USER INSTRUCTIONS

Installation
Flowserve ® CPXV-E
Operation
Enclosed column version of CPXV vertical sump pump Maintenance
PCN=87900056 12-15 (E). Original instructions.

These instructions must be read prior to installing,

operating, using and maintaining this equipment.
 CPXV-E USER INSTRUCTIONS ENGLISH 87900056 12-15

CONTENTS
Page Page
1 INTRODUCTION AND SAFETY ......................... 4 6 MAINTENANCE ................................................ 20
1.1 General .......................................................... 4 6.1 General ........................................................ 20
1.2 CE marking and approvals ............................. 4 6.2 Maintenance schedule .................................. 21
1.3 Disclaimer ...................................................... 4 6.3 Spare parts................................................... 21
1.4 Copyright ....................................................... 4 6.4 Recommended spares.................................. 22
1.5 Duty conditions .............................................. 4 6.5 Tools required .............................................. 22
1.6 Safety ............................................................ 5 6.6 Casing, seal housing and fastener torques ... 22
1.7 Nameplate and safety labels .......................... 9 6.7 Setting impeller clearance............................. 22
1.8 Specific machine performance ....................... 9 6.8 Renewal clearances ..................................... 24
1.9 Noise level ..................................................... 9 6.9 Disassembly ................................................. 24
6.10 Examination of parts .................................. 26
2 TRANSPORT AND STORAGE ......................... 10
6.11 Assembly ................................................... 26
2.1 Consignment receipt and unpacking ............. 10
2.2 Handling ...................................................... 10 7 FAULTS; CAUSES AND REMEDIES ................ 28
2.3 Lifting ........................................................... 10
8 PARTS LISTS AND DRAWINGS ....................... 30
2.4 Storage ........................................................ 11
8.1 CPXV-E........................................................ 30
2.5 Recycling and end of product life.................. 11
8.2 CPXV-E bearing options ............................... 32
3 DESCRIPTION ................................................. 11 8.3 Optional A-OP key-drive impeller .................. 32
3.1 Configurations .............................................. 11 8.4 Parts interchangeability ................................ 33
3.2 Name nomenclature ..................................... 11 8.5 General arrangement drawing ...................... 33
3.3 Design of major parts ................................... 12
9 CERTIFICATION ............................................... 33
3.4 Performance and operating limits ................. 12
10 OTHER RELEVANT DOCUMENTATION
4 INSTALLATION ................................................ 13
AND MANUALS ................................................ 33
4.1 Location ....................................................... 13
10.1 Supplementary User Instruction manuals ... 33
4.2 Part assemblies ........................................... 13
10.2 Change notes ............................................ 33
4.3 Foundation ................................................... 13
10.3 Additional sources of information ................ 33
4.4 Grouting ....................................................... 13
4.5 Piping .......................................................... 13
4.6 Electrical connections .................................. 15
4.7 Protection systems ....................................... 15
5 COMMISSIONING, START-UP, OPERATION
AND SHUTDOWN ............................................ 16
5.1 Pre-commissioning procedure ...................... 16
5.2 Pump lubricants and coolants ...................... 16
5.3 Open impeller clearance .............................. 18
5.4 Direction of rotation ...................................... 18
5.5 Guarding ...................................................... 18
5.6 Priming and auxiliary supplies ...................... 18
5.7 Starting the pump ......................................... 18
5.8 Running the pump ........................................ 19
5.9 Stopping and shutdown ................................ 19
5.10 Hydraulic, mechanical and electrical duty... 20

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INDEX
Page Page

Additional sources (10.3) ....................................... 33 Reassembly (6.11, Assembly) ............................... 26

Assembly (6.11) ..................................................... 26 Receipt and unpacking (2.1) .................................. 10
ATEX marking (1.6.4.2)............................................ 7 Recommended fill quantities (see 5.2.2) ................ 17
Bearing sizes and capacities (5.2.2) ....................... 17 Recommended grease lubricants (5.2.3) ............... 17
CE marking and approvals (1.2) ............................... 4 Recommended oil lubricants (5.2.1) ...................... 16
Certification (9) ...................................................... 46 Recommended spares (6.4) .................................. 22
Change notes (10.2) .............................................. 33 Recycling (2.5) ...................................................... 11
Clearances, impeller (6.7) ...................................... 22 Replacement parts (6.3 and 6.4)........................21/22
Commissioning and operation (5) ........................... 16 Running the pump (5.8) ......................................... 19
Compliance, ATEX (1.6.4.1)..................................... 6 Safety action (1.6.3) ................................................ 5
Configurations (3.1) ............................................... 11 Safety labels (1.7.2) ................................................ 9
Copyright (1.4) ......................................................... 4 Safety markings (1.6.1) ........................................... 5
Design of major parts (3.3) ..................................... 12 Safety, protection systems (1.6 and 4.7)
Direction of rotation (5.4)........................................ 18 Sectional drawings (see 8) .................................... 30
Disassembly (6.9) .................................................. 24 Setting impeller clearance (6.7) ............................. 22
Disclaimer (1.3)........................................................ 4 Sound pressure level (1.9, Noise level) .................... 9
Dismantling (6.9, Disassembly) .............................. 24 Sources, additional information (10.3).................... 33
Drawings (8) .......................................................... 30 Spare parts (6.3) ................................................... 21
Duty conditions (1.5) ................................................ 4 Specific machine performance (1.8) ........................ 9
Electrical connections (4.6) .................................... 15 Starting the pump (5.7) .......................................... 18
End of product life (2.5) .......................................... 11 Stop/start frequency (5.8.4) ................................... 19
Examination of parts (6.10) .................................... 26 Stopping and shutdown (5.9) ................................. 19
Fastener torques (6.6) ........................................... 26 Storage, pump (2.4) .............................................. 11
Faults; causes and remedies (7) ............................ 28 Storage, spare parts (6.3.2) ................................... 22
Foundation (4.3) .................................................... 13 Supplementary manuals or information sources..... 33
General arrangement drawing (8.5)........................ 33 Supplementary User Instructions (10.1) ................. 33
General assembly drawings (see 8) ....................... 30 Tools required (6.5) ............................................... 22
Grouting (4.4) ........................................................ 13 Torques for fasteners (6.6) .................................... 22
Guarding (5.5) ....................................................... 18 Trouble-shooting (see 7) ....................................... 28
Handling (2.2) ........................................................ 10 Vibration (5.8.3)..................................................... 19
Hydraulic, mechanical and electrical duty (5.10) ..... 20
Impeller clearance (5.3 and 6.7)
Inspection (6.2.1 and 6.2.2).................................... 21
Installation (4) ........................................................ 13
Lifting (2.3) ............................................................ 10
Location (4.1)......................................................... 13
Lubrication (5.1.1, 5.2 and 6.2.3)
Lubrication schedule (5.2.5) ................................... 18
Maintenance (6) ..................................................... 20
Maintenance schedule (6.2) ................................... 21
Name nomenclature (3.2) ...................................... 11
Nameplate (1.7.1) .................................................... 9
Operating limits (3.4.1) ........................................... 12
Ordering spare parts (6.3.1) ................................... 21
Part assemblies (4.2) ............................................. 13
Parts lists (8).......................................................... 30
Performance (3.4) .................................................. 12
Piping (4.5) ............................................................ 13
Pre-commissioning (5.1) ........................................ 16
Priming and auxiliary supplies (5.6) ........................ 18
Protection systems (4.7) ........................................ 15

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1 INTRODUCTION AND SAFETY of technical documents and safety instructions. Where

applicable this document incorporates information
1.1 General relevant to these Directives and Approvals.

These instructions must always be kept To confirm the Approvals applying and if the product is
close to the product's operating location or CE marked, check the serial number plate markings
directly with the product. and the Certification. (See section 9, Certification.)

Flowserve products are designed, developed and 1.3 Disclaimer

manufactured with state-of-the-art technologies in Information in these User Instructions is believed to
modern facilities. The unit is produced with great be complete and reliable. However, in spite of all of
care and commitment to continuous quality control, the efforts of Flowserve Corporation to provide
utilising sophisticated quality techniques, and safety comprehensive instructions, good engineering and
requirements. safety practice should always be used.

Flowserve is committed to continuous quality Flowserve manufactures products to exacting

improvement and being at service for any further International Quality Management System Standards
information about the product in its installation and as certified and audited by external Quality Assurance
operation or about its support products, repair and organisations. Genuine parts and accessories have
diagnostic services. been designed, tested and incorporated into the
products to help ensure their continued product quality
These instructions are intended to facilitate and performance in use. As Flowserve cannot test
familiarization with the product and its permitted use. parts and accessories sourced from other vendors the
Operating the product in compliance with these incorrect incorporation of such parts and accessories
instructions is important to help ensure reliability in may adversely affect the performance and safety
service and avoid risks. The instructions may not take features of the products. The failure to properly select,
into account local regulations; ensure such regulations install or use authorised Flowserve parts and
are observed by all, including those installing the accessories is considered to be misuse. Damage or
product. Always coordinate repair activity with failure caused by misuse is not covered by the
operations personnel, and follow all plant safety Flowserve warranty. In addition, any modification of
requirements and applicable safety and health laws Flowserve products or removal of original components
and regulations. may impair the safety of these products in their use.

These instructions must be read prior to 1.4 Copyright

installing, operating, using and maintaining the All rights reserved. No part of these instructions may
equipment in any region worldwide. The be reproduced, stored in a retrieval system or
equipment must not be put into service until all transmitted in any form or by any means without prior
the conditions relating to safety, noted in the permission of Flowserve.
instructions, have been met. Failure to follow and
apply the present user instructions is considered 1.5 Duty conditions
to be misuse. Personal injury, product damage,
This product has been selected to meet the
delay or failure caused by misuse are not covered
specifications of your purchaser order. The
by the Flowserve warranty.
acknowledgement of these conditions has been sent
separately to the Purchaser. A copy should be kept
1.2 CE marking and approvals with these instructions.
It is a legal requirement that machinery and equipment
put into service within certain regions of the world shall The product must not be operated beyond
conform with the applicable CE Marking Directives the parameters specified for the application. If
covering Machinery and, where applicable, Low Voltage there is any doubt as to the suitability of the
Equipment, Electromagnetic Compatibility (EMC), product for the application intended, contact
Pressure Equipment Directive (PED) and Equipment for Flowserve for advice, quoting the serial number.
Potentially Explosive Atmospheres (ATEX).
If the conditions of service on your purchase order are
Where applicable, the Directives and any additional going to be changed (for example liquid pumped,
Approvals, cover important safety aspects relating to temperature or duty) it is requested that the user seeks
machinery and equipment and the satisfactory provision the written agreement of Flowserve before start-up.

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1.6 Safety 1.6.3 Safety action

This is a summary of conditions and actions to help
1.6.1 Summary of safety markings prevent injury to personnel and damage to the
These User Instructions contain specific safety environment and to equipment. For products used
markings where non-observance of an instruction would in potentially explosive atmospheres section 1.6.4
cause hazards. The specific safety markings are: also applies.

This symbol indicates electrical safety NEVER DO MAINTENANCE WORK

instructions where non-compliance will involve a high WHEN THE UNIT IS CONNECTED TO POWER
risk to personal safety and could result in loss of life.
GUARDS MUST NOT BE REMOVED WHILE
This symbol indicates safety instructions where THE PUMP IS OPERATIONAL
non-compliance would affect personal safety and could
result in loss of life. DRAIN THE PUMP AND ISOLATE PIPEWORK
BEFORE DISMANTLING THE PUMP
This symbol indicates “hazardous and toxic fluid” The appropriate safety precautions should be taken
safety instructions where non-compliance would affect where the pumped liquids are hazardous.
personal safety and could result in loss of life.
FLUORO-ELASTOMERS (When fitted.)
When a pump has experienced temperatures over
This symbol indicates explosive atmosphere zone
250 ºC (482 ºF), partial decomposition of fluoro-
marking according to ATEX. It is used in safety
elastomers (example: Viton) will occur. In this
instructions where non-compliance in the hazardous
condition these are extremely dangerous and skin
area would cause the risk of an explosion, and will
contact must be avoided.
involve a high risk to personal safety and could result in
loss of life. HANDLING COMPONENTS
Many precision parts have sharp corners and the
This symbol indicates safety instructions
wearing of appropriate safety gloves and equipment
where non-compliance will involve some risk to safe
is required when handling these components. To lift
operation and personal safety and would damage the
heavy pieces above 25 kg (55 lb) use a crane
equipment or property.
appropriate for the mass and in accordance with
current local regulations.
This symbol is used in safety instructions to
remind not to rub non-metallic surfaces with a dry cloth; THERMAL SHOCK
ensure the cloth is damp. It is used in safety Rapid changes in the temperature of the liquid within
instructions where non-compliance in the hazardous the pump can cause thermal shock, which can result
area would cause the risk of an explosion. in damage or breakage of components and should be
avoided.
This sign is not a safety symbol but indicates
an important instruction in the assembly process. NEVER APPLY HEAT TO REMOVE IMPELLER
Trapped lubricant or vapor could cause an explosion.
1.6.2 Personnel qualification and training
All personnel involved in the operation, installation, HOT (and cold) PARTS
inspection and maintenance of the unit must be If hot or freezing components or auxiliary heating
qualified to carry out the work involved. If the personnel supplies can present a danger to operators and persons
in question do not already possess the necessary entering the immediate area action must be taken to
knowledge and skill, appropriate training and instruction avoid accidental contact. If complete protection is not
must be provided. If required the operator may possible, the machine access must be limited to
commission the manufacturer/supplier to provide maintenance staff only, with clear visual warnings and
applicable training. indicators to those entering the immediate area. Note:
bearing housings must not be insulated and drive
Always coordinate repair activity with operations and motors and bearings may be hot.
health and safety personnel, and follow all plant
safety requirements and applicable safety and health If the temperature is greater than 80 ºC (175 ºF) or
laws and regulations. below -5 ºC (23 ºF) in a restricted zone, or exceeds
local regulations, action as above shall be taken.

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1.6.4 Products used in potentially explosive

HAZARDOUS LIQUIDS atmospheres
When the pump is handling hazardous liquids care
must be taken to avoid exposure to the liquid by Measures are required to:
appropriate siting of the pump, limiting personnel • Avoid excess temperature
access and by operator training. If the liquid is • Prevent build up of explosive mixtures
flammable and or explosive, strict safety procedures • Prevent the generation of sparks
must be applied. • Prevent leakages
• Maintain the pump to avoid hazard
PREVENT EXCESSIVE EXTERNAL The following instructions for pumps and pump units
PIPE LOAD when installed in potentially explosive atmospheres
Do not use pump as a support for piping. Do not mount must be followed to help ensure explosion protection.
expansion joints, unless allowed by Flowserve in For ATEX, both electrical and non-electrical equipment
writing, so that their force, due to internal pressure, acts must meet the requirements of European Directive
on the pump flange. 2014/34/EU (previously 94/9/EC which remains valid
until 20 April 2016 during the transition). Always
NEVER RUN THE PUMP DRY
observe the regional legal Ex requirements e.g. Ex
Liquid level controls in the sump are recommended to
electrical items outside the EU may be required certified
avoid the risk of dry running.
to other than ATEX e.g. IECEx, UL.
NEVER RUN WITHOUT COLUMN
COOLANT TO THE CORRECT LEVEL 1.6.4.1 Scope of compliance
Check the dip stick to ensure the line bearings avoid the
risk of their dry running. Use equipment only in the zone for which it is
appropriate. Always check that the driver, drive
ENSURE CORRECT LUBRICATION coupling assembly, seal and pump equipment are
(See section 5, Commissioning, start-up, operation and suitably rated and/or certified for the classification of the
shutdown.) specific atmosphere in which they are to be installed.

ONLY CHECK DIRECTION OF Where Flowserve has supplied only the bare shaft
MOTOR ROTATION WITH COUPLING ELEMENT/ pump, the Ex rating applies only to the pump. The
PINS REMOVED party responsible for assembling the ATEX pump set
Starting in reverse direction of rotation will damage the shall select the coupling, driver and any additional
pump. equipment, with the necessary CE Certificate/
Declaration of Conformity establishing it is suitable for
START THE PUMP WITH OUTLET the area in which it is to be installed.
VALVE PART OPENED
(Unless otherwise instructed at a specific point in the The motor, coupling, pump thrust bearing and seal
User Instructions.) can be made compliant with ATEX Directive
This is recommended to minimize the risk of 2014/34/EU (previously 94/9/EC which remains valid
overloading and damaging the pump or motor at full or until 20 April 2016 during the transition) for
zero flow. Pumps may be started with the valve further Equipment Categories 2 and 3 as required by the
open only on installations where this situation cannot duty conditions.
occur. The pump outlet control valve may need to be
adjusted to comply with the duty following the run-up See the pump nameplate and Declaration of Conformity
process. (See section 5, Commissioning start-up, for the pump classification. The pump column below
operation and shutdown.) sole plate will be to the same category (See section
1.6.4.2.)
DO NOT RUN THE PUMP AT
ABNORMALLY HIGH OR LOW FLOW RATES
Operating at a flow rate higher than normal or at a flow Users must pay particular attention to pump operation
rate with no back pressure on the pump may overload and maintenance instructions because of the hazard
the motor and cause cavitation. Low flow rates may of the explosive atmosphere.
cause a reduction in pump/bearing life, overheating of
the pump, instability and cavitation/vibration.

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The output from a variable frequency drive (VFD) can

cause additional heating effects in the motor and so, for Temperature class Maximum surface Temperature limit of
to EN 13463-1 temperature permitted liquid handled
pump sets with a VFD, the ATEX Certification for the
T6 85 °C (185 °F) 65 °C (149 °F) *
motor must state that it is covers the situation where T5 100 °C (212 °F) 80 °C (176 °F) *
electrical supply is from the VFD. This particular T4 135 °C (275 °F) 115 °C (239 °F) *
requirement still applies even if the VFD is in a safe area. T3 200 °C (392 °F) 180 °C (356 °F) *
T2 300 °C (572 °F) 275 °C (527 °F) *
T1 450 °C (842 °F) 400 °C (752 °F) *
1.6.4.2 Marking
* The table only takes the ATEX temperature class into consideration.
An example of ATEX equipment marking is shown Pump design or material, as well as component design or material,
below. The actual classification of the pump will be may further limit the liquid maximum working temperature
engraved on the nameplate
The temperature rise at the seals and bearings and
II 2GD k IIC (T4) T135 ºC due to the minimum permitted flow rate is taken into
account in the temperatures stated.
Equipment Group
I = Mining The operator is responsible to ensure the specified
II = Non-mining maximum liquid temperature is not exceeded.
Category
Temperature classification “Tx” is used when the liquid
2 or M2 = High level protection
temperature varies and when the pump is required to be
3 = normal level of protection
used in differently classified potentially explosive
Gas and/or Dust atmospheres. In this case the user is responsible for
G = Gas, D = Dust ensuring that the pump surface temperature does not
exceed that permitted in its actual installed location.
c = Constructional safety
(in accordance with EN13463-5) Do not attempt to check the direction of rotation with the
b = Control of ignition source coupling element/pins fitted due to the risk of severe
(in accordance with EN13463-6) contact between rotating and stationary components.
k = Protection by liquid immersion
(in accordance with EN13463-8) Where there is any risk of the pump being run against
Gas Group a closed valve generating high liquid and casing
IIA – Propane (Typical) external surface temperatures fit an external surface
IIB – Ethylene (Typical) temperature protection device.
IIC – Hydrogen (Typical)
Avoid mechanical, hydraulic or electrical overload by
Maximum surface temperature (Temperature Class) using motor overload trips, a temperature or power
(see section 1.6.4.3.) monitor and make routine vibration monitoring checks.

1.6.4.3 Avoiding excessive surface temperatures In dirty or dusty environments, make regular checks
and remove dirt from areas around close clearances,
ENSURE THE EQUIPMENT TEMPERATURE bearing housings and motors.
CLASS IS SUITABLE FOR THE HAZARD ZONE
The equipment utilises seals and bearing surfaces
Pumps have a temperature class as stated in the that may be polymer based which could be
ATEX Ex rating on the nameplate. corroded if they are in contact with unsuitable
liquids or gases. These surfaces are important for
The surface temperature on the pump is influenced the operation of the pump. Contact Flowserve if
by the temperature of the liquid handled. The you are uncertain about the performance of these
maximum permissible liquid temperature depends on materials with respect to aggressive substances
the ATEX temperature class and must not exceed the that may be present in the hazardous area.
values in the table that follows:
The pump casing must be flooded with liquid to the
minimum level on the dimensional general
arrangement (GA) drawing, at any time that the pump
is operated. Monitoring of the level with a pump cut
out on low level is required.

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Where there is the potential hazard of a loss of a dual For ATEX the coupling must be selected to comply with
seal barrier fluid the barrier fluid system must be the requirements of European Directive 2014/34/EU
monitored. (previously 94/9/EC which remains valid until 20 April
2016 during the transition). Correct coupling alignment
Where there is a risk that the external flush to a dual must be maintained.
seal, for example by freezing, blocking by debris or loss
of supply pressure, then the flow must be monitored. 1.6.4.6 Preventing leakage

Visual indicators are suitable when equipment is The pump must only be used to handle liquids
regulary inspected, but sensors connected to the pump for which it has been approved to have the correct
control system must be used if the pump runs remotely. corrosion resistance.

For Category 2 equipment the monitoring must create Avoid entrapment of liquid in the pump and associated
an alarm to the plant operator or shut down the pump. piping due to closing of suction and discharge valves,
which could cause dangerous excessive pressures to
The monitoring equipment must be suitable for the occur if there is heat input to the liquid. This can occur if
hazardous area. the pump is stationary or running.

See also sections 5.8.2 to 5.8.6. Bursting of liquid containing parts due to freezing
must be avoided by draining or protecting the pump
1.6.4.4 Preventing the build-up of explosive and ancillary systems.
mixtures
If leakage of liquid to atmosphere can result in a
ENSURE THE PUMP IS PROPERLY FILLED hazard, install a liquid detection device.
AND VENTED AND DOES NOT RUN DRY
1.6.4.7 Maintenance to avoid the hazard
Ensure the pump and relevant suction and discharge
pipeline system is totally filled with liquid at all times CORRECT MAINTENANCE IS REQUIRED TO
during the pump operation, so that an explosive AVOID POTENTIAL HAZARDS WHICH GIVE A
atmosphere is prevented. In addition it is essential to RISK OF EXPLOSION
make sure that seal chambers, auxiliary shaft seal
systems and any heating and cooling systems are The responsibility for compliance with maintenance
properly filled. instructions is with the plant operator.

If the operation of the system cannot avoid this To avoid potential explosion hazards during
condition, fit an appropriate dry run protection device maintenance, the tools, cleaning and painting
(for example liquid detection or a power monitor). materials used must not give rise to sparking or
adversely affect the ambient conditions. Where there
To avoid potential hazards from fugitive emissions of is a risk from such tools or materials, maintenance
vapour or gas to atmosphere the surrounding area must be conducted in a safe area.
must be well ventilated.
It is recommended that a maintenance plan and
1.6.4.5 Preventing sparks schedule is adopted. (See section 6, Maintenance.)

To prevent a potential hazard from mechanical

contact, the coupling guard must be non-sparking
and anti-static for Category 2.

To avoid the potential hazard from random induced

current generating a spark, the sole plate must be
properly grounded.

Avoid electrostatic charge: do not rub non-metallic

surfaces with a dry cloth; ensure cloth is damp.

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1.7 Nameplate and safety labels Similarly the motor noise assumed in the “pump and
motor” noise is that typically expected from standard
1.7.1 Nameplate and high efficiency motors when on load directly driving
For details of nameplate, see the Declaration of the pump. Note that a motor driven by an inverter may
Conformity. show an increased noise at some speeds.

1.7.2 Safety labels If a pump unit only has been purchased for fitting with
your own driver then the “pump only” noise levels in
the table should be combined with the level for the
driver obtained from the supplier. Consult Flowserve
or a noise specialist if assistance is required in
combining the values.

It is recommended that where exposure approaches

the prescribed limit, then site noise measurements
should be made.

The values are in sound pressure level LpA at 1 m

(3.3 ft) from the machine, for “free field conditions
over a reflecting plane”.

For estimating sound power level LWA (re 1 pW) then

add 14 dBA to the sound pressure value.
1.8 Specific machine performance The values in below table are valid for preferred
For performance parameters see section 1.5, Duty range of pump operation, 80% to 110% of B.E.P.
conditions. Where performance data has been supplied
separately to the purchaser these should be obtained
and retained with these User Instructions if required.

1.9 Noise level

Attention must be given to the exposure of personnel
to the noise, and local legislation will define when
guidance to personnel on noise limitation is required,
and when noise exposure reduction is mandatory.
This is typically 80 to 85 dBA.

The usual approach is to control the exposure time to

the noise or to enclose the machine to reduce emitted
sound. You may have already specified a limiting
noise level when the equipment was ordered,
however if no noise requirements were defined, then
attention is drawn to the following table to give an
indication of equipment noise level so that you can
take the appropriate action in your plant.

Pump noise level is dependent on a number of

operational factors, flow rate, pipework design and
acoustic characteristics of the building, and so the
values given are subject to a 3 dBA tolerance and
cannot be guaranteed.

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Typical sound pressure level LpA at 1 m reference 20 µPa, dBA

Motor size
and speed 3 550 r/min 2 900 r/min 1 750 r/min 1 450 r/min
kW (hp) Pump Pump and Pump Pump and Pump Pump and Pump Pump and
only motor only motor only motor only motor
<0.55 (<0.75) 58 65 50 58 50 52 50 52
0.75 (1) 60 65 52 59 51 54 51 54
1.1 (1.5) 62 67 54 60 55 57 53 56
1.5 (2) 63 66 55 63 56 59 54 58
2.2 (3) 64 69 57 65 58 62 56 60
3 (4) 63 71 58 68 59 64 57 62
4 (5) 64 72 60 69 61 65 59 63
5.5 (7.5) 66 73 62 71 63 67 61 65
7.5 (10) 67 73 63 71 64 69 62 67
11 (15) 69 76 65 73 66 71 64 69
15 (20) 71 77 67 74 68 72 66 70
18.5 (25) 72 78 68 75 69 70 67 70
22 (30) 73 78 69 76 70 71 68 71
30 (40) 75 79 71 77 72 72 70 72
37 (50) 76 80 72 78 73 73 71 73
45 (60) 77 81 73 79 74 74 72 74
55 (75) 78 81 74 79 75 75 73 75
75 (100) 80 83 76 81 77 76 75 76
90 (120) 81 84 77 81 78 77 76 77
110 (150) 82 85 78 82 79 78 77 78
150 (200) 84 87 80 84 81 79 79 79
200 (270) ① ① ① ① 81 81 79 79
300 (400) – 83 86 81 82
1 The noise level of machines in this range will most likely be of values which require noise exposure control, but typical values are inappropriate.
Note: for 1 180 and 960 r/min reduce 1 450 r/min values by 2 dBA. For 880 and 720 r/min reduce 1 450 r/min values by 3 dBA.

2 TRANSPORT AND STORAGE 2.2 Handling

Boxes, crates, pallets or cartons may be unloaded
2.1 Consignment receipt and unpacking using fork lift vehicles or slings dependent on their
Immediately after receipt of the equipment it must be size and construction.
checked against the delivery/shipping documents for
its completeness and that there has been no damage 2.3 Lifting
in transportation. Any shortage and/or damage must
be reported immediately to Flowserve and must be A crane must be used for all pump sets in
received in writing within one month of receipt of the excess of 25 kg (55 lb). Fully trained personnel must
equipment. Later claims cannot be accepted. carry out lifting, in accordance with local regulations.

Check any crate, boxes or wrappings for any Pumps with drivers over approximately 7.5 kW, are
accessories or spare parts that may be packed supplied with the pump packed as a separate item
separately with the equipment or attached to side from the driver. For improved stability unbolt the
walls of the box or equipment. driver and lift the driver and pump separately. These
and should be lifted separately into their installed
Each product has a unique serial number. Check position, using lifting points on the pump soleplate,
that this number corresponds with that advised and and on the motor.
always quote this number in correspondence as well
as when ordering spare parts or further accessories. Pumps and motors often have integral
lifting lugs or eye bolts. These are intended for use in
only lifting the individual piece of equipment. Before
lifting the driver alone, refer to the manufacturer’s
instructions.

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Make sure that hazardous substances are

disposed of safely and that the correct personal
protective equipment is used. The safety
specifications must be in accordance with the current
regulations at all times.

3 DESCRIPTION

3.1 Configurations
The pump is a modular designed centrifugal pump
that can be built to achieve almost all chemical liquid
pumping requirements. (See 3.2 and 3.3 below.)

Drawing taken from B736/623 3.2 Name nomenclature

The pump size will be engraved on the nameplate
When lifting pumps with drivers fitted, typically as below:
the resulting center of gravity may be above the lifting
points, and the method of slinging must prevent the 1E50-32-125A-OP
machine tipping during the lift. Slings, ropes and other ISO bearing housing
lifting gear must be positioned where they cannot slip size (1, 2, 3 or 4)
and where a balanced lift is obtained.
Model series:
E = enclosed lineshaft column design
Most units are supplied with four lifting points on the
pump sole plate [6140]. Attach D-links onto all four Casing nominal suction size in mm
lifting points. Use a spreader beam attached to an
overhead crane and fit 2 D-links. Ensure the sling is not Casing discharge size in mm
in contact with the pin of any of the D-links. Lift the Nominal ISO maximum impeller
pump up to the vertical, as shown in the above figures, diameter in mm
using the D-links on the sole plate as shown.
A = Extended flow hydraulics
To avoid distortion, the pump unit B = Standard hydraulics
should be lifted as shown.
Impeller design - after separator:
2.4 Storage RV = reverse vane or OP = open impeller

Store the pump in a clean, dry location 2E3X2-10R-RV

away from vibration. Leave piping connection covers in
ASME impeller drive
place to keep dirt and other foreign material out of pump
size (1, 2, 3 or 4)
casing. Turn pump at intervals to prevent brinelling of
the bearings and the seal faces, if fitted, from sticking. Model series:
E = enclosed lineshaft column design
The pump may be stored as above for up to six
months. Consult Flowserve for preservative actions Casing nominal suction size in inches
when a longer storage period is needed. Casing discharge size in inches

2.5 Recycling and end of product life Nominal maximum impeller diameter in inches
At the end of the service life of the product or its R = low shear impeller
parts, the relevant materials and parts should be
recycled or disposed of using an environmentally Impeller design - after separator:
acceptable method and local requirements. If the RV = reverse vane or OP = open impeller
product contains substances that are harmful to the (High Chrome Iron and Tungsten carbide wet ends
environment, these should be removed and disposed only available with OP impeller.)
of in accordance with current regulations. This also
includes the liquids and or gases that may be used in
the "seal system" or other utilities.

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3.3 Design of major parts 3.4 Performance and operating limits

This product has been selected to meet the
3.3.1 Pump casing specifications of the purchase order. See section 1.5.
The pump casing is designed for operation when
submerged in the sump liquid. The following data is included as additional information to
help with your installation. It is typical, and factors such
High chrome iron casing has a much as temperature, materials, and seal type may influence
reduced pressure rating of 12.6 bar (183 psi). this data. If required, a definitive statement for your
particular application can be obtained from Flowserve.
3.3.1.1 Agitation system
This option is on high chrome iron/tungsten carbide 3.4.1 Operating limits
coated casings. Maximum pump ambient temperature: +55 ºC (131 ºF)
where driver, flexible coupling and thrust bearing is also
3.3.2 Impeller rated for this ambient. (Check the nameplate.)
Generally an open impeller (OP impeller) is fitted.
On the low shear impeller this is recessed within the Maximum pump speed: refer to the nameplate
back of the casing and the impeller setting is to the
rear back-vanes. A reverse vane (RV impeller) is an 3.4.2 Energy efficiency operation of pumps
option. The pump supplied will have been selected from
Flowserve’s extensive product line to have optimum
3.3.3 Shaft efficiency for the application. If supplied with an electric
The shaft has a keyed drive coupling. It is supported motor then the motor will meet or exceed current
by rolling bearing(s) above the sole plate and journal legislation for motor efficiency. However it is the way
line bearing(s) below. Rigid inter-shaft couplings and the pump is operated which has the greatest impact on
or a key drive impeller are available options that can the amount and cost of energy used during the
assist pump maintenance. operating life of the pump. The following are key points
in achieving minimum operating cost for the equipment:
3.3.4 Bearing housing • Design the pipe system for minimum friction losses
The bearing housing enables adjustment of impeller • Ensure that the control system switches off the
face clearance on the open impeller via the bearing pump when not required
carrier jacking screws. • In a multi-pump system run the minimum number
of pumps
3.3.5 Pump bearings and lubrication • Try to avoid systems which by-pass excess flow
The pump is fitted with a thrust type ball bearing that • As far as possible avoid controlling pump flow by
may be configured differently dependent on use. throttle valves
• When commissioned, check that the pump
The pump thrust type ball bearing is grease lubricated.
operates at the duty specified to Flowserve
• If the pump head and flow exceed that required,
The plain line bearings require the column coolant fill.
trim the pump impeller diameter
3.3.6 Driver • Ensure that the pump is operating with sufficient
The pump is normally driven by a flange mounted electric NPSH available
motor. An air or hydraulic motor may be utilized. • Use variable speed drives for systems that
require variable flow. A VFD for an induction
The position of the terminal box can be changed by motor is a particularly effective way of achieving
rotating the complete motor. To do this, remove the speed variation and energy/cost reduction
fasteners from the motor flange, rotate the motor and • Notes for VFD usage:
re-fit the fasteners. o make sure that the motor is compatible with VFD
o Do not over-speed the pump without checking
3.3.7 Accessories the power capability with Flowserve
Accessories may be fitted when specified by the o On systems with high static head, speed
customer. reduction is limited. Avoid running the pump
at a speed which gives low or zero flow
o Do not run a low speed and flow rate that lets
solids settle out of suspension in the pipework

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o Do not use a VFD for a fixed flow requirement; Larger size motors are shipped unfitted. The motor will
it will introduce power losses need to be fitted after completion of the pump
• Select high efficiency motors foundation installation. Turn shaft clockwise by hand to
• If replacing a standard motor with a high ensure it is free to turn.
efficiency motor it will run faster and the pump
could take more power. Reduce the impeller 4.3.2 Packing pieces
diameter to achieve energy reduction Where the sole plate and its counter-face do not each
• If the pump system pipework or equipment is have a machined face, packing pieces (metallic shims)
changed or process duty is changed, check that will need to be placed evenly adjacent to the foundation
the pump is still correctly sized (holding down) bolts to avoid “soft-foot” distortion. Turn
• Periodically check that the pipe system has not shaft clockwise by hand to ensure it is free to turn. Soft-
become corroded or blocked foot distortion may significantly increase vibration and
• Periodically check that the pump is operating at damage equipment by causing distortion and should
the flow, head and power expected and that the normally be inspected. If high vibration occurs when
efficiency has not reduced with erosion or pump is run (see section 5, Commissioning, start-up,
corrosion damage operation and shutdown) place a vibration meter at the
side of the motor as soft-foot is most effectively reduced
4 INSTALLATION when the vibration is reduced to a minimum.

Equipment operated in hazardous locations Overall vibration measurement can be used - it is not
must comply with the relevant explosion protection necessary to use a vibration spectrum to pick up soft-
regulations. See section 1.6.4, Products used in foot which occurs at 1x running speed and should be
potentially explosive atmospheres. the first issue to check.
4.1 Location To adjust for soft-foot use a dial gauge on the sole
The pump should be located to allow room for access, plate top face near to the holding down bolt, zero it,
ventilation, maintenance and inspection with ample record the soft-foot spring in the sole plate and undo
headroom for lifting and should be as close as one holding down bolt at a time.
practicable to the supply of liquid to be pumped. (Refer
to the general arrangement drawing for the pump set.) Soft-foot is removed by inserting packing pieces
(metallic shims) equal to or slightly less than the soft-
4.2 Part assemblies foot spring amount recorded at the individual holding
On pump sets the coupling elements are supplied down point locations. Re-torque the holding down bolt.
loose. It is the responsibility of the installer to ensure Continue this procedure for each holding down bolt
that the pump set is finally lined up and checked as position in turn, one at a time. The thickness of
detailed in section 4.5.5, Final checks. packing pieces (metallic shims) adjacent to an
individual holding down bolt should not exceed 3 mm
4.3 Foundation (0.12 in.); i.e. soft-foot spring is not to exceed 3 mm
(0.12 in.) at any individual location.
There are many methods of installing
pump units to their foundations. The correct method 4.4 Grouting
depends on the size of the pump unit, its location and Where applicable, grout in the foundation bolts.
noise and vibration limitations. Non-compliance with the
provision of correct foundation and installation may lead Grouting provides solid contact between the pump unit
to failure of the pump and, as such, would be outside and foundation, prevents lateral movement of vibrating
the terms of the warranty. The pump mounting should equipment and dampens resonant vibrations.
have concrete or metal to support it around its edges.
4.5 Piping
4.3.1 Levelling
The sole plate must be level so that the pump column Protective covers are fitted to the pipe
hangs vertically; confirmed by inspection. With the connections to prevent foreign bodies entering during
motor removed check the top face of the machined transportation and installation. Ensure that these covers
motor pedestal [3160] is set level to 0.05 mm (0.002 in.) are removed from the pump before connecting any
or 0.2 mm/m (0.0025 in./ft) maximum. The optional pipes.
base plate should be levelled and grouted first.

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4.5.2 Discharge piping

If sludge and debris can build up in the sump it A non-return valve should be located in the discharge
is recommended to use a strainer with a maximum pipework to protect the pump from excessive back
opening size of 6 mm (0.024 in.) and a free surface pressure and hence reverse rotation when the unit is
area greater than three times the pump suction area. stopped.

Maximum forces and moments allowed on the pump Fitting an isolation valve will allow easier maintenance.
flanges vary with the pump size and type. To minimize
these forces and moments that may, if excessive, cause 4.5.3 Maximum forces and moments allowed on
misalignment, hot bearings, worn couplings, vibration the main sole plate discharge flange
and the possible failure of the pump casing, the The table below uses the sign convention shown for the
following points should be strictly followed: pump sole plate discharge flange maximum forces and
• Prevent excessive external pipe load moments. These are valid for a pump end up to 100 ºC
• Never draw piping into place by applying force to (212 ºF) and the sole plate on a rigid foundation.
pump flange connections
• Do not mount expansion joints so that their force,
due to internal pressure, acts on the pump flange

4.5.1 Discharge pipework

In order to minimize friction losses and hydraulic
noise in the pipework it is good practice to choose
pipework that is one or two sizes larger than the
pump discharge. Typically main pipework velocities
should not exceed 3 m/s (9 ft/sec) on the discharge.

Never use the pump as a support for

piping.

Ensure piping and fittings are flushed

before use.

Ensure piping for hazardous liquids is arranged

to allow pump flushing before removal of the pump.

Discharge Maximum forces (F) in kN (lbf) and moments (M) in Nm (lbf•ft)

flange size
mm (in.) Fx Fy Fz Fr Mx My Mz Mr
40 (1.5) 0.71 (160) 0.58 (130) 0.89 (200) 1.28 (290) 0.46 (340) 0.23 (170) 0.35 (260) 0.62 (460)
50 (2.0) 0.71 (160) 0.58 (130) 0.89 (200) 1.28 (290) 0.46 (340) 0.23 (170) 0.35 (260) 0.62 (460)
80 (3.0) 1.07 (240) 0.89 (200) 1.33 (300) 1.93 (430) 0.95 (700) 0.47 (350) 0.72 (530) 1.28 (950)
100 (4.0) 1.42 (320) 1.16 (260) 1.78 (400) 2.56 (570) 1.33 (980) 0.68 (500) 1.00 (740) 1.80 (1 330)
125 (5.0) 1.95 (440) 1.58 (355) 2.45 (550) 3.50 (790) 1.93 (1 420) 0.98 (720) 1.36 (1 000) 2.56 (1 880)
150 (6.0) 2.49 (560) 2.05 (460) 3.11 (700) 4.48 (1 010) 2.30 (1 700) 1.18 (870) 1.76 (1 300) 3.13 (2 310)

4.5.4 Auxiliary piping

Special seals may require modification to auxiliary
4.5.4.1 Pumps fitted with mechanical seals piping described above. Seal on pumps in potentially
Double seals require a barrier liquid between the explosive atmospheres shall comply with section
seals, compatible with the pumped liquid. 1.6.4.3. Consult Flowserve if unsure of correct method
or arrangement.
Back-to-back double seals require that the barrier liquid
should be at a minimum pressure of 1 bar (15 psi) 4.5.5 Final checks
above the maximum pressure on the pump side of the Check the tightness of all bolts in the suction and
inner seal. The barrier liquid pressure must not exceed discharge pipework. Check also the tightness of all
limitations of the seal on the coolant . For toxic service foundation bolts.
the barrier liquid supply and discharge must be handled
safely and in line with local legislation.

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After connecting piping to the pump, rotate the shaft 4.6 Electrical connections
several times by hand to ensure there is no binding
and all parts are free. Electrical connections must be made by
a qualified Electrician in accordance with relevant
Recheck the flexible element coupling is aligned with local national and international regulations.
the permitted limits.
It is important to be aware of the EUROPEAN
Where there is the option of an additional DIRECTIVE on potentially explosive areas where
rigid coupling below the thrust bearing, above the compliance with IEC60079-14 is an additional
mechanical seal: this has full metal-to-metal joints requirement for making electrical connections.
which do not permit its adjustment.
It is important to be aware of the EUROPEAN
For couplings with narrow flanges use a dial indicator DIRECTIVE on electromagnetic compatibility when
as shown. The alignment values are maximums for wiring up and installing equipment on site. Attention
continuous service. must be paid to ensure that the techniques used during
wiring/installation do not increase electromagnetic
Parallel emissions or decrease the electromagnetic immunity of
the equipment, wiring or any connected devices. If in
any doubt, contact Flowserve for advice.

The motor must be wired up in

accordance with the motor manufacturer's instructions
Angular (normally supplied within the terminal box). Any
temperature, earth leakage, current or other appropriate
protective devices must be correctly installed and
Permissible misalignment limits at working temperature: monitored. The identification nameplate should be
• Parallel alignment checked to ensure the power supply is appropriate.
- 0.25 mm (0.010 in.) TIR maximum
• Angular alignment A device to provide emergency stopping must
- 0.3 mm (0.012 in.) TIR maximum for couplings be fitted. If not supplied pre-wired to the pump unit,
not exceeding 100 mm (4 in.) flange diameter the controller/starter electrical details will also be
- 0.5 mm (0.020 in.) TIR maximum for couplings supplied within the controller/starter. For electrical
over 100 mm (4 in.) diameter details on pump sets with controllers see the
• Use the lower of the above values and values separate wiring diagram.
indicated in the coupling manual
See section 5.4, Direction of rotation,
When checking parallel alignment, the total indicator before connecting the motor to the electrical supply.
read-out (TIR) shown is twice the value of the actual
shaft displacement. 4.7 Protection systems
If alignment needs to be adjusted, a small amount of The following protection systems are
adjustment of the motor is available within the motor recommended but are mandatory if the pump is
spigot but alignment is generally achieved installed in a potentially explosive area or is handling
automatically on assembly. Larger motors always a hazardous liquid. If in any doubt consult Flowserve.
require re-adjustment.
If there is any possibility of the system allowing the
If it is not possible to achieve the alignment accuracy pump to run against a closed valve or below
defined, it may be an indication that the pump has not minimum continuous safe flow a protection device
been installed or handled correctly. must be installed to ensure the temperature of the
liquid does not rise to an unsafe level.

If leakage of product from the pump or its associated

sealing system can cause a hazard it is recommended
that an appropriate leakage detection system is installed.

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To prevent thrust bearing damage becoming a safety 5.1 Pre-commissioning procedure

hazard it is recommended that monitoring of vibration Prior to starting the pump it is essential that the
is carried out. following checks be made.
• Motor properly secured to the motor stool
Where there is the potential hazard of a loss of a seal • All fasteners tight and to the correct torque
barrier fluid the barrier fluid sustem must be monitored. • Coupling guard is in place
• Rotation check, see section 5.4.
Where there is a risk that the external flush to a seal or
• Impeller clearance setting
bearing could fail, for example by freezing, blocking by
• Shaft seal properly installed
debris or loss of supply pressure, then the flow must be
monitored. • Column coolant
• Bearing lubrication
Where there is product flush via filters then flow must • Pump instrumentation is operational
be monitored. • Rotation of shaft is free when pump mechanically
and electrically isolated
Visual indicators are suitable when equipment is
regularly inspected, but sensors connected to the pump 5.1.1 Rolling element bearing lubrication
control system must be used if the pump runs remotely. Determine the mode of lubrication of the pump set, e.g.
pumps with grease lubricated antifriction bearings are
For Category 2 equipment the monitoring must create normally supplied fitted with grease nipples and with
an alarm to the plant operator or shut down the pump. pre-greased bearings.

The monitoring equipment must be suitable for the Grease lubricated electric motor bearings are generally
hazardous area. pre-greased. Refer to the motor User Instructions for
information on the motor lubrication schedule.
See also sections 5.8.2 to 5.8.7.
Where the ambient is very low special lubricants are
The protection sensors will generally be fitted by required. If in doubt consult Flowserve for
Flowserve, but the connection to the pump control recommendations of oil and grease types at these
system will often be by the installer of the pump. lower temperatures. Where low ambient grease for
Installers must ensure that the instructions of the less than -20 to +100 ºC (-4 to +212 ºF) has been
sensor manufacturer are followed, that any additional specially fitted this is Shell Aeroshell 22.
components are suitable for the zone in which they
are to be installed, and that their trip levels are set 5.2 Pump lubricants and coolants
and checked during commissioning. The protective
systems must also be periodically checked in 5.2.1 Column coolant
accordance with the sensor manufacturer’s
instructions or with local site standards. To facilitate the transport and handling of the
pump, it is delivered without coolant in the enclosing
When clean process liquids are used to flush columns. It is essential that before start-up that it is
bearings the user must periodically check that there filled with the recommended coolant to avoid running
is no contamination entering the sump. dry.

5 COMMISSIONING, START-UP, The filler with dip stick is on the soleplate near the
OPERATION AND SHUTDOWN motor support as shown below, ensure to fill the
minimum/maximum check level and to top up as
These operations must be carried necessary.
out by fully qualified personnel.
Do not exceed the maximum level.
Contact the factory for recommendations for
operation with pumpage of any fluid other than what the
pump was specfiically designed for.

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Drawing taken from B736/625

Use water with anti-freeze, mixing a proportion to be 5.2.3 Recommended rolling element bearing
2:1 minimum which protects for temperatures down to grease lubricants
approximately -15 ºC (5 ºF). The following table has Grease NLGI 2 * NLGI 3
recommended commercial qualities having corrosion -20 to +100 ºC -20 to +100 ºC
Temp. range
inhibitors and a defoaming agent (commercially (-4 to +212 ºF) (-4 to +212 ºF)
readily available - the same as used in most car Designation
KP2K-25 KP3K-20
radiators). Higher corrosion protection is obtained acc. to DIN
BP Energrease LS-EP2 Energrease LS-EP3
with a proportion mix of 1:1.
Elf Multis EP2 Multis EP3
Anti-freeze grade Type base
Fuchs RENOLIT EP2 RENOLIT EP3
Dow coolant D824 13F Ethylene glycol
Esso Beacon EP2 Beacon EP3
BP anti-frost Ethylene glycol
Dow frost 1.2.3 Propylene glycol Mobil Mobilux EP2 Mobilux EP3 **
BP anti-frost Propylene glycol Q8 Rembrandt EP2 Rembrandt EP3
These are claimed by their manufacturers to be Shell Alvania EP2 Alvania EP2
biologically decomposable. Texaco Multifak EP2 Multifak EP3
SKF LGEP 2
5.2.2 Rolling element bearing sizes and grease/ * NLGI 2 is an alternative grease and is not to be mixed with other
oil capacities grades.
Shaft size 1 2 ** Standard pre-packed grease for fitted antifriction bearings.
Medium duty thrust bearing duplex
3306C3 3309C3
back-to-back AC 5.2.3.1 Food grade grease (when applicable)
Heavy duty thrust bearing duplex back- 7306 7309
to-back AC pair pair
NSF H1 Klubersynth UH1 64-62 is the food grade
grease option and it is NLGI grade 2.
Grease quantities – g (oz) 14 (0.5) 25 (0.9)
Note: The bearing sizes do not constitute a purchasing specification. 5.2.4 Recommended fill quantities
Refer to section 5.2.2, Rolling element bearing sizes
and grease capacities.

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5.5 Guarding
5.2.5 Lubrication schedule
Guarding is supplied fitted to the pump set.
5.2.5.1 Grease lubricated rolling element
bearings In member countries of the EU and EFTA, it is a legal
When grease nipples are fitted, one charge between requirement that fasteners for guards must remain
grease changes is advisable for most operating captive in the guard to comply with the Machinery
conditions; i.e. 2 000 hours interval. Normal intervals Directive 2006/42/EC.
between grease changes are 4 000 hours or at least
every 6 months. For food grade grease the grease When releasing such guards, the fasteners must be
change and re-lubrication intervals are half that of the unscrewed in an appropriate way to ensure that the
conventional greases. fasteners remain captive.

The characteristics of the installation and severity of Whenever guarding is removed or disturbed ensure
service will determine the frequency of lubrication. that all the protective guards are securely refitted
Lubricant and bearing temperature analysis can be prior to start-up.
useful in optimizing lubricant change intervals.
5.6 Priming and auxiliary supplies
The bearing temperature may be allowed to rise to
55 ºC (99 ºF) above ambient, but should not exceed 5.6.1 Filling and priming
95 ºC (204 ºF). For most operating conditions, a
quality grease having a lithium soap base and NLGI The pump end needs to be
consistency of No 2 or No 3 is recommended. The completely submerged in the product.
drop point should exceed 175 ºC (350 ºF).
5.6.2 Auxiliary supplies
T5 and T6 temperature classes have more
restrictive temperature control limits, see 5.8.3. Ensure all electrical, hydraulic,
pneumatic, sealant and lubrication systems (as
Never mix greases containing different
applicable) are connected and operational.
bases, thickeners or additives.

5.3 Open impeller clearance 5.7 Starting the pump

The impeller clearance is set in the factory. This may
a) Ensure flushing and/or
require adjustment because of increase in liquid
cooling/heating liquid supplies are turned ON,
temperature. If piping attachment cause the impeller
before starting pump.
clearance to change, correct piping. For setting
b) CLOSE the outlet valve partially, but ensure that
instructions see section 6.7, Setting impeller clearance.
air is allowed to escape out of the discharge pipe.
This is especially important for pumps with
5.4 Direction of rotation product lubricated line bearings.
Serious damage can result if the c) Ensure that the liquid level in
pump is started or run in the wrong direction of rotation. the sump is above the minimum pump casing
submergence level.
The pump is shipped with the coupling element
removed. Ensure the direction of rotation of the motor is d) Ensure all vent valves are
correct before fitting the coupling element. Direction of closed before starting.
rotation must correspond to the direction arrow. e) Start motor and check the outlet pressure.
f) If the pressure is satisfactory, SLOWLY open the
If maintenance work has been outlet valve.
carried out to the site's electricity supply, the direction
of rotation should be re-checked as above in case the g) Do not run the pump with the
supply phasing has been altered. outlet valve completely closed.
h) If NO pressure, or LOW pressure, STOP the pump.
Refer to section 7, Faults; causes and remedies for
fault diagnosis.

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5.8 Running the pump

Regular monitoring of the pump
5.8.1 Pump end mechanical seals vibration is recommended to show any deterioration in
Mechanical seals require no adjustment. Any slight pump or system operating conditions. The vibration is
initial leakage will stop when the seal is run in. measured adjacent to the pump thrust bearing.

Alarm and trip values for installed pumps

Before pumping dirty liquids it is advisable, if
should be based on the actual measurements (N) taken
possible, to run the pump in using clean liquid to
on the pump in the fully commissioned as new condition.
safeguard the seal face.

External flush shall be started before the For remote installations continuous monitoring and
pump is run and allowed to flow for a period after the automatic alert and shutdown is recommended.
pump has stopped. Vibration velocity – unfiltered mm/s (in./sec) r.m.s.
Normal N ≤ 7.1 (0.28)
5.8.2 Thrust bearings Alarm N x 1.25 ≤ 9.0 (0.35)
Shutdown trip N x 2.0 ≤ 14.2 (0.56)
If the pumps are working in a potentially explosive
atmosphere without regular monitoring, temperature
Where pumps operate in a hazardous area
monitoring of the thrust bearing is recommended. For
refer to section 1.6.4.3 and 4.7 for the requirements
temperature classes T5 and T6 thrust bearing
for monitoring and protective systems.
monitoring must be fitted.
5.8.4 Stop/start frequency
If the thrust bearing temperatures are to be monitored it
Pump sets are normally suitable for the number of
is essential that a benchmark temperature is recorded
equally spaced stop/starts per hour shown in the
at the commissioning stage and after the bearing
table below. Check capability of the driver and
temperature has stabilized.
control/starting system before commissioning.
• Record the bearing temperature (t) and the
ambient temperature (ta) Maximum stop/starts
Motor rating kW (hp)
• Estimate the likely maximum ambient per hour
temperature (tb) Up to 15 (20) 15
• Set the alarm at (t+tb-ta+5) ºC (t+tb-ta+10 ºF) Between 15 (20) and 90 (120) 10
and the trip at 100 ºC (212 ºF) for oil lubrication Above 90 (120) 6
and 105 ºC (220 ºF) for grease lubrication. Where duty and standby pumps are installed it is
Ensure that the ATEX temperature class limit is recommended that they are run alternately every week.
not exceeded if the pump is operating in a
hazardous area. The normal bearing
5.9 Stopping and shutdown
temperature Tn is = t+tb-ta where Tn<Tc. In the
case of T5 and T6, the critical bearing a) Close the outlet valve, but ensure
temperature Tc = 65 oC (T6) or 80 oC (T5) that the pump runs in this condition for no more
than a few seconds.
It is important, particularly with grease lubrication, to b) Stop the pump.
keep a check on bearing temperatures. After start-up c) Switch off flushing and/or cooling/heating liquid
the temperature rise should be gradual, reaching a supplies/electrics at a time appropriate to the
maximum after approximately 1.5 to 2 hours. This process.
temperature rise should then remain constant or
marginally reduce with time. (Refer to section 0 for d) For prolonged shut-downs and
further information.) especially when ambient temperatures are likely to
drop below freezing point, the pump and any
5.8.3 Normal vibration levels, alarm and trip cooling and flushing arrangements must be drained
For guidance, pumps generally fall under a or otherwise protected.
classification for rigid support machines within the
International rotating machinery standards and the
recommended maximum levels below are based on
those standards.

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5.10 Hydraulic, mechanical and electrical If any change in NPSHA is proposed, ensure these
duty margins are not significantly eroded. Refer to the
This product has been supplied to meet the pump performance curve to determine exact
performance specifications of your purchase order, requirements particularly if flow has changed.
however it is understood that during the life of the
product these may change. The following notes may If in doubt please consult your nearest Flowserve
help the user decide how to evaluate the implications office for advice and details of the minimum allowable
of any change. If in doubt contact your nearest margin for your application.
Flowserve office.
5.10.5 Pumped flow
5.10.1 Specific gravity (SG) Flow must not fall outside the minimum and maximum
Pump capacity and total head in metres (feet) do not continuous safe flow shown on the pump performance
change with SG, however pressure displayed on a curve and or data sheet.
pressure gauge is directly proportional to SG.
6 MAINTENANCE
Power absorbed is also directly proportional to SG. It
is therefore important to check that any change in SG 6.1 General
will not overload the pump driver or over-pressurize
the pump. It is the plant operator's responsibility to ensure
that all maintenance, inspection and assembly work is
5.10.2 Viscosity carried out by authorized and qualified personnel who
For a given flow rate the total head reduces with have adequately familiarized themselves with the
increased viscosity and increases with reduced subject matter by studying this manual in detail. (See
viscosity. Also for a given flow rate the power also section 1.6.)
absorbed increases with increased viscosity, and
reduces with reduced viscosity. It is important that Any work on the machine must be performed when it
checks are made with your nearest Flowserve office if is at a standstill. It is imperative that the procedure
changes in viscosity are planned. for shutting down the machine is followed, as
described in section 5.9.
5.10.3 Pump speed
Changing pump speed effects flow, total head, power Guard fasteners must remain captive during
absorbed, NPSHR, noise and vibration. Flow varies dismantling of guards, as described in section 5.5.
in direct proportion to pump speed, head varies as On completion of work, all guards and safety devices
speed ratio squared and power varies as speed ratio must be re-installed and made operative again.
cubed. The new duty, however, will also be
dependent on the system curve. If increasing the Before restarting the machine, the relevant instructions
speed, it is important therefore to ensure the listed in section 5, Commissioning, start-up, operation
maximum pump working pressure and critical shaft and shut down, must be observed.
speed are not exceeded, the driver is not overloaded,
NPSHA > NPSHR, and that noise and vibration are Oil and grease leaks may make the ground
within local requirements and regulations. slippery. Machine maintenance must always
begin and finish by cleaning the ground and the
5.10.4 Net positive suction head (NPSHA) exterior of the machine.
NPSH available (NPSHA) is a measure of the head
available in the pumped liquid, above its vapor If platforms, stairs and guard rails are required for
pressure, at the pump suction branch. maintenance, they must be placed for easy access to
areas where maintenance and inspection are to be
NPSH required (NPSHR) is a measure of the head carried out. The positioning of these accessories
required in the pumped liquid, above its vapor pressure, must not limit access or hinder the lifting of the part to
to prevent the pump from cavitating. be serviced.

It is important that NPSHA > NPSHR. The margin When air or compressed inert gas is used in the
between NPSHA > NPSHR should be as large as maintenance process, the operator and anyone in the
possible. vicinity must be careful and have the appropriate
protection.

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Do not spray air or compressed inert gas on skin. 6.2.1 Routine inspection (daily/weekly)

Do not direct an air or gas jet towards other people. The following checks should be made
and appropriate action taken to remedy any deviations:
Never use air or compressed inert gas to clean clothes. a) Check operating behaviour. Ensure noise,
vibration and bearing temperatures are normal.
Before working on the pump, take measures to b) Check that there are no abnormal fluid or
prevent an uncontrolled start. Put a warning board lubricant leaks (static and dynamic seals) and
on the starting device with the words: that any sealant systems (if fitted) are full and
"Machine under repair: do not start". operating normally.
c) Check that shaft seal leaks are within acceptable
With electric drive equipment, lock the main switch limits.
open and withdraw any fuses. Put a warning board d) Check the level and condition of line bearing
on the fuse box or main switch with the words: coolant. (On grease lubricated pumps, check
"Machine under repair: do not connect". running hours since last recharge of grease or
complete grease change.)
Never clean equipment with inflammable solvents or e) Check any auxiliary supplies e.g. heating/cooling/
carbon tetrachloride. Protect yourself against toxic lubrication (if fitted) are functioning correctly.
fumes when using cleaning agents.
f) Refer to the manuals of any associated
6.2 Maintenance schedule equipment for routine checks needed.

It is recommended that a maintenance plan 6.2.2 Periodic inspection (six monthly)

and schedule is adopted, in line with these User
a) Check foundation bolts for
Instructions, to include the following:
security of attachment and corrosion.
a) Any auxiliary systems installed must be monitored,
b) Check pump running records for hourly usage to
if necessary, to ensure they function correctly.
determine if bearing lubricant requires changing.
b) Check for any leaks from gaskets and seals.
c) The coupling should be checked for correct
The correct functioning of the shaft seal must be
alignment and worn driving elements.
checked regularly.
c) Check bearing lubricant coolant.
d) Check that the duty condition is in the safe d) Refer to the manuals of any associated
operating range for the pump. equipment for periodic checks needed.
e) Check vibration, noise level and surface
6.2.3 Re-lubrication
temperature at the bearings to confirm
satisfactory operation. For general guidelines refer to section 0, Lubrication
f) Check dirt and dust is removed from areas around schedule.
close clearances, bearing housings and motors.
g) Check flexible coupling alignment and re-align if Lubricant and bearing temperature analysis can be
necessary. useful in optimizing lubricant change intervals.

6.2.4 Mechanical seals

Our specialist service personnel can help with
preventative maintenance records and provide When leakage becomes unacceptable the seal will
condition monitoring for temperature and vibration to need replacement.
identify the onset of potential problems.
6.3 Spare parts
If any problems are found the following sequence of
actions should take place: 6.3.1 Ordering of spares
a) Refer to section 7, Faults; causes and remedies, Flowserve keeps records of all pumps that have been
for fault diagnosis. supplied. When ordering spares the following
b) Ensure equipment complies with the information should be quoted.
recommendations in this manual. 1) Pump serial number.
c) Contact Flowserve if the problem persists. 2) Pump size.
3) Part name – taken from section 8.
4) Part number – taken from section 8.
5) Number of parts required.

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The pump size and serial number are shown on the • Range of screwdrivers
pump nameplate. • Soft mallet

To ensure continued satisfactory operation, More specialized equipment:

replacement parts to the original design specification • Bearing pullers
should be obtained from Flowserve. Any change to • Bearing induction heater
the original design specification (modification or use • Dial test indicator
of a non-standard part) will invalidate the pump safety • C-spanner (wrench) - for removing shaft nut.
certification. (If difficulties in sourcing are encountered, consult
Flowserve.)
6.3.2 Storage of spares
Spares should be stored in a clean dry area away 6.6 Casing, seal housing and fastener
from vibration. Inspection and re-treatment of
torques
metallic surfaces (if necessary) with preservative is
Fastener Screw size Torque Nm (lb•ft)
recommended at 6 monthly intervals.
M8 16 (12)
M10 25 (18)
All except where
6.4 Recommended spares otherwise stated
M12 35 (26)
(For two years operation - as per VDMA 24296) M16 80 (59)
M20 130 (96)
Number of pumps
Part M12 16 (12)
Designation (including stand-by)
no. M16 41 (31)
2 3 4 5 6/7 8/9 10(+) Impeller nut
M22 106 (79)
2100 Shaft 1 2 3 30%
M24 135 (100)
2200 Impeller 1 2 3 30%
Shaft sleeve - pump
2400.1 2 3 4 50%
end Non-metallic gaskets incur creep
3013 Bearing - thrust 1 2 3 4 50% relaxation - before commissioning the pump check
3300.1 Bearing - pump end 1 2 3 4 50% and retighten fasteners to tightening torques stated.
3300.2 Bearing - lineshaft * 1 2 3 4 50%
Shaft sleeve - For the tightening sequence also refer to good
3400.1 2 3 4 50%
intermediate *
3712 Bearing nut 1 2 3 4 50%
industry practice. See section 10.3, Reference 6, for
4200 Mechanical seals * 1 2 3 30% more detail.
Sleeve - mechanical
2400.2 2 3 4 50%
seal * 6.7 Setting impeller clearance
Shaft sleeve screw
6570.9
for 3400.1 *
2 3 4 50% This procedure may be required after the pump has
4590.1** Pump casing gasket 4 6 8 9 been dismantled or a different clearance is required.
Discharge flange
4590.2 4 6 8 9 10 100%
gasket For the OP front open impeller clearance setting this is
4610.1 O-ring impeller 4 6 8 9 as shown in the table.
4610.2 O-ring carrier 2 3 4 50% 12 150%
O-ring mechanical
4610.3 2 3 4 50% 12 150%
seal sleeve *
* When required due to fitting as part of the original build specification.

Additional spares for keyed A-OP impeller option

2912.1/
Impeller nut 1 2 3 30%
2912.2
4610.5 O-ring impeller 4 6 8 9 12 150%
6700.2 Impeller key 1 2 3 30%

6.5 Tools required ISO impeller front clearance mm (in.)

A typical range of tools that will be required to Temperature
maintain these pumps is listed below: ºC (ºF) Impellers up Impellers 211 mm Impellers
to 210 mm to 260 mm over 260 mm*
Readily available in standard tool kits, and dependent 50 (122) 0.3 (0.012) 0.4 (0.016) 0.5 (0.020)
on pump size: 100 (212) 0.4 (0.016) 0.5 (0.020) 0.6 (0.024)
• Open ended spanners (wrenches) to suit up to ASME impeller clearance
All impeller diameters
M 48 screws/nuts 50 (120) 0.45 mm (0.018 in.)
• Socket spanners (wrenches), up to M 48 screws 100 (210) 0.55 mm (0.022 in.)
• Allen keys, up to 10 mm (A/F)

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For the R low shear impeller, the back rear impeller f) Compare the original and final gaps between the
clearance is the setting. Set the back as shown in the bearing carrier and sole plate to check if the
following illustration: movement of the shaft has exceeded the
mechanical seal capability (over/under compression
of the seal). Re-position the seal to correct this.
g) Check that the shaft can turn freely without binding.
h) Ensure the coupling distance between shaft ends
(DBSE) is correct. Reset/re-align if necessary.

6.7.2 For R low shear (recessed impeller) only

a) The impeller has a rear clearance setting.
b) Loosen the bearing carrier nuts [6580.5] and
a) Before carrying out this procedure ensure that screws [6570.7].
any mechanical seal(s) fitted can tolerate a c) Tighten the bearing carrier screws [6570.6] evenly,
change in their axial setting, otherwise it will be pushing the bearing carrier away from the sole plate,
necessary to dismantle the unit and reset the until the impeller contacts the cover [1220]. Turn the
seal axial position after adjusting the impeller shaft [2100], during this procedure, until a detectable
clearance. rub is obtained. This is the zero clearance position.

b) Some mechanical seal types may be The shaft must be turned in the direction
impaired if moved more than 0.5 mm (0.02 in.) indicated on the casing and sole plate.
from their nominal setting. d) Set a dial indicator to zero on the shaft end or
c) Disconnect the coupling if it has limited axial measure the bearing carrier [3240] to motor
flexibility. pedestal [3160] gap and record the measurement.
d) Record the gap between the bearing carrier e) Ensure carrier screws [6570.7] are still slack and
[3240] and motor pedestal [3160] using feeler slacken the bearing carrier [6570.6] screws evenly
gauges. (about one flat at a time) until the dial indicator or
feeler gauge shows the correct ASME recessed
6.7.1 For OP impellers only impeller rear clearance from the zero clearance
a) Loosen the bearing carrier screws [6570.7] and position.
back off the bearing carrier using screws [6570.6]. f) Evenly tighten the bearing carrier screws [6570.7]
b) Ensure the carrier jacking screws [6570.7] are keeping the dial indicator or feeler gauges reading
slackened off evenly so as to draw the bearing carrier the correct setting. Then tighten the hexagon nuts
towards the sole plate, until the impeller just contacts [6580.5] to lock the jacking screws [6570.6] in
the pump casing. Turn the shaft [2100], during this position.
procedure, until a detectable rub is obtained. This is g) Re-position the seal to correct this.
the zero clearance position. h) Check that the shaft can turn freely without binding.
i) Ensure the coupling distance between shaft ends
The shaft must be turned in the direction (DBSE) is correct. Reset/re-align if necessary.
indicated on the casing and sole plate.
c) Set a dial indicator to zero on the shaft end or 6.7.3 For RV reverse vane only
measure the bearing carrier [3240] to motor For the reverse vane (RV) impeller the rear clearance
pedestal [3160] gap and record the measurement. setting is as shown in the table below.
d) Ensure carrier screws [6570.7] are still slack and Reverse vane
tighten the bearing carrier jacking screws [6570.6] impeller rear
evenly (about one flat at a time) until the dial clearance
indicator or feeler gauge shows the correct impeller
clearance from the zero clearance position. This
clearance should be between 0.3 and 0.6mm
(0.012 and 0.024 in.) depending on the OP impeller
in the table above.
e) Evenly tighten the bearing carrier screws [6570.7]
keeping the dial indicator or feeler gauges reading
the correct setting. Then tighten the hexagon nuts
[6580.5] to lock the jacking screws [6570.6] in
position.

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Temperature ASME RV impeller clearance setting Bearing sleeve Sleeve diameter/tolerance Bearing clearance
ºC (ºF) All impeller diameters size min diam - max diam (max/min)
mm (in.) mm (in.) mm (in.)
50 (120) 0.45 mm (0.018 in.)
45 44.98 45.00 0.35/0.19
100 (210) 0.55 mm (0.022 in.)
(1.770) (1.7709) (1.7717) (0.0138/0.0075)
65 64.98 65.00 0.39/0.23
a) Loosen the bearing carrier screws [6570.7] and
(2.559) (2.5583) (2.5591) (0.0154/0.0091)
tighten the bearing carrier using jacking screws
[6570.6]. 6.9 Disassembly
b) Ensure the carrier jacking screws [6570.6] are
tightened evenly so as to draw the bearing carrier Refer to Safety, section 1.6, before dismantling
away from the sole plate, until the impeller just the pump.
contacts the cover [1220]. Turn the shaft [2100]
during this procedure until a detectable rub is Before dismantling the pump for
obtained. This is the zero clearance position. The overhaul, ensure genuine Flowserve replacement
shaft must be turned in the direction indicated on parts are available. Refer to sectional drawings for part
the casing and sole plate. numbers and identification. (See section 8, Parts lists
c) Set a dial indicator to zero on the shaft end or and drawings.)
measure the bearing carrier [3240] to motor
pedestal [3160] gap and record the When taking out the pump be sure to
measurement. drain off coolant from the drain plug [6569.1/6569.2]
d) Ensure carrier screws [6570.7] are still slack and while the pump is still vertical to ensure none enters
slacken off the bearing carrier jacking screws and contaminates the thrust bearing housing.
[6570.6] evenly (about one flat at a time) until the
dial indicator or feeler gauge shows the correct 6.9.1 Pump disassembly
impeller rear clearance from the zero clearance a) Disconnect all auxiliary pipes and tubes where
position. This clearance should be between 0.45 applicable.
and 0.55 mm (0.018 and 0.022 in.) depending on b) Disconnect all discharge and auxiliary pipework.
the temperature of the pumped fluid, as in the c) Remove coupling guard [7450], disconnect
table above. coupling [7000] and remove motor [8100].
e) Evenly tighten the bearing carrier screws [6570.7] d) If oil lubricated unit, drain oil.
keeping the dial indicator or feeler gauges e) Remove nuts securing sole plate to foundations
reading the correct setting. Then tighten the and lift the complete unit clear.
hexagon nuts [6580.5] to lock the jacking screws f) Record the gap between bearing carrier [3240]
[6570.6] in position. and sole plate [6140] so that this setting can be
f) Compare the original and final gaps between the used during workshop assembly.
bearing carrier and sole plate to check if the g) Remove suction pipe and/or strainer [6531] if fitted.
movement of the shaft has exceeded the h) Remove all flushing lines as appropriate, casing
mechanical seal capability (over/under compression screws and discharge flange bolts.
of the seal). Re-position the seal to correct this. i) Remove pump casing [1100].
g) Check that the shaft can turn freely without binding. j) Remove pump casing [4590.1] and discharge
h) Ensure the coupling distance between shaft ends flange [4590.2] gaskets and discard. (Replacement
(DBSE) is correct. Reset/re-align if necessary. gaskets will be required for assembly.)
k) Clean the gasket mating surfaces.
6.8 Renewal clearances
As wear takes place between the impeller and casing 6.9.2 Impeller removal
ring the overall efficiency of the pump set will
NEVER APPLY HEAT TO REMOVE THE
decrease. To maintain optimum efficiency it is
IMPELLER. TRAPPED WORKING LIQUID OR
recommended that the clearances shown in section
LUBRICANT MAY CAUSE AN EXPLOSION.
6.7, Setting impeller clearance, are maintained.
6.9.2.1 Impeller removal with threaded on impeller
On product lubricated bearings it is recommended
a) Fit a chain wrench or bolt a bar to the holes in the
that these are renewed at the diametrical clearance in
coupling half, or fit a keyed shaft wrench directly
the as fitted condition stated in the following table:
to the shaft.

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b) Wearing metal mesh reinforced gloves, rotate the c) Remove impeller key [6700.2].
shaft [2100s] by turning the impeller [2200] d) Remove impeller sealing gasket [4590.4] and
clockwise as viewed from the impeller end of the discard. (A new sealing gasket will be required
shaft, so that the wrench makes contact with one for assembly.)
of the supports of the motor pedestal [3160].
c) Give the impeller a quick turn counter-clockwise so 6.9.3 Mechanical seal, support columns, shafts
that the wrench handle strikes the other side of the and bearings
window edge of the motor pedestal [3160]. A few
sharp strikes will loosen one of the shaft threads. If a) Take extreme care with silicon carbide
at this point the impeller is still firmly threaded to the or carbon-graphite seal faces or bearings to avoid
pump end shaft [2100], then the thread of an inter- chipping or cracking these relatively brittle
shaft will have started to disengage. components.
d) If the impeller is loose then unscrew it and b) For the dual mechanical seal option, remove the
discard the impeller O-ring [4610.1]. Use a new cover fasteners [1220.2]. Remove the cover
O-ring for assembly. [1220.2] taking care not to drop the inboard seal
face which is a press fit in the back of the cover.
The single mechanical seal c) Slide off the sleeve [2400.1] to which the seal
distance ring [2510] is a slide fit on the back of [4200] rotary(s) is fitted and which should come
the impeller, take care not to drop this when away together.
bringing the impeller off the shaft. d) On the single mechanical seal now remove the
e) In case one of the shafts start to disengage at fasteners which fix the cover [1220.1]. Remove
another thread ensure both sections of the the cover [1220.1] taking care not to drop the
column are well supported. Unscrew the screws seal face which is a press fit into the cover.
and nuts [6570 & 6580] at the loose joint.
Unscrew the shaft [2100s] taking great care to e) When removing the mechanical seal
support both shaft ends when they disengage to [4200] from the sleeve refer to the specific
avoid damaging the line bearings. manufacturer’s instructions for the mechanical seal.
f) Remove the lower section of the support column f) Remove the screw and nut [6570.1 & 6580.3]
and place on a level support structure. holding the next item [1350.4 or 4212] and its
g) If the pump contains more than one shaft, it can O-ring [4610].
be more efficient to remove the highest column g) Slide out the bearing support [3250.1].
pipe section by removing the studs and nuts h) Unbolt and remove support column [1350.3].
[6572.2 & 6580.4]. Then slide the support pipe i) Unscrew the overhanging shaft [2100] section prior
and line bearing assembly over the shaft while to removing the next section of support column.
ensuring the shaft is well supported. Remove the j) Any long length of shaft should be temporarily
free section of shaft [2100s]. Repeat the above supported to avoid bending or damage whilst
until only the lowest section of the support removing the optional shaft split coupling(s) [7120].
column pipe [1350] remains.
h) Fix the lowest section of the support column on a 6.9.4 Bearings and upper shaft
workbench. Fit a spanner to the flats of the a) Remove the bearing housing screws.
upper end of the shaft and ensure it can not slip. b) Pull the bearing carrier [3240] and upper shaft
i) Fit a strap wrench around the impeller and spin assembly out of the sole plate. Take care to
the impeller clockwise to lift the spanner from the support the long shaft to avoid bending or damage
work bench. to it and any attached components.
j) Spin the impeller quickly counter-clockwise with c) Pull off the coupling [7000] hub and remove the
the wrench to get the spanner to make impact on coupling key [6700].
the workbench or a wooden block. The impact d) Drive out labyrinth seal [4330] (if fitted).
will loosen the impeller. e) Unscrew the bearing outer nut [3712.2] (left hand
k) Unscrew the impeller and discard the impeller thread).
O-ring [4610.1]. Use a new O-ring for assembly. f) Remove the drive side flinger or labyrinth seal (if
fitted) from the shaft.
6.9.2.2 Impeller removal with key drive impeller g) Slide the bearing carrier off of the bearing(s).
a) Remove impeller locking nut [2912] complete h) Remove the bearing shaft nut [3712.1].
with O-ring [4610.5], which should be discarded. i) Pull off the bearing(s) [3013].
(A new O-ring will be required for assembly.) j) Any bearings or sleeves can then be pressed out
b) Pull impeller [2200] off shaft. or off, as required.

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6.10 Examination of parts b) Clean the inside of the bearing carrier and bores
for the bearings.
Used parts must be inspected before c) On grease lubricated bearings fill the bearing nut
assembly to ensure the pump will subsequently run [3712.2] internal slot with the appropriate grease.
properly. In particular, fault diagnosis is essential to The three thin grease rings may now be inserted
enhance pump and plant reliability. into this internal slot.
d) The bearing carrier retaining ring sub-assembly and
6.10.1 Casing, seal housing and impeller bearing sleeve [2400.3], applicable on shaft sizes 3
Inspect for excessive wear, pitting, corrosion, erosion and 4, should now be placed over the shaft before
or damage and any sealing surface irregularities. fitting the thrust bearing. The retaining ring must
Replace as necessary. have the C spanner slots facing the impeller end.
e) Press the thrust bearing(s) [3013] onto the shaft
6.10.2 Shaft and sleeve (if fitted) using equipment that can provide a steady, even
Obtain and fit a new shaft [2100] or sleeve [2400.1] if load to the inner race.
grooved, pitted or worn. f) Oil bath lubricated thrust bearing is an option.
g) If grease lubrication as standard, use a spatula to fill
6.10.3 Gaskets and O-rings sides of the bearing with grease of NLGI 3 grade.
After dismantling, discard and replace.
On aggressive solvent/acid vapor service
6.10.4 Bearings a special fluoro-silicone grease (Molykote FS3451)
It is recommended that bearings [3013] are not may be required. Pack the bearing fully by hand as
re-used after any removal from the shaft. no grease nipple is used in the design.
h) Fit the self-locking thrust bearing nut [3712] onto
The plain bearings may be re-used if both the bearing the shaft and tighten with a C spanner.
bush [3300] and bearing sleeve [3400] show no sign i) Fit O-ring [4610.2] on the bearing carrier [3240]
of wear, grooving or corrosion attack. It is and lubricate the bearing carrier bore and O-ring
recommended that both the bush and sleeve are with oil.
replaced at the same time. j) Ensure the shaft coupling keyway edges are free of
burrs. If optional proprietary labyrinth type bearing
6.11 Assembly housing seals [4330] are used the O-rings should
To assemble the pump consult the sectional be oiled to assist assembly.
drawings. (See section 8, Parts lists and drawings.) k) Install the bearing carrier onto the shaft/bearing
assembly and screw the bearing carrier locking
Ensure threads, gasket and O-ring mating faces are ring into the bearing carrier. Tighten up the
clean. Apply thread sealant to non-face sealing pipe bearing carrier locking ring using a C spanner.
thread fittings.
LH thread.
l) Check shaft [2100] for free rotation.
6.11.1 Mechanical seal
m) To fit an inter bearing shaft sleeve [3400], slide it
Extreme cleanliness is required during assembly.
over the shaft from the impeller end and tighten
Check that the sealing faces are free from scratches or
up the sleeve drive screw [6570.9].
other damage.
n) To fit the pump end sleeve [2400.1], slide it over
a) Use water for fitting elastomers.
the shaft; this is driven by the impeller.
b) Where an anti-rotation pin is fitted ensure that it is
correctly engaged with the slot.
6.11.3 Bearing bushes
c) Carefully press stationary mechanical seal seat(s)
a) If due to the pit depth and pump speed an
into their housing so that they are not deformed or
intermediate bearing bush [3300s] is fitted, press
damaged.
this into the upper support column. The pump
Work to the specific manufacturer’s end bush [3300.2] is fitted into the pump end
instructions for the mechanical seal. bearing support [3250.2].
b) When fitting the intermediate bearing bush, or
6.11.2 Thrust bearing carrier and shaft sub- pump end bearing bush, press these in
assembly chamfered end first.
a) Fit deflector [2540] with its O-ring and screw
Check the orientation so that the locking
[4610.3 & 6570.10] onto the shaft.
pegs [6570.11 and 6570.12] line up correctly.

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6.11.4 Installing the shaft sub-assembly 6.11.5.2 Impeller assembly with key drive impeller
a) Before assembling the shaft sub-assembly into the a) Fit a new impeller sealing gasket [4590.4] against
sole plate, fasten the upper suspension pipe/ shaft shoulder.
bearing bush sub-assembly to the sole plate. b) Fit impeller key [6700.2].
b) If the sump is short there may be no column c) Assemble impeller [2200] onto the shaft [2100].
pipes above [1350.3]. In this case, the lower d) Fit a new O-ring [4610.5] into the impeller locking
column pipe will need to be fitted to the sole plate nut groove.
to support the shaft sub-assembly. The bearing e) Apply anti-galling compound (which does not
support [3250.2] should only be fitted after the contain copper) to the impeller nut threads to
shaft sub-assembly. help any subsequent removal.
f) Fit impeller nut [2912] onto the shaft and torque up.
If there is an upper column pipe [1350.2], g) Clean the casing spigot and gasket position
the lower column pipe and pump end bearing mating surfaces.
support [3250.1] must only be fitted after the shaft h) Fit a new casing gasket [4950.1].
sub-assembly. Install the shaft assembly into the i) Install the pump casing with a new casing to
motor stool and sole plate until the bearing carrier discharge gasket [4950.2].
[3240] gap is approximately 4 mm (0.16 in.). j) Install casing hexagon screws [6570.2] to the
c) Install the bearing carrier hexagon screws specified torques.
[6570.7] and the hexagon screws [6570.6] and k) Check impeller front clearance against original
hexagon nuts [6580.5], but do not tighten. setting, or process requirement and adjust as
d) Where a labyrinth [4330] has not been provided necessary. (See section 6.7, Setting impeller
press the external deflector [2540] onto the shaft, clearance.)
where applicable. This should be set between l) Check freedom to rotate within pump casing.
0.5 and 2 mm (0.02 and 0.08 in.) from the
bearing carrier [3240]. 6.11.6 Coupling, motor and ancillaries
e) Turn the shaft [2100] to check for freedom from a) Reconnect pump ancillary fittings and piping.
rubbing. b) Install pump into sump and connect up remaining
f) Refit the coupling [7000]. fittings and piping.
c) Re-check freedom of shaft to rotate by hand.
6.11.5 Impeller and casing assembly d) Re-install motor (check for correct rotation) and
then fit coupling drive element and guards.
6.11.5.1 Impeller assembly with threaded on e) If all is correct continue with the procedure described
impeller under Section 4, Installation, and section 5,
a) Fit a new O-ring [4610.1] into the impeller using a Commissioning, start-up, operation and shutdown.
small amount of grease to hold it in place. Apply
anti-galling compound (which does not contain
copper) to the impeller thread to help subsequent
removal.
b) Assemble impeller [2200] onto the shaft [2100].
c) Tighten the impeller. Use the same method as in
disassembly but rotate in opposite direction. A
few sharp strikes will tighten it to the correct level.
d) Clean the casing spigot and gasket position
mating surfaces.
e) Fit a new casing gasket [4590.1].
f) Install the pump casing with a new casing to
discharge gasket [4590.2].
g) Install casings studs [6572.1] and nuts [6580.8] to
the specified torques.
h) Check impeller front clearance against original
setting, or process requirement, and adjust as
necessary. (See section 6.7, Setting impeller
clearance.)
i) Check freedom to rotate within pump casing.

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 CPXV-E USER INSTRUCTIONS ENGLISH 87900056 12-15

7 FAULTS; CAUSES AND REMEDIES

FAULT SYMPTOM
Pump o verheats and seiz es
⇓ B e a r i n g s h a v e s h o r t l if e
⇓ Pump vibrates o r is no is y
⇓ M echani cal seal has short l ife
⇓ M e c ha n i c a l s e a l l e a k s e x c e s s i v e l y
⇓ Pump requ ir es excessive power
⇓ Pump lose s p r ime after st art ing
⇓ I n s u f f i c i e n t p r e s s u r e d e v e lo p e d
⇓ Insuf ficient capacit y delivered
⇓ Pump does not del iver liq uid
⇓ POSSIBLE CAUSES POSSIBLE REMEDIES
A. System troubles
Insufficient margin between suction pressure and Check NPSHA > NPSHR, proper submergence,
vapor pressure. losses at strainers and fittings.
Excessive amount of air or gas in liquid. Check and purge pipes and system.
Inlet of suction pipe insufficiently submerged. Check out system design.
Speed too low. CONSULT FLOWSERVE.
Speed too high. CONSULT FLOWSERVE.
Total head of system higher than differential head
of pump. Check system losses.
Total head of system lower than pump design Remedy or CONSULT FLOWSERVE.
head.
Specific gravity of liquid different from design.
Viscosity of liquid differs from that for which Check and CONSULT FLOWSERVE.
designed.
Measure value and check minimum permitted.
Operation at very low capacity.
Remedy or CONSULT FLOWSERVE.
Measure value and check maximum permitted.
Operation at high capacity.
Remedy or CONSULT FLOWSERVE.
B. Mechanical troubles
Check the flange connections and eliminate strains
Misalignment due to pipe strain.
using elastic couplings or a method permitted.
Check setting of sole plate: tighten, adjust, grout
Improperly designed foundation.
base as required.
Check shaft runouts are within acceptable values.
Shaft bent.
CONSULT FLOWSERVE.
Rotating part rubbing on stationary part internally. Check and CONSULT FLOWSERVE, if necessary.
Bearings worn Replace bearings.
Wearing ring surfaces worn. Replace worn wear ring/surfaces.
Replace or CONSULT FLOWSERVE for improved
Impeller damaged or eroded.
material selection.
Leakage under sleeve due to joint failure. Replace joint and check for damage.
Shaft sleeve worn or scored or running off centre. Check and renew defective parts.
Check alignment of faces or damaged parts and
Mechanical seal improperly installed.
assembly method used.
Incorrect type of mechanical seal for operating
CONSULT FLOWSERVE.
conditions.
Check misalignment and correct if necessary. If
Shaft running off centre because of worn bearings
alignment satisfactory check bearings for excessive
or misalignment.
wear.
Impeller out of balance resulting in vibration.
Check and CONSULT FLOWSERVE.
Abrasive solids in liquid pumped.

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 CPXV-E USER INSTRUCTIONS ENGLISH 87900056 12-15

FAULT SYMPTOM
Pump o verheats and seiz es
⇓ B e a r i n g s h a v e s h o r t l if e
⇓ Pump vibrates o r is no is y
⇓ M echani cal seal has short l ife
⇓ M e c ha n i c a l s e a l l e a k s e x c e s s i v e l y
⇓ Pump requ ir es excessive power
⇓ Pump lose s p r ime after st art ing
⇓ I n s u f f i c i e n t p r e s s u r e d e v e lo p e d
⇓ Insuf ficient capacit y delivered
⇓ Pump does not del iver liq uid
⇓ POSSIBLE CAUSES POSSIBLE REMEDIES
Internal misalignment of parts preventing seal ring
and seat from mating properly.
Check mechanical seal condition and source of dry
Mechanical seal was run dry.
running and repair.
Check method of assembly, possible damage or
Internal misalignment due to improper repairs
state of cleanliness during assembly.
causing impeller to rub.
Remedy or CONSULT FLOWSERVE, if necessary.
Excessive thrust caused by a mechanical failure Check wear condition of impeller, its clearances and
inside the pump. liquid passages.
Excessive grease in ball bearings. Check method of regreasing.
Check hours run since last change of lubricant, the
Lack of lubrication for bearings.
schedule and its basis.
Check method of assembly, possible damage or
Improper installation of bearings (damage during
state of cleanliness during assembly and type of
assembly, incorrect assembly, wrong type of
bearing used. Remedy or CONSULT
bearing etc).
FLOWSERVE, if necessary.
Check contamination source and replace damaged
Damaged bearings due to contamination.
bearings.
C. MOTOR ELECTRICAL PROBLEMS
Wrong direction of rotation. Reverse 2 phases at motor terminal box.
Motor running on 2 phases only. Check supply and fuses.
Motor running too slow. Check motor terminal box connections and voltage.

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8 PARTS LISTS AND DRAWINGS

8.1 CPXV-E

Drawing taken from B736/627 sheet 1, rev B

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8.1.1 CPXV-E parts list

Item Description 1350.4 Column pipe
8100 Motor 1350.3 Column pipe
7450 Coupling guard 1350.2 Column pipe
7000 Coupling 1350.1 Column pipe
6700 Key 1220.1 Cover
6580.7 Nut 1100 Casing
6580.5 Nut Optional items
6580.4 Nut 6580.6 Nut
6580.3 Nut 6570.5 Screw
6580.2 Nut 6569.2 Plug
6580.1 Nut 6531 Suction strainer
6572.2 Stud 6110 Base plate
6572.1 Stud 4610.5 O-ring
6570.13 Screw 4212 Seal cover
6570.12 Screw 4200.2 Mechanical seal (dual)
6570.11 Screw 3840.2 Lubricating pipe
6570.1 Screw 3840.1 Lubricating pipe
6570.9 Screw 1220.2 Cover
6570.8 Screw
6570.7 Screw
6570.6 Screw
6570.4 Screw
6570.3 Screw
6570.2 Screw
6570.1 Screw
6569.3 Plug
6569.1 Plug
6523 Vent valve
6519 Coolant dipstick
6140 Sole plate
4610.7 O-ring
4610.6 O-ring
4610.5 O-ring
4610.4 O-ring
4610.3 O-ring
4610.2 O-ring
4610.1 O-ring
4590.2 Gasket
4590.1 Gasket
4330 Labyrinth ring
4200.1 Mechanical seal (single)
3864 Grease retainer
3853 Grease nipple
3712.2 Bearing lock nut
3712.1 Bearing lock nut
3400.2 Bearing sleeve
3400.1 Bearing sleeve
3300.2 Bearing bush
3300.1 Bearing bush
3250.2 Bearing support
3250.1 Bearing support
3240 Bearing carrier
3160 Motor pedestal
3013 Thrust ball bearing
2540 Deflector
2530.2 Retaining ring
2530.1 Retaining ring
2510 Distance ring
2400.1 Sleeve
2200 Impeller
2100.3 Shaft
2100.2 Shaft
2100.1 Shaft
1360 Discharge pipe

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8.2 CPXV-E bearing options

Pair of 40 degree angular contact bearings, grease

lubricated. (No sleeve [2400.3] fitted on shaft sizes 1 and 2.)
Shaft rigid coupling
Drawings taken from B736/048, sheet 3, rev F

Rigid coupling option Labyrinth ring option

Item Description 4330 Labyrinth ring
7120 Split coupling Flinger option (short depths)
Oil lubrication option 2540.2 Deflector
3855 Constant level oiler 6570.13 Screw
4223 Pumping ring
6569.2 Plug (breather)
6569.3 Plug (oil drain)

8.3 Optional A-OP key-drive impeller

2100

2400 Item Description

2100 Shaft
Solid
SOLID shaft
SHAFT SLEEVED
Sleeved SHAFT
shaft shown 2200 Impeller
shown
SHOWN to left
TO LEFT toSHOWN
right of TO RIGHT
center line 2400 Sleeve (if fitted)
of center line
OF CENTRE-LINE. OF CENTRE-LINE. 2912.1 Impeller nut
2912.2 Impeller nut
4610.4 4590.4 Gasket
4590.4 4610.4 O-ring (if sleeve fitted)
4610.5 O-ring
6570.6 Screw
6700.2 6700.2 Key

4610.5

2200

2912.1
(includes
(includes
heli-coil 6589)
heli-coil
[6589])

2912.2

6570.6 Drawings taken from B731/1644, sheet 2, rev -

Key drive design for 304/316 stainless steel and above.
Secure screw with PTFE sealant (Loctite 577).

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8.4 Parts interchangeability 10 OTHER RELEVANT

CPXV Bearing Casing Line DOCUMENTATION AND MANUALS
pump size carrier gasket bearing
40-25-125 1 1 1
50-32-125 1 1 1
10.1 Supplementary User Instruction
65-40-125 1 1 1 manuals
80-50-125 1 1 1 Supplementary instruction determined from the
100-80-125 1 1 1 contract requirements for inclusion into User
32-20-160 1 2 1 Instructions such as for a driver, instrumentation,
40-25-160 1 2 1 controller, sub-driver, seals, sealant system, mounting
50-32-160 1 2 1 component etc. are included under this section. If
65-40-160 1 2 1 further copies of these are required they should be
80-50-160 1 2 1 obtained from the purchaser for retention with these
100-65-160 2 2 2 User Instructions.
125-100-160 2 2 2
32-20-200 1 3 1 Where any pre-printed set of User Instructions are
40-25-200 1 3 1 used, and satisfactory quality can be maintained
50-32-200 1 3 1 only by avoiding copying these, they are included
65-40-200 1 3 1
at the end of these User Instructions such as within
80-50-200 1 3 1
a standard clear polymer software protection
100-65-200 2 3 2
envelope.
125-100-200 2 3 2
40-25-250 2 4 2 10.2 Change notes
50-32-250 2 4 2 If any changes, agreed with Flowserve, are made
65-40-250 2 4 2 to the product after its supply, a record of the
80-50-250 2 4 2 details should be maintained with these User
100-65-250 2 4 2 Instructions.
50-32-315 2 5 2
65-40-315 2 5 2 10.3 Additional sources of information
80-50-315 2 5 2
Reference 1:
NPSH for Rotordynamic Pumps: a reference guide,
8.5 General arrangement drawing Europump Guide No. 1, Europump & World
The typical general arrangement drawing and any Pumps, Elsevier Science, United Kingdom, 1999.
specific drawings required by the contract will be
sent to the Purchaser separately unless the
Reference 2:
contract specifically calls for these to be included th
Pumping Manual, 9 edition, T.C. Dickenson,
into the User Instructions. If required, copies of
Elsevier Advanced Technology, United Kingdom,
other drawings sent separately to the Purchaser
1995.
should be obtained from the Purchaser and
retained with these User Instructions. Reference 3:
nd
Pump Handbook, 2 edition, Igor J. Karassik et al,
9 CERTIFICATION McGraw-Hill Inc., New York, 1993.
Certificates determined from the Contract
requirements are provided with these Instructions Reference 4:
where applicable. Examples are certificates for CE ANSI/HI 1.1-1.5. Centrifugal Pumps -
marking, ATEX marking etc. If required, copies of Nomenclature, Definitions, Application and
other certificates sent separately to the Purchaser Operation.
should be obtained from the Purchaser for retention
with these User Instructions. Reference 5:
ANSI B31.3 - Process Piping.

Reference 6:
ESA – Guidelines for Safe Seal Usage (Flanges
and Gaskets).

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Notes:

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Notes:

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 CPXV-E USER INSTRUCTIONS ENGLISH 87900056 12-15

Your Flowserve factory contact: FLOWSERVE REGIONAL

SALES OFFICES:

USA and Canada

Flowserve Corporation
5215 North O’Connor Blvd.,
Flowserve Pumps Suite 2300
Flowserve GB Limited Irving, Texas 75039-5421, USA
Lowfield Works, Balderton Telephone +1 937 890 5839
Newark, Notts NG24 3BU
United Kingdom Europe, Middle East, Africa
Flowserve Corporation
Telephone (24 hours) +44 1636 494 600 Parallelweg 13
Sales & Admin Fax +44 1636 705 991 4878 AH Etten-Leur
Repair & Service Fax +44 1636 494 833
The Netherlands
Email: [email protected]
Telephone +31 76 502 8100

Latin America and Caribbean

Your local Flowserve representatives: Flowserve Corporation
Martín Rodriguez 4460
B1644CGN-Victoria-San Fernando
Buenos Aires, Argentina
Telephone +54 11 4006 8700
Fax +54 11 4714 1610

Asia Pacific
Flowserve Pte. Ltd
10 Tuas Loop
Singapore 637345
Telephone +65 6771 0600
North America: Fax +65 6862 2329
Flowserve Pump Division
3900 Cook Boulevard
Chesapeake, VA 23323-1626, USA

Telephone +1 757 485 8000

Customer Service Fax +1 457 485 8149

To find your local Flowserve representative please

use the Sales Support Locator System found at
www.flowserve.com