FRBHJC User Manual 2004

FRBHJC User Manual 2004
®
®
Pump Division
Type: FRBHJC
VERTICAL CANTILEVER
CENTRIFUGAL PUMPS
USER INSTRUCTIONS:
INSTALLATION, OPERATION, MAINTENANCE
PCN=71569179 11-04
These instructions must be read prior to installing,
operating, using and maintaining this equipment.
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
CONTENTS
PAGE
1 INTRODUCTION AND SAFETY ......................... 4
1.1 General ....................................................... 4
1.2 CE marking and approvals............................ 4
1.3 Disclaimer ................................................... 4
1.4 Copyright ..................................................... 4
1.5 Duty conditions ............................................ 4
1.6 Safety ......................................................... 5
1.7 Nameplate and warning labels ...................... 8
1.8 Specific machine performance ...................... 9
1.9 Noise level................................................... 9
2 TRANSPORT AND STO RAGE ......................... 10
2.1 Consignment receipt and unpacking............ 10
2.2 Handling.................................................... 10
2.3 Lifting ........................................................ 10
2.4 Storage ..................................................... 10
2.5 Recycling and end of product life ................ 11
6.5 Tools required ............................................ 29
6.6 Fastener torques ........................................ 30
6.7 Renewal clearances ................................... 30
6.8 Disassembly .............................................. 30
6.9 Examination of parts.................................. 31
6.10 Assembly ................................................. 31
6.11 Setting Impeller Clearance......................... 34
7 FAULTS; CAUSES AND REMEDIES ................. 35
8 PARTS LIST AND DRAWINGS.......................... 38
8.1 FRBHJC Sectional drawing......................... 38
8.5 General arrangement drawing ..................... 39
9 CERTIFICATION.............................................. 39
10 OTHER RELEVANT DOCUMENTATION AND
MANUALS .................................................... 39
10.1 Supplementary User Instruction manuals ... 39
10.2 Change notes........................................... 39
10.3 Additional sources of information ............... 39
3 PUMP DESCRIPTION...................................... 11
3.1 Configurations ........................................... 11
3.2 Name nomenclature ................................... 11
3.3 Design of major parts ................................. 11
3.4 Performance and operating limits................ 12
TABLE OF ENGINEERING DATA ..................... 13
MATERIALS OF CONSTRUCTION ................... 17
4 INSTALLATION................................................ 18
4.1 Location .................................................... 18
4.2 Part assemblies ......................................... 18
4.3 Foundation ................................................ 18
4.4 Baseplate installation ................................. 18
4.5 Initial alignment .......................................... 19
4.6 Grouting .................................................... 21
4.7 Piping........................................................ 21
4.8 Final shaft alignment check......................... 23
4.9 Electrical connections ................................. 23
4.10 Protection systems................................... 23
5 COMMISSIONING, STA RT-UP, OPERATION AND
SHUTDOWN................................................ 24
5.1 Pre-commissioning procedure..................... 24
5.2 Pump lubricants ......................................... 24
5.2 Pump lubricants ......................................... 25
5.3 Direction of rotation .................................... 25
5.4 Guarding ................................................... 25
5.5 Priming and auxiliary supplies ..................... 25
5.6 Starting the pump ....................................... 25
5.7 Running the pump...................................... 26
5.8 Stopping and shutdown .............................. 26
5.9 Hydraulic, mechanical and electrical duty .... 26
6 MAINTENANCE ............................................... 27
6.1 General ..................................................... 27
6.2 Maintenance schedule................................ 27
6.3 Spare parts................................................ 29
6.4 Recommended spares and consumable items29
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FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
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INDEX
PAGE
Alignment of shafting (see 4.5, 4.7 and 4.3) . 19,21,18
CE marking and approvals (1.2).............................. 4
Clearances (see 6.7, Renewal clearances)............ 30
Commissioning and operation (see 5) ................... 24
Configurations (3.1) ............................................. 11
Direction of rotation (5.3)...................................... 25
Dismantling (see 6.8, Disassembly) ...................... 30
Duty conditions (1.5) .............................................. 4
Electrical connections (4.8)................................... 23
Examination of parts (6.9) .................................... 31
Faults; causes and remedies ................................ 34
General assembly drawings (see 8) ...................... 37
Grouting (4.4) ...................................................... 21
Guarding (5.4) ..................................................... 25
Handling (2.2)...................................................... 10
Hydraulic, mechanical and electrical duty (5.9) ...... 26
Lifting (2.3).......................................................... 10
Location (4.1) ...................................................... 18
Lubrication schedule (see 5.2, Pump lubricants) .... 17
Maintenance schedule (6.2) ................................. 27
Piping (4.6).......................................................... 21
Priming and auxiliary supplies (5.5)....................... 25
Reassembly (see 6.10, Assembly)........................ 31
Replacement parts (see 6.3 and 6.4) .................... 29
Safety, protection systems (see 1.6 and 4.9) ......5,23
Sound level (see 1.9, Noise level)........................... 9
Specific machine performance (1.8)........................ 9
Starting the pump (5.6)......................................... 25
Stopping and shutdown (5.8)................................ 26
Storage (2.4) ....................................................... 10
Supplementary manuals or information sources ..... 38
Tools required (6.5).............................................. 29
Torques for fasteners (6.6) ................................... 30
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FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
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1 INTRODUCTION AND SAFETY
incorporates information relevant to these Directives.
To establish approvals and if the product itself is CE
marked, check the serial number plate and the
Certification. (See section 9, Certification.)
1.1 General
These instructions must always be kept close
to the product's operating location or directly with
the product.
Flowserve's products are designed, developed and
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great care
and commitment to continuous quality control, utilising
sophisticated quality techniques, and safety
requirements.
We are committed to continuous quality improvement
and being at your service for any further information
about the product in its installation and operation or
about its support products, repair and diagnostic
services.
These instructions are intended to facilitate
familiarization with the product and its permitted use.
Operating the product in compliance with these
instructions is important to help ensure reliability in
service and avoid risks. The instructions may not take
into account local regulations; ensure such regulations
are observed by all, including those installing the
product. Always coordinate repair activity with
operations personnel, and follow all plant safety
requirements and applicable safety and health laws and
regulations.
These instructions must be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment must not be put into service until all the
conditions relating to safety noted in the
instructions, have been met.
1.2 CE marking and approvals
It is a legal requirement that machinery and equipment
put into service within certain regions of the world shall
conform with the applicable CE Marking Directives
covering Machinery and, where applicable, Low
Voltage Equipment, Electromagnetic Compatibility
(EMC), Pressure Equipment Directive (PED) and
Equipment for Potentially Explosive Atmospheres
(ATEX).
Where applicable, the Directives and any additional
Approvals, cover important safety aspects relating to
machinery and equipment and the satisfactory
provision of technical documents and safety
instructions. Where applicable this document
1.3 Disclaimer
Information in these User Instructions is believed
to be reliable. In spite of all the efforts of Flowserve
Corporation to provide sound and all necessary
information the content of this manual may appear
insufficient and is not guaranteed by Flowserve as
to its completeness or accuracy.
Flowserve manufactures products to exacting
International Quality Management System Standards
as certified and audited by external Quality Assurance
organisations. Genuine parts and accessories have
been designed, tested and incorporated into the
products to help ensure their continued product quality
and performance in use. As Flowserve cannot test
parts and accessories sourced from other vendors the
incorrect incorporation of such parts and accessories
may adversely affect the performance and safety
features of the products. The failure to properly select,
install or use authorised Flowserve parts and
accessories is considered to be misuse. Damage or
failure caused by misuse is not covered by Flowserve's
warranty. In addition, any modification of Flowserve
products or removal of original components may impair
the safety of these products in their use.
1.4 Copyright
All rights reserved. No part of these instructions may
be reproduced, stored in a retrieval system or
transmitted in any form or by any means without prior
permission of Flowserve Pump Division.
1.5 Duty conditions
This product has been selected to meet the
specifications of your purchaser order. The
acknowledgement of these conditions has been sent
separately to the Purchaser. A copy should be kept
with these instructions.
The product must not be operated beyond the
parameters specified for the application. If there is
any doubt as to the suitability of the product for the
application intended, contact Flowserve for advice,
quoting the serial number.
If the conditions of service on your purchase order are
going to be changed (for example liquid pumped,
temperature or duty) it is requested that you/the user
seek our written agreement before start up.
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FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
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1.6 Safety
1.6.1 Summary of safety markings
These user instructions contain specific safety
markings where non-observance of an instruction
would cause hazards. The specific safety markings
are:
This symbol indicates electrical safety
instructions where non-compliance would affect
personal safety.
This symbol indicates safety instructions where
non-compliance would affect personal safety.
This symbol indicates safety instructions where
non-compliance would affect protection of a safe life
environment.
This symbol indicates safety instructions
where non-compliance would affect the safe operation or
protection of the pump or pump unit.
This symbol indicates explosive atmosphere
zone marking according to ATEX. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
This sign is not a safety symbol but indicates
an important instruction in the assembly process.
1.6.2 Personnel qualification and training
All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved. If the
personnel in question do not already possess the
necessary knowledge and skill, appropriate training and
instruction must be provided. If required the operator
may commission the manufacturer/supplier to provide
applicable training.
Always coordinate repair activity with operations and
health and safety personnel, and follow all plant safety
requirements and applicable safety and health laws
and regulations.
1.6.3 Safety action
This is a summary of conditions and actions to
prevent injury to personnel and damage to the
environment and to equipment. (For products used
in potentially explosive atmospheres section 1.6.4
also applies.)
PREVENT EXCESSIVE EXTERNAL
PIPE LOAD
Do not use pump as a support for piping. Do not mount
expansion joints, unless allowed by Flowserve in
writing, so that their force, due to internal pressure, acts
on the pump flange.
ENSURE CORRECT LUBRICATION
(See section 5, Commissioning, startup, operation and
shutdown.)
START THE PUMP WITH OUTLET
VALVE PART OPENED
(Unless otherwise instructed at a specific point in the
user instructions.)
This is recommended to minimize the risk of
overloading and damaging the pump motor at full or
zero flow. Pumps may be started with the valve further
open only on installations where this situation cannot
occur. The pump outlet control valve may need to be
adjusted to comply with the duty following the run-up
process. (See section 5, Commissioning start-up,
operation and shutdown. )
NEVER RUN THE PUMP DRY
INLET VALVES TO BE FULLY OPEN
WHEN PUMP IS RUNNING
Running the pump at zero flow or below the
recommended minimum flow continuously will cause
damage to the seal.
DO NOT RUN THE PUMP AT
ABNORMALLY HIGH OR LOW FLOW RATES
Operating at a flow rate higher than normal or at a flow
rate with no back pressure on the pump may overload
the motor and cause cavitation. Low flow rates may
cause a reduction in pump/bearing life, overheating of
the pump, instability and cavitation/ vibration.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care
must be taken to avoid exposure to the liquid by
appropriate siting of the pump, limiting personnel
access and by operator training. If the liquid is
flammable and/or explosive, strict safety procedures
must be applied.
Gland packing must not be used when pumping
hazardous liquids.
DRAIN THE PUMP AND ISOLATE PIPEWORK
BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be taken
where the pumped liquids are hazardous.
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FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
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FLUORO-ELASTOMERS (When fitted.)
When a pump has experienced temperatures over 250
ºC (482 ºF), partial decomposition of fluoro-elastomers
(eg Viton) will occur. In this condition these are
extremely dangerous and skin contact must be
avoided.
HANDLING COMPONENTS
Many precision parts have sharp corners and the
wearing of appropriate safety gloves and equipment is
required when handling these components. To lift
heavy pieces above 25 kg (55 lb) use a crane
appropriate for the mass and in accordance with
current local regulations.
GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS OPERATIONAL
THERMAL SHOCK
Rapid changes in the temperature of the liquid within
the pump can cause thermal shock, which can result in
damage or breakage of components and should be
avoided.
NEVER APPLY HEAT TO REMOVE IMPELLER
Trapped lubricant or vapour could cause an explosion.
HOT (and cold) PARTS
If hot or freezing components or auxiliary heating
supplies can present a danger to operators and
persons entering the immediate area action must be
taken to avoid accidental contact. If complete
protection is not possible, the machine access must be
limited to maintenance staff only, with clear visual
warnings and indicators to those entering the
immediate area. Note: bearing housings must not be
insulated and drive motors and bearings may be hot.
If the temperature is greater than 68 °C (175 °F) or
below 5 °C (20 °F) in a restricted zone, or exceeds
local regulations, action as above shall be taken.
1.6.4 Products used in potentially explosive
atmospheres
•
•
•
•
•
Both electrical and non-electrical equipment must meet
the requirements of European Directive 94/9/EC.
1.6.4.1 Scope of compliance
Use equipment only in the zone for which it is
appropriate. Always check that the driver, drive coupling
assembly, seal and pump equipment are suitably rated
and/or certified for the classification of the specific
atmosphere in which they are to be installed.
Where Flowserve has supplied only the bare shaft
pump, the Ex rating applies only to the pump. The party
responsible for assembling the pump set shall select the
coupling, driver and any additional equipment, with the
necessary CE Certificate/ Declaration of Conformity
establishing it is suitable for the area in which it is to be
installed.
The output from a variable frequency drive (VFD) can
cause additional heating affects in the motor and so, for
pumps sets with a VFD, the ATEX Certification for the
motor must state that it is covers the situation where
electrical supply is from the VFD. This particular
requirement still applies even if the VFD is in a safe
area.
1.6.4.2 Marking
An example of ATEX equipment marking is shown
below. The actual classification of the pump will be
engraved on the nameplate.
II 2 GD c IIC 135 ºC (T4)
Equipment Group
I = Mining
II = Non-mining
Category
2 or M2 = High level protection
3 = normal level of protection
Gas and/or Dust
G = Gas; D= Dust
c = Constructional safety
(in accordance with En13463-5)
Measures are required to:
Avoid excess temperature
Prevent build up of explosive mixtures
Prevent the generation of sparks
Prevent leakages
Maintain the pump to avoid hazard
Gas Group (Equipment Category 2 only)
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)
The following instructions for pumps and pump units
when installed in potentially explosive atmospheres
must be followed to help ensure explosion protection.
Maximum surface temperature (Temperature Class)
(See section 1.6.4.3.)
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FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
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1.6.4.3 Avoiding excessive surface temperatures
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE
Pumps have a temperature class as stated in the ATEX
Ex rating on the nameplate. These are based on a
maximum ambient of 40 °C (104 °F); refer to Flowserve
for higher ambient temperatures.
The surface temperature on the pump is influenced by
the temperature of the liquid handled. The maximum
permissible liquid temperature depends on the
temperature class and must not exceed the values in
the table that follows.
The temperature rise at the seals and bearings and due
to the minimum permitted flow rate is taken into
account in the temperatures stated.
Temperature
class to
EN 13463-1
T6
T5
T4
T3
T2
T1
Maximum
surface
temperature
permitted
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)
Temperature limit of liquid
handled (* depending on
material and construction
variant - check which is lower)
Consult Flowserve
Consult Flowserve
115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
400 °C (752 °F) *
The responsibility for compliance with the specified
maximum liquid temperature is with the plant
operator.
Temperature classification “Tx” is used when the liquid
temperature varies and when the pump is required to be
used in differently classified potentially explosive
atmospheres. In this case the user is responsible for
ensuring that the pump surface temperature does not
exceed that permitted in its actual installed location.
If an explosive atmosphere exists during the
installation, do not attempt to check the direction of
rotation by starting the pump unfilled. Even a short run
time may give a high temperature resulting from
contact between rotating and stationary components.
Where there is any risk of the pump being run against a
closed valve generating high liquid and casing external
surface temperatures it is recommended that users fit an
external surface temperature protection device.
Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, temperature monitor or a
power monitor and make routine vibration monitoring
checks.
In dirty or dusty environments, regular checks must be
made and dirt removed from areas around close
clearances, bearing housings and motors.
1.6.4.4 Preventing the build up of explosive
mixtures
ENSURE THE PUMP IS PROPERLY FILLED
AND VENTED AND DOES NOT RUN DRY
Ensure the pump and relevant suction and discharge
pipeline system is totally filled with liquid at all times
during the pump operation, so that an explosive
atmosphere is prevented. In addition it is essential to
make sure that seal chambers, auxiliary shaft seal
systems and any heating and cooling systems are
properly filled.
If the operation of the system cannot avoid this
condition the fitting of an appropriate dry run protection
device is recommended (eg liquid detection or a power
monitor).
To avoid potential hazards from fugitive emissions of
vapour or gas to atmosphere the surrounding area
must be well ventilated.
1.6.4.5 Preventing sparks
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 earth contact on the
baseplate must be used.
Avoid electrostatic charge: do not rub non-metallic
surfaces with a dry cloth; ensure cloth is damp.
The coupling must be selected to comply with 94/9/EC
and correct alignment must be maintained.
1.6.4.6 Preventing leakage
The pump must only be used to handle liquids for
which it has been approved to have the correct
corrosion resistance.
Avoid entrapment of liquid in the pump and associated
piping due to closing of suction and discharge valves,
which could cause dangerous excessive pressures to
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FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
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occur if there is heat input to the liquid. This can occur
if the pump is stationary or running.
Bursting of liquid containing parts due to freezing must
be avoided by draining or protecting the pump and
ancillary systems.
Where there is the potential hazard of a loss of a seal
barrier fluid or external flush, the fluid must be
monitored.
To avoid potential explosion hazards during
maintenance, the tools, cleaning and painting materials
used must not give rise to sparking or adversely affect
the ambient conditions. Where there is a risk from
such tools or materials, maintenance must be
conducted in a safe area.
It is recommended that a maintenance plan and
schedule is adopted. (See section 6, Maintenance.)
If leakage of liquid to atmosphere can result in a
hazard, the installation of a liquid detection device is
recommended.
1.6.4.7 Maintenance to avoid the hazard
CORRECT MAINTENANCE IS REQUIRED TO
AVOID POTENTIAL HAZARDS WHICH GIVE A RISK
OF EXPLOSION
The responsibility for compliance with maintenance
instructions is with the plant operator.
1.7 Nameplate and warning labels
1.7.1 Nameplate
For details of nameplate, see the Declaration of Conformity.
1.7.2 Warning labels
WARNING
WARNING
BEFORE STARTING THE PUMP ON SERVICE,
CHECK TO ENSURE CORRECT ROTATION OF
MOTOR. FAILURE TO DO THIS COULD RESULT
IN SERIOUS DAMAGE TO THE EQUIPMENT.
BEFORE GROUTING, REALIGN THIS UNIT.
RECHECK ALIGNMENT BEFORE STARTING,
FAILURE TO DO THIS COULD RESULT IN
SERIOUS DAMAGE TO THE EQUIPMENT.
REFER TO INSTALLATION MANUAL AND, OR
COUPLING INSTRUCTIONS FOR METHOD OF
CHECKING ALIGNMENT.
ROTATION WARNING
P/N 2113932-001
GROUT WARNING
P/N 2113934-001
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1.8 Specific machine performance
For performance parameters see section 1.5, Duty
conditions. When the contract requirement specifies
these to be incorporated into User Instructions these
are included here. 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
When pump noise level exceeds 85 dBA attention must
be given to prevailing Health and Safety Legislation, to
limit the exposure of plant operating personnel to the
noise. The usual approach is to control 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
machines above a certain power level will exceed 85
dBA. In such situations consideration must be given to
the fitting of an acoustic enclosure to meet local
regulations.
Pump noise level is dependent on a number of factors the type of motor fitted, the operating capacity,
pipework design and acoustic characteristics of the
building. The levels specified in the table below are
estimated and not guaranteed.
The dBA values are based on the noisiest ungeared
electric motors that are likely to be encountered. They
are Sound Pressure levels at 1 m (3.3 ft) from the
directly driven pump, for "free field over a reflecting
plane". For Estimating Lwa sound power level (re 1pW)
add 14Dba to the sound pressure value.
If a pump unit only has been purchased, for fitting with
your own driver, then the "pump only" noise levels from
the table should be combined with the level for the
driver obtained from the supplier. If the motor is driven
by an inverter, it may show an increase in noise level at
some speeds. Consult a Noise Specialist for the
combined calculation.
&
For units driven by equipment other than
electric motors or units contained within enclosures,
see the accompanying information sheets and
manuals.
FRBH pump size
2 FRBH-121
3 FRBH-121
3 FRBH-101
3 FRBH-141
4 FRBH-111
4 FRBH-141
6 FRBH-111
6 FRBH-142
8 FRBH-182
8 FRBH-152
10 FRBH-182
6FRBH-183
8FRBH-183
Sound Pressure
dBA @ 1 m (3 ft)
75
75
75
77
77
78
80
81
83
85
85
85
86
Page 9 of 36
Sound Power
dBA
89
89
89
91
91
92
93
95
98
99
99
100
101
Pump speed -rpm
1780
1780
1780
1780
1780
1780
1780
1780
1180
1780
1180
1780
1780
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
2 TRANSPORT AND STORAGE
rotor over by hand at least once a week to maintain a
protective film on the bearing components.
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be
checked against the delivery/shipping documents for its
completeness and that there has been no damage in
transportation. Any shortage and/or damage must be
reported immediately to Flowserve Pump Division and
must be received in writing within one month of receipt
of the equipment. Later claims cannot be accepted.
Check any crate, boxes or wrappings for any
accessories or spare parts that may be packed
separately with the equipment or attached to side walls
of the box or equipment.
Each product has a unique serial number. Check that
this number corresponds with that advised and always
quote this number in correspondence as well as when
ordering spare parts or further accessories.
2.2 Handling
Boxes, crates, pallets or cartons may be unloaded
using fork-lift vehicles or slings dependent on their size
and construction.
The pump should be lifted with suitably sized and
located slings. Do not use the shaft for lifting and take
special care to prevent the pump from rotating in the
slings due to unbalanced weight distribution.
2.3 Lifting
A crane must be used for all pump sets in excess
of 25 kg (55 lb). Fully trained personnel must carry out
lifting, in accordance with local regulations. The driver
and pump weights are recorded on their respective
nameplates or massplates.
2.4 Storage
2.2.1
Short-Term Storage
When it is necessary to store a pump for a short time
before it can be installed, place it in a dry, cool location.
Protect it thoroughly from moisture and condensation.
Protective flange covers should not be removed until
the pump is being installed.
Wrap the exposed portions of the shaft and coupling to
protect against sand, grit or other foreign matter. Oil
lubricated units should be lubricated (refer to Section
III) to protect the bearings. Grease lubricated units are
lubricated at the factory during assembly. Turn the
2.4.2 LONG-TERM STORAGE
More than precautions are required if long-term storage
in excess of 90 days from factory shipment is
unavoidable.
The internal surfaces of the pump should be sprayed
with a rust preventative such as a water soluble oil or
other suitable alternative. Particular attention should
be given to the impeller, wear plate and stuffing box.
An optional method of protection is to suspend bags of
desiccant material inside casing and completely seal all
openings from the surrounding atmosphere. The
stuffing box should be packed with clean. dry rags.
Use of this method requires that the casing be initially
free of liquid. The desiccant material should be
checked at regular intervals to ensure that it has not
absorbed excessive water vapour. A warning
instruction, advising that the desiccant must be
removed prior to installation should be wired to the
pump.
A rust inhibitor should be added to the lubricating oil of
oil lubricated units to give additional protection without
destroying the lubricating properties of the oil. For
specific recommendations, consult your lubrication
dealer. Grease lubricated units, which can be identified
by the grease fitting at each bearing location, should be
well lubricated prior to placing in storage. Small
amounts of additional grease should be added at
regular intervals during storage. Refer to Section III for
additional information related to grease lubrication.
Storage of pumps in areas of high ambient vibration
should be avoided to prevent bearing damage due to
brinelling. The risk of such damage can be reduced by
frequent rotation of the shaft.
The pump half coupling and key should be removed
from the shaft, coated with rust preventative and
wrapped to prevent metal-to-metal contact. Exposed
surfaces of the pump shaft should be protected with a
rust preventative. All dismantled parts should be
wrapped and tagged according to pump serial number
and a record kept of their location.
Pumps covered with plastic should
not be stored in a cool environment because
resulting condensation can cause rusting.
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2.5 Recycling and end of product life
At the end of the service life of the product or its parts,
the relevant materials and parts should be recycled or
disposed of using an environmentally acceptable
method and in accordance with local regulations. If the
product contains substances that are harmful to the
environment, these should be removed and disposed of
in accordance with current local regulations. This also
includes the liquids and/or gases that may be used in
the "seal system" or other utilities.
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 local
regulations at all times.
3.2 Name nomenclature
The pump size will be engraved on the nameplate. The
following example explains how the pump name
identifies the construction features and options.
8FRBH-182
Nominal discharge branch size.
Configuration – see below.
Nominal maximum impeller diameter.
Frame size
3 PUMP DESCRIPTION
JC is added for vertical cantilever
3.1 Configurations
3.3 Design of major parts
Flowserve "FRBH" pumps are single stage, end
suction centrifugal pumps specifically designed for the
pulp and paper industry and consequently are ideally
suited to many process fluids. A volute type casing
with integrally cast feet and top centerline discharge
nozzle is standard. Th e semi-open impeller with rear
pump-out vanes is capable of passing pulpy material
and solids of a limited size. A rigid steel sump cover
plate supports the pump and drive system. The three
point thrust bearing housing support permits precision
bearing alignment and impeller clearance setting.
3.3.1 Pump casing
The pump casing is a volute type casing with integrally
cast feet (for horizontal configuration) and centerline
discharge nozzle. It is a one piece pressure retaining
casting with gasket connections to the stuffing box
head and the suction and discharge flanges.
3.3.2 Impeller
The impeller is semi-open design, keyed to the shaft
and secured with a contoured impeller nut.
The pump liquid end is fitted with a non-flush restriction
bushing that also acts as a bearing for start -up
conditions.
3.3.3 Shaft
The large diameter stiff shaft, mounted on bearings,
has a keyed drive end.
All pumps are carefully inspected and prepared for
shipment. All exterior machined surfaces are coated
with a rust preventative compound and openings are
provided with covers or plugs. The axial impeller
running clearance is preset at the factory but should be
checked prior to final alignment in case of tampering.
3.3.4 Pump bearings and lubrication
Ball bearings are fitted as standard and grease
lubricated. The inboard bearing located just above the
top plate is pregreased and is sealed for life. Greasing
if necessary will only be required for the lip seal that
seals the bearing housing. The outboard bearing cover
has a grease fitting accessible through the motorstand.
3.3.5 Stuffing box housing
The stuffing box or lower housing has a spigot (rabbet)
fit between the pump casing and bearing housing for
optimum concentricity. The design enables a number
of sealing options to be fitted for horizontal
configuration.
Page 11 of 36
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
3.3.6 Driver
The driver is normally an electric motor driving via
couplings, belts, gearboxes, drive shafts etc.
3.4.1 Operating limits
Pumped liquid temperature limits
Maximum ambient temperature
Maximum soft solids in suspension
Maximum pump speed
3.3.7 Accessories
Accessories may be fitted when specified by the
customer.
3.4 Performance and operating limits
This product has been selected to meet the
specifications of your purchase order see section 1.5.
The following data is included as additional information
to help with your installation. It is typical, and factors
such as temperature, materials, and seal type may
influence this data. If required, a definitive statement
for your particular application can be obtained from
Flowserve.
up to+177 ºC (350 ºF)
up to +50 ºC (122 ºF)
up to 7 % by volume
Refer to the nameplate
3.4.2 Speed torque curves
To bring a centrifugal pump up to rated speed, the
driver must be capable of providing more torque at
each speed than required by the pump. The margin
between the available and required torque affects the
time it takes the unit to reach full speed. If the torque
required by the pump exceeds the torque capability of
the drive at any run-up speed, the unit will not
accelerate to full speed. Normally, this is not a problem
with standard induction or synchronous motors
provided the proper voltage is supplied at the motor.
For pumps started at shut valve conditions, 100 percent
full speed torque can be calculated by using the
formula:
Torque (Nm) = 9545 Shutoff Power (kW)
r/min
Torque (lbfx ft) = 5250 Shutoff Power (hp)
r/min
Torque required by the pump at any other speed during
start-up can be determined from the curve above. Note
that the driver manufacturer usually bases 100 percent
torque on the design power of the driver and
consequently the speed-torque curves should be
plotted in torque units (e.g. Nm) instead of percentage
torque to avoid confusion.
3.4.3 MAXIMUM WORKING PRESSURES -bar (psi).
CONSTRUCTION
TEMPERATURE
O
C ( OF)
-30 to 38 (-20 to100)
CAST IRON AND C.I.S.S. FITTED
UP TO 12”
14 TO 16”
DISCHARGE
DISCHARGE
10.3 (150)
10.3 (150)
18 TO 20”
DISCHARGE
6.2 (90)
STAINLESS STEEL
316,317L, WORTHITE, ETC.
UP TO 16”
18 TO 20”
DISCHARGE
DISCHARGE
13.8 (200)
8.3 (120)
65 (150)
10.3 (150)
9.7 (140)
6.2 (90)
13.8 (200)
8.3 (120)
95 (200)
10.3 (150)
9.3 (135)
6.2 (90)
13.4 (195)
8.3 (120)
120 (250)
10.3 (150)
9.0 (130)
6.2 (90)
12.6 (185)
8.3 (120)
12.1 (175)
8.3 (120)
11.0 (160)
7.6 (110)
150 (300)
175 (350)
CONSULT FACTORY FOR APPLICATIONS IN THIS RANGE.
CASTIRON NOT RECOMMENDED DUE TO THERMAL SHOCK RISKS.
Page 12 of 36
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
TABLE OF ENGINEERING DATA
(FRAMES 1 & 2 - LIQUID END)
ENGINEERING DATA
2
F
R
B
H
1
2
1
3
F
R
B
H
1
2
1
3
F
R
B
H
1
0
1
4
F
R
B
H
1
1
1
76
(3)
51
(2)
11.2
(.44)
9.7
(.38)
102
(4)
76
(3)
11.2
(.44)
9.7
(.38)
152
(6)
76
(3)
11.2
(.44)
9.7
(.38)
152
(6)
102
(4)
11.2
(.44)
9.7
(.38)
SV - SINGLE
1 / 4 NPT
6
F
R
B
H
1
1
1
3
F
R
B
H
1
4
1
4
F
R
B
H
1
4
1
6
F
R
B
H
1
4
2
8
F
R
B
H
1
5
2
3
F
R
B
H
1
8
2
4
F
R
B
H
1
8
2
8
F
R
B
H
1
8
2
10
F
R
B
H
1
8
2
152
(6)
102
(4)
11.2
(.44)
9.7
(.38)
203
(8)
152
(6)
17.5
(.69)
14.2
(.56)
254
(10)
203
(8)
17.5
(.69)
16
(.63)
DV
152
(6)
76
(3)
16
(.63)
12.7
(.50)
203
(8)
102
(4)
16
(.63)
12.7
(.50)
153
(10)
203
(8)
20.8
(.82)
16
(.63)
305
(12)
153
(10)
20.8
(.82)
17.5
(.69)
PUMP DATA
SUCTION DIA. mm
(in.)
DISCHARGE DIA. mm
(in.)
CASING
C.I.
THICKNESS mm (in.)
CASING
S.S.
THICKNESS mm (in.)
CASING TYPE
GAUGE CONNECTION
DRAIN CONNECTION
NO. OF VANES
IMP. EYE AREA
cm2
(in.2)
MAX. SPHERE DIA. mm
(in.)
WK2
kg x m2
( lb x ft2)
*PUMP WEIGHT
kg
(lb.)
IMPELLER AXIAL
CLEARANCE mm (in.)
MAXIMUM
TEMPERATURE
MAX. HYDRO
PRESSURE
C.I.
S.S.
O.D. SLEEVE mm (in.)
STUFF. BOX BORE mm (in.)
DEPTH OF BOX mm (in.)
203
152
(8)
(6)
152
76
(6)
(3)
11.2
11.2
(.44)
(.44)
9.7
9.7
(.38)
(.38)
VOLUTE
3 / 8 NPT
34
(5.2)
12.7
(.5)
.07
(1.7)
61
(9.5)
17.8
(.7)
.08
(1.9)
1 / 2 NPT
93
(14.4)
25.4
(1.0)
.07
(1.6)
137
(21.3)
30.5
(1.2)
.08
(1.9)
214
(33.2)
43.2
(1.7)
.12
(2.8)
127
4
182
247
(19.7)
(28.2)
(38.3)
25.4
(1.0)
.19
(4.6)
35.6
(1.4)
.27
(6.5)
38.1
(1.5)
.34
(8.2)
.38 - .76
(.015 - .030)
121o C
(250o F)
12.1 bar (175 psi)
20.7 bar (300 psi)
STUFFING BOX DATA
50.80 (2.000)
69.85 (2.750)
77.5 (3.05)
Page 13 of 42
361
(56)
55.9
(2.2)
.48
(11.5)
SV
1 / 2 NPT
3 / 4 NPT
DV
1” NPT
183
200
359
555
(28.3)
(31.0)
(55.6)
(86.0)
19.1
(.75)
27.9
(1.1)
55.9
(2.2)
68.6
(2.7)
.51
(12.0)
.53
(12.5)
.88
(20.8)
1.19
(28.2)
.38 - .76
(.015 - .030)
121o C
(250o F)
15.5 bar (225 psi)
20.7 bar (300 psi)
76.20 (3.000)
101.60 (4.000)
99.1 (3.90)
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
TABLE OF ENGINEERING DATA
(FRAMES 1 & 2 - FRAME DETAILS)
ENGINEERING DATA
SHAFT AND BEARING
DATA
DIA. AT IMPELLER mm
(in.)
DIA. UNDER SLEEVE mm
(in.)
DIA. BETWEEN
mm
BEARINGS
(in.)
DIA. AT COUPLING mm
(in.)
2
F
R
B
H
1
2
1
3
F
R
B
H
1
2
1
3
F
R
B
H
1
0
1
4
F
R
B
H
1
1
1
28.58
(1.125)
6
F
R
B
H
1
1
1
3
F
R
B
H
1
4
1
4
F
R
B
H
1
4
1
6
F
R
B
H
1
4
2
34.93
(1.375)
8
F
R
B
H
1
5
2
3
F
R
B
H
1
8
2
4
F
R
B
H
1
8
2
8
F
R
B
H
1
8
2
50.80
(2.000)
66.68
(2.625)
41.27
(1.625)
104.65
(4.12)
63.50
(2.500)
LINE BEARING
6321 2RS1 C3
THRUST BEARING
BEARING SPAN
mm
(in.)
7318 BECBY
691
(27.2)
B10 BEARING LIFE
BEARING SEALS
MINIMUM 3 YEARS
THRUST BEARING LIP
SEAL (1)
LINE BEARING LIP SEAL
(1)
NATIONAL 417191
C / R 49929
(1) LIP SEAL MAY BE REPLACED BY APPROPRIATE LABRYNTH SEALS
Page 14 of 42
NATIONAL 417511
10
F
R
B
H
1
8
2
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
TABLE OF ENGINEERING DATA
(FRAME 3 - LIQUID END)
ENGINEERING DATA
6
F
R
B
H
1
8
3
12
F
R
B
H
1
8
3
14
F
R
B
H
1
8
3
16
F
R
B
H
1
8
3
6
F
R
B
H
2
2
3
8
F
R
B
H
2
2
3
18
F
R
B
H
2
2
3
PUMP DATA
SUCTION DIAMETER mm
254
356
356
406
254
305
457
(in.)
(10)
(14)
(14)
(16)
(10)
(12)
(18)
DISCHARGE DIA
mm
152
305
356
406
152
203
457
(in.)
(6)
(12)
(14)
(16)
(6)
(8)
(18)
17.5
19.0
20.8
20.8
19.0
20.8
17.3
CASING
C.I. mm
(.69)
(.75)
(.82)
(.82)
(.75)
(.82)
(.68)
(in.)
14.2
15.7
17.5
17.5
16.0
17.5
14.2
THICKNESS
S.S. mm
(.56)
(.62)
(.69)
(.69)
(.63)
(.69)
(.56)
(in.)
CASING TYPE
SV
DV
SV
GA UGE CONNECTION
1 / 2 NPT
DRAIN CONNECTION
1 NPT
1 - 1 / 4 NPT
1 NPT
1.5
NO. OF VANES
4
6
5
4
5
292
755
839
1090
352
564
1510
IMPELLER EYE AREA cm2
(45.2)
(117)
(130)
(169)
(54.4)
(87.4)
(234)
(in.2)
48.3
96.5
40.6(
40.6
50.8
61
61
MAX. SPHERE DIA.
mm
(1.9)
(3.8)
1.6)
(1.6)
(2.0)
(2.4)
(2.4)
(in.)
1.64
1.88
WK2
kg x m2
.83
.93
1.57
1.39
3.91
( lb x ft2) (19.8)
(22.0) (37.2) (33.0) (38.8) (44.5) (92.9)
PUMP WT.
kg
(lb.)
IMPELLER AXIAL
mm
.38 - .76
CLEARANCE
(in.)
(.015 - .030)
MAXIMUM
121o C
TEMPERATURE
(250o F)
STUFFING BOX DATA
O.D. SLEEVE
mm
(in.)
STUFFING BOX BORE mm
(in.)
DEPTH OF BOX
mm
(in.)
95.25
(3.750)
127.00
(5.000)
122.2
(4.81)
Page 15 of 42
DV - DUAL VOLUTE
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
TABLE OF ENGINEERING DATA
(FRAMES 3 & 4 - FRAME DETAILS)
ENGINEERING DATA
DIA. AT IMPELLER
mm
(in.)
DIA. UNDER SLEEVE mm
(in.)
DIA. BETWEEN
mm
BEARINGS
(in.)
DIA. AT COUPLING
mm
(in.)
LINE BEARING
THRUST BEARING
BEARING SPAN
6
F
R
B
H
1
8
3
12
F
R
B
H
1
8
3
14
F
R
B
H
1
8
3
16
F
R
B
H
1
8
3
6
F
R
B
H
2
2
3
8
F
R
B
H
2
2
3
18
F
R
B
H
2
2
3
SHAFT AND BEARING DATA
69.85
(2.750)
82.55
(3.250)
104.65
(4.12)
63.50
(2.500)
6321 2RS1 C3
mm
(in.)
B10 BEARING LIFE
7318 BECBY
952.5
(37.5)
MINIMUM 3 YEARS
BEARING SEALS
THRUST BEARING LIP SEAL
NATIONAL 417191
LINE BEARING LIP SEAL
NATIONAL 417511
Page 16 of 42
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
MATERIALS OF CONSTRUCTION
(LIQUI D END)
BASIC
CONSTRUCTION
CASING,LOWER
HOUSING AND WEAR
PLATE
IMPELLER
IMPELLER NUT
SHAFT SLEEVE
SHAFT
PIPE PLUGS
(LIQUID END)
IMPELLER KEY
WEAR PLATE STUDS
& NUTS
GASKETS
O-RINGS (LIQUID END)
MISC. FASTNERS,
PARTS
*
**
ALL IRON
AIF
ALL 316 SS
(SS)
317 SS
317L SS
WORTHITE
W
ASTM A743
CF8M
IRON CASING
SS FITTED
(SSF)
ASTM A48
CL35
ASTM A48
CL35
ASTM A743
CG8M
ASTM A743
CG3M
ASTM A743
CN7MS
ASTM A48
CL30
ASTM A743
CG3M
ASTM A743
CG3M *
AISI 1045
ASTM A743
CF8M
ASTM A743
CG3M
ASTM A743
CG3M *
AISI 316
ASTM A743
CF8M
ASTM A743
CG3M
ASTM A743
CG3M *
AISI 1045
ASTM A743
CG8M
ASTM A743
CG3M
ASTM A743
CG3M *
AISI 317L
ASTM A743
CG3M
ASTM A743
CG3M
ASTM A743
CG8M *
AISI 317L
ASTM A743
CN7MS
ASTM A743
CN7M
ASTM A743
CN7M
AISI A20
C.I.
AISI 1045
AISI 316
AISI 316
C.I.
AISI 1045
A-20
A-20
A-20
A-20
A-20
A-20
AISI 316
A-20
SYNTHETIC FIBRE
BUNA-N ( 120o C MAX.)**
STEEL
Nickel-Chrome-Boron Coated, except for units with mechanical seals.
o
Viton will be used for all applications operating above 120 C.
Page 17 of 42
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
4 INSTALLATION
Equipment operated in hazardous locations
must comply with the relevant explosion protection
regulations. See section 1.6.4, Products used in
potentially explosive atmospheres.
4.1 Location
The pump should be located to allow room for
access, ventilation, maintenance and inspection with
ample headroom for lifting and should be as close as
practicable to the supply of liquid to be pumped.
Allow sufficient room to facilitate the back pull-out
feature on V-belt driven units.
Refer to the general arrangement drawing for the
pump set.
4.2 Part assemblies
Motors may be supplied loose on FRBH pumps,
typically on frame sizes 400 and above. It is the
responsibility of the installer to ensure that the motor
is assembled to the pump and lined up as detailed in
section 4.5.2.
4.3 Foundation
The foundation may consist of any
material that will afford permanent, rigid support to the
full area of the pump or driver supporting member. It
should be of sufficient size and mass to absorb
expected strains and shocks that may be encountered
in service. Concrete foundations built on solid ground
are desirable.
The purpose of foundation bolts is to anchor the pump
unit securely to the foundation such that the foundation
and pump assembly become a single structural unit.
High strength steel foundation bolts (SAE Gr. 5 or
equal) of the specified diameter should be located
according to the elevation drawing provided. Each bolt
should be surrounded by a pipe sleeve two or three
times the diameter of the bolt.The sleeves should be
securely anchored and designed to allow the bolts to be
moved to conform with the holes in the baseplate. The
bolts should be sufficiently long to allow for wedges or
shims or levelling nuts under the baseplate, and a
washer, heavy hex nut and hex jam nut for retention.
Since baseplate levelling is performed after the
foundation has cured, it is best to use extra long bolts
that can be shortened after the installation is complete.
Page 18 of 42
4.4 Baseplate installation
Position the baseplate and pump next to the foundation
and clean the foundation surface thoroughly. Remove
the rag packing from the pipe sleeves and place
wedges or ships as close to the foundation bolts as
possible. These may be omitted if a jacking nut on the
foundation anchor bolts is preferred for levelling. Initial
levelling should be within 0.75 mm (.030 inches).
Remove the flange covers and check inside the pump
nozzles for cleanliness. Kerosene is recommended as
the best solvent for removing factory applied rust
preventative. Ensure that all traces of rust preventative
are removed from the discharge and suction flange
faces, the exposed shafting and all coupling surfaces.
Flush the pump internals of any rust preventative
applied for long-term storage.
Lift the baseplate assembly, remove the shipping skids
and clean the underside of the baseplate. Position the
baseplate over the foundation and lower the unit over
the foundation bolts and onto the wedges, shims or
jacking nuts.
With the aid of a machinist's level, adjust the wedges,
shims or jacking nuts to level the pump and driver
mounting pads in each direction. Check to ensure that
the suction and discharge flanges are plumb, level, and
at the correct elevation. It is normal practice to set the
mounting pads slightly low in order to permit lowering of
units which may be required to suit future piping or
minor changes. Place washers over the foundation
bolts and install nuts. Tighten finger tight only.
Check the impeller axial clearance and that the rotor
turns freely by hand.
Note: Grout is not poured until an initial alignment
of the pump and driver has been performed.
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
4.5 Initial alignment
4.5.1 Thermal expansion
The pump and motor will normally
have to be aligned at ambient temperature and
should be corrected to allow for thermal expansion at
operating temperature.
In pump installations
involving high liquid temperatures, the unit should be
run at the actual operating temperature, shut down
and the alignment checked immediately.
4.5.2 Alignment methods
Ensure pump and driver are isolated
electrically and the half couplings are disconnected.
The alignment MUST be checked.
Although the pump will have been aligned at the
factory it is most likely that this alignment will have
been disturbed during transportation or handling. If
necessary, align the motor to the pump, not the pump
to the motor.
Direct Driven Units:
The importance of accurate alignment of pump and
driver shafts cannot be overemphasized.
IMPROPER ALIGNMENT IS THE PRIMARY CAUSE
OF VIBRATION PROBLEMS AND REDUCED
BEARING LIFE.
A flexible coupling is used to compensate for slight
changes in alignment which occur during normal
operation and is not used to correct for installation
errors. Install the pump and driver half couplings in
accordance with the coupling manufacturer's
instructions. Note that the coupling hub faces are not
always mounted flush with the ends of the shafts. Place
the driver on the baseplate such that the correct spacing
is obtained between the two half couplings. In the case
of electric motors, such as those with sleeve bearings, it
may be necessary to run the motor to establish the rotor
magnetic center. Consult the manufacturer's instruction
manual for details.
The purpose of the alignment procedure is to ensure
that the pump and driver shafts are in parallel and
angular alignment under the normal operating
conditions of load and temperature. (See Fig. 2)
When the pump coupling and driver are assembled at
the factory, the units are aligned prior to shipment.
However, baseplates can be sprung or distorted during
shipment or installation and the alignment must be
checked before the unit is put in service. The coupling
spacer must be removed to make this check.
Page 19 of 42
For pumps and drivers which operate at different
temperatures compensation must be made at the initial
alignment stage (when the units are at the same
temperature) to allow for thermal expansion during
operation. Consult the instruction manual supplied with
the driver for the manufacturer's recommendations.
Shaft alignment is greatly simplified by the use of a dial
indicator, or with extension rods and a magnetic base.
Before taking readings, ensure that the pump and driver
mounting bolts are secure, and that the thrust bearing
housing is properly aligned in the bearing frame or
cartridge. (See Section VII- Maintenance).
Parallel Alignment:
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
Mount the magnetic base on the pump half coupling hub
and place the dial indicator button on the outside
diameter of the driver half coupling hub. Note that the
length of extension rods should be kept at a minimum to
reduce deflection. Rotate the pump shaft and record
the dial reading at the top, bottom and each side.
Correct the parallel alignment by adding or removing
shims under the driver and/or moving the driver
horizontally. Repeat this procedure until the maximum
total indicator reading (T.I.R.) is within 0.076 mm (0.003
inch.)
Angular Alignment:
With the magnetic base mounted on the pump half
coupling hub, move the dial indicator button to indicate
on the face of the driver half coupling hub as close to
the outside diameter as possible. Turn both shafts 360°
and record the dial readings at 90° intervals. Adjust the
shims under the motor as required and repeat the
procedure until the angular alignment is within 0.0005
mm (T.I.R.) per mm (0.0005 inch per inch) of maximum
hub diameter.
grouting is complete and cured and the alignment is rechecked.
When the electric motor has sleeve bearings it is
necessary to ensure that the motor is aligned to run
on its magnetic centreline. A button (screwed into
one of the shaft ends) is normally fitted between the
motor and pump shaft ends to fix the axial position.
If the motor does not run in its
magnetic centre the resultant additional axial force
may overload the pump thrust bearing.
Complete piping as below and see sections
4.7, Final shaft alignment check up to and including
section 5, Commissioning, startup, operation and
shutdown before connecting driver and checking
actual rotation.
V-Belt Drive Units:
Check that both sheaves are free of grease, rust, nicks
or burrs. Install the correct size sheave on the pump
shaft and locate the sheave axially to minimize
overhang. Re-check the impeller axial clearance and
ensure that the pump is properly secured to the
baseplate. Install the driver on the adjustable base
provided and install the driver sheave in line with the
pump sheave. Ensure that the sheaves are tight on the
shafts. With a dial indicator, check the run-out on the
periphery and face of each sheave to ensure that each
is running true. Tighten the adjustable base and check
that the driver rotation in the correct direction and that
vibration levels are not unacceptable.
Repeat the checks on parallel and angular alignment,
ensuring the mounting bolts are secure, until the unit is
properly aligned. Note that correction in one direction
may affect the alignment in another direction. Re-check
the gap between the coupling hubs.
If any difficulty is encountered in achieving the
recommended alignment tolerances, the runout of the
pump and driver shafts and each coupling hub diameter
and face should be checked. Occasionally, due to
practical and unavoidable manufacturing tolerance
build-up associate with the pump, coupling and driver, it
may be necessary to match up the two coupling hubs in
the most advantageous relative angular position in order
to achieve an acceptable alignment.
Do not install the coupling spacer or sleeve until
Page 20 of 42
Checking V-Belt Sheave Alignment
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
Before starting the driver, refer to the
manufacturer’s instruction manual. The correct rotation
of the pump shaft is marked on the pump casing or
frame.
Check that all belts making up one drive set have
matched code numbers. Loosen the adjustable base
and install the belts in their proper grooves. Adjust the
center distance between the sheaves to obtain proper
belt tension. Check the alignment of the pump and
driver sheaves with a taught string or straight edge. For
proper alignment and the sheave faces must be parallel
to each other and in line. Adjustments are made by
slackening the belts, moving and retightening the drive
or driver sheave, and repeating the above procedure.
When the sheaves are aligned that the shafts rotate
freely by hand and install safety guard.
4.6 Grouting
The purpose of grouting is to provide rigid support to the
pump and driver by increasing the structural rigidity of
the baseplate and making it an integral mass with the
foundation.
Clean the roughed foundation surface and build a
wooden form around the baseplate (see Fig. 1). For
initial grouting forms should be placed to isolate shims
and levelling nuts. The foundation surface should be
thoroughly saturated with water before grouting. A
typical mixture for grouting-in a pump base is composed
of one part pure Portland cement and two parts of clean
building sand with sufficient water to provide the proper
consistency. The grout should flow freely but not be so
wet as to cause the sand and cement to separate.
Thoroughly puddle the grout while pouring to eliminate
air pockets and low spots. Pour sufficient grouting to
ensure that the bottom surface of the baseplate is
completely submerged. Do not fill isolated areas
around the shims or levelling nuts. Once the grout has
set sufficiently, remove the wooden forms and finish off
the sides and top as desired. At the same time,
roughen the grout surface inside the baseplate. Cover
with wet burlap and allow the grout to cure for at least
40 hours.
After grouting has cured, shims and levelling nuts
should be removed or backed off. Tighten down
baseplate to the new grout to put bolts in tension and
ensure rigidity of structure. Install jam nuts and cut the
Page 21 of 42
bolts to the desired length. Finish grouting isolated
areas. Fill the baseplate including pump and driver
support pedestals with concrete. Trowel and slope the
surface to give suitable drainage.
4.7 Piping
Protective covers are fitted to the pipe
connections to prevent foreign bodies entering during
transportation and installation. Ensure that these
covers are removed from the pump before
connecting any pipes.
4.7.1 Suction and 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 suction and discharge. Typically main
pipework velocities should not exceed 2 m/s (6 ft/sec)
suction and 3 m/s (9 ft/sec) on the discharge.
Take into account the available NPSH which must be
higher than the required NPSH of the pump.
Never use the pump as a support for
piping.
Maximum forces and moments allowed on the pump
flanges vary with the pump size and type. To
minimize these forces and moments that may, if
excessive, cause misalignment, hot bearings, worn
couplings, vibration and the possible failure of the
pump casing, the following points should be strictly
followed:
• Prevent excessive external pipe load
• Never draw piping into place by applying force to
pump flange connections
• Do not mount expansion joints so that their force,
due to internal pressure, acts on the pump flange
The table in 4.7.2 summarizes the maximum forces
and moments allowed on FRBH pump casings.
Refer to Flowserve for other configurations.
Ensure piping and fittings are flushed
before use.
Ensure piping for hazardous liquids is arranged
to allow pump flushing before removal of the pump.
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
4.7.2 Maximum forces and moments allowed on FRBH pump flanges
Flange Size
DN
(in.)
50
(2)
65
(2-1/2)
80
(3)
100
(4)
125
(5)
150
(6)
200
(8)
250
(10)
300
(12)
350
(14)
400
(16)
450
(18)
500
(20)
550
(24)
Maximum forces (F) in N (lbf) and moments (M) in Nm (lbf•ft)
Suction
Discharge
Mx
My
Mz
Fx
Fy
Fz
Mx
My
Mz
Fx
Fy
Fz
460
(340)
710
(520)
950
(700)
1330
(980)
1830
(1340)
2300
(1700)
3530
(2600)
5020
(3700)
6100
(4500)
6370
(4700)
7320
(5400)
8200
(6050)
9080
(6700)
10850
(8000)
230
(170)
350
(260)
470
(350)
680
(500)
940
(690)
1180
(870)
1760
(1300)
2440
(1800)
2980
(2200)
3120
(2300)
3660
(2700)
4200
(3100)
4750
(3500)
5830
(4300)
350
(260)
540
(400)
720
(530)
1000
(740)
1450
(1070)
1760
(1300)
2580
(1900)
3800
(2800)
4610
(3400)
4750
(3500)
5420
(4000)
6100
(4500)
6780
(5000)
8130
(6000)
890
(200)
1110
(250)
1330
(300)
1780
(400)
2450
(550)
3110
(700)
4890
(1100)
6670
(1500)
8000
(1800)
8900
(2000)
10230
(2300)
11570
(2600)
12900
(2900)
15480
(3480)
710
(160)
890
(200)
1070
(240)
1420
(320)
1960
(440)
2490
(560)
3780
(850)
5340
(1200)
6670
(1500)
7120
(1600)
8450
(1900)
9650
(2170)
10720
(2410)
13120
(2950)
5808
(130)
760
(170)
890
(200)
1160
(260)
1600
(360)
2050
(460)
3110
(700)
4450
(1000)
5340
(1200)
5780
(1300)
6670
(1500)
7560
(1700)
8450
(1900)
10230
(2300)
460
(340)
710
(520)
950
(700)
1330
(980)
1830
(1340)
2300
(1700)
3530
(2600)
5020
(3700)
6100
(4500)
6370
(4700)
7320
(5400)
8200
(6050)
9080
(6700)
10850
(8000)
230
(170)
350
(260)
470
(350)
680
(500)
940
(690)
1180
(870)
1760
(1300)
2440
(1800)
2980
(2200)
3120
(2300)
3660
(2700)
4200
(3100)
4750
(3500)
5830
(4300)
350
(260)
540
(400)
720
(530)
1000
(740)
1450
(1070)
1780
(1300)
2580
(1900)
3800
(2800)
4610
(3400)
4750
(3500)
5420
(4000)
6100
(4500)
6780
(5000)
8130
(6000)
710
(160)
890
(200)
1070
(240)
1420
(320)
1960
(440)
2490
(560)
3780
(850)
5340
(1200)
6670
(1500)
7120
(1600)
8450
(1900)
9610
(2160)
10760
(2420)
13080
(2940)
580
(130)
760
(170)
890
(200)
1160
(260)
1600
(360)
2050
(460)
3110
(700)
4450
(1000)
5340
(1200)
5780
(1300)
6670
(1500)
7560
(1700)
8450
(1900)
10230
(2300)
890
(200)
1110
(250)
1330
(300)
1780
(400)
2450
(550)
3110
(700)
4890
(1100)
6670
(1500)
8000
(1800)
8900
(2000)
10230
(2300)
11570
(2600)
12900
(2900)
15660
(3520)
Notes:
1) F = External force (tension or compression)
M = External
moment, clockwise or counter-clockwise
2) Forces and moments may be applied simultaneously in any
direction
3) Values apply to all materials
4) Higher loads may be applicable, if direction and magnitude of
individual loads are known, but these need written approval from
Flowserve
Page 22 of 42
5) Pumps must be on rigid foundations and baseplates must be
fully grouted
6) Pump/baseplate should not used as pipe anchor. Expansion
joints must be properly tied
7) The pump mounting bolt torques specified must be used to
prevent relative movement between the pump casing and
baseplate. (See section 6.6, Fastener torques.) The bolt material
must have a minimum yield strength of 600 N/mm2
(87 000 lb/in.2)
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
4.7.2 Suction piping
a) Drop pipes may be used to extend the pump
setting yet maintain cantilever design. All designs
are reviewed for shaft deflection and critical
speeds.
b) Inlet strainers, when used, should have a net `free
area' of at least three times the inlet pipe area.
4.7.3 Discharge piping
A non-return valve should be located in the discharge
pipework to protect the pump from excessive back
pressure and hence reverse rotation when the unit is
stopped.
Pipework reducers should have a maximum total
angle of divergence of 15 degrees. Fitting an isolation
valve will allow easier maintenance.
4.7.5 Final checks
Check the tightness of all bolts in the suction and
discharge pipework. Check also the tightness of all
foundation bolts.
4.8 Final shaft alignment check
After connecting piping to the pump, rotate the shaft
several times by hand to ensure there is no binding
and all parts are free.
Recheck the coupling alignment, as previously
described, to ensure no pipe strain. If pipe strain
exists, correct piping.
4.9 Electrical connections
4.9.1
Electrical connections must be
made by a qualified Electrician in accordance with
relevant local national and international regulations.
4.9.2
It is important to be aware of the
EUROPEAN DIRECTIVE on potentially explosive
areas where compliance with IEC60079-14 is an
additional requirement for making electrical
connections.
4.9.3
It is important to be aware of the
EUROPEAN DIRECTIVE on electromagnetic
compatibility when wiring up and installing equipment
on site. Attention must be paid to ensure that the
techniques used during wiring/installation do not
increase electromagnetic emissions or decrease the
electromagnetic immunity of the equipment, wiring or
any connected devices. If in any doubt contact
Flowserve for advice.
Page 23 of 42
4.9.4
The motor must be wired up in
accordance with the motor manufacturer's instructions
(normally supplied within the terminal box) including
any temperature, earth leakage, current and other
protective devices as appropriate. The identification
nameplate should be checked to ensure the power
supply is appropriate.
4.9.5
A device to provide emergency stopping
must be fitted.
4.9.6 If not supplied pre-wired to the pump unit, the
controller/starter electrical details will also be supplied
within the controller/starter.
4.9.7 For electrical details on pump sets with
controllers see the separate wiring diagram.
4.9.8
See section 5.3, Direction of
rotation before connecting the motor to the electrical
supply.
4.10 Protection systems
The following protection systems are
recommended particularly if the pump is installed in a
potentially explosive area or is handling a hazardous
liquid. If in doubt consult Flowserve.
If there is any possibility of the system allowing the
pump to run against a closed valve or below minimum
continuous safe flow a protection device should be
installed to ensure the temperature of the liquid does
not rise to an unsafe level.
If there are any circumstances in which the system
can allow the pump to run dry, or start up empty, a
power monitor should be fitted to stop the pump or
prevent it from being started. This is particularly
relevant if the pump is handling a flammable liquid.
If leakage of product from the pump or its associated
sealing system can cause a hazard it is recommended
that an appropriate leakage detection system is
installed.
To prevent excessive surface temperatures at
bearings it is recommended that temperature or
vibration monitoring are carried out. See sections
5.7.4 and 5.7.5.
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
5 COMMISSIONING, START-UP,
OPERATION AND SHUTDOWN
Approximate oil volumes are shown in section 3.4.2,
Pump and impeller data.
These operations must be carried
out by fully qualified personnel.
Grease lubricated pumps and electric motors are
supplied pre-greased.
5.1 Pre-commissioning procedure
Other drivers and gearboxes, if appropriate, should be
lubricated in accordance with their manuals.
5.1.1 Lubrication
Determine the mode of lubrication of the pump set,
eg grease, oil, product lubrication etc.
For oil lubricated pumps, fill the
bearing housing with correct grade of oil to the correct
level, ie sight glass or constant level oiler bottle.
When fitted with a constant level oiler, the bearing
housing should be filled by unscrewing or hinging
back the transparent bottle and filling the bottle with
oil. Where an adjustable body Trico oiler is fitted this
should be set to the proper height.
The oil filled bottle should then be refitted so as to
return it to the upright position. Filling should be
repeated until oil remains visible within the bottle.
Page 24 of 42
In the case of product lubricated
bearings the source of product supply should be
checked against the order. There may be
requirements for an external clean supply, particular
supply pressure or the commencement of lubrication
supply before pump start-up.
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
5.2 Pump lubricants
5.2.1 Recommended grease lubricants
Grease nipples
Grease
NLGI 2 *
NLGI 3 **
Temp. range ºC
(ºF)
-20 to +100
(-4 to +212)
-20 to +100
(-4 to +212)
Designation
according to DIN
K2K-20
K2K 30
BP
Energrease LS2
Energrease LS3
DEA
Glissando 20
Glissando 30
Elf
Elfmulti 2
Elfmulti 3
Esso
Beacon 2
Beacon 3
Mobil
Mobilux 2
Mobilux 3
Q8
Rembrandt 2
Rembrandt 3
Shell
Alvania Fett G2
Alvania Fett R2
Alvania R3
Texaco
Multilak 20
Multilak EP2
Multilak 30
Multilak EP3
Wintershall
(BASF Group)
Wiolub LFK 2
-
SKF
LGMT 2
LGMT 3
5.3 Direction of rotation
Ensure the pump is given the same
rotation as the pump direction arrow cast on the pump
casing.
To avoid dry running the pump must either be filled with
liquid or have the flexible coupling disconnected before
driver is switched on.
If maintenance work has been carried
out to the site's electricity supply, the direction of
rotation should be re-checked as above in case the
supply phasing has been altered.
5.4 Guarding
Silkolene
G55/T
G56/T
* NLGI 2 is an alternative grease and is not to be mixed with other
grades
** Factory packed bearings for the temperature range with grease
nipples
5.2.2 Recommended fill quantities
Refer to section 3.4.2, Pump and impeller data.
5.2.3
Never mix greases containing different
bases, thickeners or additives.
Lubrication schedule
5.2.3.1 Grease lubricated bearings
When grease nipples are fitted, one charge between
grease changes is advisable for most operating
conditions, ie 2 000 hours interval.
Guarding is supplied fitted to the pump set. If this
has been removed or disturbed ensure that all the
protective guards around the pump coupling and
exposed parts of the shaft are securely fixed.
5.5 Priming and auxiliary supplies
Ensure all electrical, hydraulic,
pneumatic, sealant and lubrication systems (as
applicable) are connected and operational.
Ensure the inlet pipe and pump casing
are completely full of liquid before starting continuous
duty operation.
5.6 Starting the pump
Normal intervals between grease changes are 4 000
hours or at least every 6 months.
The characteristics of the installation and severity of
service will determine the frequency of lubrication.
Lubricant and bearing temperature analysis can be useful
in optimising lubricant change intervals.
a)
Ensure flushing and/or cooling/
heating liquid supplies are turned ON before
starting the pump.
b) CLOSE the outlet valve.
c) OPEN all inlet valves.
d) Prime the pump.
The bearing temperature may be allowed to rise to
55 ºC (131 ºF) above ambient but should not exceed 95
°C (204 °F). For most operating conditions a quality
grease having a lithium soap base and NLGI consistency
of No 2 or No 3 is recommended. The drop point should
exceed 175 ºC (350 ºF).
e)
Ensure all vent connections are closed before
starting.
f) Start motor and check outlet pressure.
g) If the pressure is satisfactory, slowly OPEN outlet
control valve.
h)
Page 25 of 42
Do not run the pump with the outlet
valve closed for a period longer than 30 seconds.
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
i)
If NO pressure, or LOW pressure, STOP the pump.
Refer to section 7, Faults; causes and remedies,
for fault diagnosis.
5.7 Running the pump
5.7.1 Venting the pump
Vent the pump to enable all trapped air to escape
taking due care with hot or hazardous liquids.
Under normal operating conditions, after the pump has
been fully primed and vented, it should be unnecessary
to re-vent the pump.
Vibration velocity – unfiltered
mm/s (in./s) r.m.s.
Normal
N
≤ 7.1 (0.28)
Alarm
N x 1.25
Shutdown trip N x 2.0
≤ 9.0 (0.35)
≤ 14.2 (0.56)
5.7.6 Stop/start frequency
Pump sets are normally suitable for the number of
equally spaced stop/starts per hour shown in the table
below. Check actual capability of the driver and
control/starting system before commissioning.
Motor rating kW (hp)
Up to 15 (20)
Between 15 (20) and 90 (120)
Above 90 (120)
5.7.4 Bearings
If the pumps are working in a potentially
explosive atmosphere temperature or vibration
monitoring at the bearings is recommended
FRBHJC
Maximum stop/starts
per hour
15
10
6
Where duty and standby pumps are installed it is
recommended that they are run alternately every week.
If bearing temperatures are to be monitored it is
essential that a benchmark temperature is recorded at
the commissioning stage and after the bearing
temperature has stabilized. Record the bearing
temperature (t) and the ambient temperature (ta).
Estimate the likely maximum ambient temperature (tb).
Set the alarm at (t+tb-ta+5)°C [(t+tb-ta+10)°F] and the
trip at 100 °C (212 °F) for oil lubrication and 105 °C
(220 °F) for grease lubrication.
It is important, particularly with grease lubrication, to
keep a check on bearing temperatures. After start up
the temperature rise should be gradual, reaching a
maximum after approximately 1.5 to 2 hours. This
temperature rise should then remain constant or
marginally reduce with time. Refer to section 6.2.3.1
for further information.
5.7.5 Normal vibration levels, alarm and trip
For guidance, pumps generally fall under a
classification for rigid support machines within the
International rotating machinery standards and the
recommended maximum levels below are based on
those standards.
Alarm and trip values for installed
pumps should be based on the actual measurements
(N) taken on the pump in the fully commissioned as
new condition. Measuring vibration at regular intervals
will then show any deterioration in pump or system
operating conditions.
5.8 Stopping and shutdown
a)
Close the outlet valve, but ensure
that the pump runs in this condition for no more
than a few seconds.
b) Stop the pump.
c) Switch off flushing and/or cooling/heating liquid
supplies at a time appropriate to the process.
d)
For prolonged shut-downs and
especially when ambient temperatures are likely to
drop below freezing point, the pump and any
cooling and flushing arrangements must be drained
or otherwise protected.
5.9 Hydraulic, mechanical and electrical
duty
This product has been supplied to meet the
performance specifications of your purchase order,
however it is understood that during the life of the
product these may change. The following notes may
help the user decide how to evaluate the implications of
any change. If in doubt contact your nearest Flowserve
office.
5.9.1 Specific gravity (SG)
Pump capacity and total head in metres (feet) do not
change with SG, however pressure displayed on a
pressure gauge is directly proportional to SG. Power
absorbed is also directly proportional to SG. It is
therefore important to check that any change in SG will
not overload the pump driver or over-pressurize the
pump.
Page 26 of 42
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
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5.9.2 Viscosity
For a given flow rate the total head reduces with
increased viscosity and increases with reduced
viscosity. Also for a given flow rate the power
absorbed increases with increased viscosity, and
reduces with reduced viscosity. It is important that
checks are made with your nearest Flowserve office if
changes in viscosity are planned.
5.9.3 Pump speed
Changing pump speed effects flow, total head, power
absorbed, NPSHR , noise and vibration. Flow varies in
direct proportion to pump speed, head varies as speed
ratio squared and power varies as speed ratio cubed.
The new duty, however, will also be dependent on the
system curve. If increasing the speed, it is important
therefore to ensure the maximum pump working
pressure is not exceeded, the driver is not overloaded,
NPSHA > NPSHR , and that noise and vibration are
within local requirements and regulations.
5.9.4 Net positive suction head (NPSHA)
NPSH available (NPSHA) is a measure of the head
available in the pumped liquid, above its vapour
pressure, at the pump suction branch.
NPSH required (NPSHR ) is a measure of the head
required in the pumped liquid, above its vapour
pressure, to prevent the pump from cavitating. It is
important that NPSHA > NPSHR . The margin between
NPSHA > NPSHR should be as large as possible.
Any work on the machine must be performed when it is
at a standstill. It is imperative that the procedure for
shutting down the machine is followed, as described in
section 5.8.
On completion of work all guards and safety devices
must be re-installed and made operative again.
Before restarting the machine, the relevant instructions
listed in section 5, Commissioning, start up, operation
and shut down must be observed.
Oil and grease leaks may make the ground
slippery. Machine maintenance must always begin
and finish by cleaning the ground and the exterior
of the machine.
If platforms, stairs and guard rails are required for
maintenance, they must be placed for easy access to
areas where maintenance and inspection are to be
carried out. The positioning of these accessories must
not limit access or hinder the lifting of the part to be
serviced.
When air or compressed inert gas is used in the
maintenance process, the operator and anyone in the
vicinity must be careful and have the appropriate
protection.
Do not spray air or compressed inert gas on skin.
Do not direct an air or gas jet towards other people.
If any change in NPSHA is proposed, ensure these
margins are not significantly eroded. Refer to the pump
performance curve to determine exact requirements
particularly if flow has changed. If in doubt please
consult your nearest Flowserve office for advice and
details of the minimum allowable margin for your
application.
Never use air or compressed inert gas to clean clothes.
Before working on the pump, take measures to prevent
an uncontrolled start. Put a warning board on the
starting device with the words:
"Machine under repair: do not start".
5.9.5 Pumped flow
Flow must not fall outside the minimum and maximum
continuous safe flow shown on the pump performance
curve and/or data sheet.
With electric drive equipment, lock the main switch
open and withdraw any fuses. Put a warning board on
the fuse box or main switch with the words:
"Machine under repair: do not connect".
6 MAINTENANCE
Never clean equipment with inflammable solvents or
carbon tetrachloride. Protect yourself against toxic
fumes when using cleaning agents.
6.1 General
It is the plant operator's responsibility to ensure
that all maintenance, inspection and assembly work is
carried out by authorized and qualified personnel who
have adequately familiarized themselves with the
subject matter by studying this manual in detail. (See
also section 1.6.2.)
6.2 Maintenance schedule
It is recommended that a maintenance plan and
schedule is adopted, in line with these User
Instructions, to include the following:
a) Any auxiliary systems installed must be monitored,
if necessary, to ensure they function correctly.
Page 27 of 42
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
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Our specialist service personnel can help with
preventative maintenance records and provide
condition monitoring for temperature and vibration to
identify the onset of potential problems.
If any problems are found the following sequence of
actions should take place:
a) Refer to section 7, Faults; causes and remedies,
for fault diagnosis.
b) Ensure equipment complies with the
recommendations in this manual.
c) Contact Flowserve if the problem persists.
6.2.1 Routine inspection (daily/weekly)
The following checks should be made
and the appropriate action taken to remedy any
deviations:
a) Check operating behaviour. Ensure noise,
vibration and bearing temperatures are normal.
b) Check that there are no abnormal fluid or lubricant
leaks (static and dynamic seals) and that any
sealant systems (if fitted) are full and operating
normally.
c) Check that shaft seal leaks are within acceptable
limits.
d) Check the level and condition of oil lubricant. On
grease lubricated pumps, check running hours
since last recharge of grease or complete grease
change.
e) Check any auxiliary supplies eg heating/cooling (if
fitted) are functioning correctly.
&
b) Check pump running records for hourly usage to
determine if bearing lubricant requires changing.
c) The coupling should be checked for correct
alignment and worn driving elements.
&
equipment for periodic checks needed.
6.2 3 Re-lubrication
Lubricant and bearing temperature analysis can be
useful in optimizing lubricant change intervals. In
general however, the following is recommended.
6.2.3.1 Grease lubrication
See section 5.2.2 for grease
recommendations.
Regrease - via grease nipples every 2 000 hours or
sooner depending on the severity of the application.
It is important not to under or over grease the bearings
as this will lead to over heating and premature failure.
a) Grease lubricated bearing housings have grease
nipples fitted in the bearing covers.
b) Move the axial seal ring back so the gap between
the pump shaft and bearing cover can be seen.
c) Connect grease gun to the nipple.
d) Press grease into the bearing housing until the first
signs of it appear in the gap between the housing
and shaft, then stop greasing.
e) V-rings should be seated at the proper distance
from the sealing surface to avoid overheating.
f) The maximum allowable operating temperatures for
anti friction bearings will vary from unit to unit,
depending on ambient and fluid temperature. The
rise above ambient should not normally exceed 55
°C (131 °F) or a combined maximum of 95 °C (204
°F).
g) A continuously rising temperature or an abrupt
temperature rise indicates a problem. If these
symptoms occur, stop the pump immediately and
investigate the cause.
Refer to the manuals of any associated
equipment for routine checks needed.
TIME
6.2.2 Periodic inspection (six monthly)
a)
Refer to the manuals of any associated
TEMPERATURE
b) Check for any leaks from gaskets and seals. The
correct functioning of the shaft seal must be
checked regularly.
c) Check bearing lubricant level, and if the hours run
show a lubricant change is required.
d) Check that the duty condition is in the safe
operating range for the pump.
e) Check vibration, noise level and surface
temperature at the bearings to confirm satisfactory
operation.
f) Check dirt and dust is removed from areas around
close clearances, bearing housings and motors.
g) Check coupling alignment and re-align if
necessary.
Check foundation bolts for security
of attachment and corrosion.
Grease change - every 4 000 hours or sooner
depending on the severity of the application.
Page 28 of 42
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
a) Remove the bearing housing from the rotor
assembly.
b) Brush the bearing housing with hot kerosene (100
to 115 °C/212 to 240 °F) or other non-toxic solvent.
c) Clean and flush out the housing with a light mineral
oil.
d) Do not use waste oil to clean the housing.
To clean the bearings:
a) Wipe off as much grease as possible with a clean
lint-free cloth.
b) Brush bearings with hot kerosene (80 to 90 °C/ 175
to 195 °F) while gently spinning the outer bearing
ring.
c) Spin each ball to ensure that it is clean.
To remove badly oxidized grease which refuses to
come off:
a) Support the rotor in a vertical position and immerse
the bearing in hot kerosene or a mixture of alcohol
and light mineral solvent.
b) Gently spin the bearing outer ring.
c) Dry and reflush the bearing with clean light oil.
d) It is important not to under or over grease the
bearings as this will lead to over heating and
premature failure. It is recommended that the
bearings be filled with grease using a suitable
spatula. In addition the housings should be no
more than half filled.
6.3.2 Storage of spares
Spares should be stored in a clean dry area away from
vibration. Inspection and re-treatment of metallic
surfaces (if necessary) with preservative is
recommended at 6 monthly intervals.
6.4 Recommended spares and
consumable items
For start up purposes:
1 - restriction bushing
2 - shaft sleeves
1 - set of gaskets and seals
For 2 years operation:
1 - set of bearings (line and thrust)
2 – restriction bushings
2 - shaft sleeves
2 - sets of gaskets and seals
1 - casing wear plate
For 4 years operation:
1 - set of bearings (line and thrust)
2 – restriction bushings
2 - shaft sleeves
2 - sets of gaskets and seals
2 - casing wear plate
1 - impeller
6.5 Tools required
A typical range of tools that will be required to maintain
these pumps is listed below.
6.3 Spare parts
6.3.1 Ordering of spares
Flowserve keep records of all pumps that have been
supplied. When ordering spares the following
information should be quoted:
1) Pump serial number
2) Pump size
3) Part name – taken from section 8
4) Part number – taken from section 8
5) Number of parts required
The pump size and serial number are shown on the
pump nameplate.
To ensure continued satisfactory operation,
replacement parts to the original design specification
should be obtained from Flowserve.
Any change to the original design specification
(modification or use of a non-standard part) will
invalidate the pump’s safety certification.
Readily available in standard tool kits, and dependent
on pump size:
• Open ended spanners (wrenches) to suit up to
M 48 screws/nuts
• Socket spanners (wrenches), up to M 48 screws
• Allen keys, up to 10 mm (A/F)
• Range of screwdrivers
• Soft mallet
More specialized equipment:
• Bearing pullers
• Bearing induction heater
• Dial test indicator
• C-spanner (wrench) - for removing shaft nut.
(If difficulties in sourcing are encountered, consult
Flowserve.)
Page 29 of 42
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
6.6 Fastener torques
Bolt size
M10 (3/8 in.)
M12 (1/2 in.)
M 16 (? in.)
M 20 (¾ in.)
M 24 (? in.)
M 27 (1 in.)
M 30 (1? in.)
M 36 (1? in.)
M 42 (1? in.)
Adequate support must be provided to support columns
and liquid end to eliminate bending stresses imposed
on the shaft and column support pipes.
Torque Nm (lbŸft)
Pump feet
All other
fasteners
fasteners
23 (17)
23 (17)
54(40)
54 (40)
170 (125)
84 (62)
340 (250)
165 (120)
590 (435)
285 (210)
770 (570)
375 (275)
1 100 (810)
540 (400)
1 840 (1 350)
900 (660)
2 000 (1 475)
1 410 (1 040)
6.7 Renewal clearances
As wear takes place between the impeller and wear
ring the overall efficiency of the pump set will decrease.
To maintain optimum efficiency it is recommended that
rings are replaced and the impeller renovated when the
radial clearance detailed in section 3.4.2 has doubled
to 1.0 to 1.5 mm (0.040 to 0.060 in.), depending on
pump size.
6.8 Disassembly
Refer to section 1.6, Safety, before dismantling
the pump.
Before dismantling the pump for
overhaul, ensure genuine Flowserve replacement parts
are available.
Refer to sectional drawings for part numbers and
identification.
6.8.1 Pump unit
a) Isolate motor and lock off electrical supply in
accordance with local regulations.
b) Isolate discharge valves.
c) Remove coupling guards and disconnect the
coupling halves.
d) On units with larger drivers it is recommended to
remove the motor. If the bearing frame will be
dismantled it is suggested that the motor be left
connected to the motor. Unfasten the motorstand
from the top plate and remove.
e) Unscrew and remove discharge pipe flange bolts.
remove spool sections to allow pump to be
removed from well.
f) Unscrew and remove top plate mounting bolts.
g) Install eyebolts in top plate.
h) Using overhead crane or hoist, remove pump from
well.
i) Place the pump assembly in a horizontal position,
preferably on a V-block fixture.
6.8.2
a) With casing [1] adequately supported by a hoist
unscrew and remove bolts holding casing [1].
Remove casing [1] away from support pipe [101].
b) Inspect wear plate [181] and casing [1], if
replacement of either component is required loosen
wear plate nuts and remove wear plate [181].
c) Remove impeller nut [24], application of heat may
be required to break bond of resinous sealant on
threads [heat evenly).
d) Remove impeller [2]. For ease of removal, the
impeller hub is slotted to accept a standard bearing
puller.
e) Remove impeller key [32] and sleeve stop [82].
6.8.3 Stuffing Box Head
a) Remove stuffing box head [33A] from the support
pipe [101].
b) Inspect lower bushing [39], if replacement is
required carefully press bearing out.
c) Remove the support pipe [101].
d) Inspect shaft sleeve [6] for excessive wear.
Remove shaft sleeve only if replacement is
necessary. The sleeve is a hook type that is
normally held in place with an anaerobic sealant.
6.8.4 Bearing Frame
a) If the motor stool was not removed with the motor it
should be unfastened from the bearing frame now.
b) Unfasten and remove the line bearing cover from
the bearing frame.
c) Loosen and remove jacking stud nuts and bolts
from the thrust bearing housing [33]
d) Remove the shaft assembly from the bearing frame
[19], set on wooden V-blocks.
6.8.5 Thrust bearings
a) Loosen cap screws from thrust bearing cover [37];
remove cover.
b) Slide thrust bearing housing [33] towards the
inboard line bearing to expose bearings.
c) To remove the bearings first bend the locking tab of
the bearing lock washer [22A] from lock nut [22].
d) Using a hook type wrench unscrew the lock nut
from the shaft.
e) The bearings may be removed from the shaft by
using a puller or cutting torch.
Page 30 of 42
If a torch is used caution is required to prevent
damage to the shaft.
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
f)
The thrust bearing housing may be removed from
the shaft.
6.8.6 Line Bearing
a) The line bearing is secured in place using a snap
ring as well as an interference fit on the shaft.
Remove the snap ring.
b) The bearing may be removed by using a bearing
puller or can be cut from the shaft using a cutting
torch.
Caution should be used with the cutting torch to
prevent damaging the shaft and sleeve.
6.8.7
a) Remove the shaft sleeve from the shaft. The sleeve
has a locational fit and may be held in place with
an anaerobic sealant.
b) If required, remove bearing frame [19] from the top
plate [23].
6.9 Examination of parts
Used parts must be inspected before
assembly to ensure the pump will subsequently run
properly.
In particular, fault diagnosis is essential to enhance
pump and plant reliability.
6.9.1 Casing, wear plate, stuffing box head and
impeller
a) Inspect for excessive wear, pitting, corrosion,
erosion or damage and any sealing surface
irregularities.
b) Replace as necessary.
6.9.2 Shaft and sleeve
Replace if grooved, pitted or worn.
6.9.3 Gaskets and O-rings
a) After dismantling, discard and replace.
b) Clean and inspect all gasket surfaces.
6.9.4 Bearings and Stuffing Box Bushing
a) It is recommended that bearings are not re-used
after any removal from the shaft.
b) The plain liquid lubricated bearings may be re-used
if both the stuffing box bush and bearing sleeve
show no sign of wear, grooving or corrosion attack.
[It is recommended that both the bush and sleeve
are replaced at the same time.]
6.9.5 Bearing isolators, labyrinths or lip seals
[if fitted]
a) The lubricant, bearings and bearing housing seals
are to be inspected for contamination and damage.
b) If bearing damage is not due to normal wear and
the lubricant contains adverse contaminants, the
cause should be corrected before the pump is
returned to service.
c) Labyrinth seals and bearing isolators should be
inspected for damage but are normally nonwearing parts and can be re-used.
d) Inspect all bearing lip seals [47 & 49] and replace
move if worn, damaged or in doubt.
6.9.6 Bearing frame and housing
a) Clean and flush bearing housing internal surfaces.
6.10 Assembly
To assemble the pump consult the sectional drawings,
see section 8, Parts list and drawings.
Ensure threads, gasket and O-ring mating faces are
clean. Apply thread sealant to non-face sealing pipe
thread fittings.
The following consumable material are required for
pump assembly.
n
high strength thread locking compound equivalent
to Loctite *680 + primer T.
n medium strength thread locking compound
equivalent to Loctite *A.
n anti-seize compound
*Loctite Corporation, Newington, Conn. USA>
Care must be taken during assembly to
avoid contamination of the parts with dirt, or other
foreign matter.
6.10.1 Preparation
a) Inspect all new parts. Remove all nicks, burrs, etc,
that may have been caused by handling.
b) Lubricate internal bores of bearing frame [19] with
same grease used to lubricate bearings.
c) Install the thrust bearing housing [33] into the
applicable bore of the bearing frame [19] to ensure
a good sliding fit, then remove.
d) Clean shaft free of grease at the spacer sleeve [78]
location. Spray the area with Loctite Primer T. The
primer acts as a catalyst to ensure optimum bond
strength and rapid cure of the Loctite compound.
6.10.2 Line Bearings
a) Apply Loctite 680 to the shaft and install the sleeve
[79] at the line bearing against the shaft shoulder.
Page 31 of 42
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
b) Lightly lubricate the shaft [6] at the bearing
position.
c) Use an induction heater or oil bath to first heat up
0
the line bearing [16] to 100°C (210 F). Press the
bearing on the shaft with the aid of a sleeve
designed to push the inner race only.
Note that the inner race must seat on the shaft sleeve
shoulder.
d) After the bearing has cooled, protect the bearing by
wrapping with a clean lint free cloth.
e) Slide the retaining ring [706] over the shaft and
place in groove.
f) The bearings are sealed for life and do not need
greasing.
g) Install the grease fitting into the thrust bearing
cover [37].
h) Carefully install the lip seal [49] or labyrinth seal
into the thrust bearing cover [37] by pressing
squarely into the bore.
i) Slide the thrust bearing cover over the shaft.
Care must be taken to ensure that the lip
seal is not damaged on the shaft keyway.
j) Secure to the thrust bearing housing using the
capscrews and lockwashers, tighten in accordance with
Table in section 6.6.
6.10.4 Bearing Frame
a) Place the top plate [23] in a vertical position and
block in place with angle plates.
b) Bolt the bearing frame [19] to the top plate [23].
Use Loctite A on the capscrew threads - tighten in
accordance to Table 6.6.
c) Slide the shaft assembly through Bearing Cartridge
[19] from the drive end and align to the adjusting
bolt holes.
d) Assemble adjusting bolts and hardware.
6.10.5 Lower Column
6.10.5.1 Integral line bearing cover
In some designs the line bearing cover is integral with
the column support pipe [101]
a) Place the support pipe [101] in a horizontal position
on a V-block arrangement and install lip seal [47]
with the primary sealing lip away from the bearings.
b) Lubricate the shaft/sleeve for the line bearing seal.
c) Lift the support pipe and carefully install over the
shaft and to the top plate/bearing frame assembly.
6.10.3 Thrust Bearings
a) Slide the thrust bearing housing [33] onto the shaft
[6] between the line bearing [16] and thrust bearing
[18] Location.
b) Lightly lubricate the shaft [6] at the bearing
position.
c) Use and induction heater or not oil bath to heat the
0
bearings to 100 °C (210 F). Install the thrust
bearings [18] as noted below.
Note that the angular contact bearings are mounted
back-to-back, commonly called the “O” arrangement.
The inner race must seat on the shaft shoulder.
d) Slide the bearing lockwasher [22A] on the shaft
and fit the bearing locknut [22]. Tighten the locknut
snugly and allow to cool. Check the tightness and
bend one lockwasher tab over to lock the nut.
e) Pack the thrust bearings [18] with grease.
f) Slide the thrust bearing housing [33] over the
bearings.
The sealing lip could be damaged during the assembly
if adequate precaution not taken.
d) Fasten the support pipe to the top plate/bearing
frame assembly. Use Loctite “A”, thread locking
compound on all capscrew threads. Tighten in
accordance with Table 6.6.
6.10.5.2 Loose line bearing cover
a) Install the lipseal [47] or labyrinth seal in the line
bearing cover [37]. Place the lipseal with the
primary sealing lip away from the bearings. For
labyrinth seals the shoulder is outside and away
from the bearings.
b) Lubricate the shaft/sleeve for the line bearing seal.
c) Install the line bearing cover to the bearing frame
[19] and fasten in place with appropriate fasteners.
d) Lift the support pipe and carefully install over the
shaft and to the line bearing cover.
Page 32 of 42
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
6.10.6 Grease Fitting, frame 3
a) Install the appropriate grease fitting to the bearing
frame at the line bearing.
b) Charge grease fitting with grease
6.10.7 Bearing Frame Vent
a) Install street elbow in bearing frame and orientate
elbow to towards drive end of shaft.
b) Install Inpro vent valve
6.10.8 Stuffing Box area
a) Clean the shaft where the shaft sleeve [14] will be
located.
b) Prepare shaft and sleeve with Loctite Primer
c) Apply Loctite A to shaft.
d) Install the shaft sleeve [14] onto the shaft [6] while
turning the sleeve to spread the Loctite sealant
over the inside surface of the sleeve.
e) Assemble the throat bushing [63] into the lower
housing [33A].
f) Apply Loctite A to periphery of elastomeric bushing
[39] at one end and slide into housing [33A] using a
twisting motion. Wipe away excess compound. If
provided, install studs and fit clamp plate to hold
bushing in place.
g) Slide the lower housing [33a] over shaft and into
spigot to support pipe [101]. Clamp into position
using ‘C’ clamps.
h) Using adjusting bolts on thrust bearing housing [33]
adjust shaft forward so that the end of the sleeve
protrudes slightly beyond the face of the lower
housing [11].
i) Install impeller key [32], smear anti-seize
compound onto the shaft at the impeller location.
j) Slide impeller [2] onto the shaft [6].
k) Apply Loctite A to shaft threads and install the
impeller nut [24]. Torque impeller nut as indicated
in table below:
c) Place sealing washers over the studs. A small
amount of grease may be used to hold them into
position during assembly of wear plate.
d) Lower the wear plate [181] studs first into the
casing [1], align the studs with the casing holes.
e) Fasten the wear plate [181] to the casing using the
washers, nuts and Loctite A on nuts. Tighten in
accordance with Table 6.6.
f) Remove ‘C’ clamp from housing. Smear the casing
gasket [73] with a grease and position on lower
cover [33A].
g) Release thrust bearing housing hold down bolts.
h) Lift the casing [1] and slide over the impeller and
onto the lower housing [33].
i) Align discharge of casing [1] with slot in top plate
[23]
j) Bolt casing [1] into position using Loctite 242 on
threads. Tighten bolts in accordance with Table
6.6.
TABLE 6.10.8
MINIMUM IMPELLER NUT
TIGHTENING TORQUE
FRAME
Ft. lbs.
Nm.
1
100
140
2
300
400
3
300
400
6.10.9 Casing
a) Place the casing on the suction nozzle.
b) Screw the wear plate studs into the wear plate.
Apply Loctite A to threads.
Page 33 of 42
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
6.11 Setting Impeller Clearance
Never attempt to change the clearance when the
pump is running.
If the coupling has limited axial adjustment capability, the
pump and driver must be uncoupled prior to adjusting the
clearance in order to permit free movement.
h) the jam nuts to lock them in position.
i) Manually rotate the shaft to ensure that there is no
rubbing or binding.
j) On belt driven units, adjust the pump or driver sheave
to maintain belt alignment. (Section 4.5).
k) Check the alignment on direct driven units (refer to
Section 4.5) and reassemble the coupling
components.
l) Replace any safety guards that may have been
removed.
a) Loosen the thrust bearing housing jam nuts and back
off the three jacking screws at least 1.5 mm (0.06 in.).
b) Move the rotor towards the wear plate [181] by
tightening the three hold-down capscrews evenly and
uniformly until the impeller [2] just touches the wear
plate [181]. This can be best established by rotating
the shaft and stopping the forward motion at the first
sign of rubbing. If the shaft cannot be rotated, back
off the bearing housing with the jacking screws until a
just detectable rub is obtained.
c) Set a dial indicator on the end of the shaft or the
flange of the bearing housing [33]. Set dial to “0”.
d) Determine the required impeller axial running
clearance from Engineering Tables of Section 3.4
e) Loosen the thrust bearing housing hold down
capscrews slightly and tighten the jack screws to
achieve the clearance reading on the dial indicator.
f) Alternately and gradually tighten the hold down
capscrews and jack screws while maintaining the
reading on the dial indicator. The gap between the
housing and the bearing frame should be even within
0.08mm (0.003 in.). .
g) While preventing the jack screws from rotating, tighten
Page 34 of 42
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
7 FAULTS; CAUSES AND REMEDIES
FAULT SYMPTOM
Pump overheats and seizes
⇓
Bearings have short life
⇓
Pump vibrates or is noisy
⇓
Mechanical seal has short life
⇓
Mechanical seal leaks excessively
⇓
Pump requires excessive power
⇓
Pump loses prime after starting
⇓
Insufficient pressure developed
⇓
Insufficient capacity delivered
⇓
Pump does not deliver liquid
⇓
PROBABLE CAUSES
POSSIBLE REMEDIES
A. System troubles
l
l
l Pump not primed.
l
l
Pump or suction pipe not completely filled with
l l liquid.
l
l
l l Suction lift too high or level too low.
l
l l
l l l
Insufficient margin between suction pressure and
vapour pressure.
Excessive amount of air or gas in liquid.
Check NPSHa>NPSHr, proper submergence,
losses at strainers/fittings.
Check and purge pipes and system.
l
l l Air or vapour pocket in suction line.
Check suction line design for vapour pockets.
l
l
Air leaks into suction line.
Check suction pipe is airtight.
l
Air leaks into pump through mechanical seal,
sleeve joints, casing joint or pipe plugs.
Check and replace faulty parts.
CONSULT FLOWSERVE.
l
l
Foot valve too small.
Investigate replacing the foot valve.
l
l
Foot valve partially clogged.
Clean foot valve.
l
l
l
l l Inlet of suction pipe insufficiently submerged.
CONSULT FLOWSERVE.
Speed too high.
CONSULT FLOWSERVE.
Total head of system higher than differential head
l l l
of pump.
l
Total head of system lower than pump design
head.
l
Specific gravity of liquid different from design.
l
l
l l
l
Check out system design.
l l l Speed too low.
l
l
Check complete filling. Vent and/or prime.
l l
Viscosity of liquid differs from that for which
designed.
Check system losses.
Remedy or CONSULT FLOWSERVE.
Check and CONSULT FLOWSERVE.
Operation at very low capacity.
Measure value and check minimum permitted.
Remedy or CONSULT FLOWSERVE.
Operation at high capacity.
Measure value and check maximum permitted.
Remedy or CONSULT FLOWSERVE.
B. Mechanical troubles
l l l l l l
l
Misalignment due to pipe strain.
Check the flange connections and eliminate strains
using elastic couplings or a method permitted.
Improperly designed foundation.
Check setting of baseplate: tighten, adjust, grout
base as required.
Page 35 of 42
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
FAULT SYMPTOM
Pump overheats and seizes
⇓
Bearings have short life
⇓
Pump vibrates or is noisy
⇓
Mechanical seal has short life
⇓
Mechanical seal leaks excessively
⇓
Pump requires excessive power
⇓
Pump loses prime after starting
⇓
Insufficient pressure developed
⇓
Insufficient capacity delivered
⇓
Pump does not deliver liquid
⇓
PROBABLE CAUSES
POSSIBLE REMEDIES
Shaft bent.
Check shaft runouts are within acceptable values.
CONSULT FLOWSERVE.
Rotating part rubbing on stationary part internally.
Check and CONSULT FLOWSERVE, if necessary.
Bearings worn
Replace bearings.
l l
Wearing ring surfaces worn.
Replace worn wear ring/surfaces.
l l
Impeller damaged or eroded.
Replace or CONSULT FLOWSERVE for improved
material selection.
l l l l l
l l l
l
l l l l l
l
l
l
Leakage under sleeve due to joint failure.
Replace joint and check for damage.
l l
Shaft sleeve worn or scored or running off centre.
Check and renew defective parts.
l l l
Mechanical seal improperly installed.
Check alignment of faces or damaged parts and
assembly method used.
l l l
Incorrect type of mechanical seal for operating
conditions.
CONSULT FLOWSERVE.
l l l l l
Shaft running off centre because of worn bearings Check misalignment and correct if necessary. If
or misalignment.
alignment satisfactory check bearings for exces sive
wear.
l l l l l
Impeller out of balance resulting in vibration.
l l l
Abrasive solids in liquid pumped.
l l
Internal misalignment of parts preventing seal ring
and seat from mating properly.
l l
Mechanical seal was run dry.
Check mechanical seal condition and source of dry
running and repair.
l l
Internal misalignment due to improper repairs
causing impeller to rub.
Check method of assembly, possible damage or
state of cleanliness during assembly.
Remedy or CONSULT FLOWSERVE, if necessary.
Excessive thrust caused by a mechanical failure
inside the pump.
Check wear condition of impeller, its clearances and
liquid passages.
l l
Excessive grease in ball bearings.
Check method of regreasing.
l l
Lack of lubrication for bearings.
Check hours run since last change of lubricant, the
schedule and its basis.
l l
Improper installation of bearings (damage during
assembly, incorrect assembly, wrong type of
bearing etc).
Check method of assembly, possible damage or
state of cleanliness during assembly and type of
bearing used. Remedy or CONSULT
FLOWSERVE, if necessary.
l l
Damaged bearings due to contamination.
Check contamination source and replace damaged
bearings.
l l l
Page 36 of 42
Check and CONSULT FLOWSERVE.
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
FAULT SYMPTOM
Pump overheats and seizes
⇓
Bearings have short life
⇓
Pump vibrates or is noisy
⇓
Mechanical seal has short life
⇓
Mechanical seal leaks excessively
⇓
Pump requires excessive power
⇓
Pump loses prime after starting
⇓
Insufficient pressure developed
⇓
Insufficient capacity delivered
⇓
Pump does not deliver liquid
⇓
PROBABLE CAUSES
POSSIBLE REMEDIES
C. MOTOR ELECTRICAL PROBLEMS
l
l l
l
l l
l
Wrong direction of rotation.
Reverse 2 phases at motor terminal box.
l
Motor running on 2 phases only.
Check supply and fuses.
l
Motor running too slow.
Check motor terminal box connections and voltage.
Page 37 of 42
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
8 PARTS LIST AND DRAWINGS
8.1 FRBHJC Sectional drawing
ITEM
1
2
6
11
14
16
17
18
DESCRIPTION
Casing
Impeller
Shaft
Stuffing Box Head
Shaft Sleeve
Line Bearing
Bushing Cover
Thrust bearing (set)
ITEM
19
22
22A
23
24
30
32
33
DESCRIPTION
Bearing Frame
Bearing Lock Nut
Bearing Lock Washer
Top Plate
Impeller nut
O-ring, Impeller Nut
Impeller Key
Housing - Thrust
bearing
ITEM
35
37
40
46
47
49
53
73
Page 38 of 42
DESCRIPTION
Cover – Line Bearing
Thrust Bearing Cover
Deflector
Drive Key
Seal - Inboard
Seal – Outboard
Motorstand
Gasket-Casing
ITEM
78
89B
101
161
181
209A
215A
DESCRIPTION
Sleeve-Bearing
O-ring
Column Pipe
Discharge Pipe
Wearplate
Stud – Wearplate
Nut – Wearplate
®
8.5 General arrangement drawing
The typical general arrangement drawing and any
specific drawings required by the contract will be sent to
the Purchaser separately unless the contract specifically
calls for these to be included into the User Instructions.
If required, copies of other drawings sent separately to
the Purchaser should be obtained from the Purchaser
and retained with these User Instructions.
9 CERTIFICATION
Certificates, determined from the contract requirements
will be provided with this manual. Examples are
certificates for CE marking and ATEX marking. If
required, copies of other certificates sent separately to
the Purchaser should be obtained from Purchaser for
retention with the User Instructions. See section 1.9,
Noise level, for details of typical noise certification.
10 OTHER RELEVANT DOCUMENTATION
AND MANUALS
10.1 Supplementary User Instruction
manuals
Supplementary instruction determined from the contract
requirements for inclusion into User Instructions such as
for a driver, instrumentation, controller, sub-driver, seals,
sealant system, mounting component etc are included
under this section. If further copies of these are
required they should be obtained from the purchaser for
retention with these User Instructions.
Where any pre-printed set of User Instructions are used,
and satisfactory quality can be maintained only by
avoiding copying these, they are included at the end of
these User Instructions such as within a standard clear
polymer software protection envelope.
10.2 Change notes
If any changes, agreed with Flowserve Pump Division,
are made to the product after its supply, a record of the
details should be maintained with these User
Instructions.
10.3 Additional sources of information
Reference 1:
NPSH for Rotordynamic Pumps: a reference guide,
Europump Guide No. 1, Europump & World Pumps,
Elsevier Science, United Kingdom, 1999.
Reference 2:
th
Pumping Manual, 9 edition, T.C. Dickenson,
Elsevier Advanced Technology, United Kingdom, 1995.
Reference 3:
nd
Pump Handbook, 2 edition, Igor J. Karassik et al,
McGraw-Hill Inc., New York, 1993.
Reference 4:
ANSI/HI 1.1-1.5
Centrifugal Pumps - Nomenclature, Definitions,
Application and Operation.
Reference 5:
ANSI B31.3 - Process Piping.
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
Notes
Page 40 of 42
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
Notes:
Page 41 of 42
FRBHJC USER INSTRUCTIONS ENGLISH 71569179 11-04
®
FLOWSERVE
REGIONAL SALES OFFICES:
USA and Canada
Flowserve Corporation (Pump Division)
5215 North O’Connor Blvd. Suite 2300
Irving, Texas 75039, USA
Latin America and Caribbean
Flowserve Corporation (Pump Division)
6840 Wynnwood Lane
Houston, Texas 77008, USA
Tel +1 972 443 6500
Toll free 800 728 PUMP (7867)
Fax +1 972 443 6800
Tel +1 713 803 4434
Fax +1 713 803 4497
Europe, Middle East & Africa
Flowserve Limited (Pump Division)
Harley House, 94 Hare Lane
Claygate, Esher, Surrey KT10 0RB
United Kingdom
Asia Pacific
Flowserve Pte Ltd (Pump Division)
200 Pandan Loop, 06-03/04
Pantech 21, Singapore 128388
Tel +44 (0)1372 463 700
Fax +44 (0)1372 460 190
Tel +65 775 3003
Fax +65 779 4607
Visit our web site at: www.flowserve.com
Your Flowserve factory contact:
Your local Flowserve representative:
Flowserve Pump Division
15 Worthington Drive,
PO Box 40,
Brantford,
Ontario,
Canada N3T 5M5
Telephone
Fax
In Europe:
Flowserve Pumps Limited
PO Box 17, Newark
Notts NG24 3EN United Kingdom
+1 (519) 753 7381
+1 (519) 753 0845
Telephone (24 hours) +44 (0)1636 494 600
Sales & Admin Fax
+44 (0)1636 705 991
Repair & Service Fax +44 (0)1636 494 833
To find your local Flowserve represent ative, please
use the Sales Support Locator System found at
www.flowserve.com
Page 42 of 42
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