Flowserve HPX Programming manual

INSTRUCTIONS FOR

INSTALLATION,OPERATION

AND MAINTENANCE

___________________________________________

Centrifugal pumps

Type HPX

CE-HPX-R-FLOW.DOC – rev. 0

Pump Division

Worthington S.r.l.

FOREWORD

FLOWSERVE products are the result of more than a century of progressive study and

development. Advanced design, proper selection of materials, and precision construction reflect

this wide experience. FLOWSERVE products will give trouble-free efficient operation with

minimum maintenance and repair.

This instruction book will familiarize management and operating personnel with pertinent details

and proper procedures for the installation, operation and maintenance of one of these products.

Designate below your identification of the equipment for which this book applies.

Unit Size

Identification No.

STUDY THIS INSTRUCTION BOOK

The descriptions and instructions included in this book cover the standard design of the equipment

and any common deviations when possible. This book does not cover all design details and

variations nor does it provide for every possible contingency which may be encountered. When

information can not be found in this book, contact the nearest FLOWSERVE Service Centre.

WARNING

Do not operate this equipment in excess of its rated capacity, speed, pressure and

temperature, nor otherwise than in accordance with the instructions contained in this

Manual.

This equipment has been shop tested and found satisfactory for the conditions for which it

was sold, but its operation in excess of these conditions will subject it to stresses and

strains which it was not designed to withstand.

Failure to heed this warning may result in an accident causing personal injury.

TABLE OF CONTENTS

I INTRODUCTION 5

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

1.10

1.11

1.12

1.13

1.14

1.15

1.16

1.17

1.18

1.19

1.20

1.21

1.22

1.23

1.24

1.25

1.26

1.27

1.28

Safety

Installation, Operation and Maintenance Safety Procedures

Installation Safety Procedures

Operation Safety Procedures

Maintenance Safety Procedures

Construction

Parts description

Casing

Impeller

Casing cover

Shaft

Bearing housing

Bearings

Inducer

Coupling/Coupling guards

Baseplate

Check upon arrival

Care during storage

Long term storage

Inspection upon arrival

Storage

Inspection and maintenance

Painting and preservation

Associated equipment

Lifting equipment

To lift unit

To lift driver

To lift complete pump only

II INSTALLATION 15

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

2.10

2.11

2.12

2.13

2.14

2.15

Location

Foundation

Level the baseplate

Method of levelling baseplate using wedges or shims

Grouting

Shaft/Coupling alignment

Types of misalignment

Alignment using the Reverse Alignment method

Alignment using a graph (Reverse Alignment)

Assemble Coupling

Dowel Pump and Driver

Hot Alignment Check

Installation Check List

Piping

- Suction and Discharge Piping

- Bypass Line

Suction Strainer

III OPERATION 32

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

3.9

3.10

3.11

3.12

3.13

3.14

3.15

3.16

3.17

3.18

3.19

3.20

3.21

Technical Data

Effects of Specific Gravity

Effect of Viscosity

Changing the Pump Speed

Net Positive Suction Head (NPSH)

Minimum Continuous Stable Flow

Minimum Flow Control

Control Notes

Thermal Control

Pressure and/or Flow Control

Continuous Bypass Control

Operating Precautions

Pre-Operational Checks

Initial Start Up Procedure

Operating Checks

Normal Start Up

Securing the Pump

General Maintenance

Routine Maintenance

Trouble Shooting

Trouble Shooting Chart

IV LUBRICATION 43

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

Preparing Bearing Housing

Inspection

Replenishment

Oil Change

Lubrication Specification

Trico Oiler Setting

Bearing Housing Oil Fill Capacities

Bearing Housing Oil Limitations

V MECHANICAL SEALS 47

5.1

5.2

Description

Servicing Mechanical Seal

VI MAINTENANCE, DISMANTLING 48

6.1

6.2

6.3

Dismantling – General

Pump Disassembly Instructions

Disassembly of Pull Out Element

VII INSPECTION AND RENEWAL OF PARTS 53

7.1

7.2

7.3

7.4

7.5

7.6

7.7

7.8

7.9

7.10

7.11

7.12

General

Wear Rings (Impeller)

Case Wear Ring (and Casing Cover Wear Ring when Fitted)

Mechanical Seal

Throat Bush (If Fitted)

Bearing Handling Information

Bearing handling

Bearing Installation

Bearing Removal

Bearing Cleaning

Assembly

Torque Value Supplement

SECTION I

INTRODUCTION

This manual contains instructions for installation, operation and maintenance for your

FLOWSERVE Centrifugal Pump. The instructions are written for the use of personnel with a

general training in the operation and maintenance of Centrifugal Pumps.

Your pump has been designed to provide safe and reliable service. However, it is both a pressure

vessel and a piece of rotating machinery so that operators must exercise good judgement and

observe correct safety practices to avoid damage to the equipment and surroundings and to

prevent personal injury.

The pump has been designed for the duty specified in the customers order. F.P.D should be

consulted prior to any significant change of duty.

1.1 Safety

It is assumed that your safety department has established a safety programme based upon a

thorough analysis of industrial hazards. Before installing and operating or performing maintenance

on the pump and associated components in this manual, it is suggested that the safety

programme be reviewed to ensure that it covers the hazards arising from high speed rotating

machinery.

It is also important that due consideration be given to those hazards which arise from the presence

of electrical power, hot oil, high pressure and temperature liquids, toxic liquids and gases,

flammable liquid and gases. Correct installation and care of protective guards, shut down devices

and over pressure protection equipment should also be considered an essential part of any safety

programme.

Also essential are special precautionary measures to prevent the possibility of applying power to

the equipment at any time when maintenance work is in progress. The prevention of rotation due

to reverse flow should not be overlooked.

In general, all personnel should be guided by all the basic rules of safety associated with the

equipment and the process.

1.2 Installation, Operation and Maintenance Safety Procedures

In the following safety procedures you will encounter the words WARNING, CAUTION and NOTE.

These are intended to emphasize certain areas in the interest of personal and satisfactory pump

operation and maintenance. The definitions are as follows:

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

personal injury, or loss of life.

CAUTION: An operating procedure, practice, etc, which, if not correctly observed, could result

in damage to, or destruction of equipment.

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

These safety procedures are to be used in conjunction with the installation, operation and

maintenance instructions contained in the pump manual.

1.3 Installation Safety Procedures

1. Lifting equipment

Make sure that any equipment used to lift pump or any of its components is capable of supporting

the weights encountered. Make sure that all parts are correctly rigged before attempting to lift.

2. Coupling alignment CAUTION

Coupling alignment must be correct for successful operation. Flexible couplings will not

compensate for any appreciable misalignment, and rapid wear, noise, vibration and actual

damage to the equipment may be caused by misalignment. Therefore, the coupling must be

aligned within the limits given.

3. Driver rotation WARNING

The driver rotation must be checked before making up coupling. Actual damage to the

equipment and personal injury could result from operating the unit with incorrect rotation.

4. Suction and discharge piping

Provisio

n must be made to support suction and discharge piping to the pump to prevent excessive

nozzle loads and maintain pump to driver alignment.

1.4 Operation Safety Procedures

1. Operating conditions WARNING

In the interest of operator safety the unit must not be operated above the nameplate

conditions. such operation could result in unit failure causing injury to operating

personnel. Consult instruction book for correct operation and maintenance of the pump

and its supporting components.

2. Pumps handling heavy viscous liquids CAUTION

When pump is handling heavy viscous liquid, the temperature of the liquid must allow it to

be pumped easily. Liquid may have to be heated prior to pump start-up.

3. Pump priming CAUTION

Before starting or while operating the pump, the casing and suction line must be

completely filled with the liquid being pumped. The rotating parts depend on this liquid for

lubrication and the pump may seize if operated without liquid.

4. Pump by pass line CAUTION

When operating for some time at reduced capacity, much of the pump horsepower will go

into the liquid in the form of heat. A by pass must be provided under these conditions to

prevent the liquid in the pump from becoming hot enough to vaporize.

5. Operation at reduced capacity CAUTION

Damage to pump may result from prolonged operations at capacities less than 25% of the

best efficiency point

6. Bearing lubrication WARNING

Operation of the unit without correct lubrication can result in overheating of the bearings,

Bearing failures, pump seizures and actual breakup of the equipment, exposing operating

personnel to injury.

7. Operation inspections WARNING

Do not attempt any maintenance, inspection, repair or cleaning in the vicinity of rotating

equipment. Such action could result in injury to operating personnel.

8. Coupling guards WARNING

The unit must not be operated unless coupling guard is in place. Failure to observe this

warning could result in injury to operating personnel.

1.5 Maintenance safety procedures

1. Tagging for inspection or repair WARNING

Before attempting any inspection or repair on the pump the driver controls must be in the

"off" position, locked and tagged to prevent injury to personnel performing service to the

pump.

2. Isolating the pump WARNING

Before attempting to disassemble the pump, the pump must be isolated from the system,

by closing suction and discharge system valves, drained of liquid and cooled, if pump is

handling hot liquid.

3. Draining pump handling hot liquids WARNING

When pump is handling "hot" liquid extreme care must be taken to ensure safety of

personnel when attempting to drain pump. Hot pumps must be allowed to cool before

draining.

4. Draining pump handling caustic liquid WARNING

When pump is handling "caustic" liquid extreme care must be taken to ensure safety of

personnel when attempting to drain the pump. Protective devices of suitable protective

materials must be worn when draining the pump.

It should be understood that the information contained in this manual does not relieve

operating and maintenance personnel of the responsibility of exercising normal good

judgement in operation and care of the pump and its components.

5. Pumps on vacuum service WARNING

Before attempting any maintenance work on pumps in vacuum service, the pumps must be

isolated from suction and discharge system then carefully vented to return pressure in

pump casing to atmospheric pressure.

6. Oil ring inspection (where applicable) CAUTION

Remove the pipe plug(s) from the top of the bearing housing(s) and check to see that oil

rings are riding free on the pump shaft and are not hung up. Failure to observe this caution

could result in damage to or destruction of equipment.

1.6 Construction

1.7 Parts description

The type 'HPX' are horizontally mounted, vertically split, back pull out single stage, single suction

overhung process pumps, constructed to the requirements of API 610 specifications, for

continuous duty service in all process industries and industrial application within the pressure and

temperature limitations.

1.8 Casing

The casing is centre line supported with end suction and top discharge. It provides for the

immediate containment of liquid being pumped as the liquid is directed from the suction nozzle

through the impeller and then through the volute to the discharge nozzle. The casing also provides

the centre line attachment to the baseplate or support. A wear ring is mounted in the casing to

provide a close running clearance with the impeller wear ring.

1.9 Impeller

The impeller is a single suction, radial flow, closed design. The impeller is dynamically balanced,

keyed to the shaft and secured by locknut and lockscrew. Renewable wear rings are a press fit

onto the impeller hub and positively secured with radial screws.

1.10 Casing cover

The casing cover is designed to accommodate single, tandem or double elastomer and metal

bellow cartridge seals to the dimensional requirements of API 682. On certain models a wear ring

may be mounted in the cover to provide a close running clearance with the impeller back wear

ring.

1.11 Shaft

A high strength shaft is of stiff shaft design, machined over its entire length to close tolerances.

The shaft transmits the required power without vibration.

1.12 Bearing housing

The bearing housing is air cooled with fan type flingers provided at inboard and outboard ends.

The bearing housing contains the thrust and radial bearings and, for other than pure mist type

lubrication, serves as the oil reservoir for the bearing lubricating oil. For other than pure mist

applications, a constant level oiler is provided for maintaining required oil level. Labyrinth type

flingers help to seal the bearing housing to prevent contamination of the lubricating oil.

A finned type cooling insert is available as an option for the cooling of the lubricating oil. Provision

for purge oil mist is standard whilst pure oil mist lubrication is optional.

1.13 Bearings

Heavy duty, single row radial bearing and duplex angular contact thrust bearings arranged back to

back ensure long life under the most severe operating conditions. The bearings are a sliding fit in

the bearing housing and a light interference fit on the shaft in accordance with AFBMA

recommendations.

Lubrication of the bearings is provided by oil rings, thrower, purge mist or pure mist as a customer

option.

1.14 Inducer

Inducers are available on most pump models for low NPSH conditions. The inducer replaces the

standard impeller locknut and lockscrew. It is secured by proper cap nut and security washer.

1.15 Coupling/Coupling guards

Flexible spacer couplings are provided in various makes and models to suit customer preference.

(Fabricated heavy gauge sheet metal, or aluminium hinged or non- hinged guards are provided)

1.16 Baseplate

Standard baseplates are welded steel, drain pan type in conformance with API 610 standardized

dimensions, forces and moments. Horizontal driver alignment screws and vertical baseplate

levelling screws are provided as an option.

Special baseplates can be supplied to suit individual installation circumstances.

1.17 Check upon arrival

Your pump was carefully checked at the factory prior to shipment to assure its meeting the

requirements of your order.

It is suggested that the pump be inspected upon arrival and that any irregularities arising due to

shipping be reported immediately to the carrier and FLOWSERVE

1.18 Care During Storage

If the equipment is not to be installed immediately it should be stored in a clean, dry, vibration free

area and covered. Add "disessicant" between the covering and the pump.

Replace nozzle covers. Turn rotor in direction of rotation once a week.

Secure coverings after each check.

Electric Motors (Pump Driver) should not be stored in damp places without special protection

(Refer to Motor manufacturers instructions).

Table of contents

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