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Pump Division
Type: WDX
CENTRIFUGAL PUMPS
USER INSTRUCTIONS:
INSTA LLA TION, OPERA TION, MA INTENANCE
PCN=71576322 06-05 (E)
T h e s e i n s t r u c t i o n s m u s t b e r e a d p r i o r t o i n s t a l l i n g ,
o p e r a t i n g , u s i n g a n d m a i n t a i n i n g t h i s e q u i p m e n t .
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CONTENTSPAGE
1 INTRODUCTION AND SAFETY .......................... 4
1.1 General.......................................................41.2 CE marking and approvals...........................4
1.3 Disclaimer...................................................41.4 Copyright....................................................4
1.5 Duty conditions............................................ 41.6 Safety.........................................................5
1.7 Safety labels summary................................. 81.8 Specific machine performance...................... 8
1.9 Noise level..................................................9
2 TRANSPORT AND STORAGE..........................10
2.1 Consignment receipt and unpacking ........... 102.2 Handling..... .............................................. 10
2.3 Lifting........................................................112.4 Storage.....................................................12
2.5 Recycling and end of product life................12
3 PUMP DESCRIPTION....................................... 12
3.1 Configurations...........................................123.2 Nomenclature............................................13
3.3 Design of major parts................................. 133.4 Materials of construction ............................ 14
3.5 Performance and operating limits................ 143.6 Coverage charts........................................15
4 INSTALLATION................................................. 16
4.1 Location....................................................16
4.2 Cleaning prior to installa tion ....................... 164.3 Foundation................................................16
4.4 Grouting....................................................174.5 Initial alignment.........................................17
4.6 Piping ....................................................... 184.7 Final shaft alignment check........................ 21
4.8 Electrical connections................................214.9 Protection systems .................................... 22
5 COMMISSIONING, START-UP, OPERATION ANDSHUTDOWN................................................22
5.1 Pre-commissioning p rocedu re.................... 225.2 Pump lubricants.........................................23
5.3 Direction of rotation.................................... 245.4 Guarding...................................................24
5.5 Priming and auxiliary supplies....................245.6 Starting the pump......................................25
5.7 Running the pump..................................... 255.8 Stopping and shutdown.............................. 27
5.9 Hydraulic, mechanical and electrical duty....275.10 Pumps for Food Use o r Potable Water ...... 27
PAGE
6 MAINTENANCE................................................ 28
6.1 General.....................................................286.2 Maintenance schedule...............................28
6.3 Spare parts................................................ 316.4 Recommended spares and consumable..........
items..............................................................326.5 Tools required............................................ 32
6.6 Fastener torques.......................................326.7 Renewal clearances..................................32
6.8 Disassembly.............................................. 326.9 Inspection of components........................... 36
6.10 Assembly................................................37
7 FAULTS; CAUSES AND REMEDIES..................38
8 PARTS LISTS AND DRAWINGS........................ 40
8.1 Sectional drawings, WDXR grease lubricated
uncooled ..................................................... ... 408.2 S ectional drawin gs, variants....................... 41
8.3 Sectional drawin gs, other detail s................ 428.4 Sectional drawin gs part list......................... 43
8.5 General arrangement drawin g.................... 45
9 CERTIFICATION..............................................45
10 OTHER RELEVANT DOCUMENTATION ANDMANUALS....................................................45
10.1 Supplementary User Instructions........... ... 4510.2 Change notes..........................................45
10.3 Additional sources of information .............. 45
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INDEXPAGE
Additional sources (10.3)........ ..... ...... ..... ..... ...... ... 45Alignment of shafting (see 4.3, 4.5 and 4.7)
Assem bly (6.10)..... ...... ..... ...... ..... ...... ...... ..... ...... . 37
ATEX m arking (1.6.4.2)..... ...... ..... ...... ...... ..... ...... ... 7CE marking and approvals (1.2).............................. 4Certification (9)....................................................45
Change notes (10.2)............................................4 5Clearances (see 6.7, Renewal clearances)............ 32
Commissioning, start-up, operation (5).................. 22Compliance, ATEX (1.6.4.1)........................ ........... 6
Configurations (3.1) ............................................. 12Copyright (1.4)..................................................... .. 4
Coverage charts (3.6) .......................................... 15Design of major parts (3.3)...................................1 3
Direction of rotation (5.3)...................................... 24Disassembl y (6.8)................................................ 32
Disclaimer (1.3).....................................................4Disman tling (see 6.8, Disassembly) ...................... 32
Drawing s (8)............................................... ......... 40Duty conditions (1.5)................ .............................. 4
Electrical conne ctions (4.8)................................... 21End of product life (2.5)........................................12
Inspection of components (6.9)............................. 36Fastene r torque s (6.6).......................................... 32
Faults; causes and remedies (7)........................... 38Foundation (4.3)..................................................16
Forces and moments (4.6.3).................................20General arrangement drawing (8.5)....................... 45
Grouting (4.4)......................................................17Guarding (5.4).....................................................24
Handling (2.2)......................................................10Hydraulic, mechanical and electrical duty (5.9) ...... 27
Inspection (6.2.1 and 6.2.2)..................................29Installation (4)......................................................16
Lifting (2.3)..........................................................11Location (4.1)......................................................16
Lub rication (see 5.1.1, 5.2 and 6.2.3)Lub rication schedule (5.2.4).................................. 24
Maintenance (6)...................................................28Maintenance schedule (6.2).................................. 28
Nomenclature (3.2)..............................................13Nameplate (1.7.1)..................................................8
Operating limits (3.5.1)......................................... 14
Ordering spare parts (6.3.1).................................. 31Parts li sts (8.4) ....................................................43Performance (3.5)................................................14
Piping (4.6)..........................................................18Pre-commissio ning (5.1)....................................... 22
Protection systems (4.9)....................................... 22Pump masses (2.2.2) ........................................... 11
PAGE
Reassemb ly (see 6.10, Assembly) ........................ 37Receipt and unpackin g (2.1)................................. 10
Recommended fill quantities (see 5.2.3)................23
Recommended grease lubricants (5.2.2).. ............. 23Recommended oil lubricants (5.2.1)...................... 23Recommended spares (6.4)........... ...................... 32
Recycling (2.5) ................................................. ... 12Replacement parts (see 6.3 and 6.4)..................... 31
Running the pump (5.7)........................................25Safety action (1.6.3)...............................................5
Safety marking s (1.6.1)..........................................5Safety, protection systems (see 1.6 and 4.9)
Sectional drawings (8.1)....................................... 40Sound level (see 1.9, Noise level)...........................9
Sources, additional information (10.3) ................... 45Spare parts (6.3).................................................. 31
Specific machine performance (1.8)........................ 8Starting the pump (5.6)......................................... 25
Stop/start frequency (5.7.6)..................................26Stopping and shutdown (5.8)................................27
Storage, pump (2.4)............................................. 12Storage, spare parts (6.3.2).................................. 32
Supplementary manuals or information sources..... 45Thermal expansion (4.5.1).................................... 17
Tools required (6.5).............................................. 32Torques for fasteners (6.6)...................................3 2
Transport (2) .................................................... ... 10Trouble-shooting (see 7)......................................38
Vibration (5.7.5)...................................................26Warni ng labels (1.7.2).. .......................................... 8
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1 INTRODUCTION AND SAFETY
1.1 General
T h e s e i n s t r u c t i o n s m u s t al w a y s be k e p t c l o s e
t o t h e p r o d u c t 's o p e r a t i n g l o c a t i o n o r d i r e c t l y w i t h
t h e p r o d u c t .
Flowserve products are designed, developed and
manufactured with state-of-the-art technologies inmodern facilities. The unit is produced with great care
and commitment to continuous quality control, utilizingsophisticated quality techniques, and safety
requirements.
Flowserve i s committed to continuous qualityimprovement and being at service for any further
in formation about the product in its installation andoperation or about its support products, repair and
diagnosti c services.
These instructions are i ntended to facilitatefamilia rization with the product and its permitted use.
Operating the product in compliance with theseinstruction s is important to help ensure reliability in
service and avoid risks. The instructions may not takein to account local regula tions; ensure such regulations
are observed b y all, includin g those installing theproduct. Always coordinate repair a ctivity with
ope rations personnel, and follow all plant safetyrequirements and appli cable safety and health laws
and regulations.
T h e s e i n s t r u c t i o n s m u s t b e r e a d p r i o r t o
i n s t a l l i n g , o p e r a t i n g , us i n g a n d m a i n t a i ni n g t h e
e q u i p m e n t i n a n y re g i o n w o r l d w i d e . T h e
e q u i p m e n t m u s t n o t b e p u t i n t o s e r v i c e u n ti l a l l t h e
c o n d i t i o n s r e la t i n g t o s a fe t y n o t e d i n t h e
i n s t r u c t i o n s , h a v e b e e n m e t .
1.2 CE marking and approvalsIt i s a legal requirement that machinery and equipment
put into service within certain regions of the world shallconform with the applicable CE Marking Directives
covering Machinery and, where applicable, LowVoltage Equipment, Electromagnetic Compatibility
(EMC), Pressure Equipment Directive (PED) andEquipment for Potentially Explosive Atmospheres
(ATEX).
Where applicable the Directives and any additionalApprovals coverimportant safety aspects relating to
machinery and equipment and the satisfactory provisionof technical documents and safety in structions. Where
applicable this document incorporates informationrelevant to these Directives and Approvals.
To confirm the Approvals applying and if the product isCE marked, check the serial number plate markings and
the Certification. (See section 9, Certification.)
1.3 Disclaimer
Information in these User Instructions is believed tobe reliable. In s pite of al l the efforts of Flows erve
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 exactingInternational Quality Management System Standards as
certified and audited by external Quality Assuranceorganizations. Genuine parts and accessories have been
designed, tested and incorporated into the products tohelp ensure their continued product quality and
performance in use. As Flowserve cannot test parts andaccessori es sou rced from other vendors the incorrect
incorporation of such parts and accessories mayadversely affect the performance and safety features of
the products. The failure to properly select, install or useauthorized Flowserve parts and accessorie s is
considered to be misuse. Damage or failu re caused bymisuse is not covered by the Flowserve warranty. In
addition, any modification of Flowserve products orremoval of original components mayimpair the safety of
these productsi n their use.
1.4 CopyrightAll rig hts reserved. No part of these instructi ons ma ybe reproduced, stored in a retrieval system ortransmitted in any form or by any means without priorpermission of Flowserve Pump Division.
1.5 Duty conditionsThis product has been selected to meet thespeci fications of your purchaser order. The
acknowledgement of these conditions has been sentsepa rately to the P urchaser. A copy should be kept
with these instructions.
T h e p r o d u c t m u s t n o t b e o p e r a t e d b e y o n d
t h e p a r a m e t e r s s p ec i f i e d f o r t h e a p p l ic a t i o n . I f t h e r e i s a n y d o u b t a s t o t h e s u i t a b i l i ty o f t h e
p r o d u c t f o r t h e a p p l i c a t i o n i n t e n d e d , c o n t a c t
F l o w s e rv e f o r a d v ic e , q u o t i n g t h e s e r i a l n u m be r.
If the conditions of service on your purchase order a re
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.
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1.6 Safety
1.6.1 Summary of safety markingsThese User Instructions contain specific safety markingswhere non-ob servance of an instruction would cause
hazards. The specific safety markings are:
This symbol indicates electrical safety
in structio ns where non-compliance will involve a high
risk to p ersonal safety or the loss of l ife.
This symbol indicates safety instructions where
non -compliance would affect persona l safety and couldresult in l oss of life.
This symbol indicates hazardous substances andtoxic fluid safety instructions where non-compliance
would affect personal safety and could result in loss oflife.
This symbol indicates safety instructionswhere non-compliance will involve some risk to safe
operation and personal safety and would damage theequipment or property.
This symbol indicates explosive atmosphe rezone markin g according to ATEX. It is used in safety
in structio ns where non-compliance i n the hazardousarea would cause the risk of an explosion.
This symbol is used in safety instructions to
remind not to rub non-metallic surfaces with a drycloth; ensure cloth is damp. It is used where non-
compliance in the h azardous area would cause the riskof an explosion.
This sign is not a safety symbol but indicates
an important instruction in the a ssembly process.
1.6 .2 Personnel qualification and trainingAll personnel involved in the operation, install ation,
in spection and main tenance of the unit must bequalified to carry out the work involved. If the
personn el in question do not already posse ss thenecessary knowle dge and skil l, appropriate training
and instruction m ust be provided. If requi red theope rator may commissio n the manufacturer/supplier to
provide applicable training.
Al ways coordina te repair activity with operations andhealth and safety personnel, and follow all plant safety
requirements and appli cable safety and health lawsand regulations.
1.6.3 Safety action
T h i s i s a s u m m a r y o f c o n d i t i o n s a n d a c t i o n s t o
p r e v e n t i n j u ry t o p e rs o n n e l a n d d a m a g e t o t h e
e n v i r o n m e n t a n d t o e q u i p m e n t . Fo r p r o d u c t s u s e d
i n p o t e n t i a l l y e x p l o s iv e a t m o s p h e r e s s e c t i o n 1 . 6. 4
a l s o a p p l i e s .
NEVER DO MAINTE NANCE WORK
WHEN T HE UNIT IS CONNECTED TO POWER
GUARDS MUST NOT BE REMOVED WHILETHE PUMP IS OPERATIONAL
DRAIN T HE PUMP AND ISOLATE PIPEWORKBEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be takenwhere the pumped liquids are hazardous.
FLUORO-ELASTOMERS (When fit ted.)
When a pump has experienced temperatures over 250C (482 F), partial decomposition of flu oro-elastomers(example: Viton) will occur. In this condition these are
extremely dangerous and skin contact must beavoided.
HANDLING COMPONENTSMany precision parts have sharp corners and the
wearing of appropriate safety gloves and equipment isrequired when handling these components. To lift
heavy pieces above 25 kg (55 lb) use a craneappropriate for the mass and in a ccordance with
current lo cal regulations.
THERMAL SHOCKRapid changes in the tempe rature of the liquid within
the pump can cause thermal shock, which can result indamage or breakage of components and should be
avoided.
NEVER APPLY HEAT TO REMOVE IMPELLERTrapped lubricant or vapour could cause an explosion.
HOT (and cold) PARTSIf hot o r freezing components or auxiliary heating
supplies can present a danger to operators and
persons ente ring the immediate area action must betaken to avoid accidental contact. If completeprotection is not possibl e, the machine access must b e
limited to maintenance staff onl y, with clear visualwarnings and indicators to those entering the
immediate area. Note: bearing housings must n ot beinsulated and d rive motors and bearings may be hot.
If t he tem pe ra ture is gr eate r tha n 68 C (175 F) o r
be lo w 5 C (20 F) in a res tr ict ed zon e, or ex c eeds
l o c a l r e g u l a t i o ns , ac t i o n as a b ov e s h a l l b e t ak e n .
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HAZARDOUS LIQUIDSWhen the pump is handling hazardous liquids care must
be taken to avoid exposure to the liquid by appropriatesitting of the pump, limiting personnel access and by
operator training. If the liquid i s flammable and/orexplosive, strict safety proceduresm ust be applied.
G l a n d p ac k i n g m u s t n o t b e u s e d w h e n p u m p i n g
h a z a r d o u s l i q u i d s .
PREVENT EXCESSIVE EXTERNAL
PIPE LOADDo not use pump as a support for piping. Do not mount
expansion joints, unless al lowed by Flo wserve inwriting, so that their force, due to i nternal pressure,
acts on the pump flange.
ENSURE CORRECT LUBRICATION(See section 5, Commissi oning, startup, operation andshutdown.)
START T HE PUMP WIT H OUTLET
VALVE PART OPENED(Unl ess otherwise instructed at a specific poin t in the
User Instructions.)
This is recommended to minimize the risk ofoverloading and damaging the pump motor at full or
zero flow. Pumps may be started with the valve furtheropen only on installations where this situ ation cannot
occur. Pump outlet valve shall ma y need to beadjusted to comply with the duty following the run-up
process. (See section 5, Commissioning start-up,operation and shutdown.)
NEVER RUN THE PUMP DRY
INLET VALVES TO BE FULLY OPEN
WHEN PUMP IS RUNNINGRunning the pump at zero flow or below the
recommended minimum flow continuously will causedamage to the seal.
DO NOT RUN THE PUMP AT
ABNORMALLY HIGH OR LOW FLOW RATESOperating at a flow rate higher than normal or at a flow
rate with n o backpressure on the pump m ay overloadthe m otor and cau se cavitations. Low flow rates may
cause a reduction i n pump/bearing life, overheating o fthe 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 generation of sparks. Prevent leakages.
Maintain the pump to avoid hazard.
The following instructions for pump sand pump unitswhen 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 Sco p e o f co mp l i a n ce
Use equipment only in the zone for which it isappropriate. Always check that the driver, drive couplingassem bly, seal and pump equipment are suitably rated
and/or certified for the classification of the specificatmospherei n which they are to be installed.
Where Flowserve has supplied only the bare shaft
pump, the Ex rating applies only to the pump. The partyresponsible for assembling the pump set shall select the
coupling, driver and an y additional equipment, with thenecessary CE Decla ration of Conformity establishing i t
is sui table for the area in which it is to be installed.
The output from a variable frequency drive (VFD) cancause additional heating affects in the motor and so, forpumps sets with a VFD, the ATEX Certification for themotor must state that it is covers the situation where
electrical supply is from the VFD. This particula rrequirement still applies even if the VFDi s in a safe area.
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1.6.4.2 Marking
An example of ATEX equipment marking i s shownbelow. The actual classifi cation of the p ump will be
eng raved on the nameplate.
II 2 GD c IIC135 C (T4)
Equipment Group
I = MiningII = Non-mining
Category2 or M2 = High le vel protection
3 = normal level of protection
Gas and/or DustG = Gas; D= Dust
c = Constructional safety(in accordance with prEn13463-5)
Gas Group (Equipment Category 2 only)IIAPropane (typical)
IIBEthylene (typical)IICHydrogen (typical)
Maximum surface temperature (Temperature Class)(see section 1.6.4.3)
1 .6 .4 .3 Avo i d i n g e xce ssi ve su rfa ce te mp e ra tu re s
ENSURE THE EQUIPMENT TEMPERATURECLASS IS SUITABLE FOR THE HAZARD ZONE
Pumps have a temperature class a s stated in theATEX Ex rating on the nameplate. These are based on
a maximum ambient of 40 C (104 F); refer toFlowserve for higher ambient temperatures.
The surface temperature on the pump i s influenced by
the temperature of the liquid handled. The maximumpermissible liquid temperature depend s on the
temperature class and must not exceed the values inthe table that follows.
The temperature rise at the seal s, bearings and due tothe minimum permitted flow rate is taken into account
in the temperatures stated .
Temperatureclass to
prEN 13463-1
Maxi mumsurface
temperaturepermitted
Temperature limit of liquidhandled ( * depending onmaterial and c onstructionvariant - check which is
lower)
T6
T5
T4
T3
T2
T1
85 C (185 F)
100 C (212 F)
135 C (275 F)
200 C (392 F)
300 C (572 F)
450 C (842 F)
Consult Flowserve
Consult Flowserve
115 C (239 F) *
180 C (356 F) *
275 C (527 F) *
400 C (752 F) *
Th e re sp o n si b i l i ty fo r co mp l i a n ce w i th th e sp e ci f i e d
ma xi mu m l i q u i d te mp e ra tu re i s w i th th e p l a n t
o p e ra to r.
Temperature classif ication Tx is used when the liquid
temperature varies and th e pump could be installed indi fferent hazardou s atmospheres. In this case the user
is respon sib le for ensuring that the pump surfacetemperature does not exceed that permitted i n the
particular hazardou s atmosphere.
If an explosive atmosphere exists during theinstallation, do not attempt to check the direction of
rotation b y starting the pump unfilled. Even a short runtime may give a high temperature resul ting from
contact between rotating and stationary components.
Where there is any risk of the pump being run against aclosed valve generating high liquid and casing external
surface temperatures it is recommended that users fitan external surface temperature protection device.
Avoid me chani cal, hydraulic or electrical ove rload by
using motor overload trips, temperature monitor or apower monitor and make routine vibration monitoring
checks.
In dirty or du sty environments, regular checks must b emade and dirt removed from areas around close
clearances, bearing housings and motors.
1 .6 .4 .4 Pre ve n ti n g th e b u i l d u p o f e xp l o si ve
m i x t u r e s
ENSURE PUMP IS PROPERLY FILLED ANDVENTED AND DOES NOT RUN DRY.
Ensure pump and relevant suction and dischargepipeline system is totall y filled with liquid at all times
during the pump operation, so that an e xplosiveatmosphere is prevented. In addition it is essential to
make sure that seal chambers, auxiliary shaft sealsy stems 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 protectiondevice is recommended (eg liquid detection or powermonitor).
To a void potential hazards from fugitive emissio ns of
vapour or gas to atmosphe re the surroun ding areamust be well ventilated.
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1 .6 .4 .5 Pre v e n ti n g s p a rks
To prevent a potential hazard from mechanicalcontact, the coupling guard must be non-sparking.To avoid the potential hazard from random induced
current generating a spark the ground contact on the
basepla te must be used.
Avoid electrostatic charge: do not rub non-metallic surfaces with a dry cloth, ensure cloth isdamp.
The coupling must be selected to comply with 94/9/ECand correct alignment must be main tained.
A d d i t i o n a l r e q u i r e m e n t s f o r m e t a l l ic p u m p s o n
n o n -me ta l l i c b a se p l a te sWhen metallic components are fitted on a non-metallic
basepla te they must be individually earthed.
1 .6 .4 .6 Pre ve n ti n g le a ka g e
The pump must only be used to handle liquids
for which it has been approved to have the correctcorrosion resistance.
Avoid entrapment of liquid in the pump and associated
piping due to closing of suction and discharge valves,which could cause dangerousexcessive pressures to
occur if there is heati nput to the liquid. This can occur ifthe pump is stationary or running.
Bursting of liquid containing parts due to freezing must
be a voided by draining or p rotecting the p ump andancillary systems.
Where there is the potential hazard of a loss of a seal
barrier fluid o r external flush, the fluid must bemonitored.
If leakage of liquid to atmosphere can result in a
hazard, the i nstalla tion of a liquid detection de vice isrecommended.
1 .6 .4 .7 Ma i n te n a n ce to a vo i d th e h a za rd
CORRECT MAINTE NANCE IS REQUIRED TOAVOID POTENTIAL HAZARDS WHICH GIVE A RISKOF EXPLOSION
The responsibil i ty for compliance with maintenance
instructions is with the plant operator.
To avoid potential explosion hazards during
maintenance, the tools, cleaning and paintingmaterials used must not gi ve rise to sparkin g or
adversel y affect the ambient conditions.
Where there is a risk from such tools or materials;maintenance mu st be conducted in a safe area. It is
recommended that a maintenance plan and scheduleis adopted. (See section 6,Maintenance.)
1.7 Safety labels summary
1.7.1 NameplateFor detail s of nameplate, see theDeclaration ofConformity, or separate documentation included with
these User Instructions.
1.7.2 Warning labels
Oil lubricated units only:
1.8 Specific machine performanceFor pe rformance parameters see secti on 1.5, Dutyconditions. When the contract requirement specifies
these to be in corporated into User Instructions theseare included here. Where performance data has been
supplied separately to the purchaser these should beobtained and retained with these User In structions if
required.
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1.9 Noise levelWhen pump noise level e xceeds 85dBA attention mustbe g iven to prevailing Health and Safety Legislation, to
limit the exposure of plant operating personn el to thenoise. Th e usual approach is to control exposure time
to the noise or to enclose the machine to reduce
emitted sound. You may have already specified alimiting noise level when the equipment was ordered,however if no noise requirements were defined then
machines above a certain power level will exceed 85dB(A). In such situations consideration must be given
to the fitting of an acoustic enclo sure to meet localregulations.
Pump noise level is dependent on a number of factors
- the type of motor fitted, the operating capacity,pipework design and acoustic characteristics of the
building. Typical sound pressure levels measured indB and A-weighted are shown in the table below.
The figures are indicative only, they are subject to a +3
dB tolerance, and cannot be guaranteed.
The values are based on the noisie st ungeared electricmotors which are likely to be encountered. They are
LpAsound pressure l evel s at 1m (3.3ft) from thedi rectly driven pump, for " free field o ver a reflecting
plane". For estimating LwA sound power le vel (re 1 pW)add 14 d B(A) to the sound pressure val ue.
If a pump only has been purchased, for fitting with your
own driver, then the "pump only" noise l evels from thetable should be combined with the level fo r the driver
obtained from the supplier. If the motor is driven by aninverter, it may show an in crease in noise level at
some speeds. Consul t a Noise Specialist for thiscalculation
For units driven by equipment other thanelectric motors or units contained within enclosures,see the accompanying information sheets and
manuals.
Typical sound pressure level, dBA, LpAat 1 m reference 20 Pa (L wAso u n d p o w e r1 p W w h e re L pA >85 dBA)
3550 r/m in 2900 r/m in 1750 r/m in 1450 r/m inMotor sizeand speed
kW (hp)
Pump andmot ordBA
Pumponl ydBA
Pump andmotordBA
Pumponl ydBA
Pump andmotordBA
Pumponl ydBA
Pump andmotordBA
Pumponl ydBA
5.5 (7.5) 90 (99) 77 83 73 76 73 72 71
7.5 (10) 90 (99) 78 83 74 77 74 73 72
11 (15) 91 (100) 80 84 76 78 76 74 73
15 (20) 92 (101) 83 85 (94) 79 80 79 76 75
18.5 (25) 92 (101) 83 85 (94) 79 80 79 76 75
22 (30) 92 (101) 83 85 (94) 79 81 79 77 75
30 (40) 100 (109) 85 (94) 93 (102) 81 84 80 80 76
37 (50) 100 (109) 86 (95) 93 (102) 82 84 80 80 76
45 (60) 100 (109) 87 (96) 93 (102) 83 84 80 80 76
55 (75) 100 (109) 88 (97) 95 (104) 84 86 (95) 81 82 77
75 (100) 100 (109) 90 (99) 95 (104) 86 (95) 88 (97) 81 83 78
90 (120) 100 (109) 90 (99) 95 (104) 86 (95) 90 (99) 81 85 (94) 78
110 (1 50) 100 (109) 91 (100) 95 (104) 87 (96) 91 (100) 83 86 (95) 79
150 (200) 101 (110) 92 (101) 96 (105) 88 (97) 91 (100) 83 86 (95) 79
200 (270) * * * * * 83 * 80
300 (400) - - - - * 84 * 81
500 (670) - - - - * 85 (94) * 83
* Motors in this range areg enerall yjo b specific and noise levels should bec alculated based on actual equipment installed.For 960 rpm reduce 1450r pm values by 5 dBA.
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In areas where the staff has to intervene, remember
that when the level of the sound pressure i s:
Below 70 dBA :It is not necessary to takespecial precaution s.
Abo ve 70 dBA :People workin g continuously in
the machine room must besupplied with protective devices
against noise.
Below 85 dBA :No particular measures need to betaken for casual visitors stayi ng i n
the room during a limited period.
Abo ve 85 dBA :The room must be consid ered as adangerous area because of the
noise and a warning sign must befixed at each entry warning the
people coming into the room, evenfor a short period, that they mustwear hearing protection.
Abo ve 105 dBA:Special hearing prote ction a daptedto this noise level and to the
spectral noise components mu stbe i nstalled and a warning sign to
this effect erected at each entry.The staff in the room must wear
ear protection.
Make sure that the noise, which travels through thewalls and windows, does not generate too high noise
level s in the machine room's surroun dings.
2 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpackingImmediately after receipt of the equipment it must b echecked against the delivery and shipping documents
for its completeness and that there has been nodamage in transportation.
Any shortage and or damage mu st be reported
immediately to Flowserve Pump Division and
received in writing within one month of receipt of theequipment. Later claims cannot be accepted.
Check any crate, boxes and wrappings for anyaccessories or spare p arts that may be packed
sepa rately with the equipment or a ttached to sidewalls of the box or equipment.
Each product has a unique serial number. Check thatthis number corresponds with that advised and
always quote this number in correspondence a s wellas when ordering spare parts or further accessories.
2.2 Handling
2.2.1 General instructions concerning handling
Boxes, crates, pallets or cartons may be unloadedusing fork-lift vehicles or sli ngs dependent on their
size and construction. See 2.3.1 for positioning ofslings.
To lift heavy pie ces abo ve 55 lb (25 kg), use a crane
corresponding to the mass and in a ccordance withthe current local regulations.
To lift machines or pieces with one or several lifting
rings, only use hooks and chains in compliance with
the local regulations concerning safety. Never putcables, chains or ropes directly on or in the liftingrings. Cables, chains or lifting ropes must never
present excessive bending.
Never bend the lifting hooks, lifting rings, chains,etc...T hey are only made to endure stresse s within
calculated limits. Remember that the capacity of alifting device decreases when the direction of the
lifting force direction makes an angle with the deviceaxis.
To increase the safety and efficiency of the li fting
device, all the lifting elements must be asperpendicular as possible. If necessary a lifting beamcan be placed between the crane and the load.
When hea vy pieces are lifted up, never stay o r workunder the load or in the area which could be in the
path of the load if it were to swing or fall away. Neverleave a load hanging from a crane. The acceleration
or th e decele ration of lifting equipment must stay inthe safety limits for the staff.
A crane m ust be positio ned in such a way that the
load will be raised perpendicularly. Where possiblenecessary precautions must be taken to avoid the
swing of the load. For example use two winchesmaking approximately the same angle, less than 30 ,
with the vertical.
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2.2.2 Pump masses
All m asses, i n the table below, are fo r 3 stages, in
construction M2.
MET PUMP MASS
WDX R/C WDX E WDX S
MASSPER
STAGEPUMPSIZE
lb kg lb kg lb kg lb kg
Noncooled 298 135 271 123 243 110 23 10.5
1.5WDX
Cool ed 309 140 295 134 267 121 23 10.5
Noncooled 355 161 315 143 302 137 31 14
2WDX
Cool ed 386 175 342 155 328 149 31 14
Noncooled 483 219 450 204 421 191 46 21
3WDX
Cool ed 516 234 478 217 450 204 46 21
Noncooled 661 300 606 275 562 255 60 274WDX
Cool ed 694 315 628 285 606 275 60 27
All m asses, i n the table below, are fo r 3 stages, inconstruction M3, M4, M5, M6, M7.
2.3 Lifting
2.3.1 Slinging of motor pumps units
Use handling means in accordance with motorpump 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
shou ld be lifted as shown.
M o t o r p u m p u n i t
When handling always wear gloves, safetyshoe s and an industrial safety helmet.
For masses abo ve 55 lb (25 kg), manualhandling is forbidden.
MET PUMP MASS
WDX R/C WDX E WDX S
MASSPER
STAGEPUMPSIZE
lb kg lb kg lb kg lb kg
Noncooled 324 147 298 135 260 118 25 11.5
1.5WDX
Cooled 335 152 322 146 293 133 25 11.5
Noncooled 375 170 335 152 322 146 34 15.5
2WDXCooled 406 184 362 164 348 158 34 15.5
Noncooled 527 239 494 224 465 211 51 23
3WDX
Cooled 560 254 522 237 494 224 51 23
Noncooled 710 322 650 295 602 273 66 30
4WDX
Cooled 743 317 672 305 694 315 66 30
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2.4 Storage
Store the pump in a clean, dry location
away from vibration. Leave piping connection coversin place to keep di rt and other foreign material out of
pump casing. Turn pump a t intervals to prevent
brinelling of the bearings and t he seal faces, if fitted,from sticking.
Do not store pumps starting o n the fan guard.
The pump may be stored as above forup to 6months. Consult Flowserve for preservative actions
when a longer storage pe rio d is needed.
2.5 Recycling and end of product lifeAt the en d of the service life of the product o r itsparts, the relevant materials and p arts should be
recycled or disposed of usin g an environmentally
acceptable method and local regulations.If the produ ct contains substances which are harmfulto the en vironment, these shou ld be removed and
di sposed of in a ccordance with current regulations.This also i ncludes the liquids and or gases in the
"seal system" or other utilities.
Make sure that hazardous substances or toxicfluid are disposed of safely and that the correct
personal protective equipment is used. The safetyspeci fications must be in accordance with the current
regulations at all times.
3 PUMP DESCRIPTION
3.1 ConfigurationsThe WDX type pump is a horizontal, multistage,
radial split case, vaned diffuser type centrifugal pumpequipped with a special suction impeller for low
NPSH. It can be used with motor, steam turbine andgasoline or diesel engine drives.
The WDX pumps are of modula r construction withidentical stage s being stacked axially to achieve the
desired pressure output. Four high strength externaltie rods connecting the two end casings hold them
together. A variety of optimal features and materials
allow it to fit a wide range of applications such asboiler feed or reverse osmosis.Various orientations for the radial suction and
di scharge nozzle s are allowed every 90 excepttowards the b ottom.
The WDX can have the following configurations:
WDXRHorizontalRadial suctionDrive end on discharge side - C WThrust bearing on drive side
Radial bearing on suction side2 shaft seals
WDXC
HorizontalRadial suctionDrive end on suction side - CCWThrust bearing on suctionsi deRadial bearing on discharge side
2 shaft seals
WDXEHorizontal
End s uctionDrive end on discharge side - C WThrust bearing on drive sideSleeve bearing on sucti on si de1 shaft seal
WDXSHorizontalRadial suctionDrive end on discharge side - C WThrust bearing on drive side
Sleeve bearing on sucti on si de1 shaft seal
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3.2 Nomenclature
Characteristics shown on the nameplate fixed on the pump are a s shown below:
Each pump i s supplied with the follo wing nameplate:
Each pump unit is supp lied with the following nameplate:
Mass of the set
The pump size will be engraved on the nameplate
typically as below:
4 WDX E 6 D
Nominal discharge b ranch size.
Series name
Configuration (see 3.1 above)
Number of stages
Hydrauli c type
The typi cal nomenclature above is the general guide
to the WDX configuration description. Identify theactual pump size an d serial numbe r from the pump
nameplate. Check that this agrees with the applicablecertification provided.
3.3 Design of major parts
3.3.1 Pump casingThe pump casings (suctio n, discharge and stage) are
sealed with orings and designed to contain thepressure s generated by the pump at the various
possib le design pressure s and temperatures.
3.3.2 ImpellerThe impeller is full y shrouded and may be fitted with
optional wear rings.The suction impeller is specifi call y designed to have a
low NPSH requirement.
3.3.3 DiffuserThe diffusers are fully machined to optimise
performance.
3.3.4 ShaftThe shaft mounted on bearings with a keyed drive
end.
Pump type
Speed of rotation
Flowrate
Year of c onstruction +
Manufact ure number
Head
Radial/thrust bearing
Mass
Maxi mum admissibl e
Pressure at 20 C
Maxi mum / minimum
temperature
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3.3.5 Pump bearings and lubricationWDX pumps are designed so the antifriction bea rings
may be either oil or grease l ubricated.
WDXE and WDXS have product lubricated linebearings with sleeve and bushing m ade of silicon
carbide.
Bearing isolators or stationary labyrinths may be fittedas an option in the bearing covers to protect the
bearings.
3.3.6 Bearing housingGrease nipples enable grease lub ricated bearings to
be replenished between major service intervals. Foroil-lubricated bearings, a constant level oiler is fitted.
3.3.7 Stuffing box housingThe stuffing box housing has a spigot (rabbet) fitbetween the pump casing and bearing housing for
optimum concentricity. The design enables a numberof sealing options to be fitted.
3.3.8 Shaft sealThe mechanical seal(s) attached to the pump shaftseal s the pumped liquid from the environment.
Stuffing boxes have been designed fo r component orcartridge seals. Gland packing may be fitted as an
option.
3.3.9 DriverThe d river is normally an electric motor. Different drive
configurations may be fitted such as internal combustion
engines, turbines, hydraulic motors etc driving viacouplings, belt s, gearboxes, drive shafts etc.
3.3.10 AccessoriesAccessories ma y be fit ted when speci fied b y the
customer.
3.4 Materials of construction
Material
columnCasing Impeller Shaft
M2 Cast iron Cast iron Chrome steel
M3 Carbon s te el Cast i ron Chrome ste el
M4 Carbon s te el Stainless
steelChrome steel
M 5 C hr ome ste el Stainless
steel Chrome steel
M6 Duplex
stainless steelStainless
steelDuplex
stainless steel
M7 Stainless steel Stainless
steelDuplex
stainless steel
3.5 Performance and operating limitsThis product has been selected to meet thespecifications of your purchase order. See the
nameplate and section 1.5.
The maximum allowable speed for cast iron
impelle rsi s3600 RPM and for steel impellers is 4000RPM.
3.5.1 Minimal flow20 % of BEP up to 280 F (140 C)25 % of BEP between 280 F (140 C) and 410 F
(210 C)
3.5.2 Clearance data
Size Mat
Nominal wear
ring clearancemin/max
mm (inch)
Nominal
Interstageclearancemin/max
mm (inch)
Nominal
Balance drumclearancemin/max
mm (inch)
1.5 M2M3
0.170/0.259(0.0067/0.0102)
0.170/0.259(0.0067/0.0102)
0.150/0.226(0.0059/0.0089)
1.5 M4 to
M70.320/0.409
(0.0126/0.0161)0.170/0.259
(0.0067/0.0102)0.300/0.376
(0.0118/0.0148)
2 M2
M30.170/0.259
(0.0067/0.0102)0.170/0.259
(0.0067/0.0102)0.170/0.259
(0.0067/0.0102)
2 M4 to
M70.330/0.419
(0.0130/0.0165)0.170/0.259
(0.0067/0.0102)0.470/0.559
(0.0185/0.0220)
3 M2
M30.200/0.303
(0.0079/0.0119)0.200/0.303
(0.0079/0.0119)0.170/0.259
(0.0067/0.0102)
3 M4 to
M7
0.360/0.463
(0.0142/0.0182)
0.200/0.303
(0.0079/0.0119)
0.480/0.569
(0.0189/0.0224)
4 M2M3
0.200/0.303(0.0079/0.0119)
0.200/0.303(0.0079/0.0119)
0.180/0.269(0.0071/0.0106)
4 M4 to
M70.410/0.513
(0.0161/0.0202)0.200/0.303
(0.0079/0.0119)0.500/0.603
(0.0197/0.0237)
3.5.3 Sleeve bearing clearance (WDXE/S)
Pump sizeDiametral cl eara nce
min/maxmm( inch)
1.5 WDX 0.007 - 0.041
(0.0003 - 0.0016)
2 WDX 0.007 - 0.041
(0.0003 - 0.0016)
3 WDX 0.007 - 0.041
(0.0003 - 0.0016)
4 WDX 0.007 - 0.041
(0.0003 - 0.0016)
3.5.4 Bearing bushingsInterstage bearing bushings can be mounted on thepump. Their number and location depend on the
material chosen and the number of stages of thepump. For further in formation, see general
arrangement drawing of the pump.
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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)
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4 INSTALLATION
Equipment operated in hazardous locationsmust comply with the rele vant explosion protection
regulations. See section 1.6.4, Products used i npotentially explo sive atmospheres.
All e quipment must be grounded.
4.1 LocationThe pump should be located to allow room for
access, ventilation, maintenance and inspection withample headroom for lifting and should be as close a s
practicable to the supply of liquid to be pumped.
The pump should be located above the flood level.
The pipework should be such that there is anadequate NPSH at the pump centreline.The
foundation should provide enough supp ort so that the
pump is not supp orted by the pipework.
Refer to the general arrangement drawing for thepump set.
4.2 Cleaning prior to installationRemove glue and dirt from suction and discharge
flanges. Check motors to make sure no foreignobjects have entered through fan and cooling
openings. Remove any compounds on exposedareas of pump shaft. Clean pump and motor
nameplate.
4.3 Foundation
There are many methods of installing
pump units to their foundation s. The correct methoddepends on the size of the pump unit, its location and
noise vibration limitations. Non-compliance with theprovision of correct foundation and installation may
lead to failure of the pump and, as such, would beoutside the terms of the warranty.
4.3.1 General recommendationsFoundation bolts should be lo cated or embedded in
the concrete by lay-out o r template in relation to the
suctio n and discharge piping. Foundation bolts of thespeci fied size may be en closed i n a pipe sleeve twoor three diameters larger than the bolts to
compensate for minor variation i n alignment.
Standard accessory steel baseplates furni shed with
these pumps and motors 10 HP (7.5 kW) and undermay be bolted to machine or equipment structures,
ei ther rigidly or, if flexible pipin g is used, with properlydesigned vibration isolators.
A unit mounted on steel work or structural members
should be mounted over or adjacent to girders orwalls so tha t no misalignment will occur from yielding
or sagging of the structure.
Anchor bolts must be in accordance with the foot boltholes. Use anchor b olts of accepted standards and
sufficient to ensure seave fitting in the foundation.Particularly, this applies to individual plates where the
anchor bolts have to withstand the driving torque.Provide sufficient space in the foundation to
accommodate the anchor bolts. If necessary, provideconcrete risers.
4.3.2 Positioning on foundation
Pumps are generall y shipped mounted, and it isusually unnecessary with units of moderate size to
remove the pump or driver from its baseplate whenlevelling.
Ensure the following are met:
a) Clean the foundation thoroughly.
b) The baseplate should be mounted onto a firm
foundation, either an appropriate thickness ofquality concrete or sturdy steel framework
capable of absorbing all normal vibrations. (Itshou ld NOT be distorted or pulled down onto the
surface o f the foundation, but should besupported to maintain the original alignment).
c) Install the baseplate onto packing pie ces evenlyspaced and adjacent to foundation bolts.
d) Level with shims, about 25 mm (1), betweenbaseplate and packing pieces.
e) Check the horizontal position by means of aprecision le vel placed upon an adequate
reference (discharge fla nge, machined surfacesof casings etc...). Tolerances within 0.5 mm per
m (0.006 in per ft).
f) The pump and driver have been aligned beforedispatch however the alignment of pump and motor
half coupling must be checked. If thisi s incorrect, itindicates that the baseplate has become twisted
and should be corrected by re-shimming.
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barriers
g) If anchor bolts have been embedded in the
foundation, slightly tighten the anchor bolts.Otherwise let them hang in the foundation holes.
h) If not supplied, guarding shall be fit ted as necessaryto meet the requirements of EN292 and EN953 and
or an y applicable local safety regulations.
4.4 Grouting
Where applicable, grout in the foundation bolts.
Grouting p rovides sol id contact between the pump
unit and foundation prevents lateral m ovement ofrunning equipment and dampens resona nt vibrations.
Prepare the site for grouting. Before grouting clean
the foundation surface thoroughly. Provide externalbarriers as shown:
Prepare grouting product (concrete, resin) in
accordance with manufacturers' instructions.(Use anti-shrink products)
To grout up to the required l evel. Polish surfaces.
Take necessary p recautions to avoid air bubbles.Lay-down the barrier, break external angles and
polish the different surfaces.
Foundation bolts should only be fully tightened whenthe grout has cured.
4.5 Initial alignment
Before connecting the couplings verifythe motor rotation direction.
4.5.1 Thermal expansion
The pump a nd m otor will normally
have to b e aligned at ambient temperature and
should be corrected to allow for thermal expansion atoperating t emperature. In pump installations involving
high liquid temperatures, the unit should be run at theactual operating temperature, shut down and the
alignment checked immediately.
4.5.2 Alignment methods
Ensure pump and driver are isolated
electricall y and the half couplings are disconnected.
Ensure that the pump pipework, suction anddischarge, is disconnected.
The alignment MUST be checked.
Al though the pump will have been aligned at thefactory it is most likely that this alignment will havebeen disturbed during transportation o r handling. If
necessary, align the motor to the pump, not the pumpto the motor.
Pump-Driver unit supplied assembled on their
baseplate:
The machines have originall y been aligned in the
work-shop.
Pump and Driver supplied on separate baseplates:
The machines have originall y been mounted on their
respecti ve baseplate in the workshop . The pump is tobe i nstalle d first a nd should be considered as the
fixed point. The alignment is then performed on thedriver alone.
Before aligning verify that the pump is horizontal by
using a flange surface or other horizontal surface.Adjust if necessary by adjusting the height of the
wobble foot. Tighten any nuts that have beenloosened.
Alignment is achieved by adding or remo ving shims
under the motor feet and also moving the motor
horizontally as required. In some ca ses where thealignment cannot be achieved i t will be necessary tomove the pump before recommencing the above
procedure.
For couplings with narrow flanges use a dial indicatoras shown b elow to check both parallel and angula r
alignment.
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Paral lel
Angular
Maximum permissible misalignment at workingtemperature:
Parallel 0.2 mm (0.008 in.) TIRAngular 0.1 mm (0.004 in.) TIR
When checking parallel alignment, the total indicator
read-out (TIR) shown is twice the value of the actualshaft displacement.
Align in the ve rtical plane first, then horizontally by
moving motor. When performing final alignment, checkfor soft-foot under the driver. A TIR indicator placed on
the coupling, reading in the vertical direction, should notindicate more than 0.05 mm (0.002 in.) movement when
any driver foot fastener is loosened.
While the pump is capable of operating with themaximum misalignment shown above, maximum pump
reliability is obtained by near perfect alignment of 0.05to 0.10 mm (0.002 to 0.004in.) TIR parallel and
0.05mm (0.002 in.) per 100 mm (4 in.) of couplingflange diameter as TIR angular misalignment. This
covers the full series of couplings available.
Pumps with thick flanged non-spacer couplings canbe aligned by using a straight-edge across the
outside diameters of the coupling hubs andmeasuring the gap b etween the machined faces
using feeler gauges, measuring wedge or calipers.
When the electric motor has slee ve bearings it isnecessary to ensure that the motor is aligned to run
on its magnetic centreline.
Refer to the motor manual for details.
A bu tton (screwed into one of the shaft ends) is
normally fitted between the motor and pump shaftends to fix the a xial position.
If the motor does not run in its
magnetic centre the resul tant additional axial forcemay overload the pump thrust bearing.
Complete piping as below and see sections 4.7,Final shaft alignment checkup to and including
section 5, Commissi oning, startup, operation andshutdownbefore connecting driver and checking
actual rotation.
4.6 Piping
The user m ust verify that the equipment isisolated from any external sources of vibration.
Protective covers are fitted to the pipe
connections to prevent foreign b odies entering during
transportation and installation. Ensure that thesecovers are removed from the pump b efore connecting
any pipes.
4.6.1 Suction and discharge pipework
In order to minimize friction lo sses and hydraulicnoise in the pipework it is good practice to choosepipework that is one or two sizes larger than the
pump suction and discharge. Typically main pipeworkvelocities should not exceed 2 m/s (6 ft/sec) suction
and 3 m/ s (9 ft/sec) on the discharge.
Ta ke in to account the available NPSH must be higherthan the required NPSH of the pump. When
determining the NPSH available the vapour pressureat the o perating temperature mu st be ta ken into
account.
Never use the pump as a support forpiping.
Maximum forces and moments allowed on the pump
flanges vary with the pump size and type. Tominimize these forces and moments that may, ifexcessive , cau se misalignment, hot bearings, worn
couplings, vibration and the possible failure of thepump casing, the following p oints should be strictly
followed:
Prevent excessive external pipe load
Never draw pipin g into pla ce by applying force topump flange connections.
Do not mount expansion joints so that their force,due to internal pressure, a cts on the pump flange.It is recommended that expansion joints use
threaded rod to limit any forces of this type.
Thermal expansions must be compensated insuch a way that no additional forces act on the
pump flanges.
Make sure that piping flanges are square and
concentric to the pump flanges.
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The table in 4.6.3 summarizes the maximum fo rces
and moments allowed on WDX pump casin gs. Referto Flowserve for other configurations.
Ensure piping and fittings are flu shed
before u se.
Ensure piping for hazardous liquids is arrangedto allow pump flu shing before removal of the pump.
Excessive external strains (forces, moments)may cause mi salignment, general vibrations, hot
bearings or excessive wear on couplings and seal s.In extreme cases, leakage may resul t with potential
loss of li fe with hot or corrosive liquids.
4.6.2 Suction pipingRefer to the diagrams below for typical designs of
suction piping for both flooded suction and suction lift.
a) The inlet pipe should be one or two sizes largerthan the pump inlet bore and pipe bends shouldbe as large a radius as possible.
b) Pipework reducers should be conical and have amaximum total angle of divergence of 15 degrees.
c) Pipework should be arranged to avoid air pockets.d) If high points cannot be avoided on the suction line
equip them with air relief cocks.e) On suction lift the piping should be inclined up
towards the pump inlet with e ccentric reducersin corporated to p revent air locks.
f) On positive suction, the inlet piping must have aconstant fall towards the pump.
g) Flow should enter the pump suction with uniformflow, to minimize noise and wear. This is
particularly important on large or high-spee dpumps which should have a minimum of five
diameters of straight pipe on the pump suctionbetween 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 at an angle other than
perpendicular to the shaft axis. Elbows parallel tothe shaft axis will cause une ven flo w.
j) Excep t in un usual circumstances strai ners are
not recommended in i nlet piping. If considerableforeign matter i s expected a screen installed atthe en trance to the wet well is preferable.
k) Fitting an isolation valve will allow easiermaintenance.
l) If an inlet valve is necessary, choose a modelwith full bore so as to limit losse s. Val ve stem
should be in a vertical position. There should bea minimum of five pipe diameters between the
pump and the valve.
m) Never throttle pump on suction side and neverplace a valve directly on the pump inlet nozzle.
n) Do not tighten flanges befo re the final check.
Typical design flooded suction
Note:Ideally reducers should be limited to one pipe diameter change,ie 150 mm (6 in.) to 200 mm (8 in.). Must have a maxi mum totalangle of divergence of 15 degrees.
Typical design suction lift
Notes:1. S = Minimum submergence >3E.2. I deally r educers to be limited to one pipe diameter change,
ie 150 mm (6 in.) to 200 mm (8 in.). Must have a maxi mum totalangle of divergence of 15 degr ees.
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4.6.3 Maximum forces and moments allowed on WDX pump flanges
Direction of forces
Fx = horizontal parallel to pump axis
Fy = horizontal perpendicular to pump axisFz = vertical perpendicular to pump axis
Direction of moments
Mx = around a horizontal axis parallel to pump axisMy = around a horizontal axis nozzle axis
Mz = around a horizontal axis perpendi cular to pump a xis
PIPECONFIGURATION
FLANGE FORCES MOMENTS
Diameter Fy Fz Fx F My Mz Mx M
1.5 in 130 lbf 200 l bf 160 lbf 290 l bf 170 ft- lbf 260 ft- lbf 340 ft- lbf 460 ft- lbf
40 mm58 daN 89 daN 71 daN 128 daN 23 daN. m 35 daN. m 46 daN. m 62 daN. m2 in 130 lbf 200 l bf 160 lbf 290 l bf 170 ft- lbf 260 ft- lbf 340 ft- lbf 460 ft- lbf
Vertical pipework 50 mm 58 daN 89 daN 71 daN 128 daN 23 daN. m 35 daN. m 46 daN. m 62 daN. m
perpe ndic ular 3 i n 200 lbf 300 l bf 240 lbf 430 l bf 350 ft- lbf 530 ft- lbf 700 ft- lbf 950 ft- lbf
to the s haf t 80 mm 89 daN 133 daN 107 daN 193 daN 47 daN . m 72 daN .m 95 daN . m 128 daN .m
4 in 260 lbf 400 lbf 320 lbf 570 lbf 500 ft- lbf 740 ft-lbf 980 ft-lbf 133 0 ft-lb f
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 l bf 560 lbf 101 0 l bf 870 ft- lbf 130 0 ft- lb f 170 0 ft- lb f 231 0 ft- lb f
150 mm 205 daN 311 daN 249 daN 448 daN 118 daN.m 176 daN 230 daN.m 313 daN.m
1.5 in 130 lbf 200 l bf 160 lbf 290 l bf 170 ft- lbf 260 ft- lbf 340 ft- lbf 460 ft- lbf
40 mm 58 daN 89 daN 71 daN 128 daN 23 daN. m 35 daN. m 46 daN. m 62 daN. m
2 in 130 lbf 200 l bf 160 lbf 290 l bf 170 ft- lbf 260 ft- lbf 340 ft- lbf 460 ft- lbf
50 mm 58 daN 89 daN 71 daN 128 daN 23 daN. m 35 daN. m 46 daN. m 62 daN. m
Horizontal pipework 3 in 200 lbf 300 l bf 240 lbf 430 l bf 350 ft- lbf 530 ft- lbf 700 ft- lbf 950 ft- lbf per pe ndi c ul ar 80 mm 89 daN 133 daN 107 daN 193 daN 47 daN . m 72 daN .m 95 daN . m 128 daN .m
to the shaf t 4 in 260 lbf 400 lbf 320 lbf 570 lbf 500 ft- lbf 740 ft-lbf 980 ft-lbf 133 0 ft-lb f
100 mm 116 daN 178 daN 142 daN 256 daN 68 daN.m 100 daN.m 133 daN.m 180 daN.m6 in 460 lbf 700 l bf 560 lbf 101 0 l bf 870 ft- lbf 130 0 ft- lb f 170 0 ft- lb f 231 0 ft- lb f
150 mm 205 daN 311 daN 249 daN 448 daN 118 daN.m 176 daN 230 daN.m 313 daN.m
3 in 240 lbf 200 l bf 300 lbf 430 l bf 350 ft- lbf 530 ft- lbf 700 ft- lbf 950 ft- lbf
80 mm 107 daN 89 daN 133 daN 193 daN 47 daN . m 72 daN .m 95 daN . m 128 daN .m
Horizontal 4 in 320 lbf 260 lbf 400 lbf 570 lbf 500 ft- lbf 740 ft-lbf 980 ft-lbf 133 0 ft-lb f
within thepump axis 100 mm 142 daN 116 daN 178 daN 256 daN 68 daN.m 100 daN.m 133 daN.m 180 daN.m
6 in 560 lbf 460 l bf 700 lbf 101 0 l bf 870 ft- lbf 130 0 ft- lb f 170 0 ft- lb f 231 0 ft- lb f
150 mm 249 daN 205 daN 311 daN 448 daN 118 daN.m 176 daN.m 230 daN.m 313 daN.m
Notes:1) F = External force (tension or compression).
M = External mom ent, cl ockwise or counter-clockwise.2) Forces and moments may be applied si multaneously in an y
direction.3) Val ues apply to all materials.
4) Higher loads may be applicable, if direction and magnitude ofindivi dual loads are known, but th ese need written approvalfrom Flowserve Pump Di vision.
5) Pumps must be on rigid foundations and baseplates must befullygrouted.
6) Pump/baseplate should not be used as pipe anc hor. Suctionand discharge piping s hould be anchored as close as possibleto the pump flanges to r educe vibration and prevent strai n onthe pump casing. Expansion joints are r ecommended. Theymust be properl ytied andl ocated on the side of the pipe anchoraway fromt he pump
7) The pump mounting bolt torques specified must be used toprevent relative movem ent between the pump casing andbaseplate. (See s ection 6.6, F astener torques.). T he bolt
material must have a mini mum yiel d strength of 600 N/mm2
(87 000l b/in.2).
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4.6.4 Discharge pipingSee section 4.6.2 for typical pipework design.
A no n-return val ve should be lo cated i n th e dischargepipework to protect the pump from excessive back
pressure and hence reverse rotation when the unit isstopped.
Pipework reducers should h ave a m aximum total
angle of divergence of 9 degrees.
Fitting an isolation valve will allow easier maintenance.It should be installed downstream of the non-return
valve.
If needed a control pressure gauge may be installedon the pipework.
Do not tighten the pipe flanges before the final check.
4.6.5 Auxiliary piping
4.6.5.1 Drai ns
Pipe pump casing drain s and gland leakage to aconvenient disposal point.
4 .6 .5 .2 Pu mp s f i t te d w i th me ch a n i ca l se a l s
Single seals requiring re-circulation will normally beprovided with the auxiliary piping from pump casin g
already fitted.
If the seal requires an auxiliary quench then aconnection must be made to a suitable source of
liquid flo w, low pressure steam or static pressure froma header tank. Recommended pressure is 0.35 bar (5
psi) or less. Check General arrangement drawing.
Special seals may require different auxiliary piping tothat described above. Consult sepa rate User
Instructions and or Flowserve if unsure of correctmethod or arrangement.
For pumping hot liquids, to avoid seal damage, it isrecommended that any external flush/cooling supply
be continued after stopping the pump.
4.6.6 Final checks
Check the tightness of all bolts in the suction anddi scharge pipework. Tighten i f necessary. Check al sothe tightness of all foundation bolts. Tighten i f
necessary. Check the tightness of all auxiliary piping.Tighten i f necessary.
4.7 Final shaft alignment checkAfter connecting piping to the pump, rotate the shaftseveral times by hand to ensure there is no binding
and all parts are free.
Recheck the coupling alignment, as previouslydescribed, to ensure no pipe strain. If pipe strain
exists, correct piping.
Alignment can only be consid ered definitive afterpipework has been connected.
4.8 Electrical connections
4.8.1 Safety conditions about electricalconnections
Electrical connections must be made
by a qualified Electrician in accordance with relevantlo cal national and inte rnational regulations. This
includes any grounding.
It is important to be aware of the EUROPEANDIRECTIVE on potentially explosive areas where
compliance with IEC60079-14 i s an additionalrequirement for making electrical connections.
Avoid me chanical, hydraulic or electrical
overload b y using motor overload trips or a powermonitor and make routine vibration monitoring.
It is important to be aware of the EUROPEANDIRECTIVE on electromagnetic compatibility whenwiring up and in stalling equipment on site. Attention
must be paid to ensure that the techniques used duringwiring/installation do not increase electromagnetic
emissions or decrease the electromagnetic immunity of
the equipment, wiring or any connected devices. If inany doubt, contact Flowserve for advice.
The motor must be wired up in
accordance with the m otor manufacturer's
instructions (normally supplied within th e terminalbox) including a ny temperature, earth leakage,
current and other protective devices as appropriate.The identification nameplate should be checked to
ensure the power supply is appropria te.
A device to provide emergency stopping mustbe fitted.
If not supplied pre-wired to the pump unit, the
controller/starter electrical details will also be suppliedwithin 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.
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4.9 Protection systems
The following protection system s arerecommended particularly if the pump i s installed in a
potentially explosive area or is handling a hazardousliquid. If in doubt consult Flo wserve.
If there is any possib ility of the system allowing thepump to run against a closed valve or belowminimum continuous safe flow a protection device
shou ld be in stalled to ensure the temperature of theliquid does not rise to an unsafe le vel.
If there are any circumstances in which th e systemcan allow the pump to run dry, or start up empty, a
power monitor should be fitted to stop the pump orprevent it from being started. This is particularly
relevant if the pump is handling a flammable liquid.
If leakage of product from the pump or its associa ted
seal ing system can cause a hazard it isrecommended that an appropriate leakage detectionsystem i s installed.
To prevent excessive surface temperatures at
bearings it is recommended that temperature orvibration monitoring are carried out. See sections
5.7.4 and 5.7.5.
If a d efect of cooling can lead to temperature higher
than those acceptable a system of coolingsurveillance must be installed.
Except when explicitly required by the customer in
the specifications, when a possib ili ty of reverse
rotation exists the customer must install a reverserotation protection device.
The customer must install all equipment required to
avoid water hammer.
5 COMMISSIONING, START-UP,OPERATION AND SHUTDOWN
T h e s e o p e r a t i o n s m u s t b e c ar r i e d o u t b y
f u l l y q u a l i f ie d p e rs o n n e l .
5.1 Pre-commissioning procedure
5.1.1 LubricationDetermine the mode o f lubrication of the pump set,eg grease, oil, product lubrication etc.
Grease lubricated pumps and electric motors aresupplied pre-greased.
Other drivers and gearboxes, if appropriate, shouldbe l ubricated i n accordance with their manuals.
In the case of product lubricated
bearings the source of product supply should bechecked against the order. There may be
requirements for an external clean supply, particularsupp ly pressure or the commencement of lubrication
supp ly before pump start-up.
5.1.2 Oil LubricationThe bearings are lubricated by pins. A constant leveloiler automatically maintains the correct oil level.
The oiler supplies the necessary quantity of oil. Itoperates on the liquid seal principal and feeds with oil
only when the quantity of oil becomes too low in thebearing. It will stop to feed once a sufficient quantity
of oil is in the bearing.
The reserve contained in the reservoir refills
automatically the natural l osse s of the bearing. Assoon as the oil level approaches the minimum level of
the reservoir, refill the reservoir.
Regarding the quality and the quantity of the oil to be
used, refer to the lubrication table and informationbelow.
For oil lubricated pump s, fill the bearinghousing with correct grade of oil to the correct level, ie
sig ht glass or constant level oiler bottle.
See below for the correct side on which constant
level oile rs should be installed.
Oiler Oiler
Direction of rotation ofthe pump
Driveendside
When fitted with a constant le vel oiler, the bearing
housing should be filled onl y by unscrewing orhinging back the transparent bottle and filling t he
bottle with oil. Do not fill the bearing housing throughthe b reather hole.
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Oil l evels are as indicated below. The distance
indicated i s di stance below the shaft centreline.
Oil Level mm (inch)Pump size
Drive end Non Drive end
1.5 WDX 41 (1.61) 41 (1.61)
2 WDX 46 (1.81) 46 (1.81)
3 WDX 56 (2.20) 46 (1.81)
4 WDX 66 (2.60) 46 (1.81)
The oil filled bottle should then be refitted so as toreturn it to the upright position. Filling should be
repeated until oil remains visible within the bottle.
5.2 Pump lubricants
5.2.1 Recommended oil lubricants
Viscosity grade ISO 46Ambi ent temperature
Bearings temperature 80 C maximum
TABLE OF EQUIVALENCE AND CHARACTERISTICS
OF R ECOMMENDED OILS
MANUFACTURER TYPE
CHARACTERISTICS
BP
ENERGOL
HLP46
ELF
TURBELF
SA46
ESSO
TERESSO
46
MOBIL
DTE
Medium
SHELL
TELLUS
T 37
TOTAL
PRESLIA
46
TOTAL
AZOLLA
ZS46Density at 15 C 0.885 0.881 0.868 0.878 0.87 0.872 0.877
Viscosity at 40 C.cst 45 48.6 43 43 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 p oint 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
Colour 1 2 1 2 2 1 1
Anti erosion additive s yes yes yes yes yes
Foam inhibitors yes yes yes yes yes yes yes
Anticorrosion additive s yes yes yes yes yes yes yes
Antioxidant yes yes yes yes yes yes yes
Conradson carbon residue 0.01 0.2
Li mits on temperature C - 1 2to
120 C
- 2 1to
110 C
Saponification < 0.5 1.2
5.2.2 Recommended grease lubricants
Factory greasing : SHELL ALVANIA R2 or equiv alent
Equivalent greases : MOBIL, Mobilux EP2TOTAL, Multis 2
ELF, Elf Multi
Grease Quantity : 10 to 30 Grams
5.2.3 Recommended fill quantities
Oil QuantityISO VG 46Pump size
Drive e nd Non Drive e nd
1.5 WDX 0.26 qt (0.250 Ltr) 0.21 qt (0.200 Ltr)
2 W DX 0.3 7 q t ( 0.3 50 Ltr ) 0.25 qt (0.240 Ltr)
3 WDX 0.42 qt (0.400 Ltr) 0.25 qt (0.240 Ltr)
4 WDX 0.63 qt (0.600 Ltr) 0.32 qt (0.300 Ltr)
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5.2.4 Lubrication schedule
5.2.4.1 Oil lubricated bearings
Operating conditions and severity of service willdetermine the intervals between oil changes. In
general highe r oil temperatures will require morefrequent oil changes.
For pumps on hot service or in severely damp or
corrosive atmosphere, the oil will require changingmore frequently. If the bearings maintain a stable
temperature and if there has been no contaminatio nof the oil, the interval between changes may be
longer.
Lubricant and bearing temperature analysis can beuseful in optimising lubricant change intervals.
Generally, the oil should be changed every 6 months.If the bearing temperature increases, check
immediately for improper lubrication o r a faulty
bearing.
The lubricating oil should be a high quality mineral oil
having foam inhibitors. Synthetic oils may also be usedif checks show that the rubber oil seals will not be
adversel y affected.
The bearing temperature may be allowed to rise to 50C (122 F).above ambient, but should not exceed 82
C (180 F). A continuously rising temperature or anabrupt rise, indicate a fault.
5 .2 .4 .2 Gre a se l u b ri ca te d be a ri n gs
The bearings are prelubricated when supplied.Lubrication frequen cy is as indicated in the table
below. After a 2 years period the bearing should becompletely cleaned, checked and repacked with new
grease.
The free bearing space should not be filled up morethat 50 % to 60 % of its content see 5.2.3. Care must
be taken to avoid both under and over-lubrication.
Over lubrication will cau se the bearings to run hotterthan normal, while under-lubricated bearings could
wear prematurely.
The characteristics of the installation and severity ofservice will determine the frequency of lubrication.
Lubricant and bearing temperature analysis can beuseful in optimising lubricant change intervals.
Lubricati on frequenci es in hours of operationPump size
145 0 R PM 175 0 R PM 295 0 R PM 355 0 R PM
1,5 WDX 3000 2200 1500 1200
2 WDX 3000 2200 1500 1200
3 WDX 2700 2000 1400 1100
4 WDX 2500 1700 1300 1000
Never mix greases containing different
bases, thi ckeners or additives.
5.3 Direction of rotation
Starting or operating pumps with the
wrong direction of rotation can be harmful to thepumps.
Ensure that the pump rotation is the same a s thearrow on the pump casing.
It i s preferable to check the di rection of rotationbefore installing the coupling. If not, the pump must
be filled in with the liquid before start-up.
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 thesuppl y phasing has been altered.
5.4 Guarding
Guarding i s supplied fitted to the pump set.If this has been removed or disturbed ensure that allthe protective guards around the pump coupling and
exposed parts of the shaft are securely fixed.
5.5 Priming and auxiliary supplies
Where there is any risk of the pump being runagainst a closed valve generating high liquid andcasin g external surface temperatures it is
recommended that users fit an external surfacetemperature protection device.
Ensure all electrical, hydraulic,pneumatic, sealant and lubrication systems (asapplicable) are connected and operational.
Ensure the inlet pipe and pump casing
are completely full of liquid before starting continuousduty operation.
These operations must be carried out by personnelwith approved qualifications.
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5.5.1 Suction pressure above atmospheric
pressureOpen the ai r vent connection to allow the trapped air
to escape. Let liquid run out until free from airbubbles.
5.5.2 Suction lift w ith foot v alve fittedFill suction pipe and casing with liquid at a pressure
of 1 to 2 bar from an external source. Vent asdescribed in section 5.5.1.
Foot valves are not recommended when
the p umped li quid has suspen ded solid particles.They may lodge between foot valve seat and shutter.
5.5.3 Suction lift w ithout foot valvePump casing vents on the suction volute must beconnected to an external vacuum pump priming
system. If in doubt, please consul t Flowserve.
5.6 Starting the pump
a) Ensure fl ushing and/or cooli ng/
heating liquid supplies are turned ON beforestarting the pump.
b) CLOSE the outlet valve. If the pump is equippedwith a non -return flow valve and is to be started
with an opened discharge valve, verify that it isclosed 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 runningagainst 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 closedbefore starting.
i) Start motor and check outlet pressure.j) If the pressure is sati sfactory, slo wly OPEN outlet
control valve.
k) Do not run the pump with the
outlet valve closed for a period longer than 20seconds.
l) If NO pressure, or LOW pressure, STOP thepump. 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 toescape taking due care with ho t or hazardous liquids.
Under normal operating conditions, after the pumphas been full y primed and vented, it should be
unnecessary to re-vent the pump.
5.7.2 P umps fitted w ith packed gland
If the pump has a packed gland there must be some
leakage from the gland. Gland nuts should initially befinger-tight only. Leakage should take place soon
after the stuffing box is pressurized.
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The gland must be adjusted evenly to givevisible leakage and concentric alignment of the gland
ring [4120] to a void excess temperature. If noleakage takes pl ace the packing will begin to
overheat. If overheating takes pla ce the p ump shouldbe stopped and allowed to cool before being re-
started. When the pump is re-started, check toensure leakage is takin g pla ce at the packed gland.
If hot liquids are being pumped it may be necessary
to slacken the gland nuts to achieve leakage.
The pump should be run for ten minutes with steadyleakage a nd the gland nuts tightened by 10 degrees
at a time until lea kage is reduced to an acceptablelevel. The temperature of the gland should be
checked after each round of tightening. If thetemperature starts to climb rapidly then back off the
gland nuts until the temperature drops down. Wait for
the temperature to stabilize before tightening again.The leakage m ust not be reduced below a rate of 20drops per minute. Bedding in of the packing may take
several hours.
Care must be taken when adjusting the glandon an operatin g pump. Safety gloves are essenti al.Loose clothing must not be worn to avoid being
caught up by the pump shaft. Shaft guards must bereplaced after the gland adjustment is complete.
Never run gland packing dry, even for
a short time.
5.7.3 Pumps fitted w ith mechanical sealMechanical seal s requi re no adjustment. Any slight
initial leakage will stop when the seal i s run in.
Before pumping dirty liquids it is advisable, ifpossible, 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 i s run and allowed to flow fora period after the pump has stopp ed.
Never run a mechani cal seal dry, even
for a short time.
5.7.4 Bearings
If the pumps are working in a potentiallyexplosive atmosphere, temperature or vibration
monitoring at the bearings is recommended.
If bearing temperatures are to be monitored i t isessential that a benchmark temperature is recorded
at the commissioning stage and after the bearingtemperature has stabilized.
Record the bearing temperature (t) and theambient temperature (ta)
Estim ate the likel y maximum ambienttemperature (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 1 05 C (220 F) for grease lubrication
It is important, particularly with g rease lubrication, tokeep a check on bearing temperatures. After start up
the temperature rise should be gradual, reaching amaximum after app roximately 1.5 to 2 hours. Thi s
temperature rise should then remain constant ormarginall y reduce with time. (Refer to section 6.2.3.1
for fu rther information.)
5.7.5 Normal v ibration levels, alarm and tripFor guidance, pumps generally fall under a
classifi cation for rigid support machin es within the
International rotating m achinery standards and the
recommended ma ximum l evels below are based on
those standards.
Alarm a nd trip values for in stalled
pumps shou ld be based on the actual measurements(N) taken on site on the bearing housings of the
pump in the fully commissioned a s new condition.
The example (N) value is gi ven for the preferred
operating flo w region (typi cally this may extend to 70to 120 % of the pump best efficiency poin t); outsid ethe preferred flow region the actual vibration
experienced may be multiplied by up to 2.
These stand ard values can vary with the rotational
speed and the power absorbed by the pump. For anyspeci al case, do not hesita te to consul t us.
Measuring vibration at regular intervals will then showany deterioration in pump or system operating
conditions.
Vibration Velocit y - unfi