Flowserve 6LR-18A Manual Download

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SUBMITTAL FOR APPROVAL

JEA WEST NASSAU HIGH SERVICE PUMPS

SPECIFICATION SECTION #11216, #16150, & #01010

TWO (2) FLOWSERVE MODEL 6LR-18A LARGE HIGH SERVICE PUMPS

WITH 150HP, 1800RPM, TEFC INVERTER RATE MOTORS.

OWNER:

Jacksonville Electric Authority

21 W. Church Street

Jacksonville, FL 32202

Attn: Allan Boree

ENGINEER:

CDM Smith

8381 Dix Ellis Trail, Suite 400

Jacksonville, FL 32256

Attn: Dave Rasmussen

MANUFACTURER:

Flowserve Pump Division

3900 Cook Boulevard

Chesapeake, VA 23323

Attn: Rainier Cruz

SUPPLIER:

Carter & VerPlanck, Inc.

4910 West Cypress Street

Tampa, Florida 33607

813-287-0709

Attn: Yaricel Garcia

February 1, 2017

C&V Project #FL16029

Summary of Contents for 6LR-18A

Page 1: ...ville Electric Authority 21 W Church Street Jacksonville FL 32202 Attn Allan Boree ENGINEER CDM Smith 8381 Dix Ellis Trail Suite 400 Jacksonville FL 32256 Attn Dave Rasmussen MANUFACTURER Flowserve Pump Division 3900 Cook Boulevard Chesapeake VA 23323 Attn Rainier Cruz SUPPLIER Carter VerPlanck Inc 4910 West Cypress Street Tampa Florida 33607 813 287 0709 Attn Yaricel Garcia February 1 2017 C V Pr...

Page 2: ...op Order Service FINISHED WATER Tag S N 1244763CHP001A B WEST NASSAU REGIONAL WTP LARGE HIGH SERVICE PUMP 1 2 1244763 1 CARTER VERPLANCK Customer P O 18227 6LR 18A Model Flowserve Pump Division 3900 Cook Boulevard Chesapeake VA 23323 757 485 8000 ...

Page 3: ...ufacturer s Warranty 7 8 9 Performance Curve Forces Moments Material List Cross Sectional Drawing Spare Parts Supplied Surface Preparation Coating System Motor General Arrangement Drawing Data Pump Installation Operation Maintenance Manual Comments Clarifications General Arrangement Drawing Nameplate Drawing Pump Performance Data ...

Page 4: ...A HORIZONTAL SPLIT CASE CENTRIFUGAL PUMPS TAG LARGE HIGH SERVICE PUMP 1 2 MANUFACTURER Flowserve Pump Division 3900 Cook Blvd Chesapeake VA 23323 Attn Rainier Cruz Ph 757 485 4420 SUPPLIER Carter Verplanck Inc 4910 West Cypress Street Tampa FL 33607 Attn Sean Donovan Ph 813 287 0709 ...

Page 5: ...SECTION 1 SHIPPING METHOD Service WEST NASSAU REGIONAL WTP Model 6LR 18A Tag LARGE HIGH SERVICE PUMP 1 2 Customer P O 18227 Flowserve Corp 047 1244763 Shop Order 1244763 1 S N 1244763CHP001A B ...

Page 6: ...3 Service Finished Water S N 1244763CHP001A B P O No 18227 Rev 0 IMPORTANT NOTE TO INSTALLING CONTRACTOR THE SUBJECT PUMP S WILL BE SHIPPING ASSEMBLED WITH DRIVE MOTOR INSTALLING CONTRACTOR TO REVIEW THE SUBMITTED GENERAL ARRANGEMENT DRAWING TO ENSURE THE PUMP CAN BE INSTALLED IN THIS CONDITION INSTALLING CONTRACTOR MUST ACKNOWLEDGE THE ABOVE SHIPPING METHOD BY SIGNING AND DATING BELOW AND RETURNI...

Page 7: ...MMENTS CLARIFICATIONS CERTIFICATE OF COMPLIANCE Service WEST NASSAU REGIONAL WTP Model 6LR 18A Tag LARGE HIGH SERVICE PUMP 1 2 Customer P O 18227 Flowserve Corp 047 1244763 Shop Order 1244763 1 S N 1244763CHP001A B ...

Page 8: ... and test curves shall be submitted for approval prior to shipping Calibrated shop motor shall be used during factory testing C Pump delivery is 18 weeks upon receipt of formal release to fabrication D Start up Commissioning and Training are not part of Flowserve scope of work and shall be provided by an authorized representative II EXCLUSIONS A Off loading at jobsite any labor or tools for Assemb...

Page 9: ...s of construction for the LR product line Item 2 03 D 2 Comment Mechanical seals will be Chesterton 442 Split seals can be provided within the NSF61 certification for the LR product line The seals will have sil car vs carbon faces 316SS metal parts and EPR elastomers Item 2 04 C Comment Offered motor as per NEMA MG 1 and testing as per applicable NEMA IEEE standards Item 2 08 A Comment Section 099...

Page 10: ...sion www flowserve com 3900 Cook Boulevard Chesapeake Virginia 23323 1626 Telephone 757 485 8000 Facsimile 757 485 8191 Should you have any question please feel free to contact me Thank you very much Respectfully yours Rainier V Cruz Project Manager 757 558 4420 ...

Page 11: ...7 Certificate of Compliance Customer Carter Verplanck Tag LARGE HIGH SERVICE 1 2 Project West Nassau Regional WTP Order No 047 1244763 Service Finished Water S N 1244763CHP001A B P O No 18227 Rev 0 Flowserve certifies that the pump equipment will be in compliance with the Specification Section 11216 16150 and Addendums 1 2 with exceptions noted in the Comment and Clarification Section provided ...

Page 12: ...GENERAL ARRANGEMENT DRAWING NAMEPLATE DRAWING Service WEST NASSAU REGIONAL WTP Model 6LR 18A Tag LARGE HIGH SERVICE PUMP 1 2 Customer P O 18227 Flowserve Corp 047 1244763 Shop Order 1244763 1 S N 1244763CHP001A B ...

Page 13: ...ce Customer PO Flowserve reference 564368739 Pump size type 6LR 18A Pump speed Stages 1 750 rpm 1 Flow Head 2 000 0 USgpm 200 00 ft Driver power Frame 150 hp 112 kW 445T Volts Phase Hz 460 3 60 Hz Drawing number Date December 9 2016 Certified by Date Seal type Seal flush plan Plan 11 Copyright 2016 Flowserve All rights reserved Affinity v2 0 4 ...

Page 14: ...1244763CHP001A B LARGE HIGH SERVICE PUMP 1 2 18227 LR 6LR 18A 175 0 PSIG 1000 F ASTM A48 CL25 30 JANUARY 2017 1244763CHP001A B 2 000 0 200 00 1750 15 00 ...

Page 15: ...PERFORMANCE DATA PERFORMANCE CURVE FORCES MOMENTS Service WEST NASSAU REGIONAL WTP Model 6LR 18A Tag LARGE HIGH SERVICE PUMP 1 2 Customer P O 18227 Flowserve Corp 047 1244763 Shop Order 1244763 1 S N 1244763CHP001A B ...

Page 16: ... HI 14 6 Grade 1U Driver Sizing Max Power 3 Performance data based on standard impeller Performance Hydraulic power 101 hp Pump speed 1 750 rpm Pump overall efficiency CE 1 00 79 3 NPSH required NPSH3 10 7 ft Rated power 127 hp Maximum power 143 hp Driver power 150 hp 112 kW Casing working pressure 103 4 psig based on shut off cut dia rated SG Maximum allowable 175 0 psig Hydrostatic test pressure...

Page 17: ...ice Flowserve reference 564368739 Date December 9 2016 Capacity 1750 rpm Head 200 00 ft Density Specific gravity 1 000 Pump speed 2 000 0 USgpm Test tolerance ANSI HI 14 6 Grade 1U CURVES ARE APPROXIMATE PUMP IS GUARANTEED FOR ONE SET OF CONDITIONS CAPACITY HEAD AND EFFICIENCY Copyright 2016 Flowserve All rights reserved Affinity v2 0 4 ...

Page 18: ......

Page 19: ...NAL DRAWING MECHANICAL SEAL DRAWING COUPLING DATA SPARE PARTS SUPPLIED Service WEST NASSAU REGIONAL WTP Model 6LR 18A Tag LARGE HIGH SERVICE PUMP 1 2 Customer P O 18227 Flowserve Corp 047 1244763 Shop Order 1244763 1 S N 1244763CHP001A B ...

Page 20: ... 1244763CHP001A B P O No 18227 Rev 0 NAME OF PART MATERIAL Casing ASTM A48 Class 25 Cast Iron Casing Wear Ring 316 Stainless Steel ASTM A744 GR CF8M Impeller 316 Stainless Steel ASTM A744 GR CF8M Impeller Wear Ring Not Applicable Shaft 416 Stainless Steel ASTM A582 TYPE 416 Shaft Sleeve 316 Stainless Steel ASTM A744 GR CF8M Baseplate Fabricated Steel Mechanical Seal Chesterton 442 Split Seal Coupl...

Page 21: ......

Page 22: ......

Page 23: ...7 21 63 5 33 6 7 6 5 83 32 17 2 5 1 3 6 7 3 2 5 1 63 7 67 7 21 5 3 2 5 1 63 7 527 5 3 6 7 2 5 3 6 7 1 3 1 66 0 0 1 0 2 5 66 0 6 5 1 527 5 56 6 5 1 67 7 21 5 5 21 6 9 187 6 28 21 175 72 7 6 7 6 9 7 1 6 2 1 7 21 5 6 9 187 4 4 Ŗ 00 3 4 2 7 3 2 7 Ŗ 4 4 4 2 Ŗ Ŗ02 4 2 7 3 4 4 2 6 4 2 Ŗ Ŗ02 4 4 4 Ŗ 00 3 3 4 4 3Ŗ 5 4Ŗ 4 3Ŗ02 02 4 29Ŗ 2 4 Ŗ 2 Ŗ 52Ŗ02 5 4Ŗ Ŗ 3Ŗ Ŗ35 4Ŗ4 Ŗ2 452 Ŗ50 Ŗ Ŗ Ŗ50 Ŗ4 Ŗ 802 33 Ŗ 4 Ŗ4 ...

Page 24: ......

Page 25: ...eake Virginia 23323 1626 Telephone 757 485 8000 Facsimile 757 485 8191 January 27 2017 SPARES PARTS SUPPLIED Customer Carter Verplanck Tag LARGE HIGH SERVICE 1 2 Project West Nassau Regional WTP Order No 047 1244763 Service Finished Water S N 1244763CHP001A B P O No 18227 Rev 0 NO SPARE PARTS ARE TO BE SUPPLED ...

Page 26: ...SECTION 6 MANUFACTURER S WARRANTY Service WEST NASSAU REGIONAL WTP Model 6LR 18A Tag LARGE HIGH SERVICE PUMP 1 2 Customer P O 18227 Flowserve Corp 047 1244763 Shop Order 1244763 1 S N 1244763CHP001A B ...

Page 27: ...riting to the company within the specified period whereupon the company shall at its opinion repair the equipment or furnish a replacement part F O B point of shipment provided the owner has stored installed maintained and operated the equipment in accordance with good industry practice The company shall not be liable for any repairs replacements or adjustments to the equipment or any costs of lab...

Page 28: ...ON 7 SURFACE PREPARATION COATING SYSTEM Service WEST NASSAU REGIONAL WTP Model 6LR 18A Tag LARGE HIGH SERVICE PUMP 1 2 Customer P O 18227 Flowserve Corp 047 1244763 Shop Order 1244763 1 S N 1244763CHP001A B ...

Page 29: ...rplanck Tag LARGE HIGH SERVICE 1 2 Project West Nassau Regional WTP Order No 047 1244763 Service Finished Water S N 1244763CHP001A B P O No 18227 Rev 0 PUMP INTERIOR Casing Potapox Series 20 Thickness 3 0 to 6 0 DFT PUMP EXTERIOR includes Baseplate Guards SURFARCE PREPARATION Near White blast clean SSPC SP 3 PRIME COAT Tnemec Omnithan Series 1 Multiple passes to obtain 2 5 3 5 mils DFT Note Motors...

Page 30: ...act your Tnemec representative or Tnemec Technical Services CONCRETE Allow new concrete to cure for 28 days Abrasive blast referencing SSPC SP13 NACE 6 ICRI CSP 2 3 Surface Preparation of Concrete and Tnemec s Surface Preparation and Application Guide Holes pits voids and cracks should be filled with 63 1500 Filler and Surfacer PRIMED SURFACES Immersion Service Scarify the Series 20 or FC20 prime ...

Page 31: ...4 or 3 8 6 4 or 9 5 mm 60 mesh 250 microns Use appropriate tip atomizing pressure for equipment applicator technique and weather conditions Plural Component Spray Contact your Tnemec representative or Tnemec Technical Services Roller Roller application optional when environmental restrictions do not allow spraying Use 3 8 or 1 2 9 5 mm to 12 7 mm synthetic woven nap covers Brush Recommended for sm...

Page 32: ...r you may contact your Tnemec representative for current technical data and instructions SURFACE PREPARATION STEEL Immersion Severe Exposure SSPC SP10 NACE No 2 Near White Blast Cleaning Non Potable Non Immersion Service Exterior Exposure SSPC SP6 NACE No 3 Commercial Blast Cleaning Interior Exposure SSPC SP3 Power Tool Cleaning STEEL MAINTENANCE Abrasive blast cleaning produces the best coating p...

Page 33: ...ar with heavy mastic spring Low temperatures or longer hoses will require additional pressure Use pressure pot equipped with an agitator and keep pressure pot at same level or higher than the spray gun Compressed air must be dry Airless Spray Tip Orifice Atomizing Pressure Mat l Hose ID Manifold Filter 0 017 0 021 430 535 microns Reversible Tip 2400 3000 psi 165 207 bar 1 4 or 3 8 6 4 or 9 5 mm 60...

Page 34: ... 8 MOTOR GENERAL ARRANGEMENT DRAWING DATA Service WEST NASSAU REGIONAL WTP Model 6LR 18A Tag LARGE HIGH SERVICE PUMP 1 2 Customer P O 18227 Flowserve Corp 047 1244763 Shop Order 1244763 1 S N 1244763CHP001A B ...

Page 35: ...Representative MR BRIAN L MEYER Inside Sales Rep Phone 12604395333 Alternate Phone 260 439 2000 Model Number 5KS445SAA2067 Customer Order No 246453 Sales Order No 5200020871 Customer Item No Order Line No 1 1 Customer Part No Instruction Manual GEI 56128 Outline Drawing 239C6600ACZ Connection Diagram GEM2034E FIG7 Accessory Connection Diagrams Bearing Thermocouple None Heater 3027JE 1C RTD None Th...

Page 36: ... Enclosure TEFC Instruction Book GEI 56128 Encl Construction X D Design Code 44BD1087AA Ambient Max C 40 Type KS Alt Ambient Max C 65 Frame 445T Insulation Class H Phases 3 NEMA Design B Poles 4 Nominal Efficiency 95 8 Output Power 150HP 111 9KW Guaranteed Efficiency 95 4 RPM 1790 3 4 Load Efficiency 96 0 Voltage 460 KVA Code G Hertz 60 Max KVAR 34 5 Amps FL 167 0 Power Factor 88 0 Service Factor ...

Page 37: ... hold until prints are approved and returned When approved prints are received by GE current leadtimes will apply Approved by ________________________________________________ Date ________________ Visit us www gemotors com Page 3 of 10 115V HTR LDS TO MAIN CONDUIT BOX F1 MOUNTING STAINLESS STEEL HARDWARE OVER SIZE CONDUIT BOX NOMINAL LRA 650 OF FLA CLASS B TEMP RISE AT 1 15 SF TEFC XSD ULTRA FLOWS...

Page 38: ...7012876 01 Friday January 06 2017 Visit us www gemotors com Page 4 of 10 Diagrams for Model 5KS445SAA2067 Marks PROJECT 1244763 1 CARTER VERPLANCK Connection Diagram Heater Connection GEM2034E FIG7 3027JE 1C Thermostat Connection 3027JE 2B ...

Page 39: ...8 12 TORQ FL FT 439 97 TORQ LR FL 119 02 TORQ BD FL 251 57 AMPS LR 1001 31 PF AT START 0 25 This motor is capable of two cold or one hot start with a maximum connected load inertia of 4849 0 Lb Ft Sq 204 3 Kg meter Sq at 100 voltage where the load torque varies with the square of the speed Acceleration time with maximum inertia and the above load type is 77 seconds Safe stall time at 100 voltage i...

Page 40: ...Model Number 5KS445SAA2067 Version v17012876 01 Certified Print Friday January 06 2017 Page 6 of 10 Marks PROJECT 1244763 1 CARTER VERPLANCK ...

Page 41: ...Model Number 5KS445SAA2067 Version v17012876 01 Certified Print Friday January 06 2017 Page 7 of 10 Marks PROJECT 1244763 1 CARTER VERPLANCK ...

Page 42: ...Model Number 5KS445SAA2067 Version v17012876 01 Certified Print Friday January 06 2017 Page 8 of 10 Marks PROJECT 1244763 1 CARTER VERPLANCK ...

Page 43: ...Model Number 5KS445SAA2067 Version v17012876 01 Certified Print Friday January 06 2017 Page 9 of 10 Marks PROJECT 1244763 1 CARTER VERPLANCK ...

Page 44: ...Model Number 5KS445SAA2067 Version v17012876 01 Certified Print Friday January 06 2017 Page 10 of 10 Marks PROJECT 1244763 1 CARTER VERPLANCK ...

Page 45: ... Copyright 2016 General Electric Company 2016 04 25 g GE Power Conversion Motor Installation And Maintenance Instructions Horizontal AC Small Industrial Motors NEMA 143 to 5013 Frame GEI 56128 L ...

Page 46: ...B Mounting 5 C Sleeve Bearing Endplay 7 D Power Supply and Connections 7 IV Operation 8 A Steps Prior to Starting 8 B Initial Start 8 C Jogging and Repeated Starts 9 V Maintenance 9 A General 10 B General Cleanliness 10 C Division 1 Explosion Proof Motors 10 D Insulation and Windings 10 E Vacuum and Compressed Air Cleaning 10 F Cleaning with Water and Detergent 11 G Anti Friction Bearings and Lubr...

Page 47: ...hock to a person This symbol identifies a terminal which is intended for connection to an external grounding conductor for protection against electric shock in case of a fault The use of an exclamation point within a yellow triangle indicates to the user that important installation operating and maintenance instructions must be followed The use of a small case i enclosed in a square indicates a ge...

Page 48: ...res below 0 F the eyebolt could fail resulting in injury to personnel and or damage to equipment Drop forged eyebolts per American Society of Testing Materials A489 or equivalent must be used Do not use the motor shaft as a means for lifting Do not lift both the motor and driven equipment with the motor lifting means Do not stand on or place objects on the motor Maintenance Safe maintenance practi...

Page 49: ...test revision of the following standards a NEMA MG 1 2 Motors that have the IECEx designation have also been designed to meet the requirements of the following standards a IEC and or BS EN 60079 0 b IEC and or BS EN 60079 15 3 Motors with the CE Mark have also been designed to meet the requirements of the following EU directives a Machinery safety b Low Voltage c Electromagnetic Compatibility d Co...

Page 50: ...tely 50 full Rotate the shaft of all grease lubricated motors 10 20 revolutions at two month intervals If the purchaser has specified the machine be packaged for long term storage the foregoing recommendations do not apply and the packing should be left intact during the period of storage C Extended Storage Longer than 6 months In the event the motor is to be stored longer than six months please r...

Page 51: ... 0 and BS EN 60079 15 for the meaning and understanding of all symbols and codes 5 Division 1 Explosion proof motors bearing the Underwriters Laboratories label designating the motor s Class and Group as defined in the National Electrical Code NEC are designed for operation in areas classified by local authorities as hazardous in accordance with the NEC B Mounting 1 Mount motors securely on a firm...

Page 53: ...han 0 002 5 The application of pulleys sheaves sprockets and gears on the motor s shaft is shown in NEMA Standard MG1 14 07 The application of the V belts dimensions for alternating current motors is in MG1 14 42 V belt sheave pitch diameters should not be less than the values shown in Table 14 1 of NEMA MG 1 Sheave ratios greater than 5 1 and center to center distances less than the diameter of t...

Page 54: ...visable to eliminate the moisture in one of the following ways 1 Dry the winding in an air circulating oven with the air surrounding the winding at 110 C 5 15 C until the part has been above 90 C for at least four hours Then the air temperature may be raised to 150 C 5 C 15 C Continue to heat until the insulation resistance is constant for a one half hour period 2 Enclose the motor with canvas or ...

Page 55: ... for the first time the bearing temperature should be observed for a minimum of 2 hours If at any time the rate of temperature rise exceeds 2 C minute shut down the motor immediately and make an investigation of lineup conditions and if necessary the bearing and oil ring assembly 8 For anti friction bearings check motor operation under load for an initial period of at least one hour to observe whe...

Page 56: ... and carry its label Therefore repairs need to be made at a GE Service Shop which has been authorized to make such repairs D Insulation and Windings To obtain a long life and satisfactory operation of insulated windings they should be kept clean from dirt oil metal particles and other contaminants A variety of satisfactory and acceptable methods are available for keeping the windings clean The cho...

Page 57: ...bricant This lubricant must always be present to avoid rapid wear and bearing failure However excessive or too frequent lubrication may also damage the motor Ball bearing motors are adequately lubricated at the factory Motors with grease fittings should be lubricated in accordance with these instructions to provide maximum bearing life To obtain optimum results Exxon Mobil Polyrex EM General Elect...

Page 58: ...operation of the motor both oil reservoirs should be filled to the center of the oil level gage The oil should be maintained at this level determined with the motor at stand still Oil is added through the oil sight gauge hole above each bearing or through the inlet pipe provided 1 Oil For motors operating between 10 C and 50 C use a good grade of mineral oil having a viscosity of ISO 32 Consult GE...

Page 59: ...bearing vi Remove the upper half of the bearing vii Jack up the shaft a few mils to remove the weight of the rotor from the lower bearing surface viii Remove the split line screws from the oil ring and remove the split parts ix Rotate the lower half bearing around the shaft and remove b Cleanliness is important when working with bearings Before reassembling a bearing all bearing and machine surfac...

Page 60: ...Overheating Calibration of measuring instrument Worn out or dirty oil Rough journal Oil rings jammed Insufficient Oil Misalignment Excessive end thrust or radial loading Shaft currents Excessive or insufficient grease Worn out or dirty grease Motor Excessive Vibration Unbalance Misalignment Improper or settled foundation Non uniform air gap Rubbing parts Bent shaft Unbalanced stator current Damage...

Page 61: ... been designed to meet the rigid requirements of these standards Repair or alteration of the motor may result in the motor no longer meeting the requirements of these standards If major repairs are undertaken such as rewinding a stator proper facilities should be made available and suitable precautions observed Recommended tightening torques for various parts is listed in Tables 4A and 5B below WA...

Page 62: ...an Cover 70 96 7 9 10 8 1 4 in Grade 8 Fan Cover Mounting 100 145 11 16 5 16 in Bearing Cap 78 120 8 8 14 5 16 in All Parts except Bearing Cap 170 250 19 28 3 8 Low Carbon Steel Conduit Box Cover 180 240 20 27 3 8 in All Parts except Conduit Box Cover 250 370 28 42 1 2 in All Parts 610 920 70 100 3 4 in All Parts 2150 3200 240 360 Table 4B Tightening Torque Range Stainless Steel SAE Hardware Prope...

Page 66: ...00 1000 4 1 5 9 months 6 months 3 months 1 5 6 months 3 months 1 5 months Very Severe Dirty vibrating applications where end of shaft is hot pumps and fans high ambient temperature 1 7 5 10 40 50 150 200 350 400 1000 9 months 4 months 4 months 3 months 2 months 6 months 3 months 2 months 1 month Table 6 Number of Grease Gun Pumps Bearing Size on Motor Nameplate Number of Pumps Bearing Size on Moto...

Page 67: ...ow You Use This Publication Publication No E Mail Publication Issue Revision Date Address General Rating Excellent Good Fair Poor Additional Comments Contents Organization Technical Accuracy Clarity Completeness Drawings Figures Tables Referencing Readability Specific Suggestions Corrections information that could be expanded on and such Page No Comments Other Comments What you like what could be ...

Page 68: ...UMP INSTALLATION OPERATION MAINTENANCE MANUAL Service WEST NASSAU REGIONAL WTP Model 6LR 18A Tag LARGE HIGH SERVICE PUMP 1 2 Customer P O 18227 Flowserve Corp 047 1244763 Shop Order 1244763 1 S N 1244763CHP001A B ...

Page 69: ...se volute type centrifugal pumps for water and general service PCN 71569088 08 10 E Based on C953KH013 Original instructions Installation Operation Maintenance These instructions must be read prior to installing operating using and maintaining this equipment ...

Page 70: ...arding 20 5 5 Priming and auxiliary supplies 20 5 6 Starting the pump 20 5 7 Running the pump 21 5 8 Stopping and shutdown 22 5 9 Hydraulic mechanical and electrical duty 22 PAGE 6 MAINTENANCE 22 6 1 General 22 6 2 Maintenance schedule 23 6 3 Spare parts 25 6 4 Recommended spares and consumable items 25 6 5 Tools required 26 6 6 Fastener torques 26 6 7 Renewal clearances 26 6 8 Disassembly 26 6 9 ...

Page 71: ...rication 5 1 1 5 2 and 6 2 3 Lubrication schedule 5 2 4 19 Maintenance 6 22 Maintenance schedule 6 2 23 Name nomenclature 3 2 11 Nameplate 1 7 1 8 Operating limits 3 4 1 12 Options 8 36 Ordering spare parts 6 3 1 25 Part assemblies 4 2 12 Parts lists 8 36 Performance 3 4 12 Piping 4 6 14 PAGE Pre commissioning 5 1 18 Priming and auxiliary supplies 5 5 20 Protection systems 4 9 17 Reassembly 6 10 A...

Page 72: ...sive 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 t...

Page 73: ...ge and skill appropriate training and instruction must be provided If required the operator may commission the manufacturer supplier to provide applicable training Always coordinate repair activity with operations and health and safety personnel and follow all plant safety requirements and applicable safety and health laws and regulations 1 6 3 Safety action This is a summary of conditions and act...

Page 74: ...ction 5 Commissioning start up operation and shutdown NEVER RUN THE PUMP DRY INLET VALVES TO BE FULLY OPEN WHEN PUMP IS RUNNING Running the pump at zero flow or below the recommended minimum flow continuously will cause damage to the pump and mechanical seal DO NOT RUN THE PUMP AT ABNORMALLY HIGH OR LOW FLOW RATES Operating at a flow rate higher than normal or at a flow rate with no back pressure ...

Page 75: ...en into account in the temperatures stated The responsibility for compliance with the specified maximum liquid temperature is with the plant operator 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 permit...

Page 76: ...otecting the pump and ancillary systems Where there is the potential hazard of a loss of a seal barrier fluid or external flush the fluid must be monitored If leakage of liquid to atmosphere can result in a hazard install a liquid detection device 1 6 4 7 Maintenance to avoid the hazard CORRECT MAINTENANCE IS REQUIRED TO AVOID POTENTIAL HAZARDS WHICH GIVE A RISK OF EXPLOSION The responsibility for...

Page 77: ...Consult Flowserve or a noise specialist if assistance is required in combining the values It is recommended that where exposure approaches the prescribed limit then site noise measurements should be made The values are in sound pressure level LpA at 1 m 3 3 ft from the machine for free field conditions over a reflecting plane For estimating sound power level LWA re 1pW then add 17 dBA to the sound...

Page 78: ...fting in accordance with local regulations To avoid distortion the pump unit should be lifted as shown When there are no specific lifting points on the baseplate Before lifting the driver alone refer to the manufacturer s instructions 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 ca...

Page 79: ...he top half casing Suction and discharge branches are in the bottom half and therefore remain undisturbed 3 3 2 Impeller The impeller is 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 Oil l...

Page 80: ...as detailed in section 4 5 2 4 3 Foundation There are many methods of installing pump units to their foundations The correct method depends on the size of the pump unit its location and noise 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 3 4 2 Pump and impeller da...

Page 81: ...ce 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 Fo...

Page 82: ...axial position If the motor does not run in its magnetic centre the resultant additional axial force may overload the pump thrust bearing 4 5 3 Check for soft foot This is a check to ensure that there is no undue stress on the driver holding down bolts due to non level baseplate or twisting To check remove all shims and clean surfaces and tighten down driver to the baseplate Set a dial indicator a...

Page 83: ...e 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...

Page 84: ...20 2 40 1 770 2 88 640 3 30 740 2 40 540 1 65 1 210 0 90 660 1 20 880 6LR 18 6LR 18S 7 35 1 650 5 78 1 300 4 20 940 4 25 3 100 2 25 1 650 3 00 2 200 2 88 640 3 30 740 2 40 540 1 65 1 210 0 90 660 1 20 880 8LR12 14 7 35 1 650 5 78 1 300 4 20 940 4 25 3 100 2 25 1 650 3 00 2 200 3 84 860 4 40 990 3 20 720 2 20 1 620 1 20 880 1 60 1 180 8LR18S 8LR 20 8 82 1 980 6 93 1 550 5 04 1 130 5 10 3 760 2 70 1...

Page 85: ...l bolts in the suction and discharge pipework Check also the tightness of all foundation bolts 4 7 Final shaft alignment check After connecting piping to the pump rotate the shaft several times by hand to ensure there is no binding and all parts are free Recheck the coupling alignment as previously described to ensure no pipe strain If pipe strain exists correct piping 4 8 Electrical connections E...

Page 86: ...rication of the pump set eg grease oil product lubrication etc For oil lubricated pumps fill the bearing housing with correct grade of oil to the correct level ie sight glass or constant level oiler bottle When fitted with a constant level oiler the bearing housing should be filled by unscrewing or hinging back the transparent bottle and filling the bottle with oil Where an adjustable body Denco o...

Page 87: ...f Multis EP2 Multis EP3 Fuchs RENOLIT EP2 RENOLIT EP3 ESSO Beacon EP2 Beacon EP3 Mobil Mobilux EP2 Mobilux EP3 Q8 Rembrandt EP2 Rembrandt EP3 Shell Alvania EP2 Alvania EP2 Texaco Multifak EP2 Multifak EP3 SKF LGEP 2 NLGI 2 is an alternative grease and is not to be mixed with other grades Standard pre packed grease for fitted antifriction bearings Food type grease regreasing interval is 1200 hours ...

Page 88: ... 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 Vertical pumps open vent connection 1 at the front of the upper half casing and disconnect the seal flush line at the mechanical seal stuffing box to allow the trapped a...

Page 89: ...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 If bearing temperatures are to be monitored...

Page 90: ...r 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 Changi...

Page 91: ...s 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 foll...

Page 92: ...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 T I M E TEMPERATURE Grease change every 4 000 hours or sooner depending on the severity of the application a Remove the bearing housing from the rotor assembly b Brush the bearing housing with hot kerosene 100 to 115 C 212 to 240 ...

Page 93: ...ump and is not considered as warranty Flowserve has applied the coatings according to the supplier s instructions but will not be held responsible for coating wear or cracks that may develop over time 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 ...

Page 94: ...ump Before dismantling the pump for overhaul ensure genuine Flowserve replacement parts are available To dismantle the pump consult the sectional drawings See section 8 Parts lists and drawings 6 8 1 LR and LLR 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 Drai...

Page 95: ...ove difficult to remove the use of heat is permissible Refer to Section 1 6 Safety Applying heat to remove impeller for more details s If impeller wear rings 2300 are also fitted they are shrunk onto the impeller and fixed with locking grub screws 6814 4 between their diametral mating surfaces t To remove the impeller wear rings remove the locking grub screws and heat up the wear ring until it sli...

Page 96: ...imming between stool and pump casing g Remove screws securing the pump suction and discharge flanges h Sling pump as shown in section 2 3 and allow lifting gear to just take the pump weight Remove screws securing the pump casing to the baseplate i Remove the pump to a safe location and manoeuvre the pump shaft into a horizontal position j Remove the pump half coupling k Unbolt the seal cover from ...

Page 97: ...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 LR LLR 6 10 1 1 Impeller wear rings a Impeller rings when fitted should be heated up to...

Page 98: ...r a tab of lockwasher into bearing nut slot m Slip casing wear rings complete with anti rotation grub screws loosely over the impeller hubs n Slide the bearing housings over the bearings All pumps except the 10LR17 and 10LR18 have a shim fitted between the outside diameter of the non drive end bearing and the bearing housing Ensure shim is seated against the shoulder in the bearing housing before ...

Page 99: ... 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...

Page 100: ...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 the seal cover complete with gasket or O ring Take care not to damage the O ring if fitted and locate the c...

Page 101: ... housing before sliding housing over the bearing Ensure bearing is located square in the housing bore n One third fill the space between bearing cover and bearing with grease o Secure bearing cover complete with gasket p Fit outboard shaft seal ring q Fit the coupling hub 6 10 3 6 Casing lower half a Coat the bearing housing to casing face with liquid sealant to protect against corrosion b Place t...

Page 102: ...IES A SYSTEM TROUBLES Pump not primed Check complete filling Pump or suction pipe not completely filled with liquid Check and complete filling Suction lift too high or level too low Check NPSHA NPSHR proper submergence losses at strainers and fittings 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 l...

Page 103: ...ed parts and assembly method used Incorrect type of mechanical seal for operating conditions Consult Flowserve Shaft running off centre because of worn bearings or misalignment Check misalignment and correct if necessary If alignment satisfactory check bearings for excessive wear Impeller out of balance resulting in vibration Check and consult Flowserve Abrasive solids in liquid pumped Check and c...

Page 104: ...g 1630 Throttling bush 1690 Bush dowel 2100 Shaft 2200 Impeller 2540 Flinger liquid 2910 Shaft nut 3011 1 Ball bearing 3011 2 Ball bearing 3126 Shim 3200 Bearing housing 3260 Bearing cover 3645 Disc spacer 3712 Bearing nut 3853 Grease nipple 4120 Gland 4130 Gland packing 4134 Lantern ring 4420 Sealing pipe 4590 1 Gasket 4590 2 Gasket 6541 Lockwasher 6569 1 Plug 6569 2 Plug 6569 3 Plug 6569 4 Plug ...

Page 105: ...r ring Drawings taken from A336 044 sheet 2 rev 8 1 3 Options parts list LR single entry impeller Ref no Description 2300 Impeller wear ring 2530 Retaining ring 3855 Constant level oiler 4200 Mechanical seal cartridge 4200 1 Mechanical seal 4213 Mechanical seal cover 4610 O ring 6529 Ventilation device breather 6814 3 Grub screw 6814 4 Grub screw When required dependent on type of mechanical seal ...

Page 106: ...lf lower 1214 Casing half upper 1220 Cover 1500 Casing wear ring 1630 Throttling bush 1690 Bush dowel 2100 Shaft 2200 Impeller 2450 Shaft sleeve 2540 Flinger liquid 2910 1 Shaft nut 3011 1 Ball bearing 3011 2 Ball bearing 3126 Shim 3200 Bearing housing 3260 Bearing cover 3645 Disc spacer 3712 Bearing nut 3853 Grease nipple 4120 Gland 4130 Gland packing 4134 Lantern ring 4420 Sealing pipe 4590 1 Ga...

Page 107: ...mbly Drawings taken from A336 040 sheet 2 rev 8 2 3 Options parts list LR double entry impeller Ref no Description 2300 Impeller wear ring 2530 Retaining ring 2910 2 Shaft nut 3855 Constant level oiler 4200 Mechanical seal cartridge 4200 1 Mechanical seal 4213 Mechanical seal cover 4610 2 O ring 6529 Ventilation device breather 6814 3 Grub screw 6814 4 Grub screw 6814 5 Grub screw When required de...

Page 108: ...200 1 Impeller first stage 2200 2 Impeller second stage 2410 Interstage sleeve 2450 Shaft sleeve 2540 Flinger liquid 2910 1 Shaft nut 3011 1 Ball bearing 3011 2 Ball bearing 3200 Bearing housing 3260 Bearing cover 3712 Bearing nut 3853 Grease nipple 4120 Gland 4130 Gland packing 4134 Lantern ring 4420 Sealing pipe 4590 1 Gasket 4590 2 Gasket 4610 1 O ring 6541 Lockwasher 6569 1 Plug 6569 2 Plug 65...

Page 109: ...on optional Drawings taken from A336 042 sheet 2 rev 8 3 3 Options parts list LLR Ref no Description 1630 2 Throttle bush 2300 Impeller wear ring 2530 Retaining ring 2910 2 Shaft nut 3855 Constant level oiler 3870 Return pipe 4200 Mechanical seal cartridge 4200 1 Mechanical seal 4213 Mechanical seal cover 4610 2 O ring 6529 Ventilation device breather 6814 4 Grub screw 6814 5 Grub screw 6814 6 Gru...

Page 110: ...30 Throttling bush 1690 Bush dowel 2100 Shaft 2200 Impeller 2450 Shaft sleeve 2540 Flinger liquid 2910 Shaft nut 3011 1 Ball bearing 3011 2 Ball bearing 3200 Bearing housing 3260 Bearing cover 4120 Gland 4130 Gland packing 4134 Lantern ring 4305 1 Shaft seal ring 4305 2 Shaft seal ring 4420 Sealing pipe 4590 1 Gasket 4590 2 Gasket 4610 1 O ring 6541 Lockwasher 6544 Circlip 6569 1 Plug 6569 2 Plug ...

Page 111: ...cal seal option Drawings taken from A336 043 sheet 2 rev 8 4 3 Options parts list LR S Ref no Description 2100 2 Shaft 2300 Impeller wear ring 2530 Retaining ring 3011 3 Double row thrust bearing 3712 Bearing nut 3855 Constant level oiler 4200 Mechanical seal 4213 Mechanical seal cover 4610 2 O ring 6541 Lockwasher 6814 2 Grub screw 6814 3 Grub screw When required dependent on type of mechanical s...

Page 112: ...RUCTIONS ENGLISH 71569088 08 10 Page 44 of 48 flowserve com 8 5 Sectional drawings LRV double entry impeller grease lubricated thrust bearing component mechanical seal silicon carbide bearing Drawing taken from A336 041 sheet 1 rev ...

Page 113: ...0 1 Gasket 4590 2 Gasket 4610 1 O ring 4610 2 O ring 4610 3 O ring 6415 Cap 6541 Lockwasher 6569 1 Plug 6569 2 Plug 6569 3 Plug 6569 4 Plug 6569 5 Plug 6570 Screw 6570 1 Screw 6570 2 Screw 6570 3 Screw 6570 4 Screw 6570 5 Screw 6570 6 Screw 6579 Socket head cap screw 6700 1 Key 6700 2 Key 6814 1 Grub screw 6814 2 Grub screw 6814 3 Grub screw When required dependent on type of mechanical seal fitte...

Page 114: ...14 BB 10LR 16 CC L G G K 10LR 17 DD 10LR 18 EE M H H L 6LR 18S FF N M 10LR 14S GG N 12LR 14S HH O I I O 8LR 18S II N 10LR 18S JJ O 8LR 23S KK P J J P Notes 1 All the above pump casings can be supplied for clockwise or counter clockwise rotation The casings are interchangeable with each other although pump suction and discharge positions change refer to the relevant Sectional arrangement drawing Th...

Page 115: ...ing bearing cover ball bearing set bearing nut and lockwasher 5 Includes tolerance ring and bearing retaining ring 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 ...

Page 116: ...To find your local Flowserve representative please use the Sales Support Locator System found at www flowserve com FLOWSERVE REGIONAL SALES OFFICES USA and Canada Flowserve Corporation 5215 North O Connor Blvd Suite 2300 Irving Texas 75039 5421 USA Telephone 1 972 443 6500 Fax 1 972 443 6800 Europe Middle East Africa Flowserve FSG Italy Worthington S r l Via Rossini 90 92 20033 Desio Milan Italy T...

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