HP 8-UB-1 User Manual

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Pump Division

Type: 8-UB-1

CENTRIFUGAL PUMP

USER INSTRUCTIONS: INSTALLATION, OPERATION, MAINTENANCE

PCN=71569247 07-04(E) (supercedes 6176/6511)

These instructions must be read prior to installing,

operating, using and maintaining this equipment.

CONTENTS

PAGE

1 INTRODUCTION AND SAFETY ........................... 4

1.1 General ........................................................... 4

1.2 CE marking and approvals.............................. 4

1.3 Disclaimer ....................................................... 4

1.4 Copyright......................................................... 4

1.5 Duty conditions................................................ 4

1.6 Safety .............................................................. 5

1.7 Warning labels summary ................................ 8

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

1.9 Noise level....................................................... 9

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

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

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

2.3 Lifting............................................................. 10

2.4 Storage.......................................................... 10

2.5 Recycling and end of product life.................. 10

3 PUMP DESCRIPTION......................................... 11

3.1 Configurations ............................................... 11

3.2 Name nomenclature...................................... 11

3.3 Design of major parts .................................... 11

3.4 Performance and operating limits ................. 11

4 INSTALLATION.................................................... 12

4.1 Location......................................................... 12

4.2 Foundation .................................................... 12

4.3 Grouting ........................................................ 12

4.4 Initial alignment ............................................. 12

4.5 Piping ............................................................ 13

4.6 Final shaft alignment check .......................... 16

4.7 Electrical connections ................................... 16

4.8 Protection systems........................................ 16

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

PAGE

6 MAINTENANCE ...................................................20

6.1 General ..........................................................20

6.2 Maintenance schedule...................................20

6.3 Spare parts ....................................................22

6.4 Recommended spares and

consumable items ..........................................22

6.5 Tools required ................................................23

6.6 Fastener torques............................................23

6.7 Renewal clearances ......................................23

6.8 Disassembly ..................................................23

6.9 Examination of parts ......................................24

6.10 Assembly .....................................................24

7 FAULTS; CAUSES AND REMEDIES ...................27

8 PARTS LISTS AND DRAWINGS .........................29

8.1 Sectional drawings – UB grease

lubricated, gland packed ................................29

8.2 General arrangement drawing.......................30

9 CERTIFICATION..................................................31

10 OTHER RELEVANT DOCUMENTATION

AND MANUALS................................................31

10.1 Supplementary User Instructions ................31

10.2 Change notes ..............................................31

10.3 Additional sources of information ................31

5 COMMISSIONING, START-UP, OPERATION

AND SHUTDOWN ........................................... 16

5.1 Pre-commissioning procedure ...................... 16

5.2 Pump lubricants ............................................ 17

5.3 Direction of rotation ....................................... 17

5.4 Guarding ....................................................... 17

5.5 Priming and auxiliary supplies ...................... 17

5.6 Starting the pump.......................................... 18

5.7 Running the pump......................................... 18

5.8 Stopping and shutdown ................................ 19

5.9 Hydraulic, mechanical and electrical duty..... 19

Page 2 of 32

INDEX

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

PAGE

Additional sources (10.3) ......................................... 31

Alignment of shafting (4.2, 4.4 and 4.6)

Assembly (6.10)....................................................... 24

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

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

Certification (9) ........................................................ 31

Change notes (10.2) ................................................ 31

Clearances (6.7, Renewal clearances).................... 23

Commissioning and operation (5)............................ 16

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

Configurations (3.1) ................................................. 11

Consumable items (6.4) .......................................... 22

Design of major parts (3.3) ...................................... 11

Direction of rotation (5.3) ......................................... 17

Disassembly (6.8) .................................................... 23

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

Dismantling (6.8, Disassembly) ............................... 23

Drawings (8) ............................................................ 29

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

Electrical connections (4.7) ..................................... 16

End of product life (2.5) ........................................... 10

Examination of parts (6.9)........................................ 24

Fastener torques (6.6) ............................................. 23

Faults; causes and remedies (7) ............................. 27

Forces and moments (4.5.3) ................................... 15

Foundation (4.2) ...................................................... 12

General arrangement drawing (8.2) ........................ 30

General assembly drawings (8)............................... 29

Grouting (4.3)........................................................... 12

Guarding (5.4).......................................................... 17

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

Hydraulic, mechanical and electrical duty (5.9)....... 19

Inspection (6.2.1 and 6.2.2)..................................... 21

Installation (4) .......................................................... 12

Lifting (2.3) ............................................................... 10

Location (4.1)........................................................... 12

Lubrication (5.2 and 6.2.3)

Lubrication schedule (5.2.2) .................................... 17

Maintenance (6)....................................................... 20

Maintenance schedule (6.2) .................................... 20

Name nomenclature (3.2) ........................................ 11

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

Operating limits (3.4.1) ............................................ 11

Options (8.1.2) ......................................................... 30

Ordering spare parts (6.3.1) .................................... 22

Parts lists (8)............................................................ 29

Performance (3.4).................................................... 11

Piping (4.5) .............................................................. 13

Pre-commissioning (5.1) ..........................................16

Priming and auxiliary supplies (5.5) .........................17

Protection systems (4.8) ..........................................16

Reassembly (6.10, Assembly) .................................24

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

Recommended grease lubricants (5.2.1) .................17

Recommended spares (6.4).....................................22

Recycling (2.5) .........................................................10

Renewal clearances (6.7).........................................23

Replacement parts (6.3 and 6.4)..............................22

Running the pump (5.7)............................................18

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

Safety markings (1.6.1) ..............................................5

Safety, protection systems (1.6 and 4.8)

Sectional drawings (8) ..............................................29

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

Sources, additional information (10.3) .....................31

Spare parts (6.3) ......................................................22

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

Starting the pump (5.6).............................................18

Stop/start frequency (5.7.6)......................................19

Stopping and shutdown (5.8) ...................................19

Storage, pump (2.4) .................................................10

Storage, spare parts (6.3.2) .....................................22

Supplementary manuals or information sources......31

Supplementary User Instructions (10.1)...................31

Tools required (6.5) ..................................................23

Torques for fasteners (6.6).......................................23

Trouble-shooting (see 7) ..........................................27

Vibration (5.7.5) ........................................................19

Warning labels (1.7.2) ................................................8

Page 3 of 32

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

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 should 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.

1.2 CE marking and approvals

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

Where applicable, the Directives and any additional Approvals, cover important safety aspects relating to machinery and equipment and the satisfactory provision of technical documents and safety instructions. Where applicable this document incorporates information relevant to these Directives

and Approvals. To confirm the Approvals applying and if the product is CE marked, check the serial number plate markings and the Certification. (See section 9, Certification.)

1.3 Disclaimer

Information in these User Instructions is believed to be reliable. In spite of all the efforts of Flowserve Pump Division to provide sound and all necessary information the content of this manual may appear insufficient and is not guaranteed by Flowserve as to its completeness or accuracy.

Flowserve manufactures products to exacting International Quality Management System Standards as certified and audited by external Quality Assurance 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

1.5 Duty conditions

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

The product must not be operated beyond

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

If the conditions of service on your purchase order are going to be changed (for example liquid pumped, temperature or duty) it is requested that the user seeks the written agreement of Flowserve before start up.

Page 4 of 32

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

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 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.

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.

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

If you elect to use heat to remove the impeller, it must be applied quickly to the impeller boss. TAKE

GREAT CARE!

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.

Page 5 of 32

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

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

HOT (and cold) PARTS If hot or freezing components or auxiliary heating supplies can present a danger to operators and persons entering the immediate area action must be taken to avoid accidental contact. If complete protection is not possible, the machine access must be limited to maintenance staff only, with clear visual warnings and indicators to those entering the immediate area. Note: bearing housings must not be insulated and drive motors and bearings may be hot.

If the temperature is greater than 68 ºC (175 ºF) or below 5 ºC (20 ºF) in a restricted zone, or exceeds local regulations, action as above shall be taken.

HAZARDOUS LIQUIDS When the pump is handling hazardous liquids care must be taken to avoid exposure to the liquid by appropriate siting of the pump, limiting personnel access and by operator training. If the liquid is flammable and/or explosive, strict safety procedures must be applied.

Gland packing must not be used when pumping hazardous liquids.

PREVENT EXCESSIVE EXTERNAL PIPE LOAD Do not use pump as a support for piping. Do not mount expansion joints, unless allowed by Flowserve in writing, so that their force, due to internal pressure, acts on the pump flange.

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

START THE PUMP WITH OUTLET VALVE PARTLY OPENED (Unless otherwise instructed at a specific point in the User Instructions.) This is recommended to minimize the risk of overloading and damaging the pump motor at full or zero flow. Pumps may be started with the valve further open only on installations where this situation cannot occur. The pump outlet control valve may need to be adjusted to comply with the duty following the run-up process. (See section 5, Commissioning start-up, operation and shutdown.)

NEVER RUN THE PUMP DRY

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. Both electrical and non-electrical equipment must meet the requirements of European Directive 94/9/EC.

1.6.4.1 Scope of compliance

Use equipment only in the zone for which it is appropriate. Always check that the driver, drive coupling assembly, seal and pump equipment are suitably rated and/or certified for the classification of the specific atmosphere in which they are to be installed.

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

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

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.

Page 6 of 32

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

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 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 prEn13463-5)

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

Temperature classification “Tx” is used when the liquid temperature varies and the pump could be installed in different hazarous atmospheres. In this case the user is responsible for ensuring that the pump surface temperature does not exceed that permitted in the particular hazardous atmosphere.

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

Where there is any risk of the pump being run against a closed valve generating high liquid and casing external surface temperatures it is recommended that users fit an external surface temperature protection device.

Avoid mechanical, hydraulic or electrical overload by using motor overload trips, temperature monitor or a power monitor and make routine vibration monitoring checks.

In dirty or dusty environments, regular checks must be made and dirt removed from areas around close clearances, bearing housings and motors.

Pumps have a temperature class as stated in the ATEX Ex rating on the nameplate. These are based on a maximum ambient of 40 ºC (104 ºF); refer to Flowserve for higher ambient temperatures.

The surface temperature on the pump is influenced by the temperature of the liquid handled. The maximum permissible liquid temperature depends on the temperature class and must not exceed the values in the table that follows.

The temperature rise at the seals and bearings and due to the minimum permitted flow rate is taken into account in the temperatures stated.

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)

Temperature limit of liquid

handled (* depending on

material and construction

variant - check which is lower)

Consult Flowserve Consult Flowserve

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

The responsibility for compliance with the specified maximum liquid temperature is with the plant operator.

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 the fitting of an appropriate dry run protection device is recommended (for example liquid detection or a power monitor).

To avoid potential hazards from fugitive emissions of vapour or gas to atmosphere the surrounding area must be well ventilated.

1.6.4.5 Preventing sparks

To prevent a potential hazard from mechanical contact, the coupling guard must be non-sparking and anti-static for Category 2.

Page 7 of 32

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

To avoid the potential hazard from random induced current generating a spark, the earth contact on the baseplate must be used.

Avoid electrostatic charge: do not rub non-metallic surfaces with a dry cloth; ensure cloth is damp.

The coupling must be selected to comply with 94/9/EC and correct alignment must be maintained.

1.6.4.6 Preventing leakage

The pump must only be used to handle liquids for which it has been approved to have the correct corrosion resistance.

Avoid entrapment of liquid in the pump and associated piping due to closing of suction and discharge valves, which could cause dangerous excessive pressures to occur if there is heat input to the liquid. This can occur if the pump is stationary or running.

Bursting of liquid containing parts due to freezing must be avoided by draining or protecting the pump and ancillary systems.

1.7 Warning 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

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

If leakage of liquid to atmosphere can result in a hazard, the installation of a liquid detection device is recommended.

1.6.4.7 Maintenance to avoid the hazard

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

The responsibility for compliance with maintenance instructions is with the plant operator.

To avoid potential explosion hazards during maintenance, the tools, cleaning and painting materials used must not give rise to sparking or adversely affect the ambient conditions. Where there is a risk from such tools or materials, maintenance must be conducted in a safe area.

It is recommended that a maintenance plan and schedule is adopted. (See section 6, Maintenance.)

Oil lubricated units only:

1.8 Specific machine performance

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

these to be incorporated into User Instructions these are included here. Where performance data has been supplied separately to the purchaser these should be obtained and retained with these User Instructions if required.

Page 8 of 32

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

1.9 Noise level

When pump noise level exceeds 85 dB(A) attention

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

must be given to prevailing Health and Safety Legislation, to limit the exposure of plant operating personnel to the noise. The usual approach is to control 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

The values are based on the noisiest ungeared electric motors that are likely to be encountered. They represent sound pressure levels at 1 m (3.3 ft) from the directly driven pump, for "free field over a reflecting plane".

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 meet local regulations.

If a pump unit only has been purchased, for fitting with your own driver, then the "pump only" noise levels from the table should be combined with the level for the driver obtained from the supplier. If the motor is driven by an inverter it may show an

Pump noise level is dependent on a number of factors - the type of motor fitted, the operating

increase in noise level at some speeds. Consult a Noise Specialist for the combined calculation.

capacity, pipework design and acoustic



characteristics of the building. Typical sound pressure levels measured in dB, and A-weighted are shown in the table below.

Typical sound pressure level, dBA, L

and speed

kW (hp)

<0.55 (<0.75)

0.75 (1) 74 (91) 66 (83) 67 (84) 62 (79) 67 (84) 62 (79) 63 (80) 62 (79)

1.1 (1.5)

1.5 (2) 77 (94) 70 (87) 70 (87) 66 (83) 70 (87) 66 (83) 66 (83) 66 (83)

2.2 (3)

3 (4) 81 (98) 74 (91) 74 (91) 70 (87) 74 (91) 70 (87) 70 (87) 70 (87) 4 (5) 82 (99) 75 (92) 75 (92) 71 (88) 75 (92) 71 (88) 71 (88) 71 (88)

5.5 (7.5) 90 (107) 77 (94) 83 (100) 73 (90) 76 (93) 73 (90) 72 (89) 71 (88)

7.5 (10) 90 (107) 78 (95) 83 (100) 74 (91) 77 (94) 74 (91) 73 (90) 72 (89)

11 (15) 91 (108) 80 (97) 84 (101) 76 (93) 78 (95) 76 (93) 74 (91) 73 (90)

15 (20) 92 (109) 83 (100) 85 (102) 79 (96) 80 (97) 79 (96) 76 (93) 75 (92)

18.5 (25) 92 (109) 83 (100) 85 (102) 79 (96) 80 (97) 79 (96) 76 (93) 75 (92) 22 (30) 92 (109) 83 (100) 85 (102) 79 (96) 81 (98) 79 (96) 77 (94) 75 (92)

30 (40) 100 (117) 85 (102) 93 (110) 81 (98) 84 (101) 80 (97) 80 (97) 76 (93) 37 (50) 100 (117) 86 (103) 93 (110) 82 (99) 84 (101) 80 (97) 80 (97) 76 (93)

45 (60) 100 (117) 87 (104) 93 (110) 83 (100) 84 (101) 80 (97) 80 (97) 76 (93) 55 (75) 100 (117) 88 (105) 95 (112) 84 (101) 86 (103) 81 (98) 82 (99) 77 (94)

75 (100) 100 (117 ) 90 (107) 95 (112) 86 (103) 88 (105) 81 (98) 83 (100) 78 (95) 90 (120) 100 (117 ) 90 (107) 95 (112) 86 (103) 90 (107) 81 (98) 85 (102) 78 (95)

110 (150) 100 (117 ) 91 (108) 95 (112 ) 87 (104) 91 (108) 83 (100) 86 (103) 79 (96) 150 (200) 101 (118) 92 (109) 96 (113 ) 88 (105) 91 (108) 83 (100) 86 (103) 79 (96)

200 (270) 300 (400) ----

500 (670) ---1000 (1300) ---1500 (2000) Motors in this range are generally job specific and noise levels should be calculated based on actual equipment installed.

①

For 960 r/min reduce 1450 r/min values by 5 dBA.

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

Pump and

motor

dBA

71 (88) 66 (83) 64 (81) 62 (79) 64 (81) 62 (79) 63 (80) 62 (79)

74 (91) 68 (85) 67 (84) 64 (81) 67 (84) 64 (81) 65 (82) 64 (81)

78 (95) 72 (89) 71 (88) 68 (85) 71 (88) 68 (85) 68 (85) 68 (85)

①①①①①

----

Pump

only

dBA

at 1 m reference 20 µPa (L

Pump and

motor

dBA

Pump

only

dBA

For units driven by equipment other than electric

motors or units contained within enclosures, see the accompanying information sheets and manuals.

sound power 1 pW where LpA > 85 dBA)

Pump and

motor

dBA

①

Pump

only

dBA

83 (100) 84 (101)

85 (102) 86 (103)

90 (107)

Pump and

motor

dBA

①

Pump

only

dBA

80 (97) 81 (98)

83 (100) 86 (103)

88 (105)

Page 9 of 32

2 TRANSPORT AND STORAGE

2.1 Consignment receipt and unpacking

Immediately after receipt of the equipment it must be checked against the delivery and shipping documents for its completeness and that there has been no damage in transportation.

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

Any shortage and or damage must be reported immediately to Flowserve Pump Division and received in writing within one month of receipt of the equipment. Later claims cannot be accepted.

Check any crates, boxes and 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.

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

To avoid distortion, the pump unit

should be lifted as shown.

When there are no specific lifting points on the baseplate

A crane must be used for all pump sets in excess of 25 kg (55 lb.). Fully trained personnel must carry out lifting, in accordance with local regulations.

The driver weight is recorded on its nameplate or massplate.

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 regulations. 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.

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.

Page 10 of 32

Make sure that hazardous substances are

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

3 PUMP DESCRIPTION

3.1 Configurations

The 8-UB-1pump is a horizontal split casing two stage volute type centrifugal pump designed for water works, drainage, general service and circulating applications. It can be used with motor, steam turbine and gasoline or diesel engine drive.

It has the following horizontal configuration:

3.2 Name nomenclature

The pump size will be engraved on the nameplate typically as below:

8-UB- 1

Nominal discharge branch size

Configuration – see 3.1 above

The typical nomenclature above is the general guide to the UB 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 has its main casing gasket axial to the shaft allowing maintenance to the rotating element by removing the top half casing. Suction and discharge branches are in the bottom half and therefore remain undisturbed.

3.3.2 Impellers

The impellers are fully shrouded and may be fitted with optional hub rings.

3.3.3 Shaft

The large diameter stiff shaft, mounted on bearings, has a keyed drive end.

3.3.4 Pump bearings and lubrication

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

3.3.5 Bearing housing

Two grease nipples enable grease lubricated bearings to be replenished between major service intervals.

3.3.6 Seal housing

The design enables one of a number of sealing options to be fitted.

3.3.7 Shaft seal

The mechanical seal(s), attached to the pump shaft, seals the pumped liquid from the environment. Gland packing may be fitted as an option.

3.3.8 Driver

The driver is normally an electric motor. Different drive configurations may be fitted such as internal combustion engines, turbines, hydraulic motors etc driving via couplings, belts, gearboxes, drive shafts etc.

3.3.9 Accessories

Accessories may be fitted when specified by the customer.

3.4 Performance and operating limits

This product has been selected to meet the specifications of your purchase order, see section 1.5.

The following data is included as additional information to help with your installation. It is typical, and factors such as temperature, materials, and seal type may influence this data. If required, a definitive statement for your particular application can be obtained from Flowserve.

3.4.1 Operating limits

Pumped liquid temperature limits*

Maximum ambient temperature*

Maximum soft solids in suspension*

Maximum pump speed

*Subject to written agreement from Flowserve.

3.4.2 Pump and impeller data

Impeller

Pump

size

8-UB-1 17.5 (0.69) 266.7 (10.5) 0.19 (0.0075)

*May be up to 0.13 mm (0.005 in.) larger if casing ring and impeller have a tendency to gaul.

Pump

size

8-UB-1 127 (5) 0.11 (0.0045)

minimum

passage

size

mm (in.)

Nominal diaphragm

bush diameter

mm (in.)

- 20 to + 120 ºC (- 4 to + 250 ºF)

- 20 to + 40 ºC (- 4 to +104 ºF) up to 3 % by volume (refer for size limits) refer to the nameplate

Nominal

wear

ring

diameter

mm (in.)

Mean radial

bush clearance

mm (in.)

Mean

radial

wear ring clearance mm (in.) *

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UB USER INSTRUCTIONS ENGLISH 71569247 07-04

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 Foundation

There are many methods of installing pump units to their foundations. The correct method depends on the size of the pump unit, its location and noise vibration limitations. Non-compliance with the provision of correct foundation and installation may lead to failure of the pump and, as such, would be outside the terms of the warranty. Ensure the following are met. a) The baseplate should be mounted onto a firm

foundation, either an appropriate thickness of quality concrete or sturdy steel framework. (It should NOT be distorted or pulled down onto the surface of the foundation, but should be supported to maintain the original alignment.)

b) Install the baseplate onto packing pieces evenly

spaced and adjacent to foundation bolts.

e) If the pump is driven via a universal joint drive

shaft there may be a requirement to offset the pump shaft with respect to the driver to optimize the universal joint drive shaft bearing life. This offset will typically be in the range 0 to 4 degrees depending on shaft design. Please consult the separate User Instructions before installation.

f) Any support for the universal joint drive shaft

plummer blocks must not exhibit resonant frequencies in the range 0.8 to 1.2 N where N = pump running speed.

g) If not supplied, guarding shall be fitted as

necessary to meet the requirements of EN292 and EN953 and or any applicable local safety regulations.

4.3 Grouting

Where applicable, grout in the foundation bolts.

After adding pipework connections and rechecking the coupling alignment, the baseplate should then be grouted in accordance with good engineering practice. Fabricated steel, cast iron and epoxy baseplates can be filled with grout. Folded steel baseplates should be grouted to locate their packing pieces. If in any doubt, please contact your nearest service centre for advice.

Grouting provides solid contact between the pump unit and foundation, prevents lateral movement of running equipment and dampens resonant vibrations.

Foundation bolts should only be fully tightened when the grout has cured.

c) Level with shims between baseplate and packing

pieces.

d) The pump and driver have been aligned before

dispatch however the alignment of pump and motor half coupling must be checked. If this is incorrect, it indicates that the baseplate has become twisted and should be corrected by re-shimming.

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4.4 Initial alignment

4.4.1 Thermal expansion

The pump and motor will normally have to be aligned at ambient temperature and should be corrected to allow for thermal expansion at operating temperature. In pump installations involving high liquid temperatures, the unit should be run at the actual operating temperature, shut down and the alignment checked immediately.

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

4.4.2 Alignment methods

Ensure pump and driver are isolated

electrically and the half couplings are disconnected.

The alignment MUST be checked.

Although the pump will have been aligned at the factory it is most likely that this alignment will have been disturbed during transportation or handling. If necessary, align the motor to the pump, not the pump to the motor.

Alignment is achieved by adding or removing shims under the motor feet and also moving the motor horizontally as required. In some cases where the alignment cannot be achieved it will be necessary to move the pump before recommencing the above procedure.

For couplings with narrow flanges use a dial indicator as shown below to check both parallel and angular alignment.

Par al l el

Pumps with thick flanged non-spacer couplings can be aligned by using a straight-edge across the outside diameters of the coupling hubs and measuring the gap between the machined faces using feeler gauges, measuring wedge or callipers.

When the electric motor has sleeve bearings it is necessary to ensure that the motor is aligned to run on its magnetic centreline.



Refer to the motor manual for details.

A button (screwed into one of the shaft ends) is normally fitted between the motor and pump shaft ends to fix the axial position.

If the motor does not run in its magnetic centre the resultant additional axial force may overload the pump thrust bearing.

Complete piping as below and see sections 4.6, Final shaft alignment check up to and including section 5, Commissioning, startup, operation and shutdown before connecting driver and checking actual rotation.

Angular

Maximum permissible misalignment at working temperature:

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

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

Align in the vertical plane first, then horizontally by moving motor. When performing final alignment, check for soft-foot under the driver. A TIR indicator placed on the coupling, reading in the vertical direction, should not indicate more than 0.05 mm (0.002 in.) movement when any driver foot fastener is loosened.

While the pump is capable of operating with the maximum misalignment shown above, maximum pump reliability is obtained by near perfect alignment of 0.05 to 0.10 mm (0.002 to 0.004 in.) TIR parallel and 0.05 mm (0.002 in.) per 100 mm (4 in.) of coupling flange diameter as TIR angular misalignment. This covers the full series of couplings available.

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.

4.5.1 Suction and discharge pipework

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.

Take into account the available NPSH, which must be higher than the required NPSH of the pump.

Never use the pump as a support for piping.

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:

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UB USER INSTRUCTIONS ENGLISH 71569247 07-04

• 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

The table in 4.5.3 summarizes the maximum forces and moments allowed on horizontal shaft pump casings.

Ensure piping and fittings are flushed

before use.

Ensure piping for hazardous liquids is arranged

to allow pump flushing before removal 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) Pipework reducers should be conical and have a

maximum total angle of divergence of 15 degrees.

c) On suction lift the piping should be inclined up

towards the pump inlet with eccentric reducers incorporated to prevent air locks.

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

constant fall towards the pump.

e) Flow should enter the pump suction with uniform

flow, to minimize noise and wear. This is particularly important on large or high-speed pumps, which should have a minimum of five diameters of straight pipe on the pump suction between the elbow and inlet flange. See section

10.3, Reference 1, for more detail.

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

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

g) Do not install elbows at an angle other than

perpendicular to the shaft axis. Elbows parallel to the shaft axis will cause uneven flow.

h) Except in unusual circumstances strainers are

not recommended in inlet piping. If considerable foreign matter is expected a screen installed at the entrance to the wet well is preferable.

i) Fitting an isolation valve will allow easier

maintenance.

j) Never throttle pump on suction side and never

place a valve directly on the pump inlet nozzle.

Typical design – flooded suction

Discharge isolating valve

Note:

Ideally reducers should be limited to one pipe diameter change, ie 150 mm (6 in.) to 200 mm (8 in.). Must have a maximum total angle of divergence of 15 degrees.

Non return valve

Concentric conical reducer

Eccentric conical reducer

Suction isolating valve

Slope up from pump suction

Typical design – suction lift

Discharge isolating valve

Notes:

1. S = Minimum submergence >3E.

2. Ideally reducers to be limited to one pipe diameter change,

ie 150 mm (6 in.) to 200 mm (8 in.). Must have a maximum total angle of

Concentric conical

Non

reducer

return valve

divergence of 15 degrees.

Eccentric conical reducer

Slope down

from pump suction

Long radius bend

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UB USER INSTRUCTIONS ENGLISH 71569247 07-04

4.5.3 Maximum forces and moments allowed on the pump suction and discharge flanges of horizontal shaft pumps

Maximum forces (F) in kN (lbf) and maximum moments (M) in kNm (lbf·ft)

Type and size

8-UB-1

Fx Fy Fz Mx My Mz Fx Fy Fz Mx My Mz

7.35

(1653)

5.78

(1299)

Suction Discharge

4.20

(944)

4.25

(3134)

2.25

(1659)

3.00

(2212)

3.84

(863)

4.40

(989)

3.20

(719)

2.20

(1622)

1.20

(885)

1.60

(1180)

Notes:

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

2) Forces and moments may be applied simultaneously in any direction.

3) Values apply to all materials.

4) Higher loads may be applicable, if direction and magnitude of individual loads are known, but these need written approval from Flowserve Pumps.

5) Pumps must be on rigid foundations and baseplates must be fully grouted

6) Pump/baseplate should not be used as pipe anchor. Suction and discharge piping should be anchored as close as possible to the pump flanges to reduce vibration and prevent strain on the pump casing. Expansion joints are recommended. They must be properly tied and located on the side of the pipe anchor away from the pump.

7) The pump mounting bolt torques specified must be used to prevent relative movement between the pump casing and baseplate. (See section 6.6, Fastener torques.) The bolt material must have a minimum yield strength of 600 N/mm (87 000 lb/in.2).

4.5.4 Discharge piping

See section 4.5.2 for typical pipework design.

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.

Pipework reducers should have a maximum total angle of divergence of 9 degrees.

4.5.5 Auxiliary piping

4.5.5.1 Drains

Pipe pump casing drains and gland leakage to a convenient disposal point.

4.5.5.2 Pumps fitted with packed gland

When suction pressure is below ambient pressure it is necessary to feed the gland packing with liquid to provide lubrication and prevent the ingress of air. This is normally achieved with a supply from the pump discharge volute to the stuffing box.

If the pumped liquid is dirty and cannot be used for sealing, a separate clean compatible liquid supply to the gland at 1 bar (15 psi) above suction pressure is recommended.

4.5.5.3 Pumps fitted with mechanical seals

Single seals requiring re-circulation will normally be provided with the auxiliary piping from pump casing already fitted.

If the seal requires an auxiliary quench then a connection must be made 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. Check General arrangement drawing.

Fitting an isolation valve will allow easier maintenance.

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UB USER INSTRUCTIONS ENGLISH 71569247 07-04

Special seals may require different auxiliary piping to that described above. Consult separate User Instructions and or Flowserve if unsure of correct method or arrangement.

For pumping hot liquids, to avoid seal damage, it is recommended that any external flush/cooling supply be continued after stopping the pump.

4.5.6 Final checks

Check the tightness of all bolts in the suction and discharge pipework. Check also the tightness of all foundation bolts.

4.6 Final shaft alignment check

After connecting piping to the pump, rotate the shaft several times by hand to ensure there is no binding and all parts are free.

Recheck the coupling alignment, as previously described, to ensure no pipe strain. If pipe strain exists, correct piping.

4.7 Electrical connections

Electrical connections must be made by a qualified Electrician in accordance with relevant local, national and international regulations.

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.

See section 5.3, Direction of rotation

before connecting the motor to the electrical supply.

4.8 Protection systems

The following protection systems are recommended particularly if the pump is installed in a potentially explosive area or is handling a hazardous liquid. If in doubt consult Flowserve.

If there is any possibility of the system allowing the pump to run against a closed valve or below minimum continuous safe flow a protection device should be installed to ensure the temperature of the liquid does not rise to an unsafe level.

If there are any circumstances in which the system can allow the pump to run dry, or start up empty, a power monitor should be fitted to stop the pump or prevent it from being started. This is particularly relevant if the pump is handling a flammable liquid.

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.

A device to provide emergency stopping must

be fitted.

If leakage of product from the pump or its associated sealing system can cause a hazard it is recommended that an appropriate leakage detection system is installed.

To prevent excessive surface temperatures at bearings it is recommended that temperature or vibration monitoring are carried out. See sections

5.7.4 and 5.7.5.

5 COMMISSIONING, START-UP, OPERATION AND SHUTDOWN

These operations must be carried

out by fully qualified personnel.

5.1 Pre-commissioning procedure

Pumps and electric motors are supplied pre-greased.

Other drivers and gearboxes, if appropriate, should be lubricated in accordance with their manuals.

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UB USER INSTRUCTIONS ENGLISH 71569247 07-04

5.2 Pump lubricants

5.2.1 Recommended grease lubricants

Grease

NLGI 2 * NLGI 3 **

Temp. range ºC

(ºF)

Designation

according to DIN

DEA

Elf

Esso

Mobil

Shell

Texaco

Wintershall

(BASF Group)

SKF

Silkolene

* NLGI 2 is an alternative grease and is not to be mixed with other

grades.

** Factory packed bearings for the temperature range with grease

nipples.

-20 to +100

(-4 to +212)

Energrease LS2 Energrease LS3

Glissando 20 Glissando 30

Elfmulti 2 Elfmulti 3

Beacon 2 Beacon 3

Mobilux 2 Mobilux 3

Rembrandt 2 Rembrandt 3

Alvania Fett G2 Alvania Fett R2

Multilak 20

Multilak EP2

Wiolub LFK 2 -

5.2.2 Lubrication schedule

When grease nipples are fitted, one charge between grease changes is advisable for most operating conditions, ie 2 000 hours interval.

Normal intervals between grease changes are 4 000 hours or at least every 6 months.

Grease nipples

-20 to +100

(-4 to +212)

K2K-20 K2K 30

Alvania R3

Multilak 30

Multilak EP3

LGMT 2 LGMT 3

G55/T G56/T

5.3 Direction of rotation

Ensure the pump is given the same rotation as the pump direction arrow cast on the pump casing.

To avoid dry running the pump must either be filled with liquid or have the flexible coupling disconnected before driver is switched on.

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

5.4 Guarding

Guarding is supplied fitted to the pump set. If this has been removed or disturbed ensure that all the protective guards around the pump coupling and exposed parts of the shaft are securely fixed.

5.5 Priming and auxiliary supplies

Ensure all electrical, hydraulic, pneumatic, sealant and lubrication systems (as applicable) are connected and operational.

Ensure the inlet pipe and pump casing are completely full of liquid before starting continuous duty operation.

5.5.1 Suction pressure above atmospheric pressure

Horizontal pumps: open vent connection (1) on top of the pump upper casing to allow the trapped air to escape. Let liquid run out until free from air bubbles.

The characteristics of the installation and severity of service will determine the frequency of lubrication. Lubricant and bearing temperature analysis can be useful in optimising lubricant change intervals.

The bearing temperature may be allowed to rise to 55 °C (131 °F) above ambient but should not exceed 95 °C (204 °F). For most operating conditions a quality grease having a lithium soap base and NLGI consistency of No 2 or No 3 is recommended. The drop point should exceed 175 °C (350 °F).

Never mix greases containing different

bases, thickeners or additives.

Page 17 of 32

(1) Possible

priming

points

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

5.5.2 Suction lift with foot valve fitted

Fill suction pipe and casing with liquid at a pressure of 1 to 2 bar from an external source. Vent as described in section 5.5.1.

5.5.3 Suction lift without foot valve

Pump casing vents on the suction volute must be connected to an external vacuum pump priming system. If in doubt please consult Flowserve.

Possible

priming

points

To vacuum pump

5.6 Starting the pump

a) Ensure flushing and/or cooling/

heating liquid supplies are turned ON before

starting the pump. b) CLOSE the outlet valve. c) OPEN all inlet valves. d) Prime the pump.

f) Start motor and check outlet pressure. g) If the pressure is satisfactory, slowly OPEN outlet

Ensure all vent connections are closed

before starting.

control valve.

5.7.2 Pumps fitted with packed gland

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.

The gland must be adjusted evenly to give visible leakage and concentric alignment of the gland to avoid excess temperature. If no leakage takes place the packing will begin to overheat. If overheating takes place the pump should be stopped and allowed to cool before being re-started. When the pump is re-started, check 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 30 minutes with steady leakage and the gland nuts tightened by 10 degrees at a time until leakage is reduced to an acceptable level, normally a minimum of 120 drops per minute is required. Bedding in of the packing may take another 30 minutes.

Care must be taken when adjusting the gland on an operating pump. Safety gloves are essential. Loose clothing must not be worn to avoid being caught up by the pump shaft. Shaft guards must be replaced after the gland adjustment is complete.

Never run gland packing dry, even for

a short time.

5.7.3 Pumps fitted with mechanical seal

Mechanical seals require no adjustment. Any slight initial leakage will stop when the seal is run in.

Do not run the pump with the outlet valve closed for a period longer than 30 seconds.

i) If NO pressure, or LOW pressure, STOP the

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

5.7 Running the pump

5.7.1 Venting the pump

Vent the pump to enable all trapped air to

escape taking due care with hot or hazardous liquids.

Under normal operating conditions, after the pump has been fully primed and vented, it should be unnecessary to re-vent the pump.

Page 18 of 32

Before pumping dirty liquids it is advisable, if possible, to run in the pump mechanical seal using clean liquid to safeguard the seal face.

External flush or quench should be started before the pump is run and allowed to flow for a period after the pump has stopped.

Never run a mechanical seal dry, even for a short time.

5.7.4 Bearings

If the pumps are working in a potentially explosive atmosphere, temperature or vibration monitoring at the pump bearings is recommended.

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

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) adjacent to

the bearing and the ambient temperature (ta)

• Estimate the likely maximum ambient

temperature (tb)

• Set the alarm at (t+tb-ta+5) °C [(t+tb-ta+10) °F] and the trip at 100 °C (212 °F) for oil lubrication and 105 °C (220 °F) for grease lubrication

It is important, particularly with grease lubrication, to keep a check on bearing temperatures. After start up the temperature rise should be gradual, reaching a maximum after approximately 1.5 to 2 hours. This temperature rise should then remain constant or marginally reduce with time. (Refer to section 6.2.3.1 for further information.)

5.7.5 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 adjacent to the pump bearings at regular intervals will then show any deterioration in pump or system operating conditions.

Vibration velocity – unfiltered

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

Normal N

Alarm N x 1.25

Shutdown trip N x 2.0

Horizontal

pumps

≤ 5.6 (0.22) ≤ 7.1 (0.28) ≤ 7.1 (0.28) ≤ 9.0 (0.35)

≤ 11.2 (0.44) ≤ 14.2 (0.56)

Vertical

pumps

5.7.6 Stop/start frequency

Pump sets are normally suitable for the number of equally spaced stop/starts per hour shown in the table below. Check actual capability of the driver and control/starting system before commissioning.

Motor rating kW (hp)

Up to 15 (20) 15

Between 15 (20) and 90 (120) 10

Above 90 (120) 6

Maximum stop/starts

per hour

Where duty and standby pumps are installed it is recommended that they are run alternately every week.

5.8 Stopping and shutdown

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.

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.

5.9 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.

5.9.1 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.

5.9.2 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.

5.9.3 Pump speed

Changing pump speed effects flow, total head, power absorbed, NPSH 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, NPSH that noise and vibration are within local requirements and regulations.

, noise and vibration. Flow varies

> NPSHR, and

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UB USER INSTRUCTIONS ENGLISH 71569247 07-04

5.9.4 Net positive suction head (NPSHA)

NPSH available (NPSH

) is a measure of the head

available in the pumped liquid, above its vapour pressure, at the pump suction branch.

NPSH required (NPSH

) 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 NPSH NPSH

> NPSHR should be as large as possible.

If any change in NPSH

> NPSHR. The margin between

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.

5.9.5 Pumped flow

Flow must not fall outside the minimum and maximum continuous safe flow shown on the pump performance curve and or data sheet.

6 MAINTENANCE

6.1 General

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.

It is the plant operator's responsibility to ensure that all maintenance, inspection and assembly work is carried out by authorized and qualified personnel who have adequately familiarized themselves with the subject matter by studying this manual in detail. (See also section 1.6.2.)

Any work on the machine must be performed when it is at a standstill. It is imperative that the procedure for shutting down the machine is followed, as described in section 5.8.

On completion of work all guards and safety devices must be re-installed and made operative again.

Before restarting the machine, the relevant instructions listed in section 5, Commissioning, start up, operation and shut down must be observed.

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.

6.2 Maintenance schedule

It is recommended that a maintenance plan and schedule is adopted, in line with these User Instructions. It should include the following: a) Any auxiliary systems installed must be monitored,

if necessary, to ensure they function correctly.

b) Gland packings must be adjusted correctly to

give visible leakage and concentric alignment of the gland follower to prevent excessive temperature of the packing or follower.

c) Check for any leaks from gaskets and seals. The

correct functioning of the shaft seal must be checked regularly.

d) Check bearing lubricant level, and if the hours

run show a lubricant change is required.

e) Check that the duty condition is in the safe

operating range for the pump.

f) Check vibration, noise level and surface

temperature at the bearings to confirm satisfactory operation.

g) Check dirt and dust is removed from areas around

close clearances, bearing housings and motors.

h) Check coupling alignment and re-align if necessary.

Page 20 of 32

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

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 or

lubricant leaks (static and dynamic seals) and that any sealant systems (if fitted) are full and operating normally.

c) Check that shaft seal leaks are within acceptable

limits.

d) Check the level and condition of oil lubricant. On

grease lubricated pumps, 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.

Regrease - via grease nipples every 2 000 hours or sooner depending on the severity of the application.

a) It is important not to under or over grease the

bearings as this will lead to over heating and premature failure. Grease lubricated bearing housings have grease nipples fitted in the bearing brackets.

b) The maximum allowable operating temperatures

for anti friction bearings will vary from unit to unit, depending on ambient and fluid temperature. The rise above ambient should not normally exceed 55 °C (131 °F) or a combined maximum of 95 °C (204 °F).

c) A continuously rising temperature or an abrupt

temperature rise indicates a problem. If these symptoms occur, stop the pump immediately and investigate the cause.

TEMPERATURE

TIME

Grease change - every 4 000 hours or sooner depending on the severity of the application. a) Remove the bearing bracket from the rotor

assembly.

b) Brush the bearing bracket with hot kerosene (100 to

115 °C/212 to 240 °F) or other non-toxic solvent.

c) Clean and flush out the housing with a light

mineral oil.

6.2.2 Periodic inspection (six monthly)

security of attachment and corrosion.

b) Check pump running records for hourly usage to

determine if bearing lubricant requires changing.

c) The coupling should be checked for correct

alignment and worn driving elements.



Refer to the manuals of any associated

equipment for periodic checks needed.

6.2.3 Re-lubrication

Lubricant and bearing temperature analysis can be useful in optimizing lubricant change intervals. In general however, the following is recommended.

recommendations.

Check foundation bolts for

See section 5.2.1 for grease

Page 21 of 32

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

To clean the bearings:

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

lint-free cloth.

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

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

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

To remove badly oxidized grease that refuses to come off:

a) Support the rotor in a vertical position and

immerse the bearing in hot kerosene or a mixture of alcohol and light mineral solvent.

b) Gently spin the bearing outer ring.

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

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.

c) Dry and reflush the bearing with clean light oil. d) It is important not to under or over grease the

bearings as this will lead to over heating and premature failure. It is recommended that the bearings be filled with grease using a suitable spatula. In addition the housings should be no more than half filled.

6.2.4 Mechanical seals

No adjustment is possible. When leakage reaches an unacceptable level the seal will need replacement.

6.2.5 Gland packing

The stuffing box gland can be backed off for re-packing or to enable the addition of extra rings of packing.

The stuffing box is normally supplied with a lantern ring to enable a clean or pressurised flush to the centre of the packing. If not required, this can be replaced by an extra 2 rings of packing.

There must always be a small leakage, normally a minimum of 120 drops per minute to atmosphere to lubricate and cool the packing is required.

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 and consumable items

For start up purposes:

1 - complete set of gland packing 2 - shaft sleeves 1 - set of gaskets and seals (optional: 2 - mechanical seals)

For 2 years operation:

1 - set of bearings (line and thrust) 2 - sets of gland packing 2 - shaft sleeves 2 - sets of gaskets and seals 2 - lantern rings 2 - casing wear rings 1 – diaphragm bush (optional: 2 - mechanical seals

2 - impeller wear rings)

For 4 years operation:

1 - set of bearings (line and thrust) 2 - sets of gland packing 2 - shaft sleeves 2 - sets of gaskets and seals 2 - lantern rings 2 - casing wear rings

Page 22 of 32

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

1 – impeller 1 – diaphragm bush (optional: 2 - mechanical seals

2 - impeller wear rings)

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

• Socket spanners (wrenches), up to M 24 (

M 24 (

/8 in.) screws/nuts

/8 in.)

screws

• Allen keys, up to 6 mm (¼ in.) A/F

• Range of screwdrivers

• Soft mallet

More specialized equipment:

• Bearing pullers

• Bearing induction heater

• Dial test indicator

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

(If difficulties in sourcing are encountered, consult Flowserve.)

6.6 Fastener torques

Bolt size

M8 (5/16 in.) M10 (⅜ in.) M12 (½ in.) M16 (⅝ in.) M20 (¾ in.) M24 (⅞ in.)

Torque Nm (lbf·ft)

Pump feet

fasteners

63 (46) 170 (125) 340 (250) 590 (435)

All other

fasteners

10 (7) 20 (15) 34 (25) 84 (62)

165 (120) 285 (210)

6.7 Renewal clearances

As wear takes place between the impeller, casing ring and diaphragm bush the overall efficiency of the pump set will decrease. To maintain optimum efficiency it is recommended that rings and bush are replaced and the impeller renovated when the radial clearance detailed in section 3.4.2 has doubled.

To dismantle the pump consult the sectional drawings. See section 8, Parts lists and drawings.

a) Isolate motor and lock off electrical supply in

accordance with local regulations. b) Isolate suction and discharge valves. c) Remove coupling guards and disconnect the

coupling halves. d) Drain pump casing. Remove any auxiliary piping

if applicable. e) Release the copper lockwasher securing the

coupling nut and remove the pump half coupling. f) Unbolt the glands/seal covers from the casing.

If glands are split type, remove completely. g) With a suitable punch, drive out the two locating

dowels which are used on the horizontal split

flange to align the upper and lower half casings. h) Remove the bolts, which hold the upper and lower

half of the casing together, and remove the upper

half. Tapped holes are provided in the joint flange

to enable the use of forcing bolts to loosen the joint. i) Lift the casing upper half using the two eye bolts

provided.

Do NOT use this method to lift the bottom

half or complete pump casing.

j) Remove the 6 – screws securing each bearing

bracket to the bottom half casing. k) Lift out rotor assembly. Use care in slinging,

handling and supporting of the rotor for

subsequent dismantling. Place rotor securely on

two support blocks. l) When removing the rotor assembly, the casing rings

and diaphragm plate will be loosely attached to the

rotor. m) Remove bearing covers and slide bearing housings

off bearings. n) Release the copper lockwasher securing the

bearing locknut at the non-drive end and remove the

locknut. Pull off both ball bearings using a suitable

puller; ensuring force is applied to inner race only.

Retain the bearing distance pieces and coupling

distance piece for future use. Remove the bearing

covers. o) Depending on configuration remove glands/seal

covers, packing and lantern ring/mechanical seal.

6.8 Disassembly

Refer to section 1.6, Safety, before dismantling

the pump.

Before dismantling the pump for overhaul, ensure genuine Flowserve replacement parts are available.

Page 23 of 32



Refer to any special instructions supplied

with the mechanical seal.

p) Remove the two socket head screws securing

each shaft sleeve nut. Using C-spanner remove shaft nuts. Slide off shaft sleeves.

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

q) Remove impellers, casing rings, diaphragm plate

complete with its bush together with the impeller key.

If impellers prove difficult to remove, the use of heat is permissible. Refer to Section 1.6, Safety, APPLYING HEAT TO REMOVE IMPELLER, for more details.

r) If it is required to remove the diaphragm plate

bush then remove the 4 countersunk screws and push out the bush.

s) If impeller rings are also fitted, they are shrunk

onto the impeller and fixed with locking screws between their diametric mating surfaces.

t) To remove the impeller rings, remove the locking

screws and heat up the ring until it slides off easily.

6.9 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.

6.9.1 Casing, seal housing and impeller

a) Inspect for excessive wear, pitting, corrosion,

erosion or damage and any sealing surface irregularities.

b) Replace as necessary.

d) Bearing seals are not totally leak free devices.

Oil from these may cause staining adjacent to the bearings.

6.10 Assembly

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

Ensure threads, gasket and O-ring mating faces are clean. Apply thread sealant to non-face sealing pipe thread fittings. Coat the outside diameter of the dowel bushings with pipe compound prior to installation.

6.10.1 Impeller wear rings

a) Impeller rings (when fitted) should be heated up

to approximately 100 ºC (212 ºF) using a hotplate or hot oil bath and then slipped onto the impeller and pressed down to the shoulder. (Do NOT use a steel hammer to knock them into position.)

b) Drill and tap 3 holes approximately 120 degrees

apart into the diametral mating faces of the ring and impeller and insert socket head screws. (The existing half tapped holes from the removed impeller ring cannot be re-used.)

6.9.2 Shaft and sleeve (if fitted)

Replace if grooved, pitted or worn.

6.9.3 Gaskets and O-rings

After dismantling, discard and replace.

6.9.4 Bearings

It is recommended that bearings are not re-used after any removal from the shaft.

6.9.5 Bearing isolators, labyrinths or lip seals (if fitted)

a) The lubricant, bearings and bearing housing

seals are to be inspected for contamination and damage.

b) If bearing damage is not due to normal wear and

the lubricant contains adverse contaminants, the cause should be corrected before the pump is returned to service.

c) Labyrinth seals and bearing isolators should be

inspected for damage but are normally nonwearing parts and can be re-used.

6.10.2 Pre-assembly of casing gasket

a) Fit casing gasket to the bottom half horizontal

flange using a small amount of contact adhesive to prevent movement when the top half is fitted. Do not apply adhesive to the top surface of the gasket.

b) It is important that the external corner of the

casing gasket face and the stuffing box face is as sharp as possible.

Do not chamfer with a file.

c) If necessary trim gasket to match volute profile.

Do not trim to stuffing box face at this stage.

6.10.3 Rotating element and bearing bracket

a) Ensure all gaskets and O-rings are renewed and

replaced in the correct position during assembly.

b) Assemble the impellers on the shaft. It is

important to mount the impellers so that the vane tips point away from the apparent flow direction.

Page 24 of 32

The rotor always rotates towards the expanding

section of the volute

c) The diaphragm plate complete with its bush must

be fitted on to the shaft between the two impellers.

d) Fit the two shaft sleeves, O-rings (when fitted)

and shaft nuts and lightly secure the impellers on the shaft. Take care to protect the sleeve O-rings (when fitted) from damage on the shaft threads. The sleeves and nuts define the impeller position on the pump shaft and hence in the pump casing. Initially position the impellers centrally on its keyway. This position may be adjusted slightly later on in the assembly process.

e) It is recommended that gasket sealing compound

Loctite 574 or equivalent is used between sleeve and impeller mating faces to protect the shaft from the liquid pumped.

f) When mechanical seals are fitted the rotating

parts can be slid onto the sleeves before the sleeves are fitted onto the shaft. The seal locking collars should be left loose.

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

The bearings must be heated up to 100 ºC (212 ºF) using a hot plate, oil bath or induction heater and slid onto the shaft. Ensure bearing is fully seated against the bearing distance piece and the distance

piece is located up to the shaft shoulder. j) Fill both sides of bearing with grease. k) Fit the bearing lockwasher and tighten the

bearing shaft nut. l) Peen a segment of the copper lockwasher over a

flat on the bearing locknut. m) Slip casing rings, loosely over the impeller hubs. n) Slide the bearing housings over the bearings.

Ensure bearings are located square in the

bracket bore. o) One third fill the space between bearing cover

and bearing with grease. Secure bearing cover,

complete with gasket. p) Fit the coupling distance piece and pump half

coupling. Fit copper lockwasher and secure

coupling nut. Peen a segment of the copper

lockwasher over a flat on the coupling nut.

6.10.4 Casing lower half

a) If required, drive in two new locating dowels on

the horizontal flange. b) Coat the faces of the bearing housing brackets

with liquid sealant to protect against corrosion. c) Place the complete rotating assembly into the

casing ensuring that impeller rings and diaphragm

plate are in the correct position to allow the anti-

rotation tongues to locate correctly in the anti-

rotation grooves in the casing bores.



Refer to any special instructions supplied

with the mechanical seal. g) If gland packing is used fit the glands. h) Fit seal covers complete with seal seat, water

throwers and bearing covers complete with

gaskets. i) Fit the bearings onto the shaft. The main thrust

bearing is at the non-drive end.

Where double row bearings are fitted

these must be assembled 'back to back' as below:

The anti-rotation grooves in the bottom half casing are bigger in diameter than those in the top.

d) Locate the bearing housings in the machined

spigots in the casing and torque up the fixing screws.

e) Check rotor for free rotation. f) Centralize the impellers within the casing

waterway by adjusting the shaft nut, if necessary. Using a C-spanner fully tighten the shaft nuts and lock with the two radial socket head screws.

g) Set the seals, if fitted, to the correct working

length and tighten the seal collar screws.



Refer to any special instructions supplied

with the mechanical seal.

h) Check for free rotation.

Page 25 of 32

6.10.5 Casing upper half

a) Assemble the casing upper half over the lower

half. Take care to ensure the renewable rings and diaphragm plate are correctly located in the upper half bores and that dowel holes pick up the locating dowels in the lower half.

b) Tap horizontal flange over locating dowels to

accurately position the top half casing and torque

up all horizontal flange bolts. c) Check for free rotation. d) Using a sharp flexible-bladed knife, cut off the

exposed casing gasket in the stuffing box area

flush with the stuffing box face. e) If mechanical seals are fitted apply a small amount

of silicon rubber sealant along the horizontal joint

line on the stuffing box face and fit seal cover

complete with gasket or O-ring. Take care not to

damage O-ring, if fitted, and locate cover squarely

on stuffing box face. f) Torque up seal cover bolts and check shaft/sleeve

does not rub on seal cover or stationary seal seat

bore. Ensure any spare holes in mechanical seal

cover, particularly on cartridge seals, have sealing

plugs fitted. g) If gland packing is fitted pack the gland, ensuring

that the cut ends in each ring are staggered by

120 degrees. The glands are packed as shown on

the relevant drawings in Sections 8.1 to 8.3.

Finger tighten the gland nuts. h) Check coupling alignment, fit coupling drive

element(s) and fit guards. i) Pipe up any external auxiliary connections. j) Check for free rotation.

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

Page 26 of 32

7 FAULTS; CAUSES AND REMEDIES

FAULT SYMPTOM

Pump overheats and seizes

Bearings have short life

⇓⇓⇓⇓

Pump vibrates or is noisy

⇓⇓⇓⇓

Mechanical seal has short life

⇓⇓⇓⇓

Mechanical seal leaks excessively

⇓⇓⇓⇓

Pump requires excessive power

⇓⇓⇓⇓

Pump loses prime after starting

⇓⇓⇓⇓

Insufficient pressure developed

⇓⇓⇓⇓

Insufficient capacity delivered

⇓⇓⇓⇓

Pump does not deliver liquid

⇓⇓⇓⇓

PROBABLE CAUSES POSSIBLE REMEDIES

zzzzz

zzzzzzzzzzzz

zzzzz

zzzz

zzzzz

zzzzzzzzz

zzzzz

zzzzzzzzzzzz

zzzzz

Pump not primed. Check complete filling.

Pump or suction pipe not completely filled with liquid.

Suction lift too high or level too low.

Excessive amount of air or gas in liquid. Check and purge from pipes.

Air or vapour pocket in suction line. Check suction line design for pockets.

Air leaks into suction line. Check airtight pipe then joints and gaskets.

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 cut out system design.

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. Consult Flowserve.

Viscosity of liquid differs from design. Consult Flowserve.

Operation at very low capacity. Measure value and check minimum permitted.

Operation at high capacity. Measure value and check maximum permitted.

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

A. SYSTEM TROUBLES

Check and complete filling.

Check NPSH losses at strainers and fittings.

Check airtight assembly then joints and gaskets.

Check discharge head and head losses in discharge pipe at the valve settings. Check back pressure is not too high.

Throttle at discharge valve or ask Flowserve if the impeller can be trimmed.

>NPSHR, proper submergence,

zzzzzzzzzzzzzzzzzzzzzzzz

zzzz

zzzzzzzzzzzzzzzzzzzz

zzzzzzzzzzzzz

zzzzzzzzzzzzzzzzzzzzzzzz

zzzzz

B. MECHANICAL TROUBLES

Misalignment due to pipe strain.

Check the flange connections and eliminate strains using elastic couplings or a method permitted.

Improperly designed foundation.

Check setting of baseplate: tighten, adjust, grout base as required.

Shaft bent. Check shaft runouts within acceptable values.

Rotating part rubbing on stationary part internally.

Check for signs of this and consult Flowserve if necessary.

Bearings worn Replace bearings.

Wearing ring surfaces worn. Replace worn wear ring/surfaces.

Page 27 of 32

FAULT SYMPTOM

Pump overheats and seizes

Bearings have short life

⇓⇓⇓⇓

Pump vibrates or is noisy

⇓⇓⇓⇓

Mechanical seal has short life

⇓⇓⇓⇓

Mechanical seal leaks excessively

⇓⇓⇓⇓

Pump requires excessive power

⇓⇓⇓⇓

Pump loses prime after starting

⇓⇓⇓⇓

Insufficient pressure developed

⇓⇓⇓⇓

Insufficient capacity delivered

⇓⇓⇓⇓

Pump does not deliver liquid

⇓⇓⇓⇓

zzzzz

zzzz

zzzzzzzzzzzz

zzzzzzzzzzzzzzzzzzzzzzzz

zzzzzzzzzzzzzzzz

zzzzzzzzzzzz

zzzzzzzz

zzzzzzzzzzzzzzzzzzzzzzzz

zzzzzzzzzzzz

zzzzzzzz

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

PROBABLE CAUSES POSSIBLE REMEDIES

Impeller damaged or eroded. Replace impeller and check reason.

Leakage under sleeve due to joint failure. Replace joint and check for damage.

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. Check and consult Flowserve.

Abrasive solids in liquid pumped. Check and consult Flowserve.

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.

Damaged bearings due to contamination.

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 mechanical seal condition and source of dry running and repair.

Check method of assembly, possible damage or state of cleanliness during assembly.

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.

Check contamination source and replace damaged bearings.

zzzzz

Wrong direction of rotation. Reverse 2 phases on motor terminal box.

Motor running too slow. Check motor terminal box connections.

C. ELECTRICAL TROUBLES

Page 28 of 32

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

8 PARTS LISTS AND DRAWINGS

8.1 Sectional drawings – 8-UB-1 grease lubricated, gland packed

86345 7

17 15

15A

291812916 21 272630 3228 31

291812916 21 272625 3228 31

20A 10

8.1.1 Parts list

Ref. no. Description

1 Nameplate 2 Bearing locknut 3 Lockwasher – bearing locknut 4 Ball bearing - thrust 5 Shaft collar 6 Gland 7 Lantern ring 8 Gland packing

9 Casing – upper half 10 Casing – lower half 11 Gasket – horizontal split

'Z'

12 Casing wear ring 13 Diaphragm plate 14 Diaphragm bush 15 Impeller – first stage

15A Impeller – second stage

16 Key – impeller 17 Seal pipe assembly 18 Shaft sleeve 19 Shaft nut 20 Bearing bracket – Drive end

20A Bearing bracket – Non-drive end

21 Socket head screw for 19 & 38

2319 20 22 24 25

2319 20 22 24 30

Taken from A767/112

22 Water shield 23 Bearing cover 24 Gasket – bearing cover 25 Ball bearing – line 26 Grease nipple 27 Shaft 28 Key – coupling 29 Bearing distance piece 30 Coupling distance piece 31 Coupling nut 32 Lockwasher – for coupling nut

Page 29 of 32

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

8.1.2 Options

View on ‘Z’ impeller ring

8.1.3 Options parts list

Ref. no. Description

34 Mechanical seal 35 Mechanical seal cover 36 Gasket – mechanical seal cover 37 Socket head screw for 38 (a) 38 Seal abutment ring (a) 39 Cartridge seal assembly 40 Impeller nut 45 Impeller wear ring 46 Socket head screw for 45

a) When fitted, depends on type of mechanical seal.

8.2 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.

Component mechanical seal

Cartridge mechanical seal

Page 30 of 32

9 CERTIFICATION

Certificates determined from the Contract requirements are provided with these Instructions where applicable. Examples are certificates for CE marking, ATEX marking etc. If required, copies of other certificates sent separately to the Purchaser should be obtained from the Purchaser for retention with these User Instructions.

10 OTHER RELEVANT DOCUMENTATION AND MANUALS

10.1 Supplementary User Instructions

Supplementary instructions such as for a driver, instrumentation, controller, seals, sealant system etc are provided as separate documents in their original format. If further copies of these are required they should be obtained from the supplier for retention with these User Instructions.

10.2 Change notes

If any changes, agreed with Flowserve Pump Division, are made to the product after its supply, a record of the details should be maintained with these User Instructions.

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

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.

Reference 2:

Pumping Manual, 9 Elsevier Advanced Technology, United Kingdom, 1995.

Reference 3: Pump Handbook, 2 McGraw-Hill Inc., New York, 1993.

Reference 4:

ANSI/HI 1.1-1.5 Centrifugal Pumps - Nomenclature, Definitions, Application and Operation.

Reference 5:

ANSI B31.3 - Process Piping.

edition, T.C. Dickenson,

edition, Igor J. Karassik et al,

Page 31 of 32

UB USER INSTRUCTIONS ENGLISH 71569247 07-04

FLOWSERVE

REGIONAL SALES OFFICES:

USA and Canada

Flowserve Corporation (Pump Division) 5215 North O’Connor Blvd. Suite 2300 Irving, Texas 75039, USA

Tel +1 972 443 6500 Toll free 800 728 PUMP (7867) Fax +1 972 443 6800

Europe, Middle East and Africa

Flowserve Limited (Pump Division) Harley House, 94 Hare Lane Claygate, Esher, Surrey KT10 0RB United Kingdom

Tel +44 (0)1372 463 700 Fax +44 (0)1372 460 190

Visit our web site at: www.flowserve.com

Latin America and Caribbean

Flowserve Corporation (Pump Division) 6840 Wynnwood Lane Houston, Texas 77008, USA

Tel +1 713 803 4434 Fax +1 713 803 4497

Asia Pacific

Flowserve Pte Ltd (Pump Division) 200 Pandan Loop, 06-03/04 Pantech 21, Singapore 128388

Tel +65 775 3003 Fax +65 779 4607

Your Flowserve factory contact:

Flowserve Pumps Limited PO Box 17, Newark Notts NG24 3EN United Kingdom

Telephone (24 hours) +44 (0)1636 494 600 Sales & Admin Fax +44 (0)1636 705 991 Repair & Service Fax +44 (0)1636 494 833 E.mail inewark@flowserve.com

Page 32 of 32

Your local Flowserve representative:

To find your local Flowserve representative, please use the Sales Support Locator System found at www.flowserve.com

HP 8-UB-1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 INTRODUCTION AND SAFETY

1.1 General

1.2 CE marking and approvals

1.3 Disclaimer

1.4 Copyright

1.5 Duty conditions

1.6 Safety

1.6.1 Summary of safety markings

1.6.2 Personnel qualification and training

1.6.3 Safety action

1.6.4 Products used in potentially explosive atmospheres

1.6.4.1 Scope of compliance

1.6.4.2 Marking

1.6.4.3 Avoiding excessive surface temperatures

1.6.4.4 Preventing the build up of explosive mixtures

1.6.4.5 Preventing sparks

1.6.4.6 Preventing leakage

1.7 Warning labels summary

1.7.1 Nameplate

1.7.2 Warning labels

1.6.4.7 Maintenance to avoid the hazard

1.8 Specific machine performance

1.9 Noise level

2 TRANSPORT AND STORAGE

2.1 Consignment receipt and unpacking

2.2 Handling

2.3 Lifting

2.4 Storage

2.5 Recycling and end of product life

3 PUMP DESCRIPTION

3.1 Configurations

3.2 Name nomenclature

3.3 Design of major parts

3.3.1 Pump casing

3.3.2 Impellers

3.3.3 Shaft

3.3.4 Pump bearings and lubrication

3.3.5 Bearing housing

3.3.6 Seal housing

3.3.7 Shaft seal

3.3.8 Driver

3.3.9 Accessories

3.4 Performance and operating limits

3.4.1 Operating limits

4 INSTALLATION

4.1 Location

4.2 Foundation

4.3 Grouting

4.4 Initial alignment

4.4.1 Thermal expansion

4.4.2 Alignment methods

4.5 Piping

4.5.2 Suction piping

4.5.3 Maximum forces and moments allowed on the pump suction and discharge flanges of horizontal shaft pumps

4.5.4 Discharge piping

4.5.5 Auxiliary piping

4.5.5.1 Drains

4.5.5.2 Pumps fitted with packed gland

4.5.5.3 Pumps fitted with mechanical seals

4.5.6 Final checks

4.6 Final shaft alignment check

4.7 Electrical connections

4.8 Protection systems

5 COMMISSIONING, START-UP, OPERATION AND SHUTDOWN

5.1 Pre-commissioning procedure

5.2 Pump lubricants

5.2.1 Recommended grease lubricants

5.3 Direction of rotation

5.4 Guarding

5.5 Priming and auxiliary supplies

5.5.1 Suction pressure above atmospheric pressure

5.5.2 Suction lift with foot valve fitted

5.5.3 Suction lift without foot valve

5.6 Starting the pump

5.7.2 Pumps fitted with packed gland

5.7.3 Pumps fitted with mechanical seal