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5

SECTION I

INTRODUCTION

This  manual  contains  instructions  for  installation,  operation  and  maintenance  for  your
FLOWSERVE  Centrifugal  Pump.  The  instructions  are  written  for  the  use  of  personnel  with  a
general training in the operation and maintenance of Centrifugal Pumps.
Your pump has been designed to provide safe and reliable service. However, it is both a pressure
vessel  and  a  piece  of  rotating  machinery  so  that  operators  must  exercise  good  judgement  and
observe  correct  safety  practices  to  avoid  damage  to  the  equipment  and  surroundings  and  to
prevent personal injury.
The  pump  has  been  designed  for  the  duty  specified  in  the  customers  order.  F.P.D  should  be
consulted prior to any significant change of duty.

1.1

Safety

It  is  assumed  that  your  safety  department  has  established  a  safety  programme  based  upon  a
thorough analysis of industrial hazards. Before installing and operating or performing maintenance
on  the  pump  and  associated  components  in  this  manual,  it  is  suggested  that  the  safety
programme  be  reviewed  to  ensure  that  it  covers  the  hazards  arising  from  high  speed  rotating
machinery.
It is also important that due consideration be given to those hazards which arise from the presence
of  electrical  power,  hot  oil,  high  pressure  and  temperature  liquids,  toxic  liquids  and  gases,
flammable liquid and gases.  Correct installation and care of protective guards, shut down devices
and over pressure protection equipment should also be considered an essential part of any safety
programme.
Also  essential  are  special  precautionary measures to prevent the possibility of applying power to
the equipment at any time when maintenance work is in progress. The prevention of rotation due
to reverse flow should not be overlooked.
In  general,  all  personnel  should  be  guided  by  all  the  basic  rules  of  safety  associated  with  the
equipment and the process.

1.2

Installation, Operation and Maintenance Safety Procedures

In the following safety procedures you will encounter the words

WARNING, CAUTION

and

NOTE

.

These are intended to emphasize certain areas in the interest of personal and satisfactory pump
operation and maintenance. The definitions are as follows:

WARNING

: An operating procedure, practice, etc, which if not correctly followed, could result in

personal injury, or loss of life.

CAUTION

:

An operating procedure, practice, etc, which, if not correctly observed, could result
in damage to, or destruction of equipment.

NOTE

:

An operating procedure, etc, which is essential to highlight.

These safety procedures are to be used in conjunction with the installation, operation and
maintenance instructions contained in the pump manual.

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Содержание HPX

Страница 1: ...INSTRUCTIONS FOR INSTALLATION OPERATION AND MAINTENANCE ___________________________________________ Centrifugal pumps Type HPX CE HPX R FLOW DOC rev 0 Pump Division Worthington S r l ...

Страница 2: ...iptions and instructions included in this book cover the standard design of the equipment and any common deviations when possible This book does not cover all design details and variations nor does it provide for every possible contingency which may be encountered When information can not be found in this book contact the nearest FLOWSERVE Service Centre WARNING Do not operate this equipment in ex...

Страница 3: ...during storage Long term storage Inspection upon arrival Storage Inspection and maintenance Painting and preservation Associated equipment Lifting equipment To lift unit To lift driver To lift complete pump only II INSTALLATION 15 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 2 12 2 13 2 14 2 15 Location Foundation Level the baseplate Method of levelling baseplate using wedges or shims Grouting Sh...

Страница 4: ... Chart IV LUBRICATION 43 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 Preparing Bearing Housing Inspection Replenishment Oil Change Lubrication Specification Trico Oiler Setting Bearing Housing Oil Fill Capacities Bearing Housing Oil Limitations V MECHANICAL SEALS 47 5 1 5 2 Description Servicing Mechanical Seal VI MAINTENANCE DISMANTLING 48 6 1 6 2 6 3 Dismantling General Pump Disassembly Instructions Disasse...

Страница 5: ...trical power hot oil high pressure and temperature liquids toxic liquids and gases flammable liquid and gases Correct installation and care of protective guards shut down devices and over pressure protection equipment should also be considered an essential part of any safety programme Also essential are special precautionary measures to prevent the possibility of applying power to the equipment at...

Страница 6: ...coupling Actual damage to the equipment and personal injury could result from operating the unit with incorrect rotation 4 Suction and discharge piping Provision must be made to support suction and discharge piping to the pump to prevent excessive nozzle loads and maintain pump to driver alignment 1 4 Operation Safety Procedures 1 Operating conditions WARNING In the interest of operator safety the...

Страница 7: ...efficiency point 6 Bearing lubrication WARNING Operation of the unit without correct lubrication can result in overheating of the bearings Bearing failures pump seizures and actual breakup of the equipment exposing operating personnel to injury 7 Operation inspections WARNING Do not attempt any maintenance inspection repair or cleaning in the vicinity of rotating equipment Such action could result...

Страница 8: ...ices of suitable protective materials must be worn when draining the pump It should be understood that the information contained in this manual does not relieve operating and maintenance personnel of the responsibility of exercising normal good judgement in operation and care of the pump and its components 5 Pumps on vacuum service WARNING Before attempting any maintenance work on pumps in vacuum ...

Страница 9: ...nto the impeller hub and positively secured with radial screws 1 10 Casing cover The casing cover is designed to accommodate single tandem or double elastomer and metal bellow cartridge seals to the dimensional requirements of API 682 On certain models a wear ring may be mounted in the cover to provide a close running clearance with the impeller back wear ring 1 11 Shaft A high strength shaft is o...

Страница 10: ...plate Standard baseplates are welded steel drain pan type in conformance with API 610 standardized dimensions forces and moments Horizontal driver alignment screws and vertical baseplate levelling screws are provided as an option Special baseplates can be supplied to suit individual installation circumstances 1 17 Check upon arrival Your pump was carefully checked at the factory prior to shipment ...

Страница 11: ...ter If necessary clean and preserve the interior parts as noted above to restore the parts to the as shipped condition Install or replace covers and fasten securely 1 21 Storage If at all possible the pump and its component parts should be stored indoors where they will be protected from the elements In no case should any pump element be subjected to extended periods of submergence or wetting prio...

Страница 12: ...wrapping Six months prior to the scheduled installation date an FLOWSERVE representative is to be employed to conduct an inspection This inspection may include not necessarily in its entirety and not limited to the following 1 An inspection of all periodic inspection records as kept on file by the purchaser and all inspection reports that have been compiled during the storage period 2 An inspectio...

Страница 13: ...ves used are either FLOWSERVE standard or special as required by the contract specification Refer to your branch office through which the order was placed or FLOWSERVE for the description of paints and preservatives used on this order 1 24 Associated equipment Motors Turbines Gears etc being supplied by FLOWSERVE Generally rotors of associated equipment should be blocked to relieve bearing loads S...

Страница 14: ...om pump casing and or eye bolt on motor 1 27 To lift driver Refer to Manufacturers Instructions 1 28 To lift complete pump only Rig lifting straps at coupling end of bearing housing and at stuffing box extension Make sure straps are adjusted to obtain an even lift ...

Страница 15: ...nforced concrete These should be poured well in advance of the installation to allow sufficient time for drying and curing The General Arrangement Drawing In the last section of this manual will furnish anchor bolt locations size of bolts etc See Figure 1 below G RO UT INGUNDE R BA SEPLA T E M A KE T HIS DIST A NCE EQ UA L T O LUGO N BA SEPLA T E T EM PLA T E FO R HA NG ING FO UNDA T IO N BO L T S...

Страница 16: ...n the top of the foundation Break off any loose pieces of cement and roughen the top with a chisel to afford a good hold for grout NOTE Coupling bolting and spacer piece must be removed from between the pump and driver half couplings before lifting baseplate with pumping element NOTE When lifting baseplate with pumping element sling baseplate from all lifting eyes provided Refer to Section 1 26 Pr...

Страница 17: ...r or by installing a low level hydraulic jack Adjust the shim pack thickness and lower the baseplate Repeat this procedure in a logical manner at each bolt position until the baseplate is both straight and level A degree of 0 0035 inch per foot 25mm per metre length is achievable on most units with a maximum of 0 005 inch per foot 40mm per metre length When the baseplate is level pull down the fou...

Страница 18: ...ROWEL FINISHED GROUT DAM Figure 4 Use a good high strength non shrink grout mix and install as per manufacturer s instructions Holes are provided in the baseplate to permit pouring the grout and stirring while acting as air vents Fill under the baseplate completely stirring to assure correct distribution of the grout Check to see that the grout flows under the edges of the baseplate evenly NOTE Do...

Страница 19: ...stresses in shafts bearings and coupling Flexible couplings will not compensate for appreciable misalignment Foundation settling thermal expansion or nozzle loads resulting in baseplate foundation deflection and vibration during operation may require the full coupling misalignment capability 2 7 Types of misalignment There are two types of shaft misalignment angular and offset Therefore two sets o...

Страница 20: ...n driver to the baseplate Set a dial indicator as shown in sketch and loosen off the holding down bolt while noting any deflection reading on the Dial Test Indicator a maximum of 0 05 mm 0 002 is considered acceptable but any more will have to be corrected by adding shims for example if the Dial Test Indicator shows the foot lifting 0 15 mm 0 006 then this is the thickness of shim to be placed und...

Страница 21: ...l Test Indicator s are zeroed on the top and they are read at the bottom 180 degrees For horizontal they are zeroed at the side away from the person doing the alignment and called far in the text and read on the opposite side and called near in the text C To plot the graph the above measurements must be recorded A to B this is the distance between the Dial Test Indicator pointers which should be p...

Страница 22: ...l Plane Step 2 Position Dial Test Indicator s on the top of the hubs and zero Rotate through 180 degrees and note the readings and halve the value Plot onto the graph to determine the shimming needed to be added or removed and when carried out repeat step 1 and tighten down again Check top and bottom again and if outside tolerance repeat as necessary EXAMPLES Number 1 See Figure 2 As can be seen f...

Страница 23: ...en that Y Y intersects F1 0 002 in below and at F2 0 016in below so by moving the motor feet towards the FAR these amounts front foot moved 0 002in and the rear foot moved 0 015in we will achieve side to side alignment VERTICAL The line X X represents the reading taken from top to bottom which were A minus 0 034in and B plus 0 024in This means that A is minus so it is plotted below C C 0 017in div...

Страница 24: ...p Hub Clock Readings in FIGURE 2 EXAMPLE 1 X X Y Y VERTICAL HORIZONTAL TIR FOR TOP AND BOTTOM TIR FOR SIDE TO SIDE A 0 034 Therefore Plot A above 0 007 A 0 014 Therefore A above 0 017 B 0 024 Therefore Plot B above 0 012 B 0 008 Therefore B above 0 004 MOTORS ALTERED AS FOLLOWS MOTOR TO BE MOVED TO FAR SIDE F1 Add 0 002 of Shims F1 0 002 and F1 0 0155 F2 remove 0 0205 of Shims ...

Страница 25: ...TIR 0 0 At F1 Add 0 008 Shim At F1 Move to Far 0 012 At F2 remove 0 010 Shim At F2 Move to Far 0 039 0 0 01 0 02 0 03 0 04 0 05 0 06 0 07 A B F1 F2 0 01 0 02 0 03 0 04 0 05 0 06 0 07 28 30 32 34 36 38 40 26 24 22 20 18 16 0 2 4 6 8 10 12 14 C C Distance Over Motor Feet in Pump Hub Clock Readings in FIGURE 2 EXAMPLE 3 Y Y X X VERTICAL X X HORIZONTAL Y Y A TIR 0 036 0 018 A TIR 0 060 0 03 B TIR 0 02...

Страница 26: ...26 SERIAL NO PUMP TYPE DATE Distance Over Motor Feet 0 01 0 02 0 03 0 04 0 05 0 06 0 07 0 0 01 0 02 0 03 0 04 0 05 0 06 0 07 ALIGNED BY PUMP HUB CLOCK READINGS ...

Страница 27: ... the equipment on its mounting foot Do not use many thin shims as this may result in a spongy mounting Recommended shim design Move the equipment vertically by adding or removing the calculated thickness of shims Torque holding down bolts to required values NOTE It is recommended the complete ALIGNMENT GRAPH SHEET be retained as part of your permanent maintenance file 2 10 Assemble Coupling 1 Asse...

Страница 28: ...erature and conditions If the unit has been correctly cold set the offset misalignment will be within 005 TIR 12mm TIR and the angular misalignment will be within 0025 TIR 06mm TIR when in operation If not make adjustments WARNING Do not attempt any maintenance inspection repair or cleaning in the vicinity of rotating equipment Such action could result in injury to operating personnel WARNING Befo...

Страница 29: ...Check Foundation Bolts 3 Alignment Shaft Coupling 4 Piping Installed Correct Vent Gauge Valve Suction Strainer Locations 5 All Flange Bolting Correctly Torqued with appropriate gaskets in place 6 Check Shaft Coupling Alignment again 7 Coupling guard correctly installed ...

Страница 30: ...nd a gate valve in the discharge pipe of the pump When the pump is stopped the check valve will protect the pump against excessive pressure and will prevent the pump from running backward The check valve should be installed between the gate valve and the pump nozzle in order to permit its inspection Keep the suction pipe from the source short and direct Use a suction pipe equal to or one size larg...

Страница 31: ... 3 to 1 ratio to the area of the pump suction The FLOWSERVE standard for suction strainers consists of a conical shaped steel plate The plate has 1 16 perforations and is of sufficient size and thickness for the required flow See Figure above Other type of strainers may be used as long as they conform to the requirements stated above Pressure gauges should be installed on both sides of the screen ...

Страница 32: ...erred to FLOWSERVE for our recommendations 3 4 Changing the Pump Speed Changing the speed of a centrifugal pump changes the capacity total head and brake horsepower The capacity will vary in a direct ratio with the speed whereas the total head will vary as the square of the speed The brake horsepower will vary in the ratio of the speed cubed except in cases where the speed change also changes the ...

Страница 33: ...reaching increased flow a low pressure limit or high pressure limit setting would close the bypass flow path Care must be taken to allow for signal spread to avoid cyclic conditions 3 11 Continuous Bypass Control This is not a desired system as it requires an oversize bypass system as dictated below with excessive power losses and oversize pumping units however if used the following must be consid...

Страница 34: ...r a single pump is 27 GPM 2 Data for the head capacity curve At the rated point EQN Strongest pump head 300 300x2 over 100 306 EQN Weakest pump head 300 300x2 over 100 294 At Shutoff EQN Strongest pump head 360 360 x 5 over 100 378 EQN Weakest pump head 360 360 x 5 over 100 342 From head capacity curve Minimum weakest pump flow 27GPM Minimum strongest pump flow 65GPM Total minimum flow of pumps in...

Страница 35: ...35 FT 400 378 342 300 20 27 40 60 80 100 C A PA C IT YG PM PA R A LLE L O PE R A T IO N ST R O NG E ST W E A KE ST ...

Страница 36: ...hich may have accumulated during installation Take all possible care not to contaminate your system 3 Install suction strainer See Section 2 15 4 Fill the bearing housing with the appropriate oil to the correct level Bearing must receive a small amount of oil prior to starting to ensure adequate lubrication at start up Refer to Section 4 5 Turn pump rotor by hand or with a strap wrench to make sur...

Страница 37: ...egrees F per hour 55 C per hour 4 Prime pump and ensure suction valve is open CAUTION Before starting or while operating the pump the casing and suction line must be completely filled with the liquid being pumped The rotating parts depend on this liquid for lubrication and the pump may seize if operated without liquid 5 Ensure pump recirculating line if required is open clear and free of obstructi...

Страница 38: ...gauges 2 Check pressure gauges on each side of suction strainer 3 Check for excessive leakage at seal areas 4 Check for unusual noises 5 Check oil level in bearing housing Refer to Section 4 WARNING Operation of the unit without correct lubrication can result in overheating of the bearings bearing failures pump seizures and actual breakup of the equipment exposing operating personnel to physical i...

Страница 39: ... line 4 Turn off cooling liquid 5 If pump is subjected to freezing temperatures the pump must be drained of liquid to prevent damage to the pump 3 18 General Maintenance These pumps have been designed to simplify maintenance and make service easy Preventative maintenance and overhauls before serious troubles occur will reduce operating costs The following section outlines the various steps necessa...

Страница 40: ... MONTHLY Check For Lubricant Contamination Whether Bearing Oil Or Seal Oil If Applicable By Sample Analysis Check All Paint Or Protective Coatings Check All Power Instrument Cable Glands For Tightness 6 MONTHLY Change Lubricants YEARLY Check Foundation Fixing Bolting Grouting For Looseness Cracking Or General Distress Check Unit Alignment Against Previous Inspection Check Calibration Of Instrument...

Страница 41: ...ump and remove any foreign material Dismantle suction line and remove foreign material Dismantle pump and correct Pump loses prime after starting Insufficient liquid supply Excessive amount of air or vapour in the liquid Clogged impeller Suction pipe clogged Ensure that suction valve is wide open Check for appropriate liquid level Blocked suction strainer Check suction system for air leakage and c...

Страница 42: ...n rotor in casing High pump thrust bearing temperature rise Incorrect lubrication including inadequate cooling Insufficient oil Contaminated oil Replenish oil with correct grade lubricant and assure cooling capacity Add oil Drain and refil with clean oil change filter Excessive seal leakage Dirt across seal faces Replace seal Pump is noisy Cavitation Loose parts Noise in driver Check that pump is ...

Страница 43: ...STANT LEVEL OILER LUBRICATION The oil level must be maintained at the correct level oil lack may cause overheating and failure of the bearings while exceeding the correct level can result in leakage from the labyrinth seals The constant level oiler can be adjusted by changing the height of the cross arms which support the glass reservoir as illustrated for TRICO oiler in section 4 6 4 2 Inspection...

Страница 44: ... C Type Quantity Pour Point Flash Point Running in Period First Oil Change Further Oil Changes One Years Consumption Mineral Oil Petroleum based Ball Bearing ISO VG 32 See Table Below 0 12 litres pint per month See following page Low pour point mineral oil 4 7 c s min at 210 F 99 C 29 c s min 43 c s max at 100 F 38 C As required Minus 20 F Max 29 C max 330 F Min closed 165 C Min closed 500 hours 5...

Страница 45: ...nt from the centre line of the oiler connection in bearing housing to the upper cross arm of 6 mm 24 this can be obtained by completely screwing down the lower arm as illustrated below TRICO OILER Fill bottle with recommended oil and install on holder Remove and fill bottle as many times as is required to fill the bearing housing up to the cross arm level and no air bubbles appear in the bottle Re...

Страница 46: ... identified from the identifying marks cast on the housing on the horizontal centre line in the opposite side to the oiler 4 8 Bearing Housing Oil Limitations Maximum Oil Temperature 180 F 82 C Minimum Oil Temperature At Start Up 60 F 15 6 C Desirable Operating Temperature 140 160 F 60 71 C Housing Capacity 3 Pints 1 42 Litres Oil Level Above Oil Connection Centre line 6 mm FOR MORE DETAILS REFER ...

Страница 47: ... damage the seal faces and cause the seal to leak making an external flush or a different seal arrangement necessary The seal balancing and flushing arrangement provided for each pump is designed and fitted for the specific order requirements The HPX pump can be arranged with either a single double or tandem mechanical pump seal Refer to the General Arrangement for piping connections to be used wi...

Страница 48: ...omponents Before performing any disassembly maintenance and or inspection on the unit the following steps should be taken and warnings observed 1 Tag driver controls in the off position WARNING Before attempting any inspection or repair on the pump the driver controls must be in the off position locked and tagged to prevent injury to personnel performing service on the pump 2 Isolating Pump WARNIN...

Страница 49: ...lug situated at the bottom of the casing 6 Drain the bearing housing of oil This can be done by removing the drain plug situated at the bottom of the bearing housing 7 Disconnect and remove seal flush pipework and allow to drain CAUTION 8 It is advisable to thoroughly drain and dry off the baseplate before attempting any maintenance work on the pump This could eliminate the risk of slipping on a w...

Страница 50: ...efer to sectional arrangement drawing and bill of material section for names of parts 3 Place lifting straps around pump at coupling end of bearing housing and at casing cover bearing housing area Take a slight strain on slings LOCATION OF LIFTING STRAPS FOR REMOVING PUMPING ELEMENT 4 When applicable remove bolting holding support plate to bearing housing and baseplate Remove support plate 5 Remov...

Страница 51: ...ove the bearing housing and place horizontally on flat surface 16 Remove the four nuts securing the gland plate to the casing cover Returning to the casing cover with the gland plate uppermost Note When oil ring lubrication is provided an additional NPT plug is fitted in the top of the bearing housing adjacent to the mushroom headed vent Removal of the plug should enable the visual inspection of t...

Страница 52: ... Remove locknut and lock washer 25 Bearings can be removed by the use of a press or puller Bearing must be installed in the same manner as removed It is suggested that each bearing be marked for sequence and direction NOTE When removing bearings exert pressure on inner race only Do not exert any pressure on outer bearing race See Section 7 6 26 Remove oil rings and oil throwers from the shaft as a...

Страница 53: ...mance does not meet the system requirements Whenever it becomes necessary to replace either wear ring both rings involved impeller and casing casing cover must be ordered and replaced as a set as they are furnished standard size only impeller ring oversize Be sure to re establish the original running clearance between the two wear rings involved by machining the fitted impeller ring To remove impe...

Страница 54: ...nal diameter and running clearance NOTE Whenever an impeller has new wear rings fitted it must be dynamically balanced before being reassembled 7 3 Case Wear Ring and Casing Cover Wear Ring When Fitted Each wear ring is locked against rotation with a cylindrical pin To remove the wear ring press it out If this method does not easily effect removal of the ring it can be split apart First however dr...

Страница 55: ...ure that no dirt or other contaminates will enter the bearings Handle bearings with clean dry hands and with clean lint free rags Lay bearings on clean paper and keep covered Never expose bearings on a dirty bench or floor 3 Do not wash a new bearing It is already clean and the preservative should not be removed 4 Before mounting be sure shaft bearing areas are clean and free of nicks and burrs Ch...

Страница 56: ...all hand grinder saw through the ball roller retainer and split the inner ring about three quarters through with a grinder and break with a cold steel chisel 7 10 Bearing Cleaning NOTE Do not attempt to inspect condition of bearings until they have been cleaned 1 Solvent for cleaning bearings should be in a clean container Place bearings in solvent and let soak for a short time Agitate the bearing...

Страница 57: ...UST BEARINGS IS TO BE PLACED ON THE SHAFT WITH THE WIDE FLANGE OF THE OUTER RACE TOWARDS THE INNER BEARING When installing bearings on shaft a slight heat is required to expand the inner bearing race The use of a 150 watt light bulb with an aluminium foil cover to contain the heat is recommended Place bulb foil to cover over bearing and light bulb Heat for approximately 20 30 minutes 3 Install the...

Страница 58: ...echanical seal drive collar set screws Move setting plates from transit to run position Refit screwed piping into mechanical seal gland plates 13 For non inducer machines install key and impeller Install locking nut noting left hand thread form Torque nut to correct tightness Fit and tighten lockscrew on end of locknut throat bush if fitted 14 Install a new spiral wound gasket into position on cas...

Страница 59: ...h or by hand Make any corrections or adjustments 20 Check driver rotation Driver rotation must coincide with direction indicated by arrow on pump 21 Align pump motor coupling per ALIGNMENT instructions and install spacer piece Install coupling guard 22 Replace all auxiliary piping ...

Страница 60: ...8 ft lbs 26 30 45 50 Nm 35 41 58 68 Thrust Bearing Locknut Torque Value Bearing Size 7307 7308 7309 7310 7311 7312 7313 7314 ft lbs 27 29 37 39 48 50 60 63 73 77 87 92 102 107 117 123 Nm 37 39 50 53 65 68 81 85 99 104 118 125 138 145 159 167 Inboard Outboard Flingers Oil Thrower Torque Value Socket Head Capscrews Size Inches 1 4 ft lbs 3 4 Nm 4 5 Torque Values listed above are selected to achieve ...

Страница 61: ...pe plugs from above connections Install appropriate reclassifier in the top opening leave open vent connections connect oil recovery trap to bottom opening or leave it open to act as relief OIL SUPPLY The lubricating oil should be rust and oxidation inhibited and stray mist suppressed manufactured in accordance with good commercial practice The viscosity should be ISO VG 100 approx 470 SUS at 100 ...

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