WR and CR USER INSTRUCTIONS ENGLISH 26999968 10-12
1 INTRODUCTION AND SAFETY
1.1 General
These instructions must always be kept
close to the product's operating location or
directly with the product.
Flowserve products are designed, developed and
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great
care and commitment to continuous quality control,
utilising sophisticated quality techniques, and safety
requirements.
Flowserve is committed to continuous quality
improvement and being at service for any further
information about the product in its installation and
operation or about its support products, repair and
diagnostic services.
These instructions are intended to facilitate
familiarization with the product and its permitted use.
Operating the product in compliance with these
instructions is important to help ensure reliability in
service and avoid risks. The instructions may not
take into account local regulations; ensure such
regulations are observed by all, including those
installing the product. Always coordinate repair
activity with operations personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.
These instructions must be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment must not be put into service until all
the conditions relating to safety, noted in the
instructions, have been met. Failure to follow and
apply the present user instructions is considered
to be misuse. Personal injury, product damage,
delay or failure caused by misuse are not covered
by the Flowserve warranty.
1.2 CE marking and approvals
It is a legal requirement that machinery and
equipment put into service within certain regions of
the world shall conform with the applicable CE
Marking Directives covering Machinery and, where
applicable, Low Voltage Equipment, Electromagnetic
Compatibility (EMC), Pressure Equipment Directive
(PED), minimum efficiency for some water pumps
(Ecodesign) and Equipment for Potentially Explosive
Atmospheres (ATEX).
Where applicable, the Directives and any additional
Approvals, cover important safety aspects relating to
machinery and equipment and the satisfactory provision
of technical documents and safety instructions.
Where applicable this document incorporates
information relevant to these Directives and Approvals.
To confirm the Approvals applying and if the product is
CE marked, check the serial number plate markings
and the Certification. (See section 9, Certification.)
1.3 Disclaimer
Information in these User Instructions is believed to
be complete and reliable. However, in spite of all of
the efforts of Flowserve Corporation to provide
comprehensive instructions, good engineering and
safety practice should always be used.
Flowserve manufactures products to exacting
International Quality Management System Standards as
certified and audited by external Quality Assurance
organisations. Genuine parts and accessories have
been designed, tested and incorporated into the
products to help ensure their continued product quality
and performance in use. As Flowserve cannot test
parts and accessories sourced from other vendors the
incorrect incorporation of such parts and accessories
may adversely affect the performance and safety
features of the products. The failure to properly select,
install or use authorised Flowserve parts and
accessories is considered to be misuse. Damage or
failure caused by misuse is not covered by the
Flowserve warranty. In addition, any modification of
Flowserve products or removal of original components
may impair the safety of these products in their use.
1.4 Copyright
All rights reserved. No part of these instructions may
be reproduced, stored in a retrieval system or
transmitted in any form or by any means without prior
permission of Flowserve.
1.5 Duty conditions
This product has been selected to meet the
specifications of your purchaser order. The
acknowledgement of these conditions has been sent
separately to the Purchaser. A copy should be kept
with these instructions.
The product must not be operated beyond
the parameters specified for the application.
If there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice, quoting the serial number.
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WR and CR USER INSTRUCTIONS ENGLISH 26999968 10-12
If the conditions of service on your purchase order are
going to be changed (for example liquid pumped,
temperature or duty) it is requested that the user seeks
the written agreement of Flowserve before start up.
1.6 Safety
1.6.1 Summary of safety markings
These User Instructions contain specific safety
markings where non-observance of an instruction would
cause hazards. The specific safety markings are:
This symbol indicates electrical safety
instructions where non-compliance will involve a high
risk to personal safety or the loss of life.
This symbol indicates safety instructions where
non-compliance would affect personal safety and could
result in loss of life.
This symbol indicates “hazardous and toxic fluid”
safety instructions where non-compliance would affect
personal safety and could result in loss of life.
This symbol indicates safety instructions
where non-compliance will involve some risk to safe
operation and personal safety and would damage the
equipment or property.
This symbol indicates explosive atmosphere zone
marking according to ATEX. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
This symbol is used in safety instructions to
remind not to rub non-metallic surfaces with a dry
cloth; ensure the cloth is damp. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
This sign is not a safety symbol but indicates
an important instruction in the assembly process.
1.6.2 Personnel qualification and training
All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved. If the
personnel in question do not already possess the
necessary knowledge and skill, appropriate training
and instruction must be provided. If required the
operator may commission the manufacturer/supplier
to provide applicable training.
Always coordinate repair activity with operations and
health and safety personnel, and follow all plant
safety requirements and applicable safety and health
laws and regulations.
1.6.3 Safety action
This is a summary of conditions and actions to
help prevent injury to personnel and damage to
the environment and to equipment. For products
used in potentially explosive atmospheres
section 1.6.4 also applies.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS OPERATIONAL
DRAIN THE PUMP AND ISOLATE PIPEWORK
BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be taken
where the pumped liquids are hazardous.
FLUORO-ELASTOMERS (When fitted.)
When a pump has experienced temperatures over
250 ºC (482 ºF), partial decomposition of fluoroelastomers (example: Viton) will occur. In this
condition these are extremely dangerous and skin
contact must be avoided.
HANDLING COMPONENTS
Many precision parts have sharp corners and the
wearing of appropriate safety gloves and equipment
is required when handling these components. To lift
heavy pieces above 25 kg (55 lb) use a crane
appropriate for the mass and in accordance with
current local regulations.
THERMAL SHOCK
Rapid changes in the temperature of the liquid within
the pump can cause thermal shock, which can result
in damage or breakage of components and should be
avoided.
NEVER APPLY HEAT TO REMOVE IMPELLER
Trapped lubricant or vapour could cause an explosion.
HOT (and cold) PARTS
If hot or freezing components or auxiliary heating
supplies can present a danger to operators and
persons entering the immediate area action must be
taken to avoid accidental contact. If complete
protection is not possible, the machine access must
be limited to maintenance staff only, with clear visual
warnings and indicators to those entering the
immediate area. Note: bearing housings must not be
insulated and drive motors and bearings may be hot.
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WR and CR USER INSTRUCTIONS ENGLISH 26999968 10-12
If the temperature is greater than 80 ºC (175 ºF) or
below -5 ºC (20 ºF) in a restricted zone, or exceeds
local regulations, action as above shall be taken.
HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care
must be taken to avoid exposure to the liquid by
appropriate siting of the pump, limiting personnel
access and by operator training. If the liquid is
flammable and or explosive, strict safety procedures
must be applied.
PREVENT EXCESSIVE EXTERNAL
PIPE LOAD
Do not use pump as a support for piping. Do not mount
expansion joints, unless allowed by Flowserve in
writing, so that their force, due to internal pressure, acts
on the pump flange.
ENSURE CORRECT LUBRICATION
(See section 5, Commissioning, startup, operation and shutdown.)
START THE PUMP WITH OUTLET
VALVE PART OPENED
(Unless otherwise instructed at a specific point in the
User Instructions.)
This is recommended to minimize the risk of
overloading and damaging the pump or motor at full or
zero flow. Pumps may be started with the valve further
open only on installations where this situation cannot
occur. The pump outlet control valve may need to be
adjusted to comply with the duty following the run-up
process. (See section 5, Commissioning start-up, operation and shutdown.)
NEVER RUN THE PUMP DRY
INLET VALVES TO BE FULLY OPEN
WHEN PUMP IS RUNNING
Running the pump at zero flow or below the
recommended minimum flow continuously will cause
damage to the pump and mechanical seal.
DO NOT RUN THE PUMP AT
ABNORMALLY HIGH OR LOW FLOW RATES
Operating at a flow rate higher than normal or at a flow
rate with no back pressure on the pump may overload
the motor and cause cavitation. Low flow rates may
cause a reduction in pump/bearing life, overheating of
the pump, instability and cavitation/vibration.
1.6.4 Products used in potentially explosive
atmospheres
Measures are required to:
• Avoid excess temperature
• Prevent build up of explosive mixtures
• Prevent the generation of sparks
• Prevent leakages
• Maintain the pump to avoid hazard
The following instructions for pumps and pump units
when installed in potentially explosive atmospheres
must be followed to help ensure explosion protection.
For ATEX, both electrical and non-electrical equipment
must meet the requirements of European Directive
94/9/EC. Always observe the regional legal Ex
requirements eg Ex electrical items outside the EU may
be required certified to other than ATEX eg IECEx, UL.
1.6.4.1 Scope of compliance
Use equipment only in the zone for which it is
appropriate. Always check that the driver, drive
coupling assembly, seal and pump equipment are
suitably rated and/or certified for the classification of the
specific atmosphere in which they are to be installed.
Where Flowserve has supplied only the bare shaft
pump, the Ex rating applies only to the pump. The
party responsible for assembling the ATEX pump set
shall select the coupling, driver and any additional
equipment, with the necessary CE Certificate/
Declaration of Conformity establishing it is suitable for
the area in which it is to be installed.
The output from a variable frequency drive (VFD) can
cause additional heating effects in the motor and so,
for pump sets with a VFD, the ATEX Certification for
the motor must state that it is covers the situation
where electrical supply is from the VFD. This
particular requirement still applies even if the VFD is
in a safe area.
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1.6.4.2 Marking
An example of ATEX equipment marking is shown
below. The actual classification of the pump will be
engraved on the nameplate.
II 2 GD c IIC 135 ºC (T4)
Equipment Group
I = Mining
II = Non-mining
Category
2 or M2 = high level protection
3 = normal level of protection
Gas and/or dust
G = Gas, D = Dust
c = Constructional safety
(in accordance with EN13463-5)
Gas Group
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)
Maximum surface temperature (Temperature Class)
(see section 1.6.4.3.)
1.6.4.3 Avoiding excessive surface temperatures
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE
Pumps have a temperature class as stated in the
ATEX Ex rating on the nameplate. These are based
on a maximum ambient of 40 ºC (104 ºF); refer to
Flowserve for higher ambient temperatures.
The surface temperature on the pump is influenced
by the temperature of the liquid handled. The
maximum permissible liquid temperature depends on
the ATEX temperature class and must not exceed the
values in the table that follows:
Maximum permitted liquid temperature for pumps
Temperature class
to EN13463-1
T6
T5
T4
T3
T2
T1
* The table only takes the ATEX temperature class into consideration.
Pump design or material, as well as component design or material,
may further limit the maximum working temperature of the liquid.
Maximum surface
temperature permitted
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)
Temperature limit of
liquid handled *
Consult Flowserve
Consult Flowserve
115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
400 °C (752 °F) *
The temperature rise at the seals and bearings and
due to the minimum permitted flow rate is taken into
account in the temperatures stated.
The operator is responsible to ensure that the
specified maximum liquid temperature is not
exceeded.
Temperature classification “Tx” is used when the liquid
temperature varies and when the pump is required to be
used in differently classified potentially explosive
atmospheres. In this case the user is responsible for
ensuring that the pump surface temperature does not
exceed that permitted in its actual installed location.
If an explosive atmosphere exists during the
installation, do not attempt to check the direction of
rotation by starting the pump unfilled. Even a short
run time may give a high temperature resulting from
contact between rotating and stationary components.
Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, temperature monitors or a
power monitor and make routine vibration monitoring
checks.
In dirty or dusty environments, make regular checks
and remove dirt from areas around close clearances,
bearing housings and motors.
Where there is any risk of the pump being run against a
closed valve generating high liquid and casing external
surface temperatures fit an external surface
temperature protection device.
1.6.4.4 Preventing the build up of explosive
mixtures
ENSURE THE PUMP IS PROPERLY FILLED
AND VENTED AND DOES NOT RUN DRY
Ensure the pump and relevant suction and discharge
pipeline system is totally filled with liquid at all times
during the pump operation, so that an explosive
atmosphere is prevented.
In addition it is essential to make sure that seal
chambers, auxiliary shaft seal systems and any
heating and cooling systems are properly filled.
If the operation of the system cannot avoid this
condition, fit an appropriate dry run protection device
(for example liquid detection or a power monitor).
To avoid potential hazards from fugitive emissions of
vapour or gas to atmosphere the surrounding area
must be well ventilated.
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1.6.4.5 Preventing sparks
To prevent a potential hazard from mechanical
contact, the coupling guard must be non-sparking
and anti-static for Category 2.
To avoid the potential hazard from random induced
current generating a spark, the baseplate must be
properly grounded.
Avoid electrostatic charge: do not rub non-metallic
surfaces with a dry cloth; ensure cloth is damp.
For ATEX the coupling must be selected to comply
with 94/9/EC. Correct coupling alignment must be
maintained.
1.6.4.6 Additional requirement for metallic pumps
on non-metallic baseplates
When metallic components are fitted on a nonmetallic baseplate they must be individually earthed.
1.6.4.7 Preventing leakage
The pump must only be used to handle liquids
for which it has been approved to have the correct
corrosion resistance.
Avoid entrapment of liquid in the pump and associated
piping due to closing of suction and discharge valves,
which could cause dangerous excessive pressures to
occur if there is heat input to the liquid. This can occur if
the pump is stationary or running.
Bursting of liquid containing parts due to freezing
must be avoided by draining or protecting the pump
and ancillary systems.
Where there is the potential hazard of a loss of a seal
barrier fluid or external flush, the fluid must be monitored.
If leakage of liquid to atmosphere can result in a
hazard, install a liquid detection device
1.6.4.8 Maintenance to avoid the hazard
CORRECT MAINTENANCE IS REQUIRED TO
AVOID POTENTIAL HAZARDS WHICH GIVE A
RISK OF EXPLOSION
The responsibility for compliance with maintenance
instructions is with the plant operator.
To avoid potential explosion hazards during
maintenance, the tools, cleaning and painting
materials used must not give rise to sparking or
adversely affect the ambient conditions. Where there
is a risk from such tools or materials, maintenance
must be conducted in a safe area.
It is recommended that a maintenance plan and
schedule is adopted. (See section 6, Maintenance.)
1.7 Nameplate and safety labels
1.7.1 Nameplate
For details of nameplate, see the Declaration of
Conformity, or separate documentation included with
these User Instructions.
EU regulation 547/2012 requires the statement on a
product nameplate: MEI ≥ 0.10 [--,-]. (See section
1.8.2, Ecodesign.)
1.7.2 Safety labels
1.8 Specific machine performance
1.8.1 General
For performance parameters see section 1.5, Duty
conditions. When the contract requirement specifies
these to be incorporated into User Instructions these
are included here. Where performance data has
been supplied separately to the purchaser these
should be obtained and retained with these User
Instructions if required.
1.8.2 Ecodesign
EU regulation 547/2012 of the Directive
2009/125/EC, for the minimum efficiency of defined
classes of water pumps requires that products must
show their Minimum Efficiency Index (MEI) value.
The EU benchmark MEI ≥ 0.70. Also product
information must be available to users.
Performance curves will have been provided with the
quotation or order or are available at flowserve.com.
The efficiency of a pump with trimmed impeller is
usually lower than that of a pump with the full impeller
diameter. Trimming of the impeller will adapt the
pump to a fixed duty point, leading to reduced energy
consumption. The minimum efficiency index (MEI) is
based on the full impeller diameter.
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The operation of this water pump with variable duty
points may be more efficient and economic when
controlled by, for example, by the use of a variable
speed drive that matches the pump duty to the system.
Information on benchmark efficiency is available at;
www.europump.org/efficiencycharts
1.9 Noise level
Attention must be given to the exposure of personnel
to the noise, and local legislation will define when
guidance to personnel on noise limitation is required,
and when noise exposure reduction is mandatory.
This is typically 80 to 85 dBA.
The usual approach is to control the exposure time to
the noise or to enclose the machine to reduce emitted
sound. You may have already specified a limiting
noise level when the equipment was ordered,
however if no noise requirements were defined, then
attention is drawn to the following table to give an
indication of equipment noise level so that you can
take the appropriate action in your plant.
Pump noise level is dependent on a number of
operational factors, flow rate, pipework design and
acoustic characteristics of the building, and so the
values given are subject to a 3 dBA tolerance and
cannot be guaranteed.
Similarly the motor noise assumed in the “pump and
motor” noise is that typically expected from standard
and high efficiency motors when on load directly driving
the pump. Note that a motor driven by an inverter may
If a pump unit only has been purchased for fitting with
your own driver then the “pump only” noise levels in
the table should be combined with the level for the
driver obtained from the supplier. Consult Flowserve
or a noise specialist if assistance is required in
combining the values.
It is recommended that where exposure approaches
the prescribed limit, then site noise measurements
should be made.
The values are in sound pressure level LpA at 1 m
(3.3 ft) from the machine, for “free field conditions
over a reflecting plane”.
For estimating sound power level LWA (re 1 pW) then
add 14 dBA to the sound pressure value.
2 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be
checked against the delivery/shipping documents for its
completeness and that there has been no damage in
transportation. Any shortage and/or damage must be
reported immediately to Flowserve and must be
received in writing within one month of receipt of the
equipment. Later claims cannot be accepted.
Check any crate, boxes or wrappings for any
accessories or spare parts that may be packed
separately with the equipment or attached to side
walls of the box or equipment.
Note: for 1 180 and 960 r/min reduce 1 450 r/min values by 2 dBA. For 880 and 720 r/min reduce 1 450 r/min values by 3 dBA.
3 550 r/min 2 900 r/min 1 750 r/min 1 450 r/min
Pump
only
Pump and
Typical sound pressure level LpA at 1 m reference 20 µPa, dBA
motor
Pump
only
Pump and
motor
Pump
only
Pump and
motor
Pump
only
Pump and
motor
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Each product has a unique serial number. Check
that this number corresponds with that advised and
always quote this number in correspondence as well
as when ordering spare parts or further accessories.
2.2 Handling
Boxes, crates, pallets or cartons may be unloaded
using fork lift vehicles or slings dependent on their
size and construction.
2.3 Lifting
A crane must be used for all pump sets or
components in excess of 25 kg (55 lb.). Fully trained
personnel must carry out lifting, in accordance with
local regulations.
No specific lifting points are provided
for this complete machine (unless so specified). Any
lifting points that can be seen are provided only for
dismantling parts for servicing. Slings, ropes and
other lifting gear should be positioned where they
cannot slip and where a balanced lift is obtained.
The angle between sling or ropes used for lifting must
not exceed 60°.
Before lifting the driver alone, refer to the
manufacturer’s instructions.
The driver weight is recorded on its nameplate.
2.4 Storage
Store the pump in a clean, dry location
away from vibration. Leave piping connection covers
in place to keep dirt and other foreign material out of
pump casing. Turn pump at intervals to prevent
brinelling of the bearings and the seal faces, if fitted,
from sticking.
The pump may be stored as above for up to 6
months. Consult Flowserve for preservative actions
when a longer storage period is needed.
2.5 Recycling and end of product life
At the end of the service life of the product or its
parts, the relevant materials and parts should be
recycled or disposed of using an environmentally
acceptable method and local requirements. If the
product contains substances that are harmful to the
environment, these should be removed and disposed
of in accordance with current regulations. This also
includes the liquids and or gases that may be used in
the "seal system" or other utilities.
Make sure that hazardous substances or toxic
fluids are disposed of safely and that the correct
personal protective equipment is used. The safety
specifications must be in accordance with the current
regulations at all times.
3 DESCRIPTION
3.1 Configurations
This is a robust centrifugal pump design for a wide
range of applications.
3.2 Name nomenclature
The pump size will be engraved on the nameplate
typically as below:
50WR160
Nominal discharge branch size in mm
Pump build:
WR - cast iron construction
CR - SS316 construction
Nominal maximum impeller diameter in mm
The typical nomenclature above is the general guide
to the D-line pump configuration description.
Identify the actual pump size and serial number from
the pump nameplate. Check that this agrees with the
applicable certification provided.
3.3 Design of major parts
3.3.1 Pump casing
The pump casing is designed with a horizontal
centreline end inlet and a vertical centreline top
outlet, which makes it self-venting. For ease of
maintenance, the pump is constructed so that pipe
connections do not have to be disturbed when
internal maintenance is required.
3.3.2 Impeller
A shrouded impeller with hub rings is fitted.
3.3.3 Shaft
The pump shaft is fitted directly on to the motor shaft
via a tolerance ring drive. The pump shaft or sleeve
can be removed from the motor for maintenance or
replacement.
3.3.4 Bearing housing and lubrication
The pump uses the driver's bearings to give primary
support and positioning to the input shaft. See the
driver's instruction book for lubrication details.
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3.3.5 Seal housing
The seal housings designs provide improved
performance of mechanical seals
3.3.6 Shaft seal
The mechanical seal(s) attached to the pump shaft
seals the pumped liquid from the environment. Gland
packing may be fitted as an option.
3.3.7 Driver
The pump is driven by a close-coupled electric motor.
The position of the terminal box can be changed by
rotating the complete motor. To do this, remove the
fasteners from the motor flange, rotate the motor and
re-fit the fasteners.
3.3.8 Accessories
Accessories may be fitted when specified by the
customer.
3.4 Performance and operating limits
This product has been selected to meet the
specifications of the purchase order. (See section 1.5.)
These pumps are generally fitted with TEFC motors
with an ambient temperature limit of 40°C. Specific
pumps may be fitted with motors to suit client's
requirements with other ambient temperature limits see motor nameplate for details.
3.4.1 Pressure limits
The operating pressure has been selected to meet
your specified requirements. See paragraph 1.5,
Duty conditions, for details.
Recommended
Pump
type
WR
CR
* 140 ºC with internal water cooled box (not WS No.1 seal)
Max.
working
pressure
(bar)
16 24 5.2 2.75 -20 to 110
16 24 5.2 2.75 -20 to 110
Test
pressure
(bar)
max. suction
pressure (bar)
1 450 &
1 750
rpm
3 500 rpm
2 900 &
Liquid
temperature
limits
(°C)*
4 INSTALLATION
Equipment operated in hazardous locations
must comply with the relevant explosion protection
regulations. See section 1.6.4, Products used in
potentially explosive atmospheres.
4.1 Location
The pump should be located to allow room for access,
ventilation, maintenance and inspection with ample
headroom for lifting and should be as close as
practicable to the supply of liquid to be pumped. Refer
to the general arrangement drawing for the pump set.
4.2 Part assemblies
These pumps are not normally supplied in part
assemblies but special accessories such as loose
orifice plates are supplied loose. Ensure these are
incorporated in the final installation.
4.3 Foundation
There are many methods of installing
pump units to their foundations. The correct method
depends on the size of the pump unit, its location and
noise and vibration limitations. Non-compliance with
the provision of correct foundation and installation
may lead to failure of the pump and, as such, would
be outside the terms of the warranty.
Pumps should not be mounted with the
motor below the pump casing.
Pumps with motors up to D132 Frame size are bolted
to the foundations by the mounting bracket. Larger
sizes with D160 and larger motor frames are
mounted by the motor feet.
It is recommended that bolts (not studs) are used to
hold down the pump feet to permit easy removal from
the pipework.
These close coupled pumps feature a back pull-out
design. This means that when correctly installed, the
rotating element can be withdrawn from the casing
without disturbing the system pipework. The use of
grouted-in studs to secure the motor feet prevents
back pull-out and will make maintenance more
difficult and time consuming. The procedures in the
above paragraphs should be followed in order to
obtain the maximum benefit from the pump design.
4.4 Grouting
Where applicable, grout in the foundation bolts.
Foundation bolts should only be fully tightened when
the grout has cured.
4.5 Piping
Protective covers are fitted to the pipe
connections to prevent foreign bodies entering during
transportation and installation. Ensure that these
covers are removed from the pump before connecting
any pipes.
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4.5.1 Suction and discharge pipework
Never use pump as a support for piping.
In order to minimize friction losses and hydraulic
noise in the pipework it is good practice to choose
pipework that is one or two sizes larger than the
pump suction and discharge. Typically main
pipework velocities should not exceed 2 m/s (6 ft/sec)
suction and 3 m/s (9 ft/sec) on the discharge.
Maximum forces and moments allowed on the pump
flanges vary with the pump size and type. To minimize
these forces and moments that may, 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 draw piping into place by applying force to
pump flange connections
•Do not mount expansion joints so that their force,
due to internal pressure, acts on the pump flange
Ensure piping and fittings are flushed
before use.
Ensure piping for hazardous liquids is arranged
to allow pump flushing before removal of the pump.
Take into account the available NPSH which must be
higher than the required NPSH of the pump.
4.5.2 Suction piping
a) The inlet pipe should be one or two sizes larger
than the pump inlet bore and pipe bends should
be as large a radius as possible.
b) On suction lift the piping should be inclined up
towards the pump inlet with eccentric reducers
incorporated to prevent air locks.
c) On positive suction, the inlet piping must have a
constant fall towards the pump.
d) The pipe next to the pump should be the same
diameter as the pump suction and have a
minimum of two pipe diameters of straight section
between the elbow and the pump inlet flange.
Where the NPSH margin is not large, it is
recommended that the pipe straight is 5 to 10
pipe diameter. (See section 10.3, Reference 1.)
Inlet strainers, when used, should have a net 'free
area' of at least three times the inlet pipe area.
e) Fitting isolation and non-return valves will allow
easier maintenance.
f) Never throttle pump on suction side and never
place a valve directly on the pump inlet nozzle.
4.5.3 Discharge piping
a) A non-return valve should be located in the
discharge pipework to protect the pump from
excessive back pressure and hence reverse
rotation when the unit is stopped.
b) Fitting an isolation valve will allow easier
maintenance.
4.5.4 Flange loads
The permissible flange loading is dependent on a
number of factors such as dimensions, flange rating,
pressure, temperature, material, pump configuration
etc. The recommendations contained in the section on
pipework connections should be followed to eliminate
these loads.
When requested the permissible flange loading will
have been supplied separately to the purchaser and
should be obtained and retained with this manual. If in
doubt contact Flowserve for information.
4.5.5 Auxiliary piping
The connections that are to be piped
up will have been fitted with protective metal or
plastic plugs which will need to be removed.
4.5.5.1 Pumps fitted with packed glands
a) When suction pressure is below ambient pressure
and differential head is less than 10 m, it may be
necessary to feed gland packing with liquid to
provide lubrication and prevent the ingress of air.
b) When pumping “dirty” liquids a clean liquid supply
to the gland is recommended.
4.5.5.2 Pumps fitted with mechanical seals
a) Single seals requiring re-circulation will normally
be provided with the auxiliary piping from pump
casing already fitted.
b) Seal housings/covers having an auxiliary quench
connection require connection to a suitable source
of liquid flow, low pressure steam or static
pressure from a header tank. Recommended
pressure is 0.35 bar (5 psi) or less.
c) Double seals require a barrier liquid between the
seals, compatible with the pumped liquid.
d) With back-to-back double seals, the barrier liquid
should be at a minimum pressure of 1 bar above
the maximum pressure on the pump side of the
inner seal. The barrier liquid pressure must not
exceed limitations of the seal on the atmospheric
side. For toxic service the barrier liquid supply and
discharge must be in a safe area.
e) Special seals may require modification to auxiliary
piping described above. Consult Flowserve if
unsure of correct method or arrangement.
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f) For pumping hot liquids, to avoid seal damage, it is
recommended that any external flush/cooling
supply be continued after stopping the pump.
4.5.5.3 Pumps fitted with heating/cooling jackets
Connect the heating/cooling pipes from the site supply.
The top connection should be used as the outlet to
ensure complete filling/venting of the annulus.
4.5.6 Final checks
Check the torque of all bolts in the suction and
discharge pipework. Check also the torque of all
foundation bolts.
After connecting piping to the pump, rotate the shaft
several times by hand to ensure there is no binding
and all parts are free.
4.6 Electrical connections
Electrical connections must be made
by a qualified Electrician in accordance with relevant
local national and international regulations.
It is important to be aware of the EUROPEAN
DIRECTIVE on potentially explosive areas where
compliance with IEC60079-14 is an additional
requirement for making electrical connections.
It is important to be aware of the EUROPEAN
DIRECTIVE on electromagnetic compatibility when
wiring up and installing equipment on site. Attention
must be paid to ensure that the techniques used during
wiring/installation do not increase electromagnetic
emissions or decrease the electromagnetic immunity of
the equipment, wiring or any connected devices. If in
any doubt contact Flowserve for advice.
The motor must be wired up in
accordance with the motor manufacturer's
instructions (normally supplied within the terminal
box) including any temperature, earth leakage,
current and other protective devices as appropriate.
The identification nameplate should be checked to
ensure the power supply is appropriate.
before connecting the motor to the electrical supply.
4.7 Protection systems
The following protection systems are
recommended particularly if the pump is installed in a
potentially explosive area or is handling a hazardous
liquid. If in any doubt consult Flowserve.
If there is any possibility of the system allowing the
pump to run against a closed valve or below
minimum continuous safe flow, install a protection
device to ensure the temperature of the liquid does
not rise to an unsafe level.
If there are any circumstances in which the system
can allow the pump to run dry, or start up empty, fit a
power monitor to stop the pump or prevent it from
being started. This is particularly relevant if the pump
is handling a flammable liquid.
If leakage of product from the pump or its associated
sealing system can cause a hazard install an
appropriate leakage detection system.
To prevent excessive surface temperatures at
bearings carry out temperature or vibration
monitoring.
5 COMMISSIONING, START-UP,
OPERATION AND SHUTDOWN
out by fully qualified personnel.
5.1 Pre-commissioning procedure
5.1.1 Lubrication
Electric motors are supplied pre-greased and are
normally sealed for life. If in doubt, refer to motor
instruction manual.
See section 5.2, Direction of rotation,
These operations must be carried
5.2 Direction of rotation
A device to provide emergency stopping must
be fitted.
If not supplied pre-wired to the pump unit, the controller/
starter electrical details will also be supplied within the
controller/starter.
For electrical details on pump sets with controllers
see the separate wiring diagram.
pump is started or run in the wrong direction of
rotation. Ensure the pump is given the same rotation
as the pump direction arrow.
out to the site's electricity supply, the direction of
rotation should be re-checked as above in case the
supply phasing has been altered.
Serious damage can result if the
If maintenance work has been carried
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5.3 Guarding
Guarding is supplied fitted to the pump set.
In member countries of the EU and EFTA, it is a legal
requirement that fasteners for guards must remain
captive in the guard to comply with the Machinery
Directive 2006/42/EC. When releasing such guards,
the fasteners must be unscrewed in an appropriate
way to ensure that the fasteners remain captive.
Whenever guarding is removed or disturbed ensure
that all the protective guards are securely refitted
prior to start-up.
5.4 Priming and auxiliary supplies
5.4.1 Filling and priming
Ensure inlet pipe and pump casing is
completely full of liquid before starting continuous
duty operation.
Priming may be carried out with an ejector, vacuum
pump interceptor or other equipment, or by flooding
from the inlet source.
When in service, pumps using inlet pipes with foot
valves may be primed by passing liquid back from the
outlet pipe through the pump.
5.5 Starting the pump
a) Ensure flushing and/or cooling/
heating liquid supplies are turned ON, before
starting pump.
b) CLOSE the outlet valve.
c) OPEN all inlet valves.
d) Prime the pump.
e) Start motor and check the outlet pressure.
f) If the pressure is satisfactory, SLOWLY open the
outlet valve.
g) Do not run the pump against a
closed valve for more than 10 seconds.
h) If NO pressure, or LOW pressure, STOP the
pump. Refer to section 7, Faults; causes and
remedies, for fault diagnosis.
5.6 Running the pump
5.6.1 Pumps fitted with packed glands
If the pump has a packed gland there must be some
leakage from the gland. Gland nuts should initially be
finger-tight only. Leakage should take place soon
after the stuffing box is pressurised.
If no leakage takes place stop the unit, take out the
packing and repack to avoid the packing overheating. If
overheating takes place the pump should be stopped
and allowed to cool. before being re-packing. When
the pump is re-started it should be checked to ensure
leakage is taking place at the packed gland.
If hot liquids are being pumped it may be necessary
to slacken the gland nuts to achieve leakage.
The pump should be run for ten minutes with steady
leakage and the gland nuts tightened by 10 degrees
at a time until leakage is reduced to an acceptable
level, normally 30 to 120 drops per minute. Bedding
in of the packing may take another 15 minutes.
5.6.2 Pumps fitted with mechanical seal
Mechanical seals require no adjustment. Any slight
initial leakage will stop when the seal is run in. Seals
will always have leakage emission from the boundary
film edge in operation.
Before pumping dirty liquids it is advisable, if possible,
to run the pump in using clean liquid to safeguard the
seal face.
For external flush or quench, this
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.
5.6.3 Bearings
If the pumps are working in a potentially
explosive atmosphere monitor temperature and/or
vibration at the bearings.
If bearing temperatures are to be monitored it is
essential that a benchmark temperature is recorded
at the commissioning stage and after the bearing
temperature has stabilized.
•Record the bearing temperature (t) and the
ambient temperature (ta)
•Estimate the likely maximum ambient
temperature (tb)
•Set the alarm at (t+tb-ta+5) ºC (t+tb-ta+10) ºF
and the trip at 100 ºC (212 ºF) for oil lubrication
and 105 ºC (220 ºF) for grease lubrication
It is important, to keep a check on bearing
temperatures. After start up the temperature rise
should be gradual, reaching a maximum after
approximately 1.5 to 2 hours. This temperature should
then remain constant or marginally reduce with time.
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Horizontal pumps
≤
≤
≤
≤
≤
≤
Maximum stop/starts
5.6.3 Normal vibration levels, alarm and trip
For guidance, pumps generally fall under a classification
for rigid support machines within the International
rotating machinery standards and the recommended
maximum levels below are based on those standards.
Alarm and trip values for installed pumps
should be based on the actual measurements (N) taken
on the pump in the fully commissioned as new condition.
Measuring vibration at regular intervals will then show
any deterioration in pump or system operating
conditions.
Vibration velocity –
unfiltered
Normal N
Alarm N x 1.25
Shutdown trip N x 2.0
≤≤≤≤ 15 kW mm/sec
(in./sec) r.m.s.
3.0 (0.12)
3.8 (0.15)
6.0 (0.24)
> 15 kW
mm/sec (in./sec)
r.m.s.
4.5 (0.18)
5.6 (0.22)
9.0 (0.35)
5.6.4 Stop/start frequency
Pump sets are normally suitable for the number of
equally spaced stop/starts per hour shown in the
table below. Check capability of the driver and
control/starting system before commissioning.
Motor rating kW (hp)
Up to 15 (20) 15
Between 15 (20) and 45 (60) 10
per hour
Where duty and standby pumps are installed it is
recommended that they are run alternately every week.
5.7 Stopping and shutdown (all series)
a) Close the outlet valve, but ensure
that the pump runs in this condition for no more
than a few seconds.
b) Stop the pump.
c) Switch off flushing and/or cooling/heating liquid
supplies at a time appropriate to the process.
d) 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 or otherwise protected.
5.8 Hydraulic, mechanical and electrical
duty
This product has been supplied to meet the performance
specifications of your purchase order, however it is
understood that during the life of the product these may
change. The following notes may help the user decide
how to evaluate the implications of any change. If in
doubt contact your nearest Flowserve office.
5.8.1 Specific gravity (SG)
Pump capacity and total head in metres (feet) do not
change with SG, however pressure displayed on a
pressure gauge is directly proportional to SG. Power
absorbed is also directly proportional to SG. It is
therefore important to check that any change in SG
will not overload the pump driver or over-pressurize
the pump.
5.8.2 Viscosity
For a given flow rate the total head reduces with
increased viscosity and increases with reduced
viscosity. Also for a given flow rate the power
absorbed increases with increased viscosity, and
reduces with reduced viscosity. It is important that
checks are made with your nearest Flowserve office if
changes in viscosity are planned.
5.8.3 Pump speed
Changing pump speed effects flow, total head, power
absorbed, NPSHR, noise and vibration. Flow varies in
direct proportion to pump speed, head varies as speed
ratio squared and power varies as speed ratio cubed.
The new duty, however, will also be dependent on the
system curve. If increasing the speed, it is important
therefore to ensure the maximum pump working
pressure is not exceeded, the driver is not overloaded,
NPSHA > NPSHR, and that noise and vibration are
within local requirements and regulations.
5.8.4 Net positive suction head (NPSHA)
NPSH available (NPSHA) is a measure of the head
available in the pumped liquid, above its vapour
pressure, at the pump suction branch.
NPSH required (NPSHR) is a measure of the head
required in the pumped liquid, above its vapour
pressure, to prevent the pump from cavitating. It is
important that NPSHA > NPSHR. The margin between
NPSHA > NPSHR should be as large as possible.
If any change in NPSHA is proposed, ensure these
margins are not significantly eroded. Refer to the
pump performance curve to determine exact
requirements particularly if flow has changed.
If in doubt please consult your nearest Flowserve
office for advice and details of the minimum allowable
margin for your application.
5.8.5 Pumped flow
Flow must not fall outside the minimum and
maximum continuous safe flow shown on the pump
performance curve and or data sheet.
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6 MAINTENANCE
6.1 General
It is the plant operator's responsibility to ensure
that all maintenance, inspection and assembly work
is carried out by authorized and qualified personnel
who have adequately familiarized themselves with
the subject matter by studying this manual in detail.
(See also section 1.6.)
Any work on the machine must be performed when it
is at a standstill. It is imperative that the procedure
for shutting down the machine is followed, as
described in section 5.7.
Before restarting the machine, the relevant
instructions listed 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, stairs and guard rails are required for
maintenance, they must be placed for easy access to
areas where maintenance and inspection are to be
carried out. The positioning of these accessories
must not limit access or hinder the lifting of the part to
be serviced.
When air or compressed inert gas is 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 inert gas on skin.
Do not direct an air or gas jet towards other people.
Never use air or compressed inert gas to clean clothes.
Before working on the pump, take measures to
prevent an uncontrolled start. Put a warning board
on the starting device with the words:
"Machine under repair: do not start".
With electric drive equipment, lock the main switch
open and withdraw any fuses. Put a warning board
on the fuse box or main switch with the words:
"Machine under repair: do not connect".
Never clean equipment with inflammable solvents or
carbon tetrachloride. Protect yourself against toxic
fumes when using cleaning agents.
6.2 Maintenance schedule
It is recommended that a maintenance plan and
schedule is adopted, in line with these User Instructions,
to include the following:
a) Any auxiliary systems installed must be monitored,
if necessary, to ensure they function correctly.
b) Check for any leaks from gaskets and seals. The
correct functioning of the shaft seal must be
checked regularly.
c) Check that the duty condition is in the safe
operating range for the pump.
d) Check vibration, noise level and surface temperature
at the bearings to confirm satisfactory operation.
e) Check dirt and dust is removed from areas around
close clearances, bearing housings and motors.
Our specialist service personnel can help with
preventative maintenance records and provide
condition monitoring for temperature and vibration to
identify the onset of potential problems.
If any problems are found the following sequence of
actions should take place:
a) Refer to section 7, Faults; causes and remedies,
for fault diagnosis.
b) Ensure equipment complies with the
recommendations in this manual.
c) Contact Flowserve if the problem persists.
6.2.1 Routine inspection (daily/weekly)
The following checks should be made
and the appropriate action taken to remedy any
deviations:
a) Check operating behaviour. Ensure noise,
vibration and bearing temperatures are normal.
b) Check that there are no abnormal fluid l leaks
(static and dynamic seals).
c) Check shaft seal leaks are within acceptable limits.
d) Check running hours since last recharge of
grease or complete grease change.
e) Check any auxiliary supplies eg heating/cooling
(if fitted) are functioning correctly.
Refer to the manuals of any associated
equipment for routine checks needed.
6.2.2 Periodic inspection (six monthly)
a) Check foundation bolts for
security of attachment and corrosion.
b) Check pump running records for hourly usage to
determine if bearing lubricant requires changing.
Refer to the manuals of any associated
equipment for periodic checks needed.
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6.2.3 Re-lubrication
For general guidelines refer to section 5.1,
Lubrication.
Lubricant and bearing temperature analysis can be
useful in optimizing bearing change intervals.
6.2.4 Mechanical seals
When leakage becomes unacceptable the seal will
need replacement.
6.3 Spare parts
6.3.1 Ordering of spares
Flowserve keeps records of all pumps that have been
supplied. When ordering spares the following
information should be quoted:
1) Pump serial number.
2) Pump size.
3) Part name – taken from section 8.
4) Part number – taken from section 8.
5) Number of parts required.
The pump size and serial number are shown on the
pump nameplate.
To ensure continued satisfactory operation,
replacement parts to the original design specification
should be obtained from Flowserve. Any change to
the original design specification (modification or use
of a non-standard part) will invalidate the pump’s
safety certification.
6.3.2 Storage of spares
Spares should be stored in a clean dry area away
from vibration. Inspection and re-treatment of
metallic surfaces (if necessary) with preservative is
recommended at 6 monthly intervals.
6.4 Recommended spares
Recommended spares are defined on the following
basis and contained in the table below and in section 8.
• Class 1 (S1) – start-up and commissioning spares.
• Class 2 (S2) – two year spares requirement
covering maintenance for this period.
• Class 3 (S3) – five year capital spares
requirement.
A multiplier is provided in the last column of the table
for multiple pump purchases, which can be used
where more than one pump is purchased to give the
estimated volume of spares required.
See section 8 for recommended spares
6.5 Tools required
A typical range of tools that will be required to
maintain these pumps is listed below.
Readily available in standard tool kits, and dependent
on pump size:
•Open ended spanners (wrenches) to suit up to
M 20 screws/nuts
• Socket spanners (wrenches), up to M 20 screws
• Allen keys, up to 10 mm (A/F)
• Range of screwdrivers
• Soft mallet
• Thickness feeler gages
6.6 Fastener torques
Fastener size Torque Nm (lbf•ft)
M8
M10
M12
M16
M20
16 (12)
25 (18)
35 (26)
80 (59)
130 (96)
Non-metallic gaskets incur creep
relaxation - before commissioning the pump check
and retighten fasteners to tightening torques stated.
6.7 Disassembly
Refer to Safety section 1.6 before dismantling
the pump.
Before dismantling the pump for
overhaul, ensure genuine Flowserve replacement
parts are available. Refer to sectional drawings for
part numbers and identification. (See section 8, Parts lists and drawings.)
a) Close suction and discharge valves and drain
liquid from pump.
b) Remove screws from pump casing and pull motor
and rotating assembly complete from back of
pump casing, which is left connected in the
pipework.
c) Remove the impeller screw and pull off impeller.
(Alternatively, if the pump impeller is fitted with an
inducer, unscrew inducer and inducer stud and pull
off impeller.)
d) These pumps are packed gland as standard. To
complete dismantling, remove the gland nuts, slit
gland and stuffing box cover/mounting bracket
bolts (where fitted). Pull the stuffing box cover
from the mounting bracket and remove packing,
lantern ring and packing seating ring.
e) The mounting bracket (or the adapter where the
mounting feet are on the motor) can now be
separated from the motor after removing the fixing
screws.
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f) These pumps can also be fitted with various
proprietary mechanical seals and the
manufacturer’s instructions should be followed
when dismantling and assembling.
g) It should not be necessary to remove the pump
shaft from the motor shaft during routine
maintenance. However, if this becomes absolutely
necessary, use either of the following procedures:
•Insert a screw into the threaded hole in the end
of the pump shaft. The screw should have a
plain portion of length and diameter to engage
the bottom of the hole without damaging its
threads. The screw can then be tightened to
pull the pump shaft from the motor shaft.
•By using two levers the pump shaft and using
the motor flange as a fulcrum the shaft can be
gently prised away from the motor shaft. It is
easier if this operation is carried out with the
motor stood vertically on its intake cover.
h) It is recommended that a new tolerance ring be
fitted once the pump shaft has been removed.
6.8 Examination of parts
Used parts must be inspected before assembly to
ensure the pump will subsequently run properly. In
particular, fault diagnosis is essential to enhance pump
and plant reliability.
6.8.1 Casing, seal housing and impeller
Inspect for excessive wear, pitting, corrosion, erosion or
damage and any sealing surface irregularities. Replace
as necessary.
6.8.2 Shaft and sleeve (if fitted)
Replace if grooved, pitted or worn.
6.8.3 Gasket, O-rings and lip seals
After dismantling, discard and replace.
6.9 Assembly
To assemble the pump, consult the sectional drawings.
(See section 8, Parts lists and drawings.)
Ensure threads, gasket and O-ring mating faces are
clean. Apply thread sealant to non-face sealing pipe
thread fittings.
a) To refit the pump shaft, screw a long stud into the
end of the motor shaft and pull the pump shaft on
by tightening a nut onto the stud. A washer
should be used between the nut and the shaft to
avoid damage to the shaft end.
c) Whilst re-assembling, use new gaskets and make
sure that they are in their correct positions grease can be used to help hold the gaskets in
place during assembly.
d) The stuffing box, if fitted, should be packed with
good quality packing, suitable for the liquid
handled. Packing should be renewed before it
becomes hard and if fresh packing is required do
not replace the outer rings only, but always all the
rings at the same time.
e) It is important to replace the lantern ring and the
packing seating ring in their correct positions to
ensure that the lantern ring is situated in line with
the gland seal connections. The correct
sequence is as follows: packing seating ring, two
rings of packing, lantern ring and finally two rings
of packing. (See sectional drawings.)
f) These pumps can also be fitted with various
proprietary mechanical seals and the
manufacturer’s instructions should be followed
when dismantling and assembling.
g) Impeller hub rings and casing renewable rings,
where fitted, should be checked for excessive
wear or damage. The diametrical clearance
should be measured, as a general guide, it is
recommended that replacement should be
carried out when the diametrical clearance
exceeds 1.20 mm. A fall off in performance may
necessitate earlier action. (See chart.)
b) Make sure that the slot in the tolerance
ring is placed on the opposite side to the keyway
in the motor shaft.
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This section shows details of the seal arrangements.
Contact your nearest Flowserve sales office or service
centre if you require further information or are unsure
of the specific arrangement supplied.
6.10.1 Single seal types
6.10.1.1 Single seal with simple seal cover
6.10.1.2 Single seal arranged for recirculation
from discharge (API plan 11)
6.10.1.3 Single seal with external PTFE neck bush
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6.10.1.4 Single seal with external lip seal
6.10.2 Double seal types
6.10.2.1 Double back-to-back seal
6.10.3 Packed gland seal types
6.10.3.1 Packed gland with modern fibre packing
Note:
1. Pressed stainless steel gland illustrated.
2. Cast split gland optional.
Packed gland seal with lantern ring
Note:
1. Seal seat seating ring not fitted to Ø70 units.
2. When pinned seat used, pin is located axially.
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7 FAULTS; CAUSES AND REMEDIES
FAULT SYMPTOM
Pum p overh eats and seiz es
Bearings have short life
⇓⇓⇓⇓
⇓⇓⇓⇓
Pum p vibrates or is nois y
Mech anical seal has sh ort life
⇓⇓⇓⇓
⇓⇓⇓⇓
Mech anical seal leaks ex cessive ly
Pum p requi res excessi ve power
⇓⇓⇓⇓
⇓⇓⇓⇓
Pum p loses prime afte r starti ng
Insuffi cient pressur e developed
⇓⇓⇓⇓
⇓⇓⇓⇓
Insuffi cient capacity delivered
Pum p does not del ive r liquid
⇓⇓⇓⇓
⇓⇓⇓⇓
POSSIBLE CAUSES POSSIBLE REMEDIES
A. System troubles
Pump not primed.
Pump or suction pipe not completely filled with liquid.
Suction lift too high or level too low.
Insufficient margin between suction pressure and vapour
pressure.
Excessive amount of air or gas in liquid. Check and purge pipes and system.
Air or vapour pocket in suction line. Check suction line design for vapour pockets.
Air leaks into suction line. Check suction pipe is airtight.
Air leaks into pump through mechanical seal, sleeve
joints, casing joint or pipe lugs.
Foot valve too small. Investigate replacing the foot valve.
Foot valve partially clogged. Clean foot valve.
Inlet of suction pipe insufficiently submerged. Check out system design.
Speed too low. CONSULT FLOWSERVE.
Speed too high. CONSULT FLOWSERVE.
Total head of system higher than differential head of
pump.
Total head of system lower than pump design head.
Specific gravity of liquid different from design.
Viscosity of liquid differs from that for which designed.
Operation at very low capacity.
Operation at high capacity.
Check complete filling. Vent and/or prime.
Check NPSHA > NPSHR, proper submergence,
losses at strainers and fittings.
Check and replace faulty parts.
CONSULT FLOWSERVE.
Check system losses.
Remedy or CONSULT FLOWSERVE.
Check and CONSULT FLOWSERVE.
Measure value and check minimum permitted.
Remedy or CONSULT FLOWSERVE.
Measure value and check maximum permitted.
Remedy or CONSULT FLOWSERVE.
Misalignment due to pipe strain.
Improperly designed foundation.
Shaft bent.
Rotating part rubbing on stationary part internally. Check and CONSULT FLOWSERVE, if necessary.
B. Mechanical troubles
Check the flange connections and eliminate strains
using elastic couplings or a method permitted.
Check setting of baseplate: tighten, adjust, grout
base as required.
Check shaft runouts are within acceptable values.
CONSULT FLOWSERVE.
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FAULT SYMPTOM
Pum p overh eats and seiz es
Bearings have short life
⇓⇓⇓⇓
⇓⇓⇓⇓
Pum p vibrates or is nois y
Mech anical seal has sh ort life
⇓⇓⇓⇓
⇓⇓⇓⇓
Mech anical seal leaks ex cessive ly
Pum p requi res excessi ve power
⇓⇓⇓⇓
⇓⇓⇓⇓
Pum p loses prime afte r starti ng
Insuffi cient pressur e developed
⇓⇓⇓⇓
⇓⇓⇓⇓
Insuffi cient capacity delivered
Pum p does not del ive r liquid
⇓⇓⇓⇓
⇓⇓⇓⇓
Bearings worn Replace bearings.
Wearing ring surfaces worn. Replace worn wear ring/surfaces.
Impeller damaged or eroded.
Leakage under sleeve due to joint failure. Replace joint and check for damage.
Shaft sleeve worn or scored or running off centre. Check and renew defective parts.
Mechanical seal improperly installed.
Incorrect type of mechanical seal for operating
conditions.
Shaft running off centre because of worn bearings or
misalignment.
Impeller out of balance resulting in vibration.
Abrasive solids in liquid pumped.
Internal misalignment of parts preventing seal ring and
seat from mating properly.
Mechanical seal was run dry.
Internal misalignment due to improper repairs causing
impeller to rub.
Excessive thrust caused by a mechanical failure inside
the pump.
Excessive grease in ball bearings. Check method of regreasing.
Lack of lubrication for bearings.
Improper installation of bearings (damage during
assembly, incorrect assembly, wrong type of bearing
etc).
Damaged bearings due to contamination.
POSSIBLE CAUSES POSSIBLE REMEDIES
Replace or CONSULT FLOWSERVE for improved
material selection.
Check alignment of faces or damaged parts and
assembly method used.
CONSULT FLOWSERVE.
Check misalignment and correct if necessary. If
alignment satisfactory check bearings for excessive
wear.
Check and CONSULT FLOWSERVE.
Check mechanical seal condition and source of dry
running and repair.
Check method of assembly, possible damage or
state of cleanliness during assembly.
Remedy or CONSULT FLOWSERVE, if necessary.
Check wear condition of impeller, its clearances and
liquid passages.
Check hours run since last change of lubricant, the
schedule and its basis.
Check method of assembly, possible damage or
state of cleanliness during assembly and type of
bearing used. Remedy or CONSULT
FLOWSERVE, if necessary.
Check contamination source and replace damaged
bearings.
Wrong direction of rotation. Reverse 2 phases at motor terminal box.
Motor running on 2 phases only. Check supply and fuses.
Motor running too slow. Check motor terminal box connections and voltage.
C. MOTOR ELECTRICAL PROBLEMS
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WR and CR USER INSTRUCTIONS ENGLISH 26999968 10-12
8 SECTIONAL ARRANGEMENT DRAWINGS AND PARTS LISTS
8.1 Type WR
Page 23 of 28 flowserve.com
WR and CR USER INSTRUCTIONS ENGLISH 26999968 10-12
Spares level
**
Multiplier
Part no. Description No. off Material
0241 Tolerance ring 1 (A) Steel
1100 Casing 1 Cast iron
1220 Cover 1 Cast iron
1340 Mounting bracket 1 Cast iron
1500 Casing wear ring 1 Cast iron
1521 Cover wear ring 1 (F) Cast iron
2110 Pump shaft 1 303 S21
2200 Impeller 1 Cast iron
2215 Inducer † 1 (D) 316 SS
2540 Deflector 1 Rubber
2913 Impeller screw 1 Hi-tensile steel
4120 Gland 1 (B) Cast iron
4130 Gland packing 1 set (C)
4133 Packing seating ring 1 316 S16
4134 Lantern ring 1 PTFE
4553 Impeller screw joint 1 Klingerit
4590.1 Gasket 1 Klingerit
4590.2 Gasket 1 Klingerit
4590.3 Gasket 1 Klingerit
4590.4 Gasket 1 Klingerit
4610.1 O-ring * 1 Rubber
4610.2 O-ring * 1 Rubber
4610.3 O-ring 1 Rubber
6415 Cap * 1 Cast iron
6543 Impeller washer 1 Mild steel
(A) 2 tolerance rings are fitted on pumps with 160, 180 and 200 frame size motors.
(B) In halves.
(C) Crane style 804 SP or equal.
(D) Not shown - optional construction feature.
(E) 8 screws on WR160 and WR200 sizes.
* These items are only fitted on WR200 pump sizes with 100/112 frame size motors.
** See section 6.4, Recommended spare parts.
(A) 2 tolerance rings are fitted on pumps with 160, 180 and 200 frame size motors.
(B) In halves.
(C) Crane style SS6 or equal.
(D) Not shown - optional construction feature.
(E) 8 screws on CR160 and CR200 sizes.
(F) Integral with stuffing box cover on pump sizes 125CR250, 50CR315, 65CR315, 100CR315, 125CR315 and 150CR315.
* These items are only fitted on CR pump sizes with 100/112 frame size motors.
** See section 6.4, Recommended spare parts.
†
Not indicated on the GA drawing
Page 26 of 28 flowserve.com
WR and CR USER INSTRUCTIONS ENGLISH 26999968 10-12
8.3 General arrangement drawing
The typical general arrangement drawing and any
specific drawings required by the contract will be sent
to the Purchaser separately unless the contract
specifically calls for these to be included into the User
Instructions. If required, copies of other drawings
sent separately to the Purchaser should be obtained
from the Purchaser and retained with these User
Instructions.
9 CERTIFICATION
Certificates determined from the Contract requirements
are provided with these Instructions where applicable.
Examples are certificates for CE marking, ATEX
marking etc. If required, copies of other certificates sent
separately to the Purchaser should be obtained from
the Purchaser for retention with these User Instructions.
10 OTHER RELEVANT
DOCUMENTATION AND MANUALS
10.1 Supplementary User Instruction
manuals
Supplementary instruction determined from the contract
requirements for inclusion into User Instructions such as
for a driver, instrumentation, controller, sub-driver, seals,
sealant system, mounting component etc are included
under this section. If further copies of these are
required they should be obtained from the purchaser for
retention with these User Instructions.
Where any pre-printed set of User Instructions are
used, and satisfactory quality can be maintained only
by avoiding copying these, they are included at the
end of these User Instructions such as within a
standard clear polymer software protection envelope.
10.2 Change notes
If any changes, agreed with Flowserve Solution
Group, are made to the product after its supply, a
record of the details should be maintained with these
User Instructions.
10.3 Additional sources of information
Reference 1:
NPSH for Rotordynamic Pumps: a reference guide,
Europump Guide No. 1, Europump & World Pumps,
Elsevier Science, United Kingdom, 1999.