ME 71576287 02-13 US-English

ME 71576287 02-13 US-English
USER INSTRUCTIONS
ME centrifugal pump
Single-stage, axial suction, tangential vertical discharge type
centrifugal pump
Installation
Operation
Maintenance
PCN=71576287 – 02/13 (E) Original instructions.
These instructions must be read prior to installing,
operating, using and maintaining this equipment.
ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
CONTENTS
Page
Page
1 INTRODUCTION AND SAFETY ........................... 4
6 MAINTENANCE .................................................. 26
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 SAFETY LABELS ........................... 8
1.8 SPECIFIC MACHINE PERFORMANCE ......................... 8
1.9 NOISE LEVEL ......................................................... 9
6.1 GENERAL ........................................................... 26
6.2 MAINTENANCE SCHEDULE ................................... 26
6.3 SPARE PARTS ..................................................... 29
6.4 RECOMMENDED SPARES AND CONSUMABLE ITEMS 29
6.5 DISASSEMBLY..................................................... 30
2 TRANSPORT AND STORAGE ........................... 11
2.1 CONSIGNMENT RECEIPT AND UNPACKING .............. 11
2.2 HANDLING........................................................... 11
2.3 LIFTING............................................................... 12
2.4 STORAGE ........................................................... 12
2.5 RECYCLING AND END OF PRODUCT LIFE ................ 12
3 PUMP DESCRIPTION ......................................... 12
3.1 CONFIGURATIONS ............................................... 12
3.2 NOMENCLATURE ................................................. 14
7 FAULTS; CAUSES AND REMEDIES ................. 31
8 PARTS LIST AND DRAWINGS .......................... 32
8.1 SECTIONAL DRAWINGS........................................ 32
8.2 SECTIONAL DRAWINGS PART LIST ........................ 35
8.3 GENERAL ARRANGEMENT DRAWING ..................... 35
9 CERTIFICATION ................................................ 35
10 OTHER RELEVANT DOCUMENTATION AND
MANUALS .............................................................. 35
10.1 SUPPLEMENTARY USER INSTRUCTIONS ............. 35
10.2 CHANGE NOTES................................................ 35
10.3 ADDITIONAL SOURCES OF INFORMATION ............. 35
4 INSTALLATION .................................................... 15
4.1 LOCATION ........................................................... 15
4.2 FOUNDATION ....................................................... 16
4.3 GROUTING .......................................................... 16
4.4 INITIAL ALIGNMENT............................................... 17
4.5 PIPING ................................................................ 18
4.6 ELECTRICAL CONNECTIONS.................................. 20
4.8 PROTECTION SYSTEMS ........................................ 21
5 COMMISSIONING, START-UP, OPERATION AND
SHUTDOWN .......................................................... 21
5.1 DIRECTION OF ROTATION ..................................... 21
5.2 Guarding
21
5.3 PRIMING AND AUXILIARY SUPPLIES ........................ 21
5.4 STARTING THE PUMP............................................ 22
5.6 STOPPING AND SHUTDOWN .................................. 24
5.7 HYDRAULIC, MECHANICAL AND ELECTRICAL DUTY .. 25
5.8 PUMPS FOR FOOD USE OR POTABLE W ATER ........ 25
Page 2 of 36
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
INDEX
Page
Page
Additional sources (10.3) ....................................... 35
Alignment of shafting (see 4.2, 4.4 and 4.7)
ATEX marking (1.6.4.2) ........................................... 7
CE marking and approvals (1.2) .............................. 4
Certification (9) ...................................................... 35
Change notes (10.2) .............................................. 35
Cleaning prior to operation (5.8.1) ........................ 25
Commissioning, start-up, operation (5) ................. 21
Compliance, ATEX (1.6.4.1) .................................... 6
Configurations (3.1) ............................................... 12
Copyright (1.4) ......................................................... 4
Coverage charts (3.3) ............................................ 15
Direction of rotation (5.1) ....................................... 21
Disassembly (6.5) .................................................. 30
Discharge piping (4.5.3) ....................................... 20
Disclaimer (1.3)........................................................ 4
Dismantling (see 6.5, Disassembly) ...................... 30
Drawings (8.1) ....................................................... 32
Duty conditions (1.5) ................................................ 4
Ecodesign (1.8.1)..................................................... 9
Electrical connections (4.6) ................................... 20
End of product life (2.5) ......................................... 12
Faults; causes and remedies (7) ........................... 31
Final checks (4.5.4) .............................................. 20
First pump start up (5.4.2) .................................... 22
Foundation (4.2) .................................................... 16
Forces and moments (see 4.5.1) ........................... 18
General arrangement drawing (8.3) ...................... 35
Gland packing (6.2.5) ............................................ 28
Grouting (4.3) ......................................................... 16
Guarding (5.2)........................................................ 21
Handling (2.2) ........................................................ 11
Hydraulic, mechanical and electrical duty (5.7) ..... 25
Inspection (6.2.2 and 6.2.3) ................................... 27
Installation (4) ........................................................ 15
Internal coating (6.2.6) ........................................... 29
Lifting (2.3) ............................................................. 12
Location (4.1) ......................................................... 15
Maintenance (6) ..................................................... 26
Maintenance schedule (6.2) .................................. 26
Mechanical seal (6.2.4) ......................................... 28
Nomenclature (3.2) ................................................ 14
Nameplate (1.7.1) .................................................... 8
Operating limits (see 3.1) ...................................... 12
Ordering spare parts (6.3.1) .................................. 29
Parts lists (8.2) ....................................................... 35
Piping (4.5) ............................................................ 18
Protection systems (4.8) ........................................ 20
Pump masses (2.2.2) ............................................ 11
Receipt and unpacking (2.1).................................. 11
Recommended fill quantities (see 6.2.1) ............... 27
Recommended grease lubricants (see 6.2.1) ....... 27
Recommended spares (6.4) .................................. 29
Recycling (2.5) ....................................................... 12
Replacement parts (see 6.3 and 6.4) .................... 29
Running the pump (5.5) ......................................... 23
Safety action (1.6.3) ................................................. 5
Safety labels (1.7.2) ................................................. 8
Safety markings (1.6.1) ............................................ 5
Safety, protection systems (see 1.6 and 4.8) .......... 5
Sectional drawings (8.1) ........................................ 32
Sound level (see 1.9, Noise level) ........................... 9
Sources, additional information (10.3) ................... 35
Spare parts (6.3) .................................................... 29
Specific machine performance (1.8) ........................ 8
Standard maintenance (6.2.1) .............................. 27
Starting the pump (5.4) .......................................... 22
Stop/start frequency (5.5.6) ................................... 24
Stopping and shutdown (5.6) ................................. 24
Storage, pump (2.4) ............................................... 12
Storage, spare parts (6.3.2) ................................... 29
Suction piping (4.5.2) ............................................ 19
Supplementary manuals or information sources ... 35
Thermal expansion (4.4.1) .................................... 17
Transport and storage (2) ..................................... 11
Trouble-shooting (see 7) ........................................ 31
Vibration (5.5.5) ..................................................... 24
Page 3 of 36
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
1 INTRODUCTION AND SAFETY
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,
utilizing sophisticated quality techniques, and safety
requirements.
Flowserve is committed to continuous quality
improvement and being at 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. Failure to follow
and apply the present user instructions is
considered to be misuse. Personal injury,
product damage, delay or failure caused by
misuse are not covered by the Flowserve
warranty.
incorporates information relevant to these Directives
and Approvals.
To confirm the Approvals applying and if the product is
CE marked, check the serial number plate markings
and the Certification. (See section 9, Certification.)
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
organizations. 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 authorized Flowserve parts and
accessories is considered to be misuse. Damage or
failure caused by misuse is not covered by the
Flowserve 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.
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.
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) “minimum efficiency for some water pumps
(Ecodesign)” 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
Page 4 of 36
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
the user seeks the written agreement of Flowserve
before start up.
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
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 will involve a
high risk to personal safety or the loss of life.
This symbol indicates safety instructions where
non-compliance would affect personal safety and
could result in loss of life.
This symbol indicates “hazardous substances
and toxic fluid” safety instructions where noncompliance would affect personal safety and could
result in loss of life.
This symbol indicates safety
instructions where non-compliance will involve some
risk to safe operation and personal safety and would
damage the equipment or property.
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 symbol is used in safety instructions to
remind not to rub non-metallic surfaces with a dry
cloth; ensure cloth is damp. It is used where noncompliance 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.
1.6.3 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.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS OPERATIONAL
DRAIN THE PUMP AND ISOLATE
PIPEWORK BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be taken
where the pumped liquids are hazardous.
FLUORO-ELASTOMERS (When fitted.)
When a pump has experienced temperatures over
250 ºC (482 ºF), partial decomposition of fluoroelastomers (example: 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.
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 vapor could cause an explosion.
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.
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.
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.
If the temperature is greater than 68 °C (155 °F)
or below -5 °C (23 °F) in a restricted zone, or
exceeds local regulations, action as above shall
be taken.
Page 5 of 36
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care
must be taken to avoid exposure to the liquid by
appropriate sitting 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.
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. Pump outlet valve shall 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 backpressure 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.
Page 6 of 36
1.6.4 Products used in potentially explosive
atmospheres
The following instructions for pumps and pump
units when installed in potentially explosive
atmospheres must be followed to help ensure
explosion protection.
The terminology and procedures ensure that the
installed pump is in compliance with the European
Directive 94/9/EC, known as the ATEX Directive,
which is mandatory in Europe and may also be
specified in other countries. Where applicable, both
electrical and non-electrical equipment must meet the
requirements 94/9/EC.
Even if the installation is in a region where ATEX is not
the applicable regulation, the general measures
described shall be followed to ensure safe operation.
The measures are explained under the headings of:
• Avoiding excessive surface temperature
• Preventing build up of explosive mixtures
• Preventing the generation of sparks
• Preventing leakages
• Maintaining the pump to avoid hazard
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 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.
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
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 EN 13463-5)
Gas Group (Equipment Category 2 only)
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)
Maximum surface temperature (Temperature Class)
(see section 1.6.4.3)
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, bearings and due
to the minimum permitted flow rate is taken into
account in the temperatures stated.
Temperature
class to
EN 13463-1
Maximum
surface
temperature
permitted
Temperature limit of liquid
handled (* depending on
material and construction
variant - check which is
lower)
T6
T5
T4
T3
T2
T1
85 °C (185 °F)
100 °C (212 °F)
135 °C (275 °F)
200 °C (392 °F)
300 °C (572 °F)
450 °C (842 °F)
Consult Flowserve
Consult Flowserve
115 °C (239 °F) *
180 °C (356 °F) *
275 °C (527 °F) *
400 °C (752 °F) *
Page 7 of 36
The responsibility for compliance with the
specified maximum liquid temperature is with the
plant operator.
Temperature classification “Tx” is used when the
liquid temperature varies and the pump could be
installed in different hazardous atmospheres. In this
case the user is responsible for ensuring that the
pump surface temperature does not exceed that
permitted in the particular hazardous atmosphere.
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. Furthermore, confinement of liquid in
the pump and pipes must be avoided (valve closed).
If the liquid heats up this may cause excessive
pressure and lead to bursting of pump 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 PUMP IS PROPERLY FILLED AND
VENTED AND DOES NOT RUN DRY.
Ensure 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 power monitor).
To avoid potential hazards from fugitive emissions of
vapor or gas to atmosphere the surrounding area
must be well ventilated.
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
1.6.4.5 Preventing sparks
To prevent a potential hazard from mechanical
contact, the coupling guard must be non-sparking.
To avoid the potential hazard from random induced
current generating a spark the ground contact on the
baseplate must be used.
Avoid electrostatic charge: do not rub nonmetallic surfaces with a dry cloth, ensure cloth is
damp.
Where applicable the coupling must be selected to
comply with 94/9/EC and correct alignment must be
maintained.
Additional requirements for metallic pumps on
non-metallic baseplates.
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.)
1.7 Nameplate and safety labels
1.7.1 Nameplate
For details of nameplate, see the Declaration of
Conformity, or separate documentation included
with these User Instructions.
1.7.2 Safety labels
When metallic components are fitted on a nonmetallic baseplate they must be individually earthed
(grounded).
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
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.
Oil lubricated units only:
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.
Page 8 of 36
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.
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
1.8.1 Ecodesign
EU Regulation 547/2012 of the Directive
2009/125/EC, for the minimum efficiency of defined
classes of water pumps, requires that products must
show their Minimum Efficiency Index (MEI) value.
The EU Benchmark MEI ≥ 0.70.
Also product information must be available to users.
Performance curves will have been provided with
the quotation or order or are available at
flowserve.com.
The efficiency of a pump with trimmed impeller is
usually lower than that of a pump with the full
impeller diameter. The trimming of the impeller will
adapt the pump to a fixed duty point, leading to
reduced energy consumption. The minimum
efficiency index (MEI) is based on the full impeller
diameter.
The operation of this water pump with variable duty
points may be more efficient and economic when
controlled, for example, by the use of a variable
speed drive that matches the pump duty to the
system.
Information on benchmark efficiency is available at
www.europump.org/efficiencycharts.
Similarly the motor noise assumed in the “pump and
motor” noise is that typically expected from standard
and high efficiency motors when on load directly
driving the pump. Note that a motor driven by an
inverter may show an increased noise at some
speeds.
If a pump unit only has been purchased for fitting
with your own driver then the “pump only” noise
levels in the table should be combined with the level
for the driver obtained from the supplier. Consult
Flowserve or a noise specialist if assistance is
required in combining the values.
It is recommended that where exposure approaches
the prescribed limit, then site noise measurements
should be made.
The values are in sound pressure level LpA at 1 m
(3.3 ft) from the machine, for “free field conditions
over a reflecting plane”.
For estimating sound power level LWA (re 1 pW)
then add 17 dBA to the sound pressure value.
1.9 Noise level
Attention must be given to the exposure of
personnel to the noise, and local legislation will
define when guidance to personnel on noise
limitation is required, and when noise exposure
reduction is mandatory. This is typically 80 to 85
dBA.
The usual approach is to control the exposure time
to the noise or to enclose the machine to reduce
emitted sound.
You may have already specified a limiting noise
level when the equipment was ordered, however if
no noise requirements were defined, then attention
is drawn to the following table to give an indication of
equipment noise level so that you can take the
appropriate action in your plant.
Pump noise level is dependent on a number of
operational factors, flow rate, pipework design and
acoustic characteristics of the building, and so the
values given are subject to a 3 dBA tolerance and
cannot be guaranteed.
Page 9 of 36
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
Motor size
and speed
kW (hp)
Typical sound pressure level LpA at 1 m reference 20 µPa, dBA
3 550 r/min
Pump
Pump and
motor
only
2 900 r/min
Pump
Pump and
only
motor
1 750 r/min
Pump
Pump and
only
motor
1 450 r/min
Pump
Pump and
only
motor
< 0.55 (< 0.75)
72
72
64
65
62
64
62
64
0.75 (1)
72
72
64
66
62
64
62
64
1.1 (1.5)
74
74
66
67
64
64
62
63
1.5 (2)
74
74
66
71
64
64
62
63
2.2 (3)
75
76
68
72
65
66
63
64
3 (4)
75
76
70
73
65
66
63
64
4 (5)
75
76
71
73
65
66
63
64
5.5 (7.5)
76
77
72
75
66
67
64
65
7.5 (10)
76
77
72
75
66
67
64
65
11 (15)
80
81
76
78
70
71
68
69
69
15 (20)
80
81
76
78
70
71
68
18.5 (25)
81
81
77
78
71
71
69
71
22 (30)
81
81
77
79
71
71
69
71
30 (40)
83
83
79
81
73
73
71
73
37 (50)
83
83
79
81
73
73
71
73
45 (60)
86
86
82
84
76
76
74
76
55 (75)
86
86
82
84
76
76
74
76
75 (100)
87
87
83
85
77
77
75
77
90 (120)
87
88
83
85
77
78
75
78
110 (150)
89
90
85
87
79
80
77
80
150 (200)
89
90
85
87
79
80
77
80
200 (270)
1
1
1
1
85
87
83
85
87
90
85
86
300 (400)
1 The noise level of machines in this range will most likely be of values which require noise exposure control, but typical values are
inappropriate.
Note: for 1 180 and 960 r/min reduce 1 450 r/min values by 2 dBA. For 880 and 720 r/min reduce 1 450 r/min values by 3 dBA.
Page 10 of 36
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
In areas where the staff has to intervene, remember
that when the level of the sound pressure is:
• below 70 dBA: it is not necessary to take special
precautions.
• above 70 dBA: people working continuously in
the machine room must be supplied with
protective devices against noise.
• below 85 dBA: no particular measures need to
be taken for casual visitors staying in the room
during a limited period.
• above 85 dBA: the room must be considered as
a dangerous area because of the noise and a
warning sign must be fixed at each entry
warning the people coming into the room, even
for a short period, that they must wear hearing
protection.
• above 105 dBA: special hearing protection
adapted to this noise level and to the spectral
noise components must be installed and a
warning sign to this effect erected at each entry.
The staff in the room must wear ear protection.
Make sure that the noise, which travels through the
walls and windows, does not generate too high
noise levels in the machine room's surroundings.
2 TRANSPORT AND STORAGE
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be
checked against the delivery and shipping
documents for its completeness and that there has
been no damage in transportation.
To lift machines or pieces with one or several
suspension rings, only use hooks and chains in
compliance with the local regulations concerning
safety. Never put cables, chains or ropes directly on
or in the suspension rings. Cables, chains or lifting
ropes must never present excessive bending.
Never bend the lifting hooks, suspension rings,
chains, etc., which should only be made to endure
stresses within, calculated limits. Remember that the
capacity of a lifting device decreases when the
direction of the lifting force direction makes an angle
with the device axis.
To increase the safety and the efficiency of the lifting
device, all the lifting elements must be as
perpendicular as possible. If necessary a lifting
beam can be placed between the winch and the
load.
When heavy pieces are lifted up, never stay or work
under the load or in the area, which could be in the
path of the load if it were to swing or fall away.
Never leave a load hanging from a winch. The
acceleration or the slowing-down of lifting equipment
must stay in the safety limits for the staff.
A winch must be positioned in such a way that the
load will be raised perpendicularly. Where possible
necessary precautions must be taken to avoid the
swing of the load, using for example two winches
making approximately the same angle, below 30°,
with the vertical.
2.2.2 Pump masses
Any shortage and or damage must be reported
immediately to Flowserve and received in writing
within one month of receipt of the equipment. Later
claims cannot be accepted.
Check any crate, boxes and wrappings for any
accessories or spare parts that may be packed
separately with the equipment or attached to
sidewalls 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
2.2.1 General instructions concerning handling
Boxes, crates, pallets or cartons may be unloaded
using forklift vehicles or slings dependent on their
size and construction. See 2.3.1 for positioning of
slings.
To lift heavy pieces above 25 kg (55 lb), use a winch
adapted to the mass and in accordance with the
current local regulations.
Page 11 of 36
PUMP TYPE
PUMP MASS
kg
lb
ME 150 - 200
130
287
ME 150 - 500
475
1047
ME 200 - 250
175
386
ME 200 - 315
260
573
ME 200 - 355
265
584
ME 200 - 400
370
816
ME 200 - 500
420
926
ME 250 - 250
290
639
ME 250 - 315
330
728
ME 250 - 355
370
816
ME 250- -400
415
915
ME 250 - 500
500
1102
ME 300 - 300
370
816
ME 300 - 400
480
1058
ME 300 - 450
550
1213
ME 300 - 500
710
1565
ME 350 - 350
700
1543
ME 400 - 500
1100
2425
ME 400 - 650
1250
2756
ME 500 - 500
1450
3197
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
All motors (for masses see the motor
description plate) must be handled with a winch.
For masses above 25 kg (55 lb), manual
handling is forbidden.
2.3 Lifting
2.3.1 Slinging of motor pumps units
Use handling means in accordance with motor
pump unit mass mentioned on the CE plate. For the
masses of the pumps bare end of shaft see table §
2.2.2 and nameplate.
To avoid distortion, the pump unit
should be lifted as shown.
A crane must be used for all pump sets in
excess of 25kg (55 Ib). Fully trained personnel must
carry out lifting, in accordance with local regulations.
Motor pump unit
2.4 Storage
Store the pump in a clean, dry
location away from vibration. Leave piping
connection covers in place to keep dirt and other
foreign material out of pump casing.
Turn pump at intervals to prevent brinelling of the
bearings and the seal faces, if fitted, from sticking.
Do not store pumps starting on the fan guard.
The pump may be stored as above for up to 6
months. Consult Flowserve for preservative actions
when a longer storage period is needed.
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 local regulations.
If the product contains substances which are
harmful to the environment, these should be
removed and disposed of in accordance with current
regulations. This also includes the liquids and or
gases in the "seal system" or other utilities.
Make sure that hazardous substances or toxic
fluid are disposed of safely and that the correct
personal protective equipment is used. The safety
specifications must be in accordance with the
current regulations at all times.
3 PUMP DESCRIPTION
3.1 Configurations
Bareshaft pump
The centrifugal motor pump unit is designed for the
pumping of cold water or all clear liquids which are
not solid and liquid mixtures, corrosive, abrasive or
explosive when in contact with the pump motor unit
and its working parts (Important: for other liquids
consult Flowserve for preliminary advice).
The ME type pump is a single-stage pump with axial
suction, support under pump casing (Standard NF
EN 733) and tangential vertical discharge.
When handling always wear gloves, safety
boots and an industrial safety helmet.
For masses above 25 kg (55 lb), manual
handling is forbidden.
Page 12 of 36
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
The pumps of this range allow to the removal of the
pump rotor whilst leaving the pump casing
connected to the suction and discharge pipework.
The maximum values specified in this manual must
never be exceeded.
The pump must be stored in a non-explosive,
ventilated location, sheltered from bad weather, dust
and vibrations.
The reliability of the delivered machine can only be
ensured if it is used according to the conditions
given in this manual.
•
Maximum working pressure at discharge
Maximum effective pressure at discharge in bar (psi)
ME (cast iron EN-GJL-250) - PN 10
ME (cast iron EN-GJS-400-15) - PN 16 - PN 10
∅
DN 150 DN 200 DN 250 DN 300 DN 350 DN 400 DN 500 DN 150 DN 200 DN 250 DN 300 DN 350 DN 400 DN 500
Impeller
4
6
200
(58)
(87)
4
4
6
6
250
(58)
(58)
(87)
(87)
4
6
300
(58)
(87)
8
8
12
12
315
(116)
(116)
(174)
(174)
4
6
350
(58)
(87)
8
8
12
12
355
(116)
(116)
(174)
(174)
8
8
8
12
12
12
400
(116)
(116)
(116)
(174)
(174)
(174)
8
12
450
(116)
(174)
16
10
10
10
6.5
4
15
15
15
10
6
500
(232)
(145)
(145)
(145)
(94)
(58)
(217)
(217)
(217)
(145)
(87)
6.5
10
650
(94)
(145)
•
•
Maximum working pressure at suction: in the
limit of the maximum working pressure at
discharge for zero flow according to the pump
type
Maximum pumped fluid temperature
- Gland packing without cooling
................................................≤ 105 °C (221 °F)
- Mechanical seal without cooling
..................... ≤ 80 °C (176 °F) (for ME 55/70)
..................... ≤ 120 °C (248 °F) (for ME 32/42)
Page 13 of 36
•
•
•
•
•
Maximum solid suspension
3
3
....................................... 50 g/m (0.003 lbm/ft )
Density.................................... 1
Viscosity ................................. 1 mm²/s (31 SSU)
Frequency .................................................. 50 Hz
-1
Maximum speed ............1450 min for all pumps
-1
except 990 min for ME 400-500, ME 400650, ME 500-500
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
3.2 Nomenclature
Characteristics shown on the nameplate fixed on the pump are as shown below:
Each pump is supplied with the following nameplate:
Speed of rotation
Pump type
Flow rate
Head
Radial/thrust bearing
Mass
Maximum admissible
Pressure at 20 °C (68 °F)
Maximum / minimum
temperature
Year of construction +
Manufacture number
Each pump unit is supplied with the following nameplate:
Mass of the set
EU Regulation 547/2012 requires the statement on a product nameplate:
• MEI ≥ 0.10 [--.-] (Between 1st January 2013 and 1st January 2015)
• MEI ≥ 0.40 [--.-] (From 1st January 2015)
Page 14 of 36
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
3.3 Coverage charts
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.
All equipment must be grounded.
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.
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
4.2 Foundation
There are many methods of installing
pump units to their foundations. The correct method
depends on the size of the pump unit, its location
and noise vibration limitations. Non-compliance with
the provision of correct foundation and installation
may lead to failure of the pump and, as such, would
be outside the terms of the warranty.
c) Lay the base plate and level in both directions
with extra shims. The base plate should be level
to within 0.5 mm per 1 m (0.02 in. per 3.3 ft).
The base plate should be mounted onto a firm
foundation, either an appropriate thickness of quality
concrete or sturdy steel framework. It should NOT
be distorted or pulled down onto the surface of the
foundation, but should be supported to maintain the
original alignment.
Anchor bolts must be in accordance with the foot
bolt holes. Use anchor bolts of accepted standards
and sufficient to ensure a secure fitting in the
foundation. Particularly, this applies to individual
plates where the anchor bolts have to withstand the
driving torque.
d) If anchor bolts have been pre-cast in the
foundation slightly tighten the anchor bolts.
Otherwise let them hang in the foundation holes.
4.3 Grouting
4.3.1 Base plate grouting
a) Prepare the site for grouting. Before grouting
clean the foundation surface thoroughly and
provide external barriers as shown:
NF E 27 811
Provide sufficient space in the foundation to
accommodate the anchor bolts. If necessary,
provide concrete risers.
Usually the pump and its drive are mounted on a
common base plate. If not, individual base plates
underneath each machine foot shall be installed.
Base plates are to be fully grouted.
b) Prepare grouting product (concrete, resin) in
accordance with manufacturers' instructions.
4.2.1 Setting the base plate for anchoring
a) Clean the foundation surface thoroughly.
b) Put shims on the foundation surface [approx 2025 mm (0.79-0.98 in.) thick], one on each side of
the bolt hole (as an alternative, leveling screws
can be used).
c) Use grouting products with anti-shrinking
components.
d) To grout up to the required level. Polish
surfaces. Take necessary precautions to avoid
air bubbles.
e) Lay-down the barrier, break external angles, and
polish the different surfaces.
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
f)
After grout starts to cure, definitively tighten
anchor bolts.
g) Control the alignment such as described as
follows.
4.4 Initial alignment
Admissible margin for a motor with roller bearings
with European couplings:
= 0.15 mm parallel checking
= 0.1 mm angular checking
For US supplied couplings values to be used are:
Before connecting the couplings
verify the motor rotation direction.
4.4.1 Thermal expansion
= 0.02 in. parallel checking
= 0.05 in. angular checking
Check the couplings manual for further details.
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.
Angular checking:
4.4.2 Alignment methods
with a sliding rule
Ensure pump and driver are isolated
electrically and the half couplings are disconnected.
Ensure that the pump pipework, suction and
discharge, is disconnected.
The alignment will be definitive only
after pipe connection (see § 4.5.1).
with a caliper gauge
If necessary, improve the machine alignment:
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.
Alignment
Parallelism and concentricity check:
Check the alignment at three or four
points, before piping assembly.
→ Complete unit mounted on common base plate:
The machines are first aligned accurately in our
workshops. Usually, any misalignment observed on
site is due to a wrong adjustment under the base
plate (disturbed during transport or because of
forces exerted by the piping). It is only necessary to
rectify the adjustment under base plate. If it proves
to be insufficient, modify the motor and the piping.
→ Pump and motor mounted on individual base
plates:
Machines are (or must be) first mounted on their
own base plate in the workshop. Once the pump is
set, it will be regarded as the fixed piece. Any
alignment necessary shall be carried out on the
motor.
Never connect the electric motor
before the setting has been completely finished.
with a rule
Page 17 of 36
with a comparator
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
4.5 Piping
The user must verify that the equipment is
isolated from any external sources of vibration.
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.
4.5.1 Suction and discharge piping
The dimensions of the pipes do not directly depend
on suction and discharge diameters of the pump:
a) First, choose a flow speed < 2 m/s (7 ft/s) at
suction, and about 3 m/s (10 ft/s) at discharge.
b) Take into account the available NPSH, which
must be superior to the required NPSH of the
pump.
Never use pump as a support for
piping.
Do not mount expansion joints in
such a way that their force, due to internal pressure,
may act on the pump flange.
Maximum forces and moments allowed on the pump
flanges vary with the pump size and type. These
external strains may cause misalignment, hot
bearings, worn couplings, vibrations and the
possible failure of the pump casing.
When designing the pipes (§ 4.5.2.1, § 4.5.2.2, §
4.5.3.1) take necessary precautions in order not to
exceed maximum allowed strains.
Forces and moments applied to the pump flanges
must never exceed the values shown in the table
below:
Page 18 of 36
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Horizontal suction,
Vertical
discharge
ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
Forces (daN)
Moments (m.daN)
Forces (lbf)
Moments (lbf.ft)
DN
Flange
Fy
Fz
Fx
∑F
My
Mz
Mx
DN
∑M Flange Fy
Fz
Fx
∑F
My
Mz
Mx
∑M
150
160
200
180
310
45
60
80
110
6"
360
450
405
698
332
443
591
812
200
215
265
240
415
85
100
125
180
8"
484
596
540
934
627
738
923
1329
250
270
335
300
520
125
145
180
260
10"
608
754
675
1170
923
1070 1329 1919
300
320
400
360
625
170
200
240
355
12"
720
900
810
1406 1255 1476 1772 2621
350
375
465
420
730
220
255
310
455
14"
844
1046
945
1643 1624 1882 2288 3359
400
430
530
480
835
275
320
390
570
16"
968
1193 1080 1879 2030 2362 2879 4208
450
485
600
540
940
340
390
480
705
18"
1091 1350 1215 2115 2510 2879 3543 5204
500
540
665
600
1040
410
470
580
850
20"
1215 1496 1350 2340 3027 3470 4282 6275
150
180
160
200
315
45
60
80
110
6"
405
360
450
709
332
443
591
812
200
240
215
265
415
85
100
125
180
8"
540
484
596
934
627
738
923
1329
250
300
270
335
520
125
145
180
260
10"
675
608
754
1170
923
1070 1329 1919
300
360
320
400
625
170
200
240
355
12"
810
720
900
1406 1255 1476 1772 2621
350
420
375
465
730
220
255
310
455
14"
945
844
1046 1643 1624 1882 2288 3359
400
480
430
530
835
275
320
390
570
16"
1080
968
1193 1879 2030 2362 2879 4208
450
540
485
600
940
340
390
480
705
18"
1215 1091 1350 2115 2510 2879 3543 5204
500
600
540
665
1040
410
470
580
850
20"
1350 1215 1496 2340 3027 3470 4282 6275
Valve
Non-return valve
Forces and moments values are applied to the
whole flanges and not flange-by-flange. For their
sharing out on the pump flanges, refer to standard
NFCR 13 931.
Continuous
flow valve
Flooded suction configuration
Ensure piping and fittings are flushed
before use.
Ensure piping for hazardous liquids is
arranged to allow pump flushing before removal of
the pump.
4.5.2 Suction piping
4.5.2.1 Design of a flooded suction line
The suction line must be as short and direct as
possible, never mount an elbow directly on the inlet
flange of the pump.
Page 19 of 36
a) Avoid sharp elbows or sudden narrowing. Use
convergent ≤ 20° (total angle).
b) Arrange the piping so that there are no air
pockets (no bulges).
c) If high points cannot be avoided in suction line,
provide them with air relief cocks.
d) If a strainer is necessary, its net area should be
three or four times the area of the suction pipe.
e) If an inlet valve is necessary, choose a model
with direct crossing.
Do not tighten flanges before the final
check (see § 4.5.4).
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
4.5.2.2 Design of a suction lift line
The inlet pipe must be as short and as direct as
possible, never place an elbow directly on the pump
inlet nozzle.
Valve
Non-return
valve
I : Sufficient
immersion
Do not tighten flanges before the final
check (see § 4.5.4).
4.5.4 Final checks
a) Check the tightening of anchor bolts. Tighten
them if necessary.
b) Check that protective covers on suction and
discharge flanges are removed.
c) Check that holes of piping flanges are parallel
and correspond to those of the pump.
d) Tighten suction and discharge flanges.
4.6 Electrical connections
I≥3xD
Valve-strainer
a) Avoid sharp elbows or sudden narrowing. Use
convergent ≤ 20° (total angle) with upright
generating.
b) Arrange that the suction piping is inclined
upwards towards the pump ensuring that there
are no peaks.
c) If a foot valve is necessary, do not oversize it
because it would generate pulsations (valve
beating).
Do not tighten flanges before the final
check (see § 4.5.4).
4.5.3 Discharge piping
4.5.3.1 Design of a discharge line
a) If discharge line is provided with a divergent, its
total angle will be between 7° and 12°.
b) Install the discharge valve after the non-return
valve downstream.
The non-return valve will be set in the discharge
pipe to protect the pump from any excessive
pressure surge and from reverse rotation.
If necessary, a control manometer (pressure gauge)
can be connected on the piping.
C o n tr o l
m a n o m e te r
Electrical connections must be made
by a qualified Electrician in accordance with relevant
local national and international regulations. This
includes any grounding.
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.
Avoid mechanical, hydraulic or electrical overload
by using motor overload trips or a power monitor and
make routine vibration monitoring.
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
doubt, contact Flowserve for advice.
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.
A device to provide emergency stopping shall be
fitted.
Carry out the ground connections according to the
current local regulations.
To avoid any risk of jamming, the
direction of rotation will be checked after priming of
the pump (§ 5.3.1, 5.3.2) and before the first start (§
5.4.2).
Installation of the control manometer
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
4.7 Final shaft alignment check
a) Check the alignment pump-motor according to
the procedure § 4.4.2. Rectify if necessary by
adjusting the motor only.
b) Check by hand that the pump turns freely.
A binding indicates a distortion of the pump,
which is due to excessive pipe strain. If
necessary the pipe design must be re-examined.
c) If it provided, connect auxiliary pipe systems
(hydraulic, pneumatic, sealing system).
d) Control tightness and functionality of auxiliary
piping.
4.8 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
5.5.4 and 5.5.5.
If a defect of cooling can lead to temperature higher
than those acceptable a system of cooling
surveillance must be installed.
Except when explicitly required by the customer in
the specifications, when a possibility of reverse
rotation exists the customer must install a reverse
rotation protection device.
The customer must install all equipment required to
avoid water hammer.
Page 21 of 36
5 COMMISSIONING, START-UP,
OPERATION AND SHUTDOWN
These operations must be carried out by
fully qualified personnel.
5.1 Direction of rotation
Starting or operating pumps with the
wrong direction of rotation can be harmful to the
pumps. Ensure that the pump rotation is the same
as the arrow on the pump casing.
It is preferable to check the direction of rotation
before installing the coupling. If not, the pump must
be filled in with the liquid before start-up.
If maintenance work has been carried
out to the site's electricity supply, the direction of
rotation should be re-checked as above in case the
supply phasing has been altered.
5.2 Guarding
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.
5.3 Priming and auxiliary supplies
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.
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.
These operations must be carried out by personnel
with approved qualifications.
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
5.3.1 Priming of a flooded pump
a) Close the discharge valve; fill the pump by
opening the suction valve. Let air escape by
removing the plug located on the piping.
b) The discharge pipe is headed and there is a bypass valve on the check valve, open slightly the
discharge valve and the by-pass of the check
valve.
c) When the pump is totally free of air bubbles,
replace the plugs.
*Without foot valve:
Priming may be accomplished by means of venting
system.
Foot valves are not recommended when
the pumped liquid has suspended solid particles.
They may lodge between foot valve seat and
shutter.
5.4 Starting the pump
5.4.1 Bring controls and preparation before the
first starting and after each service call
Air escape
Necessarily:
a) Check the tightening of the different plugs.
b) Check that the gland lightly tightens the packing
rings.
c)
Risk of seal ring overheating.
d) Check the direction of rotation of the motor.
Refer to the rotation arrow of the pump.
e)
Priming of a flooded suction pump
5.3.2 Priming of a sump suction pump
* With foot valve:
a) Fill suction pipe and casing with liquid from an
independent source (pressure 1 to 2 bars or 15
to 30 psi).
b) Let air escape by removing the plugs located on
the piping.
c) When the pump is totally free of air bubbles,
replace the plugs.
EXTE RN AL SO U R CE
A ir escape
Install all protection systems and more
particularly the coupling guard and the shield
grid (reference [9331]) of the bearing.
f) Open all suction valves (if existing).
g) Close the outlet valve and the bypass valve.
h) Ensure inlet pipe and pump casing are
completely full of liquid.
5.4.2 First pump start-up
Suction valves must be fully open
when pump is running. Never run the pump dry, it
will cause damage.
a) Start motor and check outlet pressure.If
pressure is satisfactory, slowly OPEN outlet
valve.
c) Do not run the pump with the outlet valve closed
for a period longer than 30 seconds.
d) If NO pressure, or LOW pressure, STOP the
pump. Refer to faultfinding chart for fault
diagnosis.
The pump should run smoothly and without
vibration.
The pump must never run at a capacity of less than
40 % of that at the best efficiency.
Priming of a sump suction
configuration with foot valve
Page 22 of 36
Never remove a plug when the pump is
running.
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
5.5 Running the pump
5.5.1 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.
5.5.2 Pump fitted with a stuffing box
If the pump has a packed gland there must be some
leakage from the gland. Gland nuts should initially
be finger tight only. Leakage should take place soon
after the stuffing box is pressurized. If no leakage
takes place the packing will begin to overheat. If
overheating takes place the pump should be
stopped and allowed to cool before being restarted.
When the pump is restarted it should be checked to
ensure leakage is taking place at the packed gland.
When adjusting an operating stuffing box
(shield grids removed for this operation) the operator
must be very careful. Safety gloves are compulsory
and loose clothes are not allowed (above all to the
arms) to avoid being caught by the pump shaft.
The pump should be run for ten minutes with steady
leakage and the gland nuts tightened by 10 degrees
at a time until leakage is reduced to an acceptable
level. The temperature of the gland should be
checked after each round of tightening.
If the temperature starts to climb rapidly then back
off the gland nuts until the temperature drops down.
Wait for the temperature to stabilize before
tightening again. The leakage must not be reduced
below a rate of 20 drops per minute. Bedding in of
the packing may take several hours.
5.5.3 Pump fitted with mechanical seal
A mechanical seal ensures a seal without leakage
and does not need any adjustment. Nevertheless if a
light leakage occurs during start-up, it should
disappear after the initial running in of the friction
faces.
Mechanical Seal
For ME 150-200,
200-250, 200-315
200-355, 250-250
250-315, 300-300
Simple mechanical
seal
Others ME
Balanced
mechanical seal
Others ME
NEVER RUN A MECHANICAL SEAL
DRY, EVEN FOR A SHORT WHILE.
SAFETY INSTRUCTIONS WHEN THE PUMP IS
RUNNING:
If hot or freezing components of the machine
can present a danger to operators, they must be
shielded to avoid accidental contact. If a 100 %
protection is not possible, the machine access must
be confined to the maintenance staff only.
Shield grids being removed during installation
of the gland packing, it must be ensured that they
are replaced as soon as this operation is completed.
Page 23 of 36
If the temperature is greater than 80 °C (176
°F), a warning plate must be clearly placed on the
pump.
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
It is strictly forbidden to open switch
cupboards, switch boxes, or all other live electric
equipment. If it is necessary to open them in order to
take readings, to carry out tests or adjustments for
example, only a skilled technician may do them with
adapted tools. Make sure that physical protections
against electrical risks are used.
5.5.4 Bearings
If the pumps are working in a potentially
explosive atmosphere, temperature or vibration
monitoring at the bearings is recommended. 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.
5.5.5 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 site on the bearing
housings of the pump in the fully commissioned as
new condition. The example (N) value is given for
the preferred operating flow region (typically this
may extend to 70 to 120 % of the pump best
efficiency point); outside the preferred flow region
the actual vibration experienced may be multiplied
by up to 2.
These standard values can vary with the rotational
speed and the power absorbed by the pump. For
any special case, do not hesitate to consult us.
Measuring vibration at regular intervals will then
show any deterioration in pump or system operating
conditions.
Page 24 of 36
Vibration Velocity - unfiltered
Normal
N
Alarm
N x 1.25
Horizontal Configuration
mm/s (in./s) r.m.s.
≤ 5.6 (0.22)
≤ 7.1 (0.28)
≤ 11.2 (0.44)
Shutdown Trip N x 2.0
5.5.6 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)
Maximum stop/starts
per hour
Up to 15 (20)
15
Between 15 (20) and 90 (120)
10
90 (120) to 150 (200)
6
Above 150 (200)
Refer
Where duty and standby pumps are installed it is
recommended that they are run alternately every
week.
5.6 Stopping and shutdown
According to hydraulic conditions of
the installation and its automation degree, stop and
restart procedures can have different forms.
Nevertheless all of them must respect imperatively
the following rules:
5.6.1 Stopping < 1 hour
a) Isolate motor.
b) Avoid reverse rotation of the pump.
c) Make sure that the discharge line pressure does
not reach the foot valve.
5.6.2 Stopping < 1 month
a) Isolate motor.
b) Avoid reverse rotation of the pump.
c) Make sure that the discharge line pressure does
not reach the foot valve.
d) Close the outlet valve. Eventually close the inlet
valve.
e) Switch off external power supply,
flushing/quench, cooling liquid.
5.6.3 Shutdown > 1 month
a) Isolate motor.
b) Avoid reverse rotation of the pump.
c) Make sure that the discharge line pressure does
not reach the foot valve.
d) Close the outlet valve. Eventually close the inlet
valve.
e) Switch off external power supply,
flushing/quench, cooling liquid.
flowserve.com
ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
f)
Keep the pump fully filled with water. In case of
pumped liquid other than water, drain the pump
entirely.
g) Turn once per week the pump shaft of one or
two turns.
h) Never restart the pump without carrying out the
verifications recommended before starting (see
§ 5.4.1).
When ambient temperatures are
likely to drop below freezing point, the pump and any
cooling and flushing arrangements must be drained
or otherwise protected.
5.6.4 Restarting in continuous running
a) Ensure that the pump is completely full of liquid.
b) Ensure a continuous supply with a sufficient
available NPSH.
c) Ensure a backpressure so that the motor power
is not in excess.
d)
Respect the starting frequency
imposed by the motor manufacturer.
e)
Protect the pump against water hammer
when stopping or starting.
5.7 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.
5.7.1 Specific gravity (SG)
Pump capacity and total head in meters (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 overpressurize the pump.
5.7.2 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.
Page 25 of 36
5.7.3 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.
5.7.4 Net positive suction head (NPSHA)
NPSH available (NPSHA) is the head available at the
impeller inlet, above the vapor pressure of the
pumped liquid.
NPSH required (NPSHR) is the minimum head required
at the impeller inlet, above the vapor pressure of the
pumped liquid, to avoid excessive cavitation and
extreme performance degradation.
It is important that NPSHA > NPSHR. The margin
between NPSHA > NPSHR should be as large as
possible.
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.
5.7.5 Pumped flow
Flow must not fall outside the minimum and
maximum continuous safe flow shown on the pump
performance curve and or data sheet.
5.8 Pumps for Food Use or Potable
Water
If the pump has not been specifically ordered for a
food or drinking water application it must not be
used for these types of applications. If it has been
ordered for this type of application the following
recommendations are to be followed.
5.8.1 Cleaning prior to operation
Pumps that are to be used for a food or drinking
water application should be cleaned before being
put into initial operation and after the installation of
spare parts that are in contact with the liquid.
Cleaning once the pump has been commissioned
will depend on the application and operating
conditions. The user must ensure that the cleaning
procedures are suitable for the application and
operating conditions, and local regulations.
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
6 MAINTENANCE
6.1 General
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".
If a belt drive is used, the assembly and
tension of the belts must be verified during regular
maintenance procedure.
Never clean equipment with inflammable solvents or
carbon tetrachloride. Protect yourself against toxic
fumes when using cleaning agents.
In dirty or dusty environments, regular checks
must be made and dirt removed from areas around
close clearances, bearing housings and motors.
6.2 Maintenance schedule
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).
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 5.6.
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 guardrails 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.
Never use air or compressed inert gas to clean
clothes.
It is recommended that a maintenance plan
and schedule is adopted, in line with these User
Instructions. It should include the following:
a) The pump must be completely vented and
drained and rendered inert before any
disassembly operation.
b) Any auxiliary systems installed must be
monitored, if necessary, to ensure they function
correctly.
c) During cleaning of the pump ensure the
compatibility between the cleaning products and
the gaskets.
d) Verify the condition of the gaskets.
e) Gland packing must be adjusted correctly to give
visible leakage and concentric alignment of the
gland follower to prevent excessive temperature
of the packing or follower. Mechanical seals
should present no leakage.
f) Check for any leaks from gaskets and seals.
The correct functioning of the shaft seal must be
checked regularly.
g) Check bearing lubricant level, and if the hours
run show a lubricant change is required.
h) Check that the duty condition is in the safe
operating range for the pump.
i) Check vibration, noise level and surface
temperature at the bearings to confirm
satisfactory operation.
j) Check the tightness of the connections.
k) Check dirt and dust is removed from areas
around close clearances, bearing housings and
motors.
l) Check coupling alignment and re-align if
necessary.
m) Verify the correct operation of the system.
The equipment used for maintenance and
disassembly in an ATEX zone must be in conformity
with the requirements zone.
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.
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".
Page 26 of 36
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
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.
Grease
nipple
Grease
nipple
6.2.1 Standard maintenance
Roller bearing
6.2.1.1 For ME 150-200, 200-250, 200-315, 200355, 250-250, 250-315, 300-300
The bearing housings are provided with sealed for
life ball bearings. No maintenance is required.
6.2.1.2 For other ME
The bearings fitted are prepacked with grease at the
factory. When the regressing period is reached it is
necessary to remove as much of the old grease as
possible with a clean lint free cloth and repack the
bearings with fresh grease.
Pump type
ME 150 - 500
ME 200 - 400
ME 200 - 500
ME 250 - 355
ME 250 - 400
ME 250 - 500
ME 300 - 400
ME 300 - 450
ME 300 - 500
ME 350 - 350
ME 400 - 500
ME 400 - 650
ME 500 - 500
Lubrication in
Added quantity in
hours frequency *of
cm3 (oz)
operation
Coupling
Pump
Coupling
Pump
side
side
side
side
4 000
4 000
30 (1.01) 30 (1.01)
8 000
8 000
25 (0.85) 25 (0.85)
4 000
4 000
30 (1.01) 30 (1.01)
8 000
8 000
25 (0.85) 25 (0.85)
8 000
8 000
25 (0.85) 25 (0.85)
4 000
4 000
30 (1.01) 30 (1.01)
8 000
8 000
25 (0.85) 25 (0.85)
4 000
4 000
30 (1.01) 30 (1.01)
3 500
3 500
50 (1.69) 50 (1.69)
4 000
4 000
40 (1.35) 40 (1.35)
3 500
3 500
50 (1.69) 50 (1.69)
3 500
3 500
50 (1.69) 50 (1.69)
3 500
3 500
50 (1.69) 50 (1.69)
* At least once a year
The grease used in factory for first filling is:
SHELL ALVANIA R2
Its equivalents: MOBIL: Mobilux EP 2,
TOTAL: Multis 2,
ELF : ELF MULTI
6.2.2 Routine inspection (daily/weekly)
The following checks should be made
and the appropriate action taken to remedy any
deviations:
a) Check operating behavior. 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) Pump fitted with a stuffing box: leakage of 20
drops per minute.
d) Pump fitted with a mechanical seal: no leakage.
e) Check the level and condition of oil lubricant. On
grease lubricated pumps, check running hours
since last recharge of grease or complete
grease change.
6.2.3 Periodic inspection (six monthly)
Check foundation bolts for
security of attachment and corrosion.
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.
a)
If a check shows a bad running of the
motor pump unit, the user must:
a)
Refer to the "fault finding chart" chapter 7
of this leaflet to apply the recommended
solutions.
b) Ensure that your equipment corresponds to the
arrangements of this leaflet.
c) Contact Flowserve after-sales Department if the
problem persists.
Page 27 of 36
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
6.2.4 Mechanical seals
The current maintenance is limited to seal control. It
is necessary to detect any small leakage which
announces the beginning of the deterioration of
friction faces or secondary seal elements (rings,
bellows, synthetic membranes). It is advisable to
stop the pump as soon as possible. Have an
approved seal vendor replace or repair the seal.
SETTING OF PACKING
Follow the instructions:
a) Assemble of the packing in S.
b) Stagger by about 90° between two rings.
c) Assemble packing after packing.
6.2.5 Gland packing
6.2.5.1 Pump fitted with a packed gland
A well run in and correctly adjusted packing gland
requires little maintenance.
If, after some time, the leakage becomes too great,
the gland should be tightened again in order to
return these to a normal level.
If re-tightening is not possible, new packing must be
installed.
6.2.5.2 Gland packing inspection and removal
a) Remove the shield guards.
b) Slide back the gland.
c) Remove the packing rings with an extractor
designed for this purpose (including the lantern
ring if it exists; note its position and its direction
of rotation).
d) Inspect the state of the sleeve surface; the
presence of many marked grooves will indicate
that it must be replaced.
e) Carefully clean the different pieces of the
packing gland.
After setting the last packing ring, secure the
packing with the gland and tighten the nut by hand.
After tightening, the shaft should turn by hand as
easily as before the setting of the packing.
6.2.5.3 Gland packing fitting
If the packing is supplied as cord the packing must
be cut so that the external diameter is lightly
tightened and there is an initial gap between the
sleeve and the packing ring. For that purpose, wind
the packing helically around the shaft sleeve or a
chuck of the same diameter. (Take precautions to
avoid damaging sleeve).
Example of straight cut
Example of bevel cut
Ensure a tightening on the stuffing
box housing and not on the sleeve.
Page 28 of 36
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
Dimensions in mm (in.)
Gland packing
PUMP
Stuffing
box
size
D1
D2
D3
D4
D5
L1
Qty
mm
(in)
ME 150-200
ME 150-500
ME 200-250
ME 200-315
ME 200-355
ME 200-400
ME 200-500
ME 250-250
ME 250-315
ME 250-355
ME 250-400
ME 250-500
ME 300-300
ME 300-400
ME 300-450
ME 300-500
ME 350-350
ME 400-500
ME 400-650
44/64
55/90
44/64
56/76
56/76
49/85
55/90
56/76
56/76
49/85
55/90
55/90
56/76
55/90
55/90
74/120
55/90
74/120
74/120
38 (1.50)
55 (2.16)
38 (1.50)
50 (1.97)
50 (1.97)
49 (1.93)
55 (2.16)
50 (1.97)
50 (1.97)
49 (1.93)
55 (2.16)
55 (2.16)
40 (1.57)
55 (2.16)
55 (2.16)
74 (2.91)
55 (2.16)
74 (2.91)
74 (2.91)
44 (1.73)
65 (2.56)
44 (1.73)
56 (2.20)
56 (2.20)
60 (2.36)
65 (2.56)
56 (2.20)
56 (2.20)
60 (2.36)
65 (2.56)
65 (2.56)
56 (2.20)
65 (2.56)
65 (2.56)
90 (3.54)
65 (2.56)
90 (3.54)
90 (3.54)
64 (2.52)
90 (3.54)
64 (2.52)
76 (2.99)
76 (2.99)
85 (3.35)
90 (3.54)
76 (2.99)
76 (2.99)
85 (3.35)
90 (3.54)
90 (3.54)
76 (2.99)
90 (3.54)
90 (3.54)
120 (4.72)
90 (3.54)
120 (4.72)
120 (4.72)
86 (3.39)
120 (4.72)
86 (3.39)
86 (3.39)
86 (3.39)
110 (4.33)
120 (4.72)
86 (3.39)
86 (3.39)
110 (4.33)
120 (4.72)
120 (4.72)
86 (3.39)
120 (4.72)
120 (4.72)
150 (5.90)
120 (4.72)
150 (5.90)
150 (5.90)
M12
M16
M12
M12
M12
M14
M16
M12
M12
M14
M16
M16
M12
M16
M16
M16
M16
M16
M16
45 (1.77)
65 (2.56)
45 (1.77)
45 (1.77)
45 (1.77)
65 (2.56)
65 (2.56)
45 (1.77)
45 (1.77)
65 (2.56)
65 (2.56)
65 (2.56)
45 (1.77)
65 (2.56)
65 (2.56)
64 (2.52)
65 (2.56)
64 (2.52)
64 (2.52)
4
5
4
4
4
5
5
4
4
5
5
5
4
5
5
4
5
4
4
10 (0.39)
12 (0.47)
10 (0.39)
10 (0.39)
10 (0.39)
12 (0.47)
12 (0.47)
10 (0.39)
10 (0.39)
12 (0.47)
12 (0.47)
12 (0.47)
10 (0.39)
12 (0.47)
12 (0.47)
14 (0.55)
12 (0.47)
14 (0.55)
14 (0.55)
ME 500-500
80/132
80 (3.15)
100 (3.94) 132 (5.20) 180 (7.09)
M16
72 (2.83)
4
16 (0.63)
6.2.6 Internal coating
If the pump has an internal coating, this coating
must be inspected periodically. Any wear or cracks
of the coating found must be immediately repaired.
Failure to do this may lead to accelerated wear of
the coating during operation and corrosion of the
exposed base metal, depending on the material and
pumped liquid. Special attention must be paid to the
coating edges. Any loss of coating material is
considered to be normal wear and tear on the pump
and is not considered as warranty. Flowserve has
applied the coatings according to the supplier's
instructions but will not be held responsible for
coating wear or cracks that may develop over time.
6.3 Spare parts
6.3.1 Ordering of spares
Flowserve keeps records of all pumps that have
been supplied. When ordering spares the following
information should be quoted:
1) Pump serial number.
2) Pump size
3) Part name
4) Part number
5) Number of parts required
the original design specification (modification or use
of a non-standard part) will invalidate the pump’s
safety certification.
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
[1500], [2250], [3011], [3012], [4130], [4610]
a) Destroy all the gaskets after dismantling, replace
them when reassembling.
b)
It is recommended that bearings
are not reused after any removal from the shaft.
c) After serving during two years, replace the gland
packing.
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
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
6.5 Disassembly
Refer to section 1.6, Safety, and section 6
Maintenance, 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.
REPAIR OF THE PUMP
If the pump presents abnormalities or a
persistent malfunction, contact immediately:
FLOWSERVE
After-sales Service
Tel.: 02 43 40 57 57
(33) 2 43 40 57 57
Fax.: 02 43 40 58 17
(33) 2 43 40 58 17
According to the After-sales Service instructions,
disassembly will be limited to the dismantling of the
pump:
a)
DISCONNECT THE UNIT FROM
POWER.
b) Close the inlet valve (if fitted) and outlet valve.
c) Wait for the moment when the pump casing is
cooled and at ambient temperature.
d)
DRAIN PUMP
e) Dismantle inlet and outlet pipeworks as well as
all pipeworks.
f)
REMOVE PUMP TAKING INTO
ACCOUNT SAFETY (§ 1) AND HANDLING (§
2.2) PROCEDURES.
ANY DISASSEMBLY, REPAIR OR
REASSEMBLY WILL BE CARRIED OUT UNDER
FLOWSERVE' RESPONSABILITY, EITHER
DIRECTLY BY THE AFTER-SALES SERVICE OR
BY OTHER FLOWSERVE-AGENTS WHO WILL
GET THE REQUIRED INSTRUCTIONS AND
APPROVALS. THIS IS THE CASE OF
AUTHORIZED REPAIRERS WHOSE ADDRESSES
AND TELEPHONE NUMBERS WILL BE GIVEN
ON REQUEST.
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
7 FAULTS; CAUSES AND REMEDIES
POSSIBLE CAUSES
Pump or suction pipe not completely filled
Air bubbles in pipes
Suction level too low
Wrong rotation
The motor is running on 2 phases only
Motor running too low
Total manometric head system higher than
pump differential head
Total manometric head system lower than
pump differential head
Pipes (valves, filter...)
Insufficient flow rate
Worn wear-ring surfaces
Seizure, jamming
Excessive strains on flanges
Defective gland packing on the shaft
Defective motor bearings
Specific gravity or viscosity of liquid too high
Misalignment
Foundations not sufficiently rigid
POSSIBLE CAUSES
Rotation speed too low (check the driver)
Presence of air
Suction pressure insufficient
Mechanical defects
Air leak in the suction pipe
Restriction in suction pipe
Suction level too low
Insufficient flow rate
Irregular pump running
Driver overloaded
Mechanical seal leak
Equipment vibration
Excessive pump casing temperature
SOLUTIONS
- Check and complete filling
- Check and desecrate the pipes
- Check: the available NPSH > the required NPSH
- Reduce geometrical suction lift
- Reduce head losses in pipes and in fittings (diameter increase
and appropriate fitting positions)
- Check valves and strainers
- Check the immersion head of the suction valve
- Reverse 2 phases on motor terminal boxes
- Check and control the motor electrical power supply
- Check the connection in the terminal box according to the
voltage
- Check the discharge head
- Check the head losses in discharge pipes (partly closed valve,
foreign particles, back pressure too high)
- Modify the installation or change the pump set
-Throttle at discharge valve or trim the impeller (contact our local
agent): CONSULT FLOWSERVE
- Control, dismantle and clean
- Check the suction and discharge pipes (valves, back pressure)
- Foresee pump mending: CONSULT FLOWSERVE
- CONSULT FLOWSERVE
- Check the flange connections and eliminate strains (pipe
positioning or elastic sleeves mounting)
- Check and replace all the gland packing parts
- Mechanical seal: CONSULT FLOWSERVE
- CONSULT FLOWSERVE
- Consult our local agent to analyze the problem
- Check the alignment of the pump and of its driver
- Check the setting of base plates: tightening, bad adjustment,
seal
Insufficient pressure
Pump looses prime after starting
SOLUTIONS
- Check the connection in the terminal box according to the
voltage
- Check and de-aerate
- Check: the available NPSH > the required NPSH
- CONSULT FLOWSERVE
- Check suction pipe is airtight
- Check diameter of suction pipe
- Check the NPSH >NPSH
- Reduce geometrical suction lift
- Reduce head losses in pipes and in fittings (diameter increase
and appropriate fitting positions)
- Check valves and strainers
- Check the immersion head of the suction valve
Obstruction of suction pipe
Defective gland packing on the shaft
- Check condition of pipe
- Check and replace all the gland packing.
- Mechanical seal: CONSULT FLOWSERVE
Defective gasket
- CONSULT FLOWSERVE
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
8 PARTS LIST AND DRAWINGS
8.1 Sectional drawings
Pump ME Bearing Size 32/42
9331
1500-02
1500-01
With wear-rings
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
Pump ME Bearing Size 55
9331
Bearing 55A
1500-02
1500-01
Bearing 55B
With wear-rings
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
Pump ME Bearing Size 70
9331
1500-02
1500-01
With wear-rings
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
8.2 Sectional drawings part list
ITEM
DESIGNATION
ITEM
4200
DESIGNATION
1110
Pump casing
1221
Casing cover
4590-01 Gasket
1221-01 Casing cover
4590-02 Gasket
1221-02 Casing cover
4590-03 Gasket
1500-01 Wear ring
4610-01 O-ring
1500-02 Wear ring
4610-02 O-ring
Mechanical seal
2110
Pump shaft
6511
Priming plug
2250
Radial flow impeller
shrouded
6515
Drain plug
2450
Shaft sleeve
6541
Lockwasher
2450-01 Shaft sleeve
6544
Circlip
2540
Thrower
6544-01 Circlip
2905
Washer
6544-02 Circlip
2905-01 Washer
6569
Screwed plug
2905-02 Washer
6572
Stud
2912
Impeller nut
6572-01 Stud
3011
Radial ball bearing
6572-02 Stud
3012
Radial roller
bearing
6572-03 Stud
3126
Shim
6577-01 Hexagon head bolt
3134
Support foot
6577-02 Hexagon head bolt
3200
Bearing housing
6577-03 Hexagon head bolt
3260
Bearing cover
6581
Hexagon nut
3260-01 Bearing cover
6581-01 Hexagon nut
3260-02 Bearing cover
6581-02 Hexagon nut
3712
Bearing nut
6581-03 Hexagon nut
3853
Grease nipple
6581-04 Hexagon nut
3863
Grease regulator
6700-01 Coupling key
4120
Gland
6700-02 Impeller key
4130
Gland packing
9331
Cover plate
8.3 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 are provided with these instructions
where applicable. Examples are certificates for CE
marking, ATEX marking etc. If required, copies of
other certificates sent separately to the Purchaser
should be obtained from the Purchaser for
retention with these User Instructions.
10 OTHER RELEVANT
DOCUMENTATION AND MANUALS
10.1 Supplementary User Instructions
Supplementary instructions such as for a driver,
instrumentation, controller, seals, sealant system
etc are provided as separate documents in their
original format. If further copies of these are
required they should be obtained from the supplier
for retention with these User Instructions.
10.2 Change notes
If any changes, agreed with Flowserve, 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 Rotor dynamic Pumps: a reference
guide, Euro pump Guide No. 1, Euro pump &
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.
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ME USER INSTRUCTIONS ENGLISH 71576287 - 02/13
Your Flowserve factory contacts:
FLOWSERVE REGIONAL
SALES OFFICES:
USA and Canada
Flowserve Corporation
5215 North O’Connor Blvd.,
Suite 2300
Irving, Texas 75039-5421 USA
Telephone 1 972 443 6500
Fax 1 972 443 6800
Europe, Middle East, Africa
Flowserve Pompes SAS
13, rue Maurice Trintignant
CS 10001
72234 Arnage Cedex, France
Telephone (24 hours): +33 2 43 40 58 47
Sales & Admin:
+33 2 43 40 57 57
Repair & Service Fax: +33 2 43 40 58 17
Flowserve FSG - Italy
Worthing S.P.A.
Via Rossini 90/92
20033 Desio (Milan) Italy
Telephone 39 0362 6121
Fax 39 0362 628 882
Latin America and Caribbean
Flowserve Corporation
6840 Wynnwood Lane
Houston, Texas 77008 USA
Local Flowserve factory representatives:
Telephone 1 713 803 4434
Fax 1 713 803 4497
North America:
Flowserve Pump Division
5310 Taneytown Pike, PO Box 91
Taneytown, MD 21787-0091, USA
Asia Pacific
Flowserve Pte. Ltd
10 Tuas Loop
Singapore 637345
Telephone:
+1 (410) 756 2602
Customer Service FAX: +1 (410) 756 2615
Parts inquiry/Order PH: +1 (800) 526 3569
South America:
Flowserve do Brasil Ltda
Av. Don Helder Camara, 5451
20771-001 Rio de Janerio, Brasil
Telephone:
Fax:
+55-21-2108-4000
+55-21-2108-4184
To find your local Flowserve representative please
use the Sales Support Locator System found at
www.flowserve.com
Telephone 65 6771 0600
Fax 65 6862 2329
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