Flowserve WDX User Manual

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)

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