf 58 daN 89 daN 71 daN 128 daN 23 daN.m 35 daN.m 46 daN.m 62 daN.m 130 lbf 200 lbf 160 lbf 290 lbf 170 ft-lbf 260 ft-lbf 340 ft-lbf 460 ft-lbf 58 daN 89 daN 71 daN 128 daN 23 daN.m 35 daN.m 46 daN.m 62 daN.m 200 lbf 300 lbf 240 lbf 430 lbf 350 ft-lbf 530 ft-lbf 700 ft-lbf 950 ft-lbf 89 daN 133 daN 107 daN 193 daN 47 daN.m 72 daN.m 95 daN.m 128 daN.m 260 lbf 400 lbf 320 lbf 570 lbf 500 ft-lbf 740 ft-lbf 980 ft-lbf 1330ft-lbf 116 daN 178 daN 142 daN 256 daN 68 daN.m 100 daN.m 133 daN.m 180 daN.m

460 lbf 700 lbf 560 lbf 1010lbf 870 ft-lbf 1300 ft-lbf 1700 ft-lbf 2310 ft-lbf 205 daN 311 daN 249 daN 448 daN 118 daN.m 176 daN 230 daN.m 313 daN.m 240 lbf 200 lbf 300 lbf 430 lbf 350 ft-lbf 530 ft-lbf 700 ft-lbf 950 ft-lbf 107 daN 89 daN 133 daN 193 daN 47 daN.m 72 daN.m 95 daN.m 128 daN.m 320 lbf 260 lbf 400 lbf 570 lbf 500 ft-lbf 740 ft-lbf 980 ft-lbf 1330ft-lbf 142 daN 116 daN 178 daN 256 daN 68 daN.m 100 daN.m 133 daN.m 180 daN.m 560 lbf 460 lbf 700 lbf 1010lbf 870 ft-lbf 1300 ft-lbf 1700 ft-lbf 2310 ft-lbf 249 daN 205 daN 311 daN 448 daN 118 daN.m 176 daN.m 230 daN.m 313 daN.m

Notes:

1) F = External force (tension or compression). M = External moment, clockwise or counter-clockwise.

2) Forces and moments may be appliedsimultaneously inany direction.

3) Values apply to all materials.

4) Higher loads maybe applicable, if direction and magnitude of individual loads are known, but these need written approval fromFlowserve PumpDivision.

5) Pumps must be onrigidfoundations andbaseplates must be fullygrouted.

6) Pump/baseplate should not be used as pipe anchor. Suction and dischargepiping should beanchored asclose as possible

tothe pump flanges toreduce vibration and prevent strainon the pump casing. Expansion joints are recommended. They must be properlytied andlocated on thesideof the pipe anchor awayfromthe pump

7) The pump mounting bolt torquesspecifiedmust be usedto prevent relative movement betweenthe pump casing and

baseplate.(Seesection 6.6, Fastener torques.). The bolt materialmust havea minimum yieldstrength of 600N/mm

(87000lb/in.2).

Page 20 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

4.6.4 Discharge piping

See section 4.6.2 for typical pipeworkdesign. A non-return valve should belocated in the discharge

pipeworkto protect the pump from excessive back pressure and hence reverse rotation when the unit is

stopped. Pipeworkreducers should have a maximum total

angle of divergence of 9 degrees. Fitting anisolation valve will alloweasiermaintenance.

It should be installed downstream of thenon-return valve.

If needed a control pressure gaugemay be installed on the pipework.

Do not tighten the pipe flanges before the final check.

4.6.5 Auxiliary piping

4.6.5.1 Drains

Pipe pump casing drains and glandleakage to a convenient disposal point.

4.6.5.2 Pumps fitted with mechanical seals

Single seals requiring re-circulation will normally be provided with the auxiliarypiping from pump casing

already fitted. If the seal requires an auxiliary quench then a

connectionmust be made to a suitable source of liquid flow,lowpressure steam or static pressure from

a header tank. Recommended pressure is0.35 bar (5 psi) or less. Check General arrangement drawing.

Special seals may requiredifferent auxiliary piping to that described above. Consult separate User

Instructionsand or Flowserve if unsure of correct method orarrangement.

For pumping hot liquids, to avoid seal damage,it is recommended that any external flush/cooling supply

be continued after stopping the pump.

4.6.6 Final checks

Check the tightnessof all bolts in the suction and discharge pipework. Tightenif necessary. Check also

the tightnessof all foundation bolts. Tighten if necessary. Checkthe tightness of all auxiliary piping.

Tightenif necessary.

4.7 Final shaft alignment check

After connecting piping to the pump, rotate the shaft several times by hand to ensure there is no binding

and all partsare free.

Recheck the coupling alignment, aspreviously described, to ensure no pipe strain. If pipe strain

exists, correct piping. Alignment can only be considered definitive after

pipeworkhas been connected.

4.8 Electrical connections

4.8.1 Safety conditions about electrical

connections

Electrical connectionsmust be made

by a qualified Electrician in accordance with relevant local national and international regulations.This

includes any grounding.

It is important to be aware of the EUROPEAN DIRECTIVE on potentially explosive areaswhere compliance with IEC60079-14 is an additional

requirement for making electrical connections.

Avoid mechanical, hydraulic or electrical

overload byusing motor overload tripsor a power monitor and make routine vibration monitoring.

Itis important tobe aware of the EUROPEAN DIRECTIVEon electromagneticcompatibility when wiringup andinstalling equipment on site.Attention

must be paid toensure that the techniquesused during wiring/installationdonotincrease electromagnetic

emissionsor decrease the electromagneticimmunityof theequipment, wiring oranyconnected devices. Ifin

anydoubt, contact Flowserve foradvice.

The motormust be wired upin accordance with the motor manufacturer's instructions(normally supplied within the terminal

box)including anytemperature, earth leakage, current and otherprotective devices asappropriate.

Theidentification nameplate should be checked to ensure the power supply is appropriate.

A device toprovide emergency stopping must

be fitted. If not supplied pre-wired to the pump unit, the

controller/starterelectrical detailswill also be supplied within the controller/starter.

For electrical detailson pump sets with controllers see the separate wiring diagram.

See section 5.3, Direction of rotation

before connecting the motor to the electrical supply.

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4.9 Protectionsystems

The following protection systemsare

recommended particularly if the pump is installed in a potentially explosive area or is handling a hazardous

liquid. Ifin doubt consult Flowserve. If there is any possibilityof the system allowing the

pump to run against a closed valve or below minimum continuoussafe flowa protection device

should beinstalled to ensure the temperatureof the liquid does not rise to an unsafe level.

If there are any circumstancesin which the system can allow the pump to run dry, or start up empty, a

powermonitor should be fitted to stop the pump or preventit from being started.This is particularly

relevant if the pump ishandling a flammable liquid. If leakage of product from the pump or its associated

sealing system can cause a hazard it is recommended that an appropriate leakage detection

system isinstalled. To prevent excessive surface temperatures at

bearingsit is recommended that temperature or vibration monitoring are carried out. See sections

5.7.4 and 5.7.5. If a defect of cooling can lead to temperature higher

than those acceptable a system of cooling surveillance must be installed.

In the case of product lubricated

bearingsthe sourceof product supply should be checked against the order.There maybe

requirementsfor an external clean supply, particular supply pressure or the commencement of lubrication

supply before pump start-up.

5.1.2 Oil Lubrication

The bearingsare lubricated by pins. A constant level oiler automatically maintainsthe correct oil level.

The oiler suppliesthe necessary quantity of oil. It operates on theliquid seal principal and feedswith oil

only when the quantity of oil becomes toolow in the bearing. It will stop to feed once a sufficient quantity

of oil is in the bearing. The reserve contained in the reservoir refills

automatically the natural losses of the bearing. As soon as the oil level approaches the minimum level of

the reservoir, refill the reservoir. Regarding the qualityand the quantity of the oil to be

used, refer to the lubrication table and information below.

Foroil lubricated pumps,fill the bearing

housing with correctgrade of oil to thecorrectlevel,ie sightglassor constant level oilerbottle.

Except when explicitly required bythe customerin the specifications, when a possibility of reverse

rotation existsthe customermust 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 be carried out by

fully qualified personnel.

5.1 Pre-commissioning procedure

5.1.1 Lubrication

Determine the mode of lubrication of the pump set, eg grease, oil, product lubrication etc.

Grease lubricated pumpsand electric motors are supplied pre-greased.

Otherdriversand gearboxes, if appropriate, should be lubricatedin accordance with their manuals.

See below for the correct side on which constant level oilersshould be installed.

Oiler

Direction of rotation of

thepump

Driveendside

Oiler

When fitted with a constant level oiler, the bearing housing should be filled onlybyunscrewing or

hinging backthe transparent bottle and filling the bottle with oil.Do notfill the bearing housing through

the breather hole.

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Oil levels are as indicated below. The distance indicated is distance below the shaft centreline.

The oil filled bottle should then be refitted so as to

returnit to the upright position. Filling should be

repeated until oil remainsvisible within the bottle.

Pump size

Oil Level mm (inch)

Drive end Non Drive end

1.5 WDX 41 (1.61) 41 (1.61) 2 WDX 46 (1.81) 46 (1.81) 3 WDX 56 (2.20) 46 (1.81) 4 WDX 66 (2.60) 46 (1.81)

5.2 Pump lubricants

5.2.1 Recommended oil lubricants

Viscosity grade ISO 46 Ambient temperature

Bearings temperature 80 °C maximum

MANUFACTURER TYPE

CHARACTERISTICS

ENERGOL

HLP 46

ELF

TURBELF

SA 46

Density at 15 C 0.885 0.881 0.868 0.878 0.87 0.872 0.877 Viscosity at 40 °C.cst 45 48.6 43 43 46 46 46

Viscosity at 50 °C.cst 30 31.5 29.4 28 30 29.5 30 Viscosity at 100 °C.cst 6.9 7.1 6.7 7 6.9 6.9 6.8 Pour-point °C - 30 - 27 - 12 - 15 - 30 - 12 - 21 Flash-point °C 210 220 220 220 214 230 230

Fire-point °C 240 252 280 240 245 Aniline point °C 99 102 110 102 109 101 101 Viscosityindex 105 106 109 105 113 100 100 Acid value 0.2 0.6 0.2 0.13 0.7 0.1 0.7 to 1.2

Colour 1 ½ 2 1 2 2 1 ½ 1

TABLE OF EQUIVALENCEAND CHARACTERISTICS

OF RECOMMENDED OILS

ESSO

TERESSO

MOBIL

DTE

Medium

SHELL

TELLUS

T 37

TOTAL

PRESLIA

TOTAL

AZOLLA

ZS 46

Anti erosion additives yes yes yes yes yes Foaminhibitors yes yes yes yes yes yes yes

Anticorrosion additives yes yes yes yes yes yes yes Antioxidant yes yes yes yes yes yes yes Conradson carbon residue 0.01 0.2

Limits on temperature °C - 12

120 °C

110 °C

Saponification < 0.5 1.2

5.2.2 Recommended grease lubricants

Factory greasing : SHELL ALVANIAR2 or equivalent

Equivalent greases : MOBIL, Mobilux EP2

TOTAL, Multis 2 ELF, Elf Multi

Grease Quantity : 10 to 30 Grams

5.2.3 Recommended fill quantities

Oil Quantity

ISOVG 46Pump size

Driveend NonDrive end

1.5 WDX 0.26qt (0.250 Ltr) 2WDX 0.37qt (0.350 Ltr)

3WDX 4WDX

0.42qt (0.400 Ltr) 0.25qt (0.240 Ltr)

0.63qt (0.600 Ltr) 0.32qt (0.300 Ltr)

0.21qt (0.200 Ltr)

0.25qt (0.240 Ltr)

Page 23 of 46

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5.2.4 Lubrication schedule

5.2.4.1 Oil lubricated bearings

Operating conditions and severity ofservice will determine the intervals between oil changes. In

general higheroil temperatures will require more frequent oil changes.

For pumps on hotservice orin severely damp or corrosive atmosphere, theoil will requirechanging

more frequently. If the bearings maintain a stable temperature andif there has been no contamination

of the oil,the interval between changes maybe longer.

Lubricantand bearing temperature analysis can be useful in optimising lubricant changeintervals.

Generally, the oil should be changed every 6 months. If the bearing temperature increases, check

immediately for improperlubrication or a faulty bearing.

The lubricatingoil shouldbe a high qualitymineral oil having foam inhibitors. Syntheticoils mayalso be used

if checks show that the rubberoil seals will notbe adversely affected.

The bearing temperature may be allowed to rise to 50 ºC (122 ºF).above ambient, but should not exceed 82

ºC (180 ºF).A continuously rising temperature or an abrupt rise, indicate a fault.

5.2.4.2 Grease lubricated bearings

The bearingsare prelubricated when supplied. Lubrication frequencyis asindicated in the table

below. After a 2 yearsperiod the bearing should be completely cleaned, checked and repacked with new

grease. The free bearing space shouldnot be filled up more

that 50 % to 60 % of its content see 5.2.3. Care must be taken to avoid both under and over-lubrication.

Over lubrication will cause the bearings to run hotter than normal, while under-lubricated bearingscould

wear prematurely. The characteristics of theinstallation and severityof

service will determine the frequencyof lubrication. Lubricantand bearing temperature analysis can be

useful in optimising lubricant changeintervals.

Pump size

1,5 WDX 3000 2200 1500 1200

2WDX 3000 2200 1500 1200 3WDX 2700 2000 1400 1100 4WDX 2500 1700 1300 1000

Lubrication frequencies in hours of operation

1450 RPM 1750 RPM 2950 RPM 3550RPM

Never mix greasescontaining different

bases, thickenersor additives.

5.3 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 ispreferable to check the direction of rotation before installing the coupling. If not, the pump must

be filledin with theliquid beforestart-up.

If maintenance work has been carried out to the site's electricity supply, the direction of rotation should be re-checked asabove in case the

supply phasing has been altered.

5.4 Guarding

Guarding is supplied fitted to the pump set. If this has been removed or disturbedensure that all the protective guardsaround the pump coupling and

exposed parts of the shaft are securely fixed.

5.5 Primingand auxiliary supplies

Where there is any riskof the pump being run against a closed valve generating highliquid and casing external surface temperatures it is

recommended that usersfit anexternal surface temperature protection device.

Ensure all electrical, hydraulic,

pneumatic, sealant andlubrication systems(as applicable) areconnected and operational.

Ensure theinlet pipe and pump casing

are completely full of liquid before starting continuous duty operation.

These operationsmust be carried out by personnel with approved qualifications.

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WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

5.5.1 Suction pressure above atmospheric pressure

Open the air vent connection to allow the trapped air to escape. Let liquid run out until free from air

bubbles.

5.5.2 Suction liftwith footvalve fitted

Fill suction pipe and casing with liquid at a pressure of 1 to 2 bar from an external source. Vent as

describedin section 5.5.1.

h) Ensure all vent connectionsare closed

before starting.

i) Start motorand check outlet pressure. j) If the pressure is satisfactory, slowly OPEN outlet

control valve.

k) Do not run the pump with the

outlet valve closed for a period longer than 20 seconds.

l) If NO pressure, or LOWpressure, STOP the

pump. Refer to section 7, Faults; causesand remedies, for fault diagnosis.

5.7 Running the pump

5.7.1 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

hasbeen fullyprimed and vented, it should be unnecessary to re-ventthe pump.

5.7.2 Pumps fittedwith packed gland

Foot valves are not recommended when

the pumped liquid has suspended solid particles. Theymay lodge between foot valve seat and shutter.

5.5.3 Suction liftwithout foot valve

Pump casing vents on the suction volute must be connected to an external vacuum pump priming

system. If in doubt, please consult Flowserve.

5.6 Startingthe pump

a) Ensure flushing and/or cooling/

heating liquid supplies are turned ON before starting the pump.

b) CLOSE the outlet valve. If the pump isequipped

with a non-return flow valve andis to be started with an opened discharge valve, verify that it is

closed by an adequate back pressure.

c) OPEN all inlet valves. d) Open all valves of theminimal flowline to ensure

a minimal flow for the period the pump isrunning against the closed discharge valve.

e) Prime the pump. f) Check that all plugs are tight.

g) Checkthat the gland lightly tightens the packing.

If the pump has a packed gland theremust be some leakage from the gland. Gland nutsshould initially be

finger-tight only. Leakage should take place soon afterthe stuffing boxis pressurized.

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WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

The gland must be adjusted evenly to give

visible leakage and concentric alignment of the gland ring [4120] to avoid excesstemperature. If no

leakage takes place the packing will begin to overheat. If overheating takesplace the pump should

be stopped and allowed to cool beforebeing restarted. When the pump isre-started, check to

ensure leakage is taking place at thepacked gland. If hotliquids are being pumped it may be necessary

to slacken the gland nuts to achieve leakage. The pump should be run forten minuteswith steady

leakage and the gland nuts tightened by 10 degrees at a time until leakage isreduced to an acceptable

level.The temperature of the gland should be checked aftereach round of tightening.If the

temperature startsto climb rapidly then back off the gland nuts until the temperature drops down. Wait for

the temperature to stabilize beforetightening again. Theleakage must not be reduced belowa rate of 20

dropsperminute. Bedding in ofthe packing may take several hours.

Care must be taken when adjusting the gland on an operating pump. Safety gloves are essential. Loose clothing must not be worn to avoid being

caughtup by the pump shaft.Shaft guards must be replaced after the gland adjustmentis complete.

If bearing temperaturesare to be monitored it is essential that a benchmarktemperature isrecorded

at the commissioning stage and after thebearing 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) foroil lubrication and 105 C (220 F) for grease lubrication

It isimportant, particularly with grease lubrication, to keep a checkon bearing temperatures. After start up

the temperature rise should be gradual, reaching a maximum afterapproximately1.5 to 2 hours. This

temperature rise should then remain constant or marginallyreduce with time. (Refer to section 6.2.3.1

for furtherinformation.)

5.7.5 Normalvibration 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

pumpsshould be based on the actual measurements (N) taken on site on the bearing housingsof the

pump in the fully commissioned as new condition.

Never run gland packing dry,even for

a short time.

5.7.3 Pumps fittedwith mechanical seal

Mechanical sealsrequire no adjustment. Any slight initial leakage will stop when the seal isrun in.

Before pumping dirty liquids it isadvisable, if possible, to run in the pump mechanical seal using

clean liquid to safeguard the seal face.

External flush orquench should be

started before the pump is run and allowed to flow for a period after the pump has stopped.

Never run a mechanical seal dry,even

for a short time.

5.7.4 Bearings

If the pumps are working in a potentially

explosive atmosphere, temperature or vibration monitoring at the bearingsis recommended.

The example (N) valueisgiven for the preferred operating flow region (typically this mayextend to 70

to 120 % of the pump best efficiency point); outside the preferred flow region theactual vibration

experienced may be multipliedby up to 2. These standard valuescan 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 intervalswill then show anydeteriorationin pump or system operating

conditions.

Vibration Velocity - unfiltered

Normal N 5.6 (0.22) Alarm N x 1.25 7.1(0.28) ShutdownTrip N x 2.0 11.2( 0.44)

Horizontal Configuration

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

5.7.6 Stop/start frequency

Pump setsare normally suitable for the numberof equally spaced stop/startsper hour shown in the

table below. Checkactual capability of the driverand control/starting system before commissioning.

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WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

Motor rating kW (hp)

Up to 15 (20) 15

Between 15( 20) and 90 (120) 10

90(120)to150( 200) 6

Above150( 200) Refer

Maximum stop/starts

perhour

Where dutyand standbypumps are installeditis recommended thattheyare run alternately every week.

5.8 Stopping and shutdown

a) Close the outlet valve, but ensure

that the pump runsin this condition for no more than a few seconds.

b) Stop the pump. c) Avoid having the unit turn in the opposite

direction of the normal running conditions

d) Protect the pump against water hammer. e) Make sure that the discharge line pressure does

not reach the foot valve.

f) Switch off flushing and/or cooling/heating liquid

supplies at a time appropriate to the process.

g) For prolonged shut-downs and

especially when ambient temperatures are likely to drop below freezing point, the pump and any

cooling and flushing arrangements must be drained orotherwise protected. When draining

the pump, first verify that theliquid temperature hascooled sufficientlyto allow safe maintenance.

5.9 Hydraulic, mechanical and electrical duty

This product has been supplied to meet the performance specifications of your purchase order,

however it isunderstood thatduring the life of the product these may change.The followingnotesmay

help the user decide how to evaluate the implications of any change. If in doubt contact your nearest

Flowserve office.

5.9.1 Specific gravity (SG)

Pump capacity and total headin meters(feet) do not change with SG, howeverpressure displayed on a

pressure gaugeis directly proportional to SG.Power absorbed is also directly proportional to SG. It is

thereforeimportant to checkthat any change in SG will not overload the pump driveror over-pressurize

the pump.

5.9.2 Viscosity

For a given flow rate the total head reduceswith increased viscosity and increaseswith reduced

viscosity.Also fora given flow rate the power absorbed increaseswith increased viscosity, and

reduces with reduced viscosity.

It isimportant that checks are made with yournearest Flowserve office if changesin viscosity are planned.

5.9.3 Pump speed

Changing pump speed effectsflow, total head, power absorbed, NPSHR, noise and vibration. Flow variesin

direct proportion to pump speed, head varies as speed ratio squared and power variesas speed ratio

cubed.The new duty, however, will also be dependent on the system curve. If increasing the

speed, it isimportant thereforeto ensure the maximum pump working pressure is not exceeded,

the driver is not overloaded, NPSHA> NPSHR, and that noise and vibration arewithin local requirements

and regulations.

5.9.4 Net positiv e suction head (NPSHA)

NPSH available (NPSHA)isthe head available at the impeller inlet, above the vapourpressure of the

pumpedliquid. NPSH required (NPSHR)isthe minimum head required

at theimpellerinlet,above thevapourpressure of the pumpedliquid,to avoid excessive cavitation and

extreme performance degradation. It isimportantthat NPSHA> NPSHR. The margin

between NPSHA> NPSHRshould beas large as possible.

If any change in NPSHAisproposed,ensure these margins are not significantly eroded. Referto the

pump performance curve to determine exact requirementsparticularlyif flow has changed. If in

doubtplease consult yournearest Flowserve office for advice and detailsof the minimum allowable

margin for your application.

5.9.5 Pumped flow

Flowmust not fall outside the minimum and maximum continuoussafe flow shown on the pump

performance curve and or data sheet.

5.10 Pumps for Food Use or Potable Water

If the pump has notbeen specifically ordered for a food or drinking water application it must not be used

for these typesof applications. If it hasbeen ordered for this type of application the following

recommendationsare to be followed.

5.10.1 Cleaning prior to operation

Pumpsthat are to be used for a food or drinking water application should be cleaned before being put

intoinitial operation and after the installationof spare partsthat are in contact with the liquid.

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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 fromareas around close clearances, bearing housingsand motors.

It is the plant operator'sresponsibility to ensure that all maintenance, inspectionand assembly work iscarried out byauthorized and qualified personnel

who have adequatelyfamiliarized themselveswith the subjectmatter by studying this manual in detail.

(See also section 1.6.2.) Any workon the machine must be performed when it

isat a standstill. Itisimperative that the procedure for shutting down themachine isfollowed, asdescribed

in section 5.8. On completion ofwork all guards and safetydevices

must be re-installed and made operative again. Before restarting the machine, the relevant

instructionslisted in section 5, Commissioning, start up, operation and shut down must be observed.

Oil and grease leaks may make the ground slippery. Machine maintenance must always

begin and finish by cleaning the ground and the exterior of the machine.

If platforms, stairsand guard railsare required for maintenance, they must be placed for easy accessto

areaswhere maintenance and inspection are to be carried out. The positioning ofthese accessories

must notlimit accessor hinder the lifting of the part to be serviced.

When air or compressed inert gasis used in the maintenance process, the operator and anyone in the

vicinity must be careful and have the appropriate protection.

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

Never use air or compressed inertgasto clean clothes.

Before working on the pump, take measures to prevent an uncontrolled start. Put a warning boardon

the starting device with the words: "Machine under repair: do not start".

With electric drive equipment, lockthe main switch open and withdraw any fuses. Put a warning board

on the fuse box ormain switch with the words:

"Machine under repair: do not connect".

Never clean equipment with inflammable solventsor carbon tetrachloride. Protectyourself against toxic

fumeswhen using cleaning agents.

6.2 Maintenance schedule

It is recommended that a maintenance plan and

schedule is adopted, in line with these User Instructions. It shouldinclude 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) Verifythe condition of the gaskets e) Gland packings must be adjusted correctly to

give visible leakage and concentric alignment of the gland follower to preventexcessive

temperature of the packing or follower. Mechanical sealsshould present no leakage.

f) Check for any leaksfrom gasketsand seals. The

correct functioning of the shaft seal must be checked regularly.

g) Checkbearinglubricantlevel, and if the hours

run show a lubricant changeisrequired.

h) Checkthat the duty condition is in the safe

operating range for the pump.

i) Check vibration, noiselevel and surface

temperature at the bearings to confirm satisfactory operation.

j) Check the tightnessof the connections. k) Checkdirtand dustisremoved from areasaround

close clearances, bearinghousingsandmotors.

l) Check coupling alignment and re-alignif necessary. m) Verify the correctoperation of the system.

The equipment used formaintenanceanddisassembly in an ATEX zone mustbein conformity with the

requirementszone.

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TEMPERATURE

Our specialist service personnel can help with preventative maintenance recordsand 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

recommendationsin this manual.

c) Contact Flowserve if the problem persists.

6.2.1 Routine inspection (daily/weekly)

The following checksshould be made

and the appropriate action taken to remedy any deviations:

a) Checkoperating behaviour. Ensure noise,

vibration and bearing temperaturesare normal.

b) Checkthat there areno abnormal fluid or

lubricant leaks(static and dynamicseals) and that any sealant systems (if fitted) are full and

operating normally.

c) Check that shaft seal leaksare within acceptable

limits.

d) Checkthe level and condition of oil lubricant.

On grease lubricated pumps, check running hourssince last recharge of grease or complete

grease change.

e) Checkany auxiliary supplies eg heating/cooling,

if fitted, are functioning correctly.

 Refer to themanuals of anyassociated

equipment for routine checks needed.

6.2.2 Periodic inspection (six monthly)

a) Check foundation bolts for

security of attachment and corrosion.

b) Checkpump running records for hourly usage to

determineif bearing lubricant requires changing.

c) The coupling should be checked for correct

alignment and worn driving elements.

6.2.3.1 Oil lubrication

Maintaining the correct oil level is very

important. If the pump is supplied with a constant level oiler the

oil level will be automaticallymaintained and aslong as oil isvisible in the glassbottle thereis no need to

refill. If however a sight glass has been fitted then regular checks should be made toensure the level is

maintained at the centre of the glasswindow. Refer to section 5.1.1 for methods of oil fill,section

5.2.1 for oil grade recommendations and 5.2.4 for the schedule and temperature limits.

6.2.3.2 Grease lubrication

See section 5.2.2 for grease

recommendations. Regrease –refer to section 5.2.4.2.

a) It isimportant not to under orovergrease the

bearingsas this will lead to over heating and premature failure. Grease lubricatedbearing

housings have grease nipples fitted in the bearing covers.

b) The used grease should be seen to evacuate

through the bottom of the bearing housing.

c) The maximum allowable operating temperatures

for anti friction bearings will vary from unit tounit, depending on ambient and fluid temperature. The

rise aboveambient should not normallyexceed 55 C (131 F)or a combinedmaximum of 95 C (204 F).

d) A continuously rising temperature oran abrupt

temperature rise indicates a problem. If these symptomsoccur, stop the pump immediately and

investigate the cause.

 Refer to themanuals of anyassociated

equipment for periodic checks needed.

Grease change - every2 yearsor sooner depending

6.2.3 Re-lubrication

Lubricantand bearing temperature analysis can be useful in optimising lubricant changeintervals. In

general however, the following is recommended.

Page 29 of 46

on the severityof the application. a) Remove the bearing housing from the pump

assembly.

b) Brushthe bearinghousing with hot kerosene (100

to 115 °C/212 to240 °F)orother non-toxic solvent.

TIME

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

c) Clean and flush out the housing with a light

mineral oil.

d) Do not use waste oil to clean the housing.

To clean the bearings:

a) Wipe off as much grease as possible with a clean

lint-free cloth.

b) Brush bearings with hot kerosene (80 to 90 °C/

175 to 195 °F) while gently spinning the outer bearing ring.

c) Spin each ball to ensure that it is clean.

To remove badly oxidized greasewhich refuses to come off:

Dry and reflush the bearing with clean light oil. It isimportant notto under or over grease the

bearingsas this will lead to over heating and premature failure. It isrecommended thatthe

bearingsbe filled with grease using a suitable spatula. In addition the housingsshould be no more

than half filled.

6.2.5 Gland packing

6.2.5.1 Pump fitted with a packed gland

A well run in and correctly adjusted packing gland requireslittle maintenance.

If, after some time, theleakage becomestoo great, the gland should be tightened againin order to return

these to a normal level.

If re-tightening is notpossible, new packing must be installed.

6.2.5.2 Gland packing inspectionand removal

a) Remove the shield guards b) Slide back the gland

c) Remove the packing ringswith an extractor designed for thispurpose (including the lantern ring if

it exists; note itsposition and itsdirection of rotation). d) Inspect the state of the sleeve surface; the

presence of many marked grooveswill indicate thatit must be replaced.

e) Carefully clean the different pieces of the packing gland.

6.2.5.3 Gland packing fitting

If the packingis supplied as cord the packing must be cut so that the external diameterislightly tightened

and thereis an initial gap between the sleeve and the packing ring.

For that purpose, wind the packing helicallyaround the shaft sleeve or a chuckof the same diameter.

(Take precautions to avoid damaging sleeve).

6.2.4Mechanical seals

The currentmaintenance is limited to seal control.It isnecessary to detect any small leakage which

announces the beginning of the deterioration of friction faces or secondary seal elements(rings,

bellows, synthetic membranes). It isadvisable to stop the pump as soon aspossible. Have an approved

Example of straight cut Example of bevel cut

seal vendor replace or repair the seal.

Ensure a tightening on the stuffing box

housing and not on the sleeve.

Page 30 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

If the packingis in rings: Follow the instructions:

Assemble of the packing in S. Staggerby about 90° between two rings.

Place the rings one ata time.

After setting the last packing ring, secure the packing with the gland and tighten the nut by hand.

After tightening, the shaft should turn by hand as easilyas before the setting of the packing.

6.2.5.4 Gland packing dimensions

Pump

size

1.5 2

3 4

D 45

(1.77)

Non-Drive End

(2.56)

(1.97)

Packing



(0.394)

6.2.6 Gland cooling

WDX Pumpsare designed with an optional stuffing box cooling.The purpose of this is to cool the

pumpedliquid before it reaches the packing. Such cooling is required if the liquid temperature is over

220° F (105°C).

Pump

size

1.5 2 3 4

D 45

(1.77)

(1.89)

(2.17)

(2.36)

6.3 Spare parts

6.3.1 Ordering of spares

Flowserve keeps records of all pumpsthat have been supplied. When ordering spares the following

information should be quoted:

1) Pump serial number.

2) Pump size.

DriveEnd

D 65

(2.56)

(2.68)

(2.95)

(3.15)

(1.97)

Packing



(0.394)

3) Part name –taken from assembly drawing.

4) Part number –taken from assembly drawing.

5) Number of partsrequired.

The pump size and serial number areshown 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-standardpart) will

invalidate the pump’s safety certification.

Page 31 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

6.3.2 Storage of spares

Spares should be stored in a clean dryarea away from vibration. Inspection and re-treatment of metallic

surfaces (if necessary) with preservativeis recommended at 6 monthlyintervals.

6.4 Recommended spares and consumable items

For startup purposes:

1 - complete set of gland packing 1 - complete set of mechanical seals

1 - set of gasketsand seals 1 - set of bearings

For 2 years operation:

1 - set of bearings(line and thrust) 1 - set of gasketsand seals

1 - set of bearing sleeves 1 - complete set of gland packing

1 - complete set of piston drum and sleeve

(optional: 2 - mechanical seals with sleeves

1 set of impeller wear rings)

For 4 years operation:

1 - set of bearings(line and thrust) 1 - set of gasketsand seals

1 - set of bearing sleeves 1 - complete set of gland packing

1 - complete set of mechanical seals and sleeves 1 - complete set of piston drum and sleeve

1 - complete set of wear rings(casing and impeller)

1 - complete set of impellers 1 - shaft

6.6 Fastener torques

6.6.1 Tie rods

Pump size

1.5 WDX 2WDX 3WDX

4WDX

Torque Nm (lbft)

305 (225) 430 (320) 650 (480)

905 (670)

6.6.2 Other fasteners

Torque Nm (lbft)

Bolt size

M6 M8

M10 M12

Steel fastener

N/A 17(12.5) 33(24.3)

58(42.8)

Stainless steel

fastener

2.5 (1.84) 6(4.43)

13(9.59) 22(16.2)

6.7 Renewal clearances

As weartakes placebetween theimpellerand casing ring the overall efficiency of thepump set will decrease.

To maintainoptimum efficiencyit isrecommended that rings are replaced andthe impeller renovated when the

diametral clearance detailed in section3.5.2has doubled.

For WDXE and WDXS it isrecommended to renovate or change line bearings when clearanceshave

doubled from those indicated in section 3.5.3.

6.8 Disassembly

Refer to section 1.6, Safety, and section 6.1

Maintenance,before dismantling the pump.

6.5 Tools required

A typical range of tools that will be required to maintain these pumpsislisted below.

Readily available in standard tool kits, and dependent on pump size:

 Open ended spanners(wrenches) to suit up to

M 33 screws/nuts

 Socket spanners(wrenches), up to M 33 screws  Allen keys, up to 10 mm (A/F)  Range of screwdrivers  Soft mallet

More specialized equipment:

 Bearing pullers  Bearinginduction heater  Dial test indicator

 C-spanner (wrench) - for removing shaft nut.

(If difficultiesin sourcing are encountered, consult Flowserve.)

Page 32 of 46

Before dismantling the pump for

overhaul,ensure genuine Flowserve replacement partsare available.

Refer to sectional drawingsforpartnumbersand identification.

When dismantling, for convenience at reassembly, lay out all parts in the order in which they are

removed. Protectall machined faces against metalto-metal contact and corrosion.

Disassembly is preferably carried out with the pump in a vertical position.

6.8.1 Initial procedure

1. If bearings are oil lubricated,drain housingsand remove oilers.

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

2. Disconnect external piping such as balancing drum bleed line, cooling connections or mechanical seal

pipework.

3. Disconnect the coupling halves. If oil-lubricated couplingsare used,drain the oil before unbolting.

4. Remove the coupling half from the pump shaft and take off the key.

6.8.2 Dismantling antifriction thrust bearing

For all WDX variants

6.8.2.1 Oil lubricated bearings

Remove the spacer sleeve [2460-02]. Remove the snap ring [6544-02].

Remove the spacer sleeve [2460-01]. The whole thrust bearing assembly can then be

removed from the shaft.

6.8.2.2 Grease lubricated bearings

Dismount the fan cover [8162] byloosening the screws.

Remove the fan [2450-03] by loosening screw [657001].

Unscrew the four bearing nuts [6572]. Remove the bearing cover [3211].

Straighten tab on bearinglockwasher [6541-01] and

Dismount the fan cover [8162] byloosening the screws.

Remove the fan [2450-03] by loosening screw [657001].

Unscrew the four bearing nuts [6572]. Remove the bearing cover [3211].

Straighten tab on bearinglockwasher [6541-01] and

unscrew bearinglocknut [3712]. Repeat the operation forthe second blockage.

Remove the spacer sleeve [2460-02]. Remove the snap ring [6544-02].

Remove the spacer sleeve [2460-01]. The whole thrust bearing assembly can then be

removed from the shaft.

unscrew bearinglocknut [3712]. Repeat the operation forthe second blockage.

Page 33 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

6.8.3 Dismantling radial bearing

6.8.3.1 Antifriction bearings (WDXR and WDXC)

Grease lubricated

6.8.3.2 Line bearings (WDXE)

Free the bearing byremoving screw [6570-02]. Remove the bearing bushing [3300] bymeans of a

disassembling screw M10. Remove the snap ring [6544-03] and slide off the

shaft sleeve [3400-01].

Oil lubricated

Remove the four cap screws of the bearing cover [6577-03].

Remove the bearing cover [3263]. Straighten tab on bearinglockwasher [6541-03] and

unscrew bearinglocknut [3712-03]. Remove the coupling spacer piece [2460-03].

Remove the eight cap screws of the bearinghousing [6577-04].

The wholeline bearing assembly can then be removed.

6.8.3.3 Line bearings (WDXS)

Unscrew the bearing cap screws [6577-04]. Remove the bushing cover [3260].

Remove the snap ring [6544-01] and slide off the shaft sleeve [3400-01].

Page 34 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

6.8.4 Dismantling shaft sealing

6.8.4.1 Packing

The gland packing replacement does not require further dismounting operations.

Remove the gland nuts [6581]. Remove the flange [4120].

Pull the gland [4131] asfaras possible away from the stuffing box.

Pull out the packing [4130]one after the other taking care to avoidmarking the sleeve.

Check the surface quality of the sleeve for any running marksmade by the packing (for sleeve

changing, thrust and line bearing assembliesmust be dismounted, see sections 6.8.2 and 6.8.3).

6.8.4.1 Mechanical seal

The replacement of a mechanical seal requires the dismantling of thrust and line bearing assembly. The

dismantling procedure of the mechanical seal is self explanatory when viewing the respective seal

drawing.

6.8.5 Dismantling of balancing drum and ring

6.8.5.1 Variants WDXR/E/S

Dismantle the thrust bearing assembly see section

6.8.2. Provide independent supportunder the discharge

casing. Remove the eight cap screws [6570-06] of the

bearing support [3140]. Remove the bearing support and the sealing housing

with all seal components. Remove the drum screws [6570-05] and the drum

ring [6234]. Remove the split ring [2510].

Pull out the drum bymeans of threaded holesin the drum:

M8 (4 WDX and 3 WDX) M6 (2 WDX and 1.5 WDX)

Remove the bushing cap screws [6570-07]. Pull out the bushing by meansof threaded holes in

the bush [1600].

Page 35 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

6.8.5.2 Variant WDXC

Dismount the line bearing assembly; see section

6.8.3. Remove the seal component.

Remove the drum screws [6570-06] and the drum ring [2500].

Remove the split ring [2510]. Pull out the drum bymeans of threaded holesin the

drum. Remove the bushing cap screws [6570-05].

Pull out the bushing [1600] by meansof threaded holes in the bush.

6.8.6 Disassembly of pump casings

Afterhaving dismounted bearings and shaft seals, unscrew the fourtie rod nuts. The rest of dismounting

isself explanatory when viewing the respective sectional drawing.

For WDX pumps of construction M4 M5 M6 M7 (steel or stainlesssteel), anintermediate bushing is

assembled at the middle of the pump. Take note of its position and on reassembly, assemble it in the same

place.

6.9 Inspection of components

With pump dismantled, clean all parts and check for worn anddamaged areas. Clean and inspectgasket

and O-ringsseals. Check wearing ring,interstage seal and balancing drum surfaces. Casing and

impeller wearing ring and interstage seal surfaces may be either be part of the individual casing diffuser

and impeller or separate parts. See sections 3.5.2 and 3.5.3 for standard clearances for impeller

wearing ring, interstage seal and balancing drum.

6.9.1 Precision surfaces

Check for damage to precision surfaces that locate casings and bearing housings to preserveproper

internal alignment. Check for corrosion due to leakage. Check axial impellerhub and sleeve

surfaces for damage to insure proper axial alignment of rotor.

6.9.2 Stuffing box

Remove anydirtor scale from stuffing box cavity. Replace O-ring seals. Replace gland studsif badly

corroded.

6.9.3Mechanical seals

It isnot recommended that mechanical seals be reused. Using an old one leavestoo much chance of

failure tomake the risk worthwhile, considering the usual cost of installing and removing a pump from its

system. Attemptsto lap the mechanical seal faces may be possible but require specialized technical

knowledge, skills and equipment beyond the scope of these instructions. Complete mechanical seal rotors

and seatsare available from your FLOWSERVE representative asare anyother repair parts.

6.9.4 Stuffing box sleeves

Check the stuffing box shaft sleeve outside surface for scoring. If used with packing,any scoring will

shorten the life of the packing proportional to the amount of scoring present. Ifused with a mechanical

seal, the outside surface must not be scored in the area where the seal rotor bellowsor sealing ring

touches.

6.9.5 Ball bearings

It isnot recommended that the bearings be reused. However,if reuse isintended, clean bearings with

petroleum solvent or kerosene and inspect forany indicationsof damage or wear, such as metal

shavings, rust or surface galling. Further,judge the condition of the bearings by rotating byhand.

Replace any bearing which showsany sign of damageor that has been in service for an extended

period. Serviceable bearings should be spun in light oil to completelyremove the solventafter cleaning, or

coated by hand with an anti-corrosion agent if they are not to be reassembled immediately and wrap at

once in clean oil proof paper while awaiting reassembly. The use of chlorinated solvents of any

kind isnot recommended in bearing cleaning operations because of the rust hazard involved, nor is

the use of compressed air found desirable in cleaning operations.

Page 36 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

6.9.6 Diffusers and interstage casings

Thereis normally no need to separate the diffusers and interstage casings, however,if they do become

separated, ornewinterstage casingsor diffusersare to beinstalled, care must be taken to insure that the

diffuser is seated (in contact) with theback surface of the interstage casing, and that the pin fitscorrectly in

the hole.

6.10 Assembly

To assemble the pump consult the sectional drawings, see section 8, Partslist and drawings.

Ensure threads, gasket and O-ring mating facesare clean and that ball bearings are C3 fit. Apply thread

sealant to non-face sealing pipe thread fittings. Do not force when assembling the various

components. Coat all fittings with an antifriction product.

To assemble the pump, start from the suction side. Assembly workshould be preferably carried out with

the pump in a vertical position. To assemble the pump, reverse the dismantling

procedurespreviouslydescribed, see the cross sectional drawings. Consult the sectional drawing to

organize the required operations. Replace all componentsin their original place.

6.10.3 Anti friction bearings

Antifriction bearings should be preassembled so that the complete bearing set can bemounted on the

pump casing.To do this, reverse the dismantling in sections 6.8.2 and 6.8.3.

6.10.1 Shaft seal assembly

Packed Stuffing box: as per section 6.2.5.

Mechanical seal: Refer to assemblydrawings for the seal and pump.

Great caremust be taken concerning the cleanliness during the mounting operation.

Remove the surface protection of the ringsjust before installation.

As some O-ring materialsdo not support grease or oil, water is preferred for easingassembling, where

compatible with the product to be pumped.

6.10.2 Product lubricated bearings (WDXE/S)

Install the bearing components after the whole pump hasbeen assembled; see sections6.8.3.2 and

6.8.3.3 for diagrams.

- Put the sleeve onto the shaft end in taking carethat the shaft pin fits into the slot.

- Put the circlip [6544-01]in the shaft groove.

- Install the bushing [3300] in the suction casing.

Page 37 of 46

7 FAULTS; CAUSES AND REMEDIES

FAULT SYMPTOM Pu mp ov erheats and seiz es

 B earings h av e sh ort l ife

 Pump vib rat es o r is no i s y

 M echanic al seal h as short life

 M echanic al seal l ea ks ex cessiv el y

 Pump req uir es ex ces sive po wer

 Pump loses p rim e af ter start ing

 Insuff icient pre ssur e dev elop ed

 Insuf ficien t capacit y del ivered

 Pump does no t deliv er liquid



PROBABLE C AUSES POSSIBLE REMEDIES

 

   

  

 

   

  



  



  

 

  

     



    

Pump not primed. Pump or suctionpipe not completelyfilled with

liquid. Suctionlifttoo high or level toolow. Insufficient margin betweensuction pressure and

vapour pressure. Excessive amount of air or gas in liquid. Checkand purge pipes andsystem.

Air or vapour pocket insuctionline. Checksuctionline design for vapour pockets. Air leaks intosuction line. Checksuction pipeis airtight. Air leaks intopumpthrough mechanical seal,

sleeve joints,casing joint or pipe plugs. Foot valvetoosmall. Investigatereplacing thefoot valve.

Foot valvepartiallyclogged. Cleanfoot valve. Inlet ofsuction pipe insufficientlysubmerged. Checkoutsystemdesign. Speed toolow. CONSULT FLOWSERVE.

Speed too high. CONSULT FLOWSERVE. Total head ofsystem higher than differential head

ofpump. Total head ofsystemlower than pump design

head. Specific gravity of liquiddifferent from design. Viscosityof liquiddiffers from thatfor which

designed. Operation at very lowcapacity.

Operation at high capacity.

Misalignment due to pipe strain.

Improperlydesigned foundation.

Shaft bent.

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

A. System troubles

Checkcomplete filling. Vent and/or prime.

CheckNPSHA>NPSHR, proper submergence, losses at strainers andfittings.

Checkandr eplacefaulty parts. CONSULT FLOWSERVE.

Checksystemlosses. Remedyor CONSULT FLOWSERVE.

CheckandCONSULT FLOWSERVE.

Measure value andcheck minimum permitted. Remedyor CONSULT FLOWSERVE.

Measure value andcheck maximum permitted. Remedyor CONSULT FLOWSERVE.

B. Mechanical troubles

Checktheflangeconnections and eliminatestrains using elastic couplings or a method permitted.

Checksetting of baseplate: tighten, adjust, grout base asrequired.

Checkshaftrunouts are within acceptable values. CONSULT FLOWSERVE.

Page 38 of 46

FAULT SYMPTOM

wear.

Pu mp ov erheats and seiz es

 B earings h av e sh ort l ife

 Pump vib rat es o r is no i s y

 M echanic al seal h as short life

 M echanic al seal l ea ks ex cessiv el y

 Pump req uir es ex ces sive po wer

 Pump loses p rim e af ter start ing

 Insuff icient pre ssur e dev elop ed

 Insuf ficien t capacit y del ivered

 Pump does no t deliv er liquid



PROBABLE C AUSES POSSIBLE REMEDIES

   

    

  



 

  

    

Rotating part rubbing on stationary part internally. CheckandCONSULT FLOWSERVE, if necessary. Bearings worn. Replace bearings.

Wearing ring surfaces worn. Replace worn wear ring/surfaces. Impeller damaged or eroded. Replace or CONSULT FLOWSERVE for improved

Leakageunder sleevedue tojoint failure. Replace joint and checkfor damage. Shaft sleeve worn or scored or running offcentre. Checkandrenew defectiveparts.

Mechanicalseal improperlyinstalled. Checkalignment of faces or damaged parts and

Incorrect type of mechanicalseal for operating conditions.

Shaft running off centre because of worn bearings or misalignment.

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

materialselection.

assembly method used. CONSULT FLOWSERVE.

Check misalignment andcorrectif necessary.If alignment satisfactory check bearings for excessive

    

  

 

  

 

   

 

  

Impeller out of balance resulting in vibration. Abrasivesolids in liquid pumped.

CheckandCONSULT FLOWSERVE.

Internal misalignment ofpartspreventing seal ring and seat from mating properly.

Mechanicalseal wasrun dry. Check mechanical seal condition andsource of dry

running andr epair.

Internal misalignment dueto improper repairs causing impeller torub.

Check method of assembly, possible damageor state ofcleanliness during assembly. Remedyor CONSULT FLOWSERVE, if necessary.

Excessivethrustcaused by a mechanical failure insidethe pump.

Check wear condition of impeller,its clearances and liquidpassages.

Excessivegreasein ball bearings. Check method of regreasing. Lack of lubrication for bearings. Checkhours run since last change oflubricant, the

schedule and its basis.

Improper installation ofbearings (damage during assembly, incorrect assembly, wrong type of

bearing etc).

Check method of assembly, possible damageor state ofcleanliness during assembly andtype of

bearing used. Remedy or CONSULT FLOWSERVE, if necessary.

Damagedbearings due to contamination. Checkcontamination source and replace damaged

bearings.

C. MOTOR ELECTRICAL PROBLEMS

Wrong direction ofrotation. Reverse2 phases at motor terminal box. Motor running on 2 phases only. Checksupply andfuses.

Motor running tooslow. Check motor terminal boxconnections and voltage.

Page 39 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

8 PARTS LISTS AND DRAWINGS

8.1 Sectionaldrawings, WDXR grease lubricated uncooled

Page 40 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

8.2 Sectionaldrawings, variants

8.2.1 WDXE and WDXS

8.2.2 WDXC

Page 41 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

9331-02

9331-0

8162

8.2.3 Cooled version

8.3.2 Intermediate bearing bush

8.3.3 Oil bearing drive end

8.3 Sectionaldrawings, other details

8.3.1 Wear rings

8161

8.3.4 Oil bearing non drive end

Page 42 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

8.4 Sectionaldrawings part list

ITEM DESIGNATION

1130-01 Suction casing, radial 1130-02 Suction casing,axial

1140 Discharge casing 1150-01 Stage casing 1150-02 Stage casingforinternal bearing bush 1150-03 Stage casing, End 1410 DiffuserC

1410 DiffuserD 1470 Closing platedischarge 1500-01 Casing wear ring, stagecasing 1500-02 Casing wear ring, suction casing 1600 Bush, Balance drum

1630 Throttling bush 2110 Pump shaft 2210 Impeller, suction stage 2250-01 Impeller C 2250-01 Impeller D

2250-02 Impeller C forinternal bearing bush 2250-02 Impeller D forinternal bearing bush 2300-01 Impeller wear ring, suction impeller 2300-02 Impeller wear ring, stage impeller

2445-01 2445-02

2450-01 Shaft sleeve, Driveside 2450-02 Shaft sleeve, Nondrive side

2450-03 Inside fan Drive side 2450-04 Inside fan Non drive side 2460-01 Spacer sleeve forbearing Drive side 2460-02 Spacer sleeve forbearing Drive side

2460-03 2471-01 Bush,underbearing Drive side

2471-02 Bush,underbearing Non drive side 2500 Ring, Drum

2510 Spacer ring,drumin2 parts 2540 Deflector,Non drive side

2905-01 2905-02

2905-03 Washer, plain 2905-04 Washer, Curved spring

Shaft sleeve formechanical seal, Drive side

Shaft sleeve formechanical seal, Non drive side

Spacer sleeve for bearing Non drive side

Washerfor gland packing Drive side (cooled) Washerfor gland packing Non drive side (cooled)

ITEM DESIGNATION

3011-01 Radial ball bearing, Drive side2x7300 3011-02

Radial ball bearing, Non drive side 6000

3134 Support foot 3140 Bearing bracket, Drive side

3211 Bearing housing, Drive side 3212 Bearing housing, Nondrive side 3260 Bearing cover, Drive side 3261 Bearing cover, Drive side 3263 Bearing cover, Non drive side

3300 Bearing bush 3311 Bearing bush,internal 3400-01 Bearing sleeve for bearing bush

3400-02

Bearing sleeveforinternal bearing bush

3712-01 Bearing nut, Drive side 3712-02 Bearing nut, Drive side 3712-03 Bearing nut,non-Drive side 3853 Greasenipple 3855 Constant level oiler

4120-01 Gland, flange Drive side 4120-02

Gland, flange Non drive side (no cooled)

4120-03 Gland, flange Non driveside (cooled) 4130-01 Glandpacking, Drive side

4130-02

Gland packing, Non drive side (no cooled)

4130-02 Glandpacking, Nondriveside (cooled) 4131-01 Follower,Drive side 4131-02 Follower,Non driveside (no cooled)

4131-02 FollowerNondrive side (cooled) 4200-01 Mechanical seal, Drive side 4200-02 Mechanical seal, Non drive side

4210-01 4210-02

Gland packing and/ormechanical seal housing, no cooled Drive side Gland packing and/ormechanical seal housing, no cooled Non dive side

4213-01 Mechanical seal cover, Drive side 4213-02 Mechanical seal cover, Non drive side

Coolant housing, forGland packing

4410-01

and/ormechanical seal housing cooled Drive side

Coolant housing, forGland packing

4410-02

and/ormechanical seal housing cooled Non drive side

4590-01 Gasketforoil bearing cover Drive side 4590-02

Gasket formechanical seal cover Drive side

Page 43 of 46

WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

ITEM DESIGNATION

4590-03 4590-04 4590-05

4590-06

Gasket forseal housing cooled Drive side Gasket forseal housing cooled Non drive side Gasket formechanical seal cover Non drive side

Gasket foroil bearing cover Nondrive side

4590-07 Gasket, bearing bush cover 4610-01 O ring bushunderbearing Drive side

4610-02 O ring shaft sleeve Drive side 4610-03 O ring Sealhousing Drive side 4610-04 O ring under balance drum 4610-05 O ring balance drum bush 4610-06 O ring stage casing

4610-07

O ringbush underbearing Non drive side

4610-08 O ring shaft sleeve Nondrive side 4610-09 O ring Sealhousing Nondrive side

4610-10 O ring Sealhousing cooled Drive side 4610-11

4610-12 4610-13

O ringSeal housing cooled Nondrive side O ring,mechanical seal cover Drive side

O ring,mechanical seal cover Non drive side

6230 Balance drum 6521 Snifter valve 6541-01 Lockwasher, Drive side

6541-02 Lockwasher, Drive side 6541-03 Lockwasher, Nondrive side 6544-01 Circlip for shaft 6544-02 Circlip,bore 6544-03 Circlip,bore

6569-01 Plug,Screwed 1/4" NPT Drive side 6569-02

6569-03 6569-04

Plug, Screwed 1/2" NPT bearing Drive side Plug, Screwed 1/4" NPT bearing Non drive side

Plug, Screwed 1/2" NPT bearing Non drive side

6569-05 Plug,Screwed discharge 6569-06 Plug,Screwed discharge 6569-07 Plug,Screwed suction 6569-08 Plug,Screwed suction

6569-09 6569-10

Plug, Screwed forbearing Nondrive side Plug, Screwed forbearing Nondrive side

ITEM DESIGNATION

6570-01 Screw,cap Hc, Fan 6570-02 Screw,cap Hc, Bearing bush 6570-03 Screw,cap Hc, Internal bearingbush 6570-04 Screw,cap Hc

6570-05 Screw,cap Hc 6570-06

6570-07

Screw, Hexagon socket head cap Chc Drum Screw, Hexagon socket head cap Bearing bush

6571-01 Tie bolt,upper 6571-02 Tie bolt,lower

6572-01 Stud, Bearing Drive side 6572-02 Stud, gland packing /MS Drive side

6572-03

Stud,gland packing /MS Non drive side

6577-01 Hexagon head Screw, Drive side 6577-02 Hexagon head Screw, Nondrive side 6577-03 Hexagon head Screw, Nondrive side

6577-04

HexagonheadScrew,Bearing bush cover

6577-05 Hexagon head Screw, Support foot 6581-01

Nut, Hexagon H, bearing cover drive side

6581-02 Nut, Hexagon H,MS drive side 6581-03

Nut, Hexagon H, GlandPacking/MS non drive side

6581-04 Nut, tiebolt 6700-01 Key,coupling

6700-02 Key,under shaft sleeve 6700-03 Key,last impeller 6700-04 Key,underimpeller 6700-05 Key,underbearing sleeve 6810-01 Grooved pin,MS Drive side

6810-02

Grooved pin, shaft seal housing Drive side

6810-03 Grooved pin, stage casing 6810-04 Grooved pin,bearing sleeve

6810-05

Grooved pin, shaft seal housing Non drive side

6810-06 Grooved pin,MS Nondrive side 8161 Outside fan 8162 Fan cover 9220-01 Fitting,balancing line 9220-02 Fitting,union T

9220-03 Fitting, reduction coupling 9331-01 Coverplate, Drive side 9331-02 Coverplate, Non drive side

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WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

8.5 General arrangement drawing

The typical general arrangement drawingand any specificdrawingsrequired by thecontract will be sent to

thePurchaser separatelyunlessthe contract specifically calls fortheseto beincluded into the User

Instructions. If required, copies of otherdrawings sent separatelyto the Purchaser should be obtained from

thePurchaser and retained with these User Instructions.

9 CERTIFICATION

Certificates determined from the Contract requirementsare provided with these instructions

where applicable. Examples are certificatesfor CE marking, ATEXmarking etc. If required, copies of

other certificatessent separately to the Purchaser should be obtained from the Purchaser for retention

with these User Instructions.

10 OTHER RELEVANT DOCUMENTATION ANDMANUALS

10.1 Supplementary User Instructions

Supplementaryinstructionssuch as for a driver, instrumentation, controller, seals, sealant system etc

are provided as separate documents in theiroriginal 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 FlowservePump Division, aremadetotheproduct afterits supply, a recordof the

details shouldbemaintained with these User Instructions.

10.3 Additional sources of information

Reference1:

NPSH for Rotordynamic Pumps: a reference guide, Europump Guide No. 1, Europump & World Pumps,

Elsevier Science, United Kingdom, 1999.

Reference2:

Pumping Manual, 9thedition,T.C. Dickenson, ElsevierAdvancedTechnology, UnitedKingdom,1995.

Reference3: Pump Handbook, 2ndedition, Igor J. Karassiket al,

McGraw-Hill Inc., NewYork, 1993.

Reference4:

ANSI/HI1.1-1.5, Centrifugal Pumps - Nomenclature, Definitions, Application and Operation.

Reference5:

ANSI B31.3 - Process Piping.

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WDX USER INSTRUCTIONS ENGLISH 71576322 06-05

FLOWSERVE

REGIONAL SALES OFFICES:

Europe, Middle East & Africa Flowserve Limited (Pump Division) Harley House, 94 Hare Lane Claygate, Esher, Surrey KT10 0RB United Kingdom

Tel +44 (0) 1372 463 700 Fax +44 (0) 1372 460 190

USA and Canada Flowserve Corporation (Pump Division) Millennium Center, 222 Las Colinas Blvd. 15thFloor, Irving, TX 75039-5421, USA

Tel +1 972 443 6500 Toll free 800 728 PUMP (7867) Fax +1 972 443 6800

Visit our web site at: www.flowserve.com

Latin America Flowserve S.A. de C.V. Avenida Paseo de la Reforma 30 2ndFloor, Colonia Juarez Centro Mexico, D.F.Z.C. 06040

Tel +52 5705 5526 Fax +52 5705 1125

Asia Pacific Flowserve Pte Ltd(Pump Division) 200 Pandan Loop, 06-03/04 Pantech 21, Singapore 128388

Tel +65 775 3003 Fax +65 779 4607

Your Flowserve factory contacts:

North America:

South America, Europe, Africa, Asia: Flowserve Pompes

Route d'Angers 72234 ARNAGE Cedex - FRANCE

Telephone (24 hours) +33 43 4057 75 Sales& Admin +33 43 4057 57

Repair & Service Fax +33 4340 58 17

Your local Flowserve office/representative:

To find your local Flowserve representative, please use the SalesSupport Locator System

Found at www.flowserve.com

Page 46 of 46

Flowserve WDX User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual