Flowserve WDX E Installation, Operation, Maintenance Manual Download Page 1

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Pump Division

Type:

WDX

CENTRIFUGAL PUMPS

USER INSTRUCTIONS:
INSTALLATION, OPERATION, MAINTENANCE

PCN=71576322 06-05 (E)

These instructions must be read prior to installing,

operating, using and maintaining this equipment.

Summary of Contents for WDX E

Page 1: ...Division Type WDX CENTRIFUGAL PUMPS USER INSTRUCTIONS INSTALLATION OPERATION MAINTENANCE PCN 71576322 06 05 E These instructions must be read prior to installing operating using and maintaining this equipment ...

Page 2: ...s 22 5 COMMISSIONING START UP OPERATION AND SHUTDOWN 22 5 1 Pre commissioning procedure 22 5 2 Pump lubricants 23 5 3 Direction of rotation 24 5 4 Guarding 24 5 5 Priming and auxiliary supplies 24 5 6 Starting the pump 25 5 7 Running the pump 25 5 8 Stopping and shutdown 27 5 9 Hydraulic mechanical and electrical duty 27 5 10 Pumps for Food Use or Potable Water 27 PAGE 6 MAINTENANCE 28 6 1 General...

Page 3: ...tion see 5 1 1 5 2 and 6 2 3 Lubrication schedule 5 2 4 24 Maintenance 6 28 Maintenance schedule 6 2 28 Nomenclature 3 2 13 Nameplate 1 7 1 8 Operating limits 3 5 1 14 Ordering spare parts 6 3 1 31 Parts lists 8 4 43 Performance 3 5 14 Piping 4 6 18 Pre commissioning 5 1 22 Protection systems 4 9 22 Pump masses 2 2 2 11 PAGE Reassembly see 6 10 Assembly 37 Receipt and unpacking 2 1 10 Recommended ...

Page 4: ...cable thisdocument incorporatesinformation relevant to these Directives and Approvals To confirm the Approvalsapplying and if the productis 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 theefforts of Flowserve Pump Division to provide sound and all n...

Page 5: ...d 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 prevent injury to personnel and damage to the environment and to equipment For products used in potentially explosive atmospheres section 1 6 4 also applies NEVER DO MAINTENANCE WORK WHEN THE UNIT IS CONNECTE...

Page 6: ...w rate higher than normal or at a flow rate with no backpressure on the pump may overload the motor and cause cavitations Low flow rates may cause a reduction in pump bearing life overheating of the pump instability and cavitations vibration 1 6 4 Products used in potentially explosive atmospheres Measures are required to Avoid excess temperature Prevent build up of explosive mixtures Prevent the ...

Page 7: ...id temperature is with the plant operator Tem per at ur e c l assi f i cat i on Tx i sused when t he l i qui d temperature varies and the pump could be installed in different hazardous atmospheres In this case the user is responsible for ensuring that the pump surface temperature does not exceed that permitted in the particular hazardous atmosphere If an explosive atmosphere exists during the inst...

Page 8: ...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 w...

Page 9: ... 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 increase in noise level at some speeds Consult a Noise Specialist for this calculation For units driven by equipment other than electric motors or units contained within enclosures see the accompanying ...

Page 10: ... Each product has a unique serial number Check that this number corresponds with that advised and always quote this number in correspondence as well as when ordering spare parts or further accessories 2 2 Handling 2 2 1 General instructions concerning handling Boxes crates pallets or cartons may be unloaded using fork lift vehicles or slings dependent on their size and construction See 2 3 1 for p...

Page 11: ... 3 Lifting 2 3 1 Slinging of motor pumps units Use handling means in accordance with motor pump unit mass mentioned on the CE plate For the masses of the pumps bare end of shaft see table 2 2 2 and nameplate To avoid distortion the pump unit should be lifted as shown Motor pump unit When handling always wear gloves safety shoes and an industrial safety helmet For masses above 55 lb 25 kg manual ha...

Page 12: ...the current regulations at all times 3 PUMP DESCRIPTION 3 1 Configurations The WDX type pump is a horizontal multistage radial split case vaned diffuser type centrifugal pump equipped with a special suction impeller for low NPSH It can be used with motor steam turbine and gasoline or diesel engine drives The WDX pumps are of modular construction with identical stages being stacked axially to achie...

Page 13: ...e pump nameplate Check that this agrees with the applicable certification provided 3 3 Design of major parts 3 3 1 Pump casing The pump casings suction discharge and stage are seal ed wi t h o r i ngsand desi gned t o cont ai n t he pressures generated by the pump at the various possible design pressures and temperatures 3 3 2 Impeller The impeller is fully shrouded and may be fitted with optional...

Page 14: ...Stainless steel Duplex stainless steel M7 Stainless steel Stainless steel Duplex stainless steel 3 5 Performance and operating limits This product has been selected to meet the specifications of your purchase order See the nameplate and section 1 5 The maximum allowable speed for cast iron impellersis3600 RPM and for steel impellers is4000 RPM 3 5 1 Minimal flow 20 of BEP up to 280 F 140 C 25 of B...

Page 15: ...3 6 Coverage charts 3 3 1 2970 min 1 50 Hz coverage charts Q H 3 3 2 3550 min 1 60 Hz coverage charts Q H ...

Page 16: ...y steel baseplates furnished with these pumps and motors 10 HP 7 5 kW and under may be bolted to machine or equipment structures either rigidly or if flexible piping is used with properly designed vibration isolators A unit mounted on steel work or structural members should be mounted over or adjacent to girders or walls so that no misalignment will occur from yielding or sagging of the structure ...

Page 17: ... involving high liquid temperatures the unit should be run at the actual operating temperature shut down and the alignment checked immediately 4 5 2 Alignment methods Ensure pump and driver are isolated electrically and the half couplings are disconnected Ensure that the pump pipework suction and discharge is disconnected The alignment MUST be checked Although the pump will have been aligned at th...

Page 18: ...d see sections 4 7 Final shaft alignment check up to and including section 5 Commissioning startup operation and shutdown before connecting driver and checking actual rotation 4 6 Piping The user must verify that the equipment is isolated from any external sources of vibration Protective covers are fitted to the pipe connections to prevent foreign bodies entering during transportation and installa...

Page 19: ...uction 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 h Inlet strainers when used should have a net free area of at least three times the inlet pipe area i Do not install elbows a...

Page 20: ... lbf perpendicular 80 mm 89 daN 133 daN 107 daN 193 daN 47 daN m 72 daN m 95 daN m 128 daN m to the shaft 4 in 260 lbf 400 lbf 320 lbf 570 lbf 500 ft lbf 740 ft lbf 980 ft lbf 1330 ft lbf 100 mm 116 daN 178 daN 142 daN 256 daN 68 daN m 100 daN m 133 daN m 180 daN m 6 in 460 lbf 700 lbf 560 lbf 1010 lbf 870 ft lbf 1300 ft lbf 1700 ft lbf 2310 ft lbf 150 mm 205 daN 311 daN 249 daN 448 daN 118 daN m ...

Page 21: ...g 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 Alignment can only be considered definitive after pipework has been connected 4 8 Electrical connections 4 8 1 Safety conditions about electrical connections Electrical c...

Page 22: ...ualified personnel 5 1 Pre commissioning procedure 5 1 1 Lubrication Determine the mode of lubrication of the pump set eg grease oil product lubrication etc Grease lubricated pumps and electric motors are supplied pre greased Other drivers and gearboxes if appropriate should be lubricated in accordance with their manuals In the case of product lubricated bearings the source of product supply shoul...

Page 23: ... 46 46 46 Viscosity at 50 C cst 30 31 5 29 4 28 30 29 5 30 Viscosity at 100 C cst 6 9 7 1 6 7 7 6 9 6 9 6 8 Pour point C 30 27 12 15 30 12 21 Flash point C 210 220 220 220 214 230 230 Fire point C 240 252 280 240 245 Aniline point C 99 102 110 102 109 101 101 Viscosity index 105 106 109 105 113 100 100 Acid value 0 2 0 6 0 2 0 13 0 7 0 1 0 7 to 1 2 Colour 1 2 1 2 2 1 1 Anti erosion additives yes y...

Page 24: ...while under lubricated bearings could wear prematurely 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 changeintervals Lubricati on frequenci es in hours of operation Pump size 1450 RPM 1750 RPM 2950 RPM 3550 RPM 1 5 WDX 3000 2200 1500 1200 2 WDX 3000 2200 15...

Page 25: ...t is closed by an adequate back pressure c OPEN all inlet valves d Open all valves of the minimal flow line to ensure a minimal flow for the period the pump is running against the closed discharge valve e Prime the pump f Check that all plugs are tight g Check that the gland lightly tightens the packing h Ensure all vent connections are closed before starting i Start motor and check outlet pressur...

Page 26: ...ibration monitoring at the bearings is recommended If bearing temperatures are to be monitored it is essential that a benchmark temperature is recorded at the commissioning stage and after the bearing temperature has stabilized Record the bearing temperature t and the ambient temperature ta Estimate the likely maximum ambient temperature tb Set the alarm at t tb ta 5 C t tb ta 10 F and the trip at...

Page 27: ...r 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 NPSHR noise and vibration Flow varies in direct proportion to pump speed head varies as speed ratio squared and power varies as speed r...

Page 28: ... 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 ...

Page 29: ...nt for periodic checks needed 6 2 3 Re lubrication Lubricant and bearing temperature analysis can be useful in optimising lubricant change intervals In general however the following is recommended 6 2 3 1 Oil lubrication Maintaining the correct oil level is very important If the pump is supplied with a constant level oiler the oil level will be automatically maintained and as long as oil is visibl...

Page 30: ...approved seal vendor replace or repair the seal 6 2 5 Gland packing 6 2 5 1 Pump fitted with a packed gland A well run in and correctly adjusted packing gland requires little maintenance If after some time the leakage becomes too great the gland should be tightened again in order to return these to a normal level If re tightening is not possible new packing must be installed 6 2 5 2 Gland packing ...

Page 31: ...50 1 97 10 0 394 4 45 1 77 65 2 56 50 1 97 10 0 394 6 2 6 Gland cooling WDX Pumps are designed with an optional stuffing box cooling The purpose of this is to cool the pumped liquid before it reaches the packing Such cooling is required if the liquid temperature is over 220 F 105 C 6 3 Spare parts 6 3 1 Ordering of spares Flowserve keeps records of all pumps that have been supplied When ordering s...

Page 32: ...vers 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 6 6 1 Tie rods Pump size Torque Nm lb ft 1 5 WDX 2 WDX 3 WDX 4 WDX 305 225 430 320 650 480 905 670 6 6 2 Other fasteners Torque Nm lb ft Bolt size Steel fastener Stainless ...

Page 33: ...ng cover 3211 Straighten tab on bearing lock washer 6541 01 and unscrew bearing lock nut 3712 Repeat the operation for the second blockage Remove the spacer sleeve 2460 02 Remove the snap ring 6544 02 Remove the spacer sleeve 2460 01 The whole thrust bearing assembly can then be removed from the shaft 6 8 2 2 Grease lubricated bearings Dismount the fan cover 8162 by loosening the screws Remove the...

Page 34: ...3712 03 Remove the coupling spacer piece 2460 03 Remove the eight cap screws of the bearing housing 6577 04 The whole line bearing assembly can then be removed 6 8 3 2 Line bearings WDXE Free the bearing by removing screw 6570 02 Remove the bearing bushing 3300 by means of a disassembling screw M10 Remove the snap ring 6544 03 and slide off the shaft sleeve 3400 01 6 8 3 3 Line bearings WDXS Unscr...

Page 35: ...placement of a mechanical seal requires the dismantling of thrust and line bearing assembly The dismantling procedure of the mechanical seal is self explanatory when viewing the respective seal drawing 6 8 5 Dismantling of balancing drum and ring 6 8 5 1 Variants WDXR E S Dismantle the thrust bearing assembly see section 6 8 2 Provide independent support under the discharge casing Remove the eight...

Page 36: ...tuffing box cavity Replace O ring seals Replace gland studs if badly corroded 6 9 3 Mechanical seals It is not recommended that mechanical seals be reused Using an old one leaves too much chance of failure to make the risk worthwhile considering the usual cost of installing and removing a pump from its system Attempts to lap the mechanical seal faces may be possible but require specialized technic...

Page 37: ...mantling procedures previously described see the cross sectional drawings Consult the sectional drawing to organize the required operations Replace all components in their original place 6 10 1 Shaft seal assembly Packed Stuffing box as per section 6 2 5 Mechanical seal Refer to assembly drawings for the seal and pump Great care must be taken concerning the cleanliness during the mounting operatio...

Page 38: ...ght Air leaks into pump through mechanical seal sleeve j oints casing joint or pi pe plugs Checkand r eplace faulty parts CONSULT FLOWSERVE Foot valve too small Investigate repl acing the foot val ve Foot valve partiall yclogged Clean foot val ve Inlet of suction pipe insufficientl ysubmerged Checkout system design Speed too low CONSULT FLOWSERVE Speed too high CONSULT FLOWSERVE Total head of syst...

Page 39: ...sfactory check bearings for excessi ve wear Impeller out of balance resulting in vibration Abrasi ve solids in liquid pumped Internal misalignment of parts preventing seal ring and seat from mati ng properl y Checkand CON SULT FLOWSERVE Mechanical seal was run dr y Check mechanical seal condition and source of dr y running and r epair Internal misalignment due to improper repairs causing impeller ...

Page 40: ...WDX USER INSTRUCTIONS ENGLISH 71576322 06 05 Page 40 of 46 8 PARTS LISTS AND DRAWINGS 8 1 Sectional drawings WDXR grease lubricated uncooled ...

Page 41: ...WDX USER INSTRUCTIONS ENGLISH 71576322 06 05 Page 41 of 46 8 2 Sectional drawings variants 8 2 1 WDXE and WDXS 8 2 2 WDXC ...

Page 42: ...ISH 71576322 06 05 Page 42 of 46 8 2 3 Cooled version 8 3 Sectional drawings other details 8 3 1 Wear rings 8 3 2 Intermediate bearing bush 8 3 3 Oil bearing drive end 8 3 4 Oil bearing non drive end 9331 0 2 9331 0 1 8161 8162 ...

Page 43: ...ain 2905 04 Washer Curved spring ITEM DESIGNATION 3011 01 Radial ball bearing Drive side 2x7300 3011 02 Radial ball bearing Non drive side 6000 3134 Support foot 3140 Bearing bracket Drive s ide 3211 Bearing housing Drive side 3212 Bearing housing Non drive side 3260 Bearing cover Drive side 3261 Bearing cover Drive side 3263 Bearing cover Non drive side 3300 Bearing bush 3311 Bearing bush interna...

Page 44: ...scharge 6569 07 Plug Screwed suction 6569 08 Plug Screwed suction 6569 09 Plug Screwed for bearing Non drive side 6569 10 Plug Screwed for bearing Non drive side ITEM DESIGNATION 6570 01 Screw cap Hc Fan 6570 02 Screw cap Hc Bearing bush 6570 03 Screw cap Hc Internal bearingbush 6570 04 Screw cap Hc 6570 05 Screw cap Hc 6570 06 Screw Hexagon socket head cap Chc Drum 6570 07 Screw Hexagon socket he...

Page 45: ...UMENTATION 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 FlowserveP...

Page 46: ...A de C V Avenida Paseo de la Reforma 30 2 nd Floor Colonia Juarez Centro Mexico D F Z C 06040 Tel 52 5705 5526 Fax 52 5705 1125 Asia Pacific Flowserve Pte Ltd Pump Division 200 Pandan Loop 06 03 04 Pantech 21 Singapore 128388 Tel 65 775 3003 Fax 65 779 4607 Visit our web site at www flowserve com Your Flowserve factory contacts North America South America Europe Africa Asia Flowserve Pompes Route ...

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