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Flowserve ECPJ PDF
Flowserve ECPJ PDF
Flowserve ECPJ PDF
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ECPJ USER INSTRUCTIONS ENGLISH - 05/16
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ECPJ USER INSTRUCTIONS ENGLISH - 05/16
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ECPJ USER INSTRUCTIONS ENGLISH - 05/16
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ECPJ USER INSTRUCTIONS ENGLISH - 05/16
run-up process (See section 5 Commissioning, condition these are extremely dangerous and skin
startup, operation and shutdown). contact must be avoided.
NEVER RUN THE PUMP DRY GUARDS MUST NOT BE REMOVED WHILE
PUMP IS OPERATIONAL
INLET VALVES TO BE FULLY
OPEN WHEN PUMP IS RUNNING THERMAL SHOCK
Running the pump at zero flow or below the Rapid changes in the temperature of the liquid within
recommended minimum flow continuously will cause the pump can cause thermal shock, which can result
damage to the seal. in damage or breakage of components and should be
avoided.
DO NOT RUN THE PUMP AT
ABNORMALLY HIGH OR LOW FLOW RATES NEVER APPLY HEAT TO REMOVE
Operating at a flow rate higher than normal or at a IMPELLER
flow rate with no back pressure on the pump may Trapped lubricant or vapour could cause an
overload the motor and cause cavitation. Low flow explosion.
rates may cause a reduction in pump/bearing life,
overheating of the pump, instability and HOT AND COLD PARTS
cavitation/vibration. If hot or freezing components or auxiliary heating
supplies can present a danger to operators, they
When ambient temperatures are must be shielded to avoid accidental contact. If
likely to drop below freezing point, the pump and any complete protection is not possible, the machine
cooling and flushing arrangements must be drained access must be limited to maintenance staff only.
or otherwise protected. Note: bearing housings must not be insulated and
drive motors and bearings may be hot.
If the temperature is greater than 68 °C (155 °F) or
HANDLING COMPONENTS
below 5 °C (41 °F) in a restricted zone, or exceeds
Many precision parts have sharp corners and the
local regulations, action as above shall be taken.
wearing of appropriate safety gloves and equipment
is required when handling these components. To lift
heavy pieces above 25 kg (55 lbs) use a crane 1.6.4 Products used in potentially explosive
corresponding to the mass and in accordance with atmospheres
current local regulations.
Measures are required to:
• Avoid excess temperature
NEVER DO MAINTENANCE WORK WHILST THE • Prevent build up of explosive mixtures
UNIT IS CONNECTED TO POWER • Prevent the generation of sparks
• Prevent leakages
HAZARDOUS LIQUIDS • Maintain the pump to avoid hazard
When the pump is handling hazardous liquids care
must be taken to avoid exposure to the liquid by The following instructions for pumps and pump units
appropriate sitting of the pump, limiting personnel when installed in potentially explosive atmospheres
access and by operator training. If the liquid is must be followed to help ensure explosion protection.
flammable and/or explosive strict safety procedures Both electrical and non-electrical equipment must
must be applied. meet the requirements of European Directive
Gland Packing must not be used when pumping 94/9/EC.
hazardous liquids.
1.6.4.1 Scope of compliance
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The responsibility for compliance with the Ensure the pump and relevant suction and discharge
specified maximum liquid temperature is with the pipeline system is totally filled with liquid at all times
plant operator. during the pump operation, so that an explosive
atmosphere is prevented. In addition it is essential to
Temperature classification “Tx” is used when the make sure that seal chambers, auxiliary shaft seal
liquid temperature varies and when the pump is systems and any heating and cooling systems are
required to be used in differently classified potentially properly filled.
explosive atmospheres. In this case the user is
responsible for ensuring that the pump surface If the operation of the system cannot avoid this
temperature does not exceed that permitted in its condition the fitting of an appropriate Dry Run
actual installed location. protection device is recommended (eg liquid
detection or a Power Monitor).
Do not attempt to check the direction of rotation with
the coupling element/pins fitted due to the risk of To avoid potential hazards from fugitive emissions of
severe contact between rotating and stationary vapour or gas to atmosphere the surrounding area
components. must be well ventilated.
Where there is any risk of the pump being run against 1.6.4.5 Preventing sparks
a closed valve generating high liquid and casing
external surface temperatures it is recommended that To prevent a potential hazard from mechanical
users fit an external surface temperature protection contact the coupling guard must be non-sparking and
device. anti-static.
Avoid mechanical, hydraulic or electrical overload by To avoid the potential hazard from random induced
using motor overload trips or a Power Monitor and current generating a spark the earth contact on the
make routine vibration monitoring. baseplate must be used.
In dirty or dusty environments, regular checks must
be made and dirt removed from areas around close
clearances, bearing housings and motors. Avoid electrostatic charge: do not rub non-
metallic surfaces with a dry cloth; ensure cloth is
The equipment utilises polymer based seals and damp.
bearing surfaces that could be corroded if they
are in contact with unsuitable liquids or gases. The coupling must be selected to comply with
These surfaces are important for the operation of 94/9/EC and correct alignment must be maintained.
the pump. Contact Flowserve if you are uncertain
about the performance of these materials with 1.6.4.6 Preventing leakage
respect to aggressive substances that may be
present in the hazardous area.
The pump must only be used to handle liquids
for which it has been approved to have the correct
The pump casing must be flooded with liquid to the
corrosion resistance.
minimum level on the dimensional General
Arrangement (GA) drawing, at any time that the pump
Avoid entrapment of liquid in the pump and
is operated. On pumps furnished to Group II
associated piping due to closing of suction and
Category 1 below the soleplate, monitoring of the
discharge valves, which could cause dangerous
level with a pump cut out on low level is required.
excessive pressures to occur if there is heat input to
the liquid. This can occur if the pump is stationary or
For pumps furnished to Category 1/2 and 1/3, if the
running.
pump is operating remotely without regular checking,
it must be installed with continuous monitoring of
Bursting of liquid containing parts due to freezing
vibration level, set to shut down the pump at high
must be avoided by draining or protecting the pump
vibration levels, see also section 5.8.1.
and ancillary systems.
1.6.4.4 Preventing the build up of explosive
Where there is the potential hazard of a loss of a seal
mixtures
barrier fluid or external flush, the fluid must be
monitored.
ENSURE THE PUMP IS PROPERLY FILLED
AND VENTED AND DOES NOT RUN DRY If leakage of liquid to atmosphere can result in a
hazard, the installation of a liquid detection device is
recommended.
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Sound pressure readings are for information only and are not subject to guarantee by Flowserve/IDP.
Decibel readings do not include driver or system noise.
Pump tested at 100% of the best efficiency point at max.impeller diameter with water.
Note :
1) The values showed are measured at a distance of 1 mt. (horizontally) from major pump
surfaces and 1.5 mt. above the floor.
2) The values shown are expressed in dB (A)
3) For Noise Test Procedure refer to Works Standard L-109
4) The values shown have been derived from actual noise-test data and are based on the following conditions:
- Equipment is located in a free field above a reflecting plane in which the reductionin noise level
in all directions is 6db in each octave band for each doubling of distance.
- Background noise is 10dB minimum below all noise levels in each octave band.
- The values shown are at a distance of 1 meter (horizontally) from the major pump surface and
1,5 meters above the floor, using a standard pressure reference of 0,00002 newton per square meter.
- Overall noise level, dB(A) is determined at points of maximum noise level and the values of all
mid-band frequences are basis A scale readings.
When the required condition flow is outside the range of 75 to 125% BEP, a part load correction (PLC) must be
added to the noise level as follows:
Percent of BEP @
required impeller PLC in dB
diameter
74 to 62 or 126 to 136 +1
61 to 50 or 137 to 150 +2
49 to 38 +3
37 to 25 +4
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1.10 CE Declaration
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2.2 Handling
Boxes, crates, pallets or cartons may be unloaded
using fork lift vehicles or slings dependent on their
size and construction.
2.3 Lifting
Lift points for the pump or the A crane must be used for all pump sets in
pump and the driver
excess of 25 kg (55 lb). Fully trained personnel
must carry out lifting, in accordance with local
regulations. The driver and pump weights are
recorded on their respective nameplates.
2.4 Storage
If the pump will not be put immediately into service,
it should be stored in a dry room. To avoid any
damage during the storage period, the influence of
any low or high frequency vibration must be totally
inhibited. If the pump is delivered sealed in a
The pump can be lifted in the horizontal position plastic-wrapper, it is of max. importance to avoid
with a single point lift. any damage of that wrapper, because this will
protect the pump against humidity. Therefore it
must be checked if this wrapper has become
cracked and if so, the wrapper must be renewed. If
When lifting pumps with drivers
a vertical pump will be stored in horizontal position,
fitted, the resulting center of gravity may be above
be sure to support the pump sufficiently to avoid
the lifting points, and the method of slinging must
any deformation or bending of the pump.
prevent the machine tipping during the lift.
To avoid the presence of dust and humidity on the
Slings, ropes and other lifting gear must be
driver, it shall also be wrapped in the same way.
positioned where they cannot slip and where a
balanced lift is obtained.
3.3.4.3 Inducer
The sense of rotation of the pump is
All different impellers can be optionally equipped
clockwise (CW), looking from the coupling to the
with an inducer for low NPSHA applications.
shaft end of the pump.
3.3.4.4 Semi open radial vaned impeller
3.2 Nomenclature
A semi open radial vaned impeller is used to
Example: ensure optimal performance.
ECPJ 32-250-X 3.3.4.5 Semi open impeller
ECPJ Vertical sump pump The pump casing is equipped with an integrated
wear plate.The axial thrust is balanced by back
vanes.
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3.3.5 Heat jacket version consist of concrete or of steel. It must be rigid and
For crystallizing fluids, e.g. liquid sulphur, a fully heavy enough to absorb normal vibrations and
heat jacket version is available, including discharge shocks. The baseplate must be supported on the
pipe, columns and pump casing. whole surface. It should be at least 20 - 30 mm (0.8
– 1.2 in) higher than the surrounding to avoid the
3.3.5.1 Procedure of Preheating the pump deposit of dust and humidity.
before Start-up
4.3.1 Vertical alignment
Before priming the pump preheat it for at least one
hour to avoid any distortion. Vertical alignment is done with levelling screws.
Use a spirit level for correct horizontal alignment of
the baseplate.
Refer to General Arrangement drawing
for required steam pressure and flowrate.
The max. vertical misalignment is 0.5 mm/m
pump length.
Dry steam shall be used to
avoid condensation and a condensate lock in the 4.3.2 Steel foundation
heat jacket.
When the pump unit is mounted directly on structural
steel frame, it shall be well supported by
3.4 Performance and operating limits constructural beams. It is recommended to check the
natural frequency of the steel frame, because it shall
In the interest of operator not coincide with the pump speed. The baseplate has
safety the unit must not be operated above the to be fixed on a flat surface with studs or hex screws,
nameplate conditions. Such operation could result the exact horizontal alignment is very important!
in unit failure causing injury to operating personnel.
Consult instruction book for correct operation and 4.3.3 Concrete foundation
maintenance of the pump and its supporting A concrete foundation must have an exact
components. horizontal alignment and must be placed on solid
ground. First a basic foundation shall be built with
4.0 INSTALLATION square shaped holes for embedding the foundation
bolts. After putting the baseplate in the foundation
the proper alignment can be obtained by adjusting
Equipment operated in hazardous locations it with shims. Now insert the foundation bolts and
must comply with the relevant explosion protection grout the space between the basic foundation and
regulations, see section 1.6.4, Products used in the baseplate with grouting cement (refer to
potentially explosive atmospheres. illustration)
It is very helpful to use a properly made and stable
4.1 Location wooden frame around the baseplate. So the grouting
cement will not flow a side. When the grouting is
The pump should be located to allow room for totally
access, ventilation, maintenance and inspection set and hardened the foundation bolts shall be
with ample headroom for lifting and should be as tightened in a firm and symmetrical way.
close as practicable to the supply of liquid to be
pumped.
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A non-return valve shall be located in the discharge After a service of the pump, e.g. change of line
pipework to protect the pump from excessive back bearings, the lubricating lines must be refilled
pressure and hence reverse rotation when the unit according to the following procedure:
is stopped. a) Flush the lubricating lines with oil before
refilling it with grease.
If sludge can build up in the sump it is b) Disconnect each lubricating line pipe from the
recommended to use a strainer with a maximum connection at the line bearing.
opening size of 6 mm (0.024 in.) and a free surface c) Fill the pipe with grease using a hand press
area greater than three times the pump suction until a grease leakage occurs at the loose
area. piping connection at the line bearing
d) Tight the piping connection at the line bearing.
Piping for corrosive liquids shall be arranged to e) Install the pump on its foundation. The shaft
allow pump flushing before removal of a unit. must be rotated by hand during the filling.
f) Start the pump and grease all lines according
4.5.2 External Lubrication above settings.
An external lubrication system with clean fluid is
required, if the pumpage is not suitable to flush the Ensure that the grease nipples are clean, not
line bearings. The necessary connection is damaged and fixed before connecting the filling
provided at the baseplate and shown on the unit.
General Arrangement drawing.
Grease quality:
Type: Interflon FIN GREASE MP 00 or
The external flushing system is not similar
scope of Flowserve´s supply.
Viscosity: 00 NLGI
4.5.3 Internal Lubrication with Inline Filter
The drop point of the grease must be above
An inline filter is required, if the pumpage contents
the service temperature from the pump.
solids and no clean fluid for external line bearing
flushing is available. Refer to General Arrangement
Drawing for the piping arrangement. 4.6 Electrical connections
For each additional line bearing 115cm³ has to be It is important to be aware of the EUROPEAN
added. Refer to General Arrangement drawing for DIRECTIVE on electromagnetic compatibility when
the required number of line bearings. wiring up and installing equipment on site.
Attention must be paid to ensure that the
techniques used during wiring/installation do not
All lubricating lines must be increase electromagnetic emissions or decrease
completely filled with grease before start up of the the electromagnetic immunity of the equipment,
pump. wiring or any connected devices. If in any doubt
contact Flowserve for advice.
During operation all bearings will be greased
according to grease supplier data sheet.
The motor must be wired up in accordance with the
If the pump is not in service for more than motor manufacturer's instructions (normally
24h, bearings must be greased with 2cm³ before supplied within the terminal box) including any
start up. temperature, earth leakage, current and other
protective devices as appropriate. The
identification nameplate should be checked to
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2000 service hours or at least every 6 month. Frame. Oil quantity l (Fl.oz.) Bearing size
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OMV OMV turb HTU 32** OMV turb HTU 46** OMV turb HTU 68 -
* Note that it normally takes 2 hours for bearing temperature stabilize and the final temperature will depend on the ambient, r/min, pumpage temperature and pump size.
Viscosity index shall be at least 95.
** For ambient temperature from -12°C (10 °F) upwards
For temperatures below -5 °C (-23 °F) use lubrication oil class SAE 5W-50 or API-SJ.
The sequence of the suppliers of the lubricants does not represent any indication of their superiority.
¹ Viscosity at 40 °C (104 °F) in cSt [mm²/s] DIN 51562
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5.2.7 Lubrication
The bearing housing shall be filled with proper
lubricating oil prior to start up. If the pump will be
started after a longer storage period, the bearing
housing should be first flushed and cleaned with
gasoline. It is not necessary to remove the
preservation oil as this will mix up thoroughly with the
lubrication oil.
Lubrication is provided by the pumping effect of the
rotating ball bearings. Maintaining the correct oil level
(middle of the oil sight glass) ensures that the lower
ball bearing is covered with oil.
For recommended lubricating oils refer to the
lubrication table 5.2.6
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The bearing housing requires a minimum SCFM 5.2.13 Purge oil mist Lubrication
value as follows: Purge oil mist system utilize a continuous oil mist flow
through the bearing housing to deliver clean oil
Bearing Frame
Reclassifier at directly to the bearing housing to maintain an outward
Manifold
flow of air from the housing to prevent the ingress of
Frame 1 1 x 0.18 SCFM moisture and other corrosive contaminants.
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To change the oil use the following procedure: h) Measure again the dimension from the shaft nut
to the end of the shaft.
a) Open the oil drain on the bearing housing to i) For closed impeller with back wear rings (Type R)
remove the oil. take the mean value of the two dimensions and
b) Close the oil drain and fill in Oil through the vent adjust the rotor to this value by turning the shaft
connection on the bearing cover until the oil level nut.
reaches the middle of the sight glass. For standard semi open or standard free flow
c) Fill the reservoir of the constant level oiler. impeller (Type O,F) adjust the rotor to 0.7 mm
(0.03 in.) of its highest position.
d) If necessary, the oil level can be adjusted by
referring to section 5.2.4 Oil level. The type of hydraulic is shown on the
nameplate (refer to section 3.2 Nomenclature)
5.2.15 Oil level j) Fix the shaft nut with the socket head cap
The correct oil level is in the middle of the oil sight glass screws.
and shall be checked when pump is not in operation.
Periodically check if the lubricating oil is mixed with any Turn the shaftnut always in
condensed water. Careful opening of the oil drain downwards direction to meet the whole for the
during a stop of the pump will show any water. socket head cap screw.
k) Fix the shaft sleeve with the clamping unit and
During operation a small increase of the oil level turn the assembling jigs out of the groove from
can occur due to the oil mist supply. the shaft sleeve and fix them on the seal end
plate.
A too high oil level will result in higher bearing l) Check if the shaft can be turned easy by hand
temperatures and therefore poorer lubrication. m) Mount fan (when delivered) coupling hub and
spacer again.
5.3 Impeller clearance
5.4 Direction of rotation
Correct axial rotor setting is essential for trouble free
operation of the pump.
The sense of rotation of the
5.3.1 Adjusting of the rotor pump is clockwise (CW); looking from the coupling to
a) Remove coupling spacer, coupling hub on pump the shaft end of the pump.
shaft and vane [8161.2] (when delivered).
b) Fix the position of the mechanical seal by putting The rotation of the driver shall be checked.
the assembly jigs, mounted on the seal end plate,
into the groove in the shaft sleeve. 5.5 Guarding
Be sure that the coupling guards are mounted
No requirements for softpacking, correctly at the thrust motor stool prior to start up.
V-ring or throttle bushing.
c) Open screws from the clamping unit, located on
the end of the shaft sleeve (refer to shaft seal
5.6 Priming and auxiliary supplies
drawing). Ensure that the minimum liquid level is maintained.
d) Loose and remove socket head cap screws
[6579.1] from the shaft nut [2910]. The minimum liquid level is shown on the
e) Turn shaft nut upside till the rotor moves in the General Arrangement Drawing.
lowest position and cannot turned by hand. Open external flushing line, if provided. (refer to
f) Measure the dimension from the shaft nut to the section 4.5.2 External Lubrication.
end of the shaft. Auxiliary systems, e.g. barrier /buffer fluid systems,
g) Now lift the rotor by turning the shaft nut in the cooling circuits, shall be filled according to the user
other direction till it is in the highest position. instructions.
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product these may change. The following notes will 6.0 MAINTENANCE
help the user to decide how to evaluate the
implications of any change. If in doubt contact your 6.1 General
nearest Flowserve office.
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Never clean equipment with inflammable solvents or hours since last recharge of grease or complete
carbon tetrachloride. Protect yourself against toxic grease change.
fumes when using cleaning agents. e) Check any auxiliary supplies eg. heating/cooling
(if fitted) are operating correctly.
6.2 Maintenance schedule f) Refer to the manuals of any associated
equipment if routine checks needed.
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[Nm] [lbf.ft] [Nm] [lbf.ft] [Nm] [lbf.ft] [Nm] [lbf.ft] [Nm] [lbf.ft]
M4 4.2 (3.1) 3 (2.2) 0.8 (0.6) 1.1 (0.8) 4.6 (3.4)
M5 8.3 (6.1) 5.9 (4.4) 1.6 (1.2) 2.2 (1.6) 8.6 (6.3)
M6 14.2 (10.5) 10.1 (7.4) 2.8 (2.1) 3.7 (2.7) 14.9 (11)
M8 35 (26) 24.6 (18.1) 6.8 (5) 9.1 (6.7) 36 (27)
M10 68 (50) 48 (35) 13.7 (10.1) 18.3 (13) 71 (52)
M12 118 (87) 84 (62) 23 (17) 31 (23) 123 (91)
M14 187 (138) 133 (98) 37 (27) 50 (37) 195 (144)
M16 290 (214) 206 (152) 57 (42) 76 (56) 302 (223)
M18 335 (247) 295 (218) 80 (59) 106 (78) 421 (311)
M20 472 (348) 415 (306) 112 (83) 150 (111) 592 (437)
M22 644 (475) 567 (418) 151 (111) 202 (149) 807 (595)
M24 811 (598) 714 (527) 193 (142) 257 (190) 1017 (750)
M27 1193 (880) 1050 (774) 284 (209) 379 (280) 1496 (1103)
M30 1614 (1190) 1420 (1047) 386 (285) 515 (380) 2033 (1500)
M33 2191 (1616) 1928 (1422) 523 (386) 697 (514) 2747 (2026)
M36 2820 (2080) 2482 (1831) 672 (496) 897 (662) 3535 (2607)
M39 3645 (2689) 3208 (2366) 870 (642) 1160 (856) 4569 (3370)
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ECPJ USER INSTRUCTIONS ENGLISH - 05/16
M42 3920 (2891) 3980 (2936) 1146 (845) 1447 (1067) 5670 (4182)
M45 4875 (3596) 4950 (3651) 1425 (1051) 1800 (1328) 7050 (5200)
M48 5899 (4351) 5990 (4418) 1724 (1272) 2178 (1606) 8530 (6292)
M64 14083 (10388) 14300 (10548) 4117 (3037) 5201 (3836) 20370 (15025)
M68 16998 (12538) 17260 (12731) 4969 (3665) 6277 (4630) 24580 (18130)
M76 25230 (18610) 8270 (6100)
A193 B8/B8M,
Size of S32760, S31803,
A193 B8M Cl2 A4-70, A2-70 A193 B8MA (NACE) N08825
Screw 1.4462
A2-50, A4-50
[Nm] [lbf.ft] [Nm] [lbf.ft] [Nm] [lbf.ft] [Nm] [lbf.ft] [Nm] [lbf.ft]
M4 2.1 (1.5) 3.2 (2.4) 1.9 (1.4) 0.9 (0.7) 1.1 (0.8)
M5 4.1 (3) 6.4 (4.7) 3.6 (2.7) 1.6 (1.2) 2.2 (1.6)
M6 7.1 (5.2) 10.9 (8) 6.3 (4.6) 2.9 (2.1) 3.7 (2.7)
M8 17 (12.5) 27 (19.9) 15 (11.2) 7.1 (5.2) 9.1 (6.7)
M10 34 (25) 52 (38) 30 (22) 14 (10.3) 18.3 (13)
M12 59 (44) 91 (67) 51 (38) 24 (17.7) 31 (23)
M14 94 (69) 143 (105) 82 (60) 38 (28) 50 (37)
M16 145 (107) 222 (164) 126 (93) 58 (43) 76 (56)
M18 201 (148) 308 (227) 176 (130) 82 (60) 106 (78)
M20 283 (209) 434 (320) 247 (182) 115 (85) 150 (111)
M22 387 (285) 473 (349) 337 (249) 157 (116) 202 (149)
M24 487 (359) 595 (439) 426 (314) 198 (146) 257 (190)
M27 716 (528) 716 (528) 602 (444) 292 (215) 379 (280)
M30 968 (714) 968 (714) 817 (603) 397 (293) 515 (380)
M33 1315 (970) 1008 (744) 1112 (820) 536 (395) 697 (514)
M36 1692 (1248) 1297 (957) 1428 (1053) 690 (509) 897 (662)
M39 2187 (1613) 1849 (1364) 890 (656) 1160 (856)
M42 2714 (2002) 2287 (1687) 1067 (787) 1447 (1067)
M45 3375 (2489) 1800 (1328)
M48 4084 (3012) 2178 (1606)
M64 9750 (7192) 5201 (3836)
M68 11768 (8680) 6277 (4630)
M76
Above mentioned torques are for all screwed unions, which works under dynamical load. For all other
connections you can use a corresponding smaller torque.
Anchor bolts are usually made of 4.6 material. Tightening torques indicated in above table shall not be
exceeded.
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6.7.2 Dismantling of the thrust bearing 65-250 138 (5.4) 0.35 (0.014)
80-160 138 (5.4) 0.35 (0.014)
Frame Bearing size
80-200 169 (6.7) 0.35 (0.014)
1 7210 BECBJ 100-200 169 (6.7) 0.35 (0.014)
40-315 105 (4.1) 0.3 (0.012)
2 7213 BECBJ
50-315 124 (4.9) 0.35 (0.014)
3 7215 BECBJ 65-315 138 (5.4) 0.35 (0.014)
4 7218 BECBJ 80-250 138 (5.4) 0.35 (0.014)
80-315 169 (6.7) 0.35 (0.014)
FRAME 3
80-404 169 (6.7) 0.35 (0.014)
6.7.2.1 Bearing housing 100-250 169 (6.7) 0.35 (0.014)
1) Remove the bearing assembly consisting of the 100-315 169 (6.7) 0.35 (0.014)
thrust ball bearing [3013], bearing adaptor sleeve 100-400 184 (7.2) 0.35 (0.014)
[2471] and the bearing lock nut [3712] as a 125-250 179 (7.1) 0.35 (0.014)
cartridge. 125-315 184 (7.2) 0.35 (0.014)
125-400 184 (7.2) 0.35 (0.014)
2) Open the bearing lock nut [3712] and pull off the
200-254 242 (9.5) 0.4 (0.016)
thrust ball bearing [3013]
50-380 124 (4.9) 0.35 (0.014)
65-400 138 (5.4) 0.35 (0.014)
Take care about the labyrinth ring 80-400 169 (6.7) 0.35 (0.014)
FRAME 4
[4330.1]. 150-315 225 (8.9) 0.4 (0.016)
150-404 225 (8.9) 0.4 (0.016)
200-250 235 (9.3) 0.4 (0.016)
6.8 Examination of parts 200-319 256 (10.1) 0.4 (0.016)
1) Check the line bearing sleeves and bushings 200-404 256 (10.1) 0.4 (0.016)
against any wear. The diametrical clearance 250-319 300 (11.8) 0.4 (0.016)
between sleeves and bushings must not exceed
twice the value in new condition.
2) Check the casing wear ring and the impeller wear
Gaps apply approximately for wear rings
ring against any wear. The diametrical clearance in all materials and in assembled condition.
between the rings must not exceed twice the
value in new condition.
3) Check all parts against corrosion and erosion. 6.9 Assembly
4) Carefully check the coupling against any wear. To assemble the pump consult the sectional
5) Rotate the angular contact bearing by hand, to drawings.
check against abnormal sound. Check the
bearing cages against any wear and the outer Ensure threads, gasket and O-ring mating faces are
and inner race against running marks. Check the clean. Apply thread sealant to non-face sealing pipe
runout of the shafts. TIR (Total Indicated Runout) thread fittings.
shall not exceed 0.04 mm/m (0.0005 in./ft) of
length. TIR shall not exceed 0.08 mm (0.003 in.) After complete assembly the rotor
over total shaft length. must be lifted!, see section 5 .3 Impeller clearance
32-200 78 (3.1) 0.3 (0.012) Item [3140] is only provided with rigid
40-125 90 (3.5) 0.3 (0.012) coupling arrangement.
40-160 90 (3.5) 0.3 (0.012) 2) Proceed with reverse disassembly procedure,
40-200 105 (4.1) 0.3 (0.012)
starting with point 7 to 1.
50-125 95 (3.7) 0.3 (0.012)
After finishing the upper part proceed with the lower
50-160 105 (4.1) 0.3 (0.012)
50-200 105 (4.1) 0.3 (0.012)
part, starting with point 16.
65-125 114 (4.5) 0.3 (0.012)
32-250 90 (3.5) 0.3 (0.012)
FRAME 2
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7.0 AUXILIARIES process fluid with the problems that result, including
possible seal failure.
Try to turn the rotor by hand.If the Try to turn the rotor by hand.If the
rotor cannot be turned readjust it following procedure rotor cannot be turned readjust it following procedure
in section 5.3.1 Adjusting of the rotor. in section 5.3.1 Adjusting of the rotor.
The mechanical seal requires no adjustment The mechanical seal requires no adjustment
anymore. Check if the mounting plates are already anymore. Check if the mounting plates are already
swung out. swung out.
Actions after start up: Actions after start up:
Check all connections to the seal gland and the Check all connections to the seal gland and the
mechanical seal itself against leakage. Check the mechanical seal itself against leakage. Check the
temperature of the seal gland. I slight increase of temperature of the seal gland. I slight increase of
temperature may be observed during the run in temperature may be observed during the run in
period. period.
Plan 53 pressurized dual seal systems are used in Plan 54 pressurized dual seal systems are used in
services where no leakage to atmosphere can be services where no leakage to atmosphere can be
tolerated. A Plan 53a system consists of dual tolerated. A Plan 54 system consists of dual
mechanical seals with a liquid barrier fluid between mechanical seals with a liquid barrier fluid between
them. The barrier fluid is contained in a seal pot them. The barrier fluid is supplied from an external
which is pressurized to a pressure of approximately source, which is pressurized to a pressure of
1.5 bar (23 psi) greater than the pump seal chamber. approximately 1.5 bar (23 psi) greater than the pump
Inner seal leakage will be barrier fluid leakage into seal chamber. Inner seal leakage will be barrier fluid
the product. There will always be some leakage leakage into the product. There will always be some
(max.5 ml/hour). leakage (max.5 ml/hour).
The leakage rate is monitored by monitoring the seal The barrier fluid pressure must not be less than the
pot level. The product must be able to accommodate sealed pressure. If it were, the failure of one inner
a small amount of contamination from the barrier seal could contaminate the entire barrier fluid system
fluid. The seal pot pressure must be maintained at and cause additional seal failures.
the proper level. If the seal pot pressure drops, the
system will begin to operate like a Plan 52, or Carefully consider the reliability of
unpressurized dual seal, which does not offer the the barrier fluid source. If the source is interrupted or
same level of sealing integrity. Specifically, the inner contaminated, the resulting seal failures are very
seal leakage direction will be reversed and the barrier expensive.
fluid will, over time, become contaminated with the
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Refer to mechanical seal drawing and 7.1.6 Single Mechanical Seal with API–Plan 32+62
auxiliary piping drawing.
The pump is equipped with a single mechanical seal. Refer to mechanical seal drawing and
The cartridge design allows to change the auxiliary piping drawing.
mechanical seal without taking it apart.
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ECPJ USER INSTRUCTIONS ENGLISH - 05/16
The pump is equipped with a single mechanical seal. Flowserve for any service of the mechanical seal. We
The cartridge design allows to change the recommend to have a spare cartridge seal on stock
mechanical seal without taking it apart. for easy replacement.
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FAULT SYMPTOM
Pump overheats and seizes
⇓ Bearings have short life
⇓ Pump vibrates or is noisy
⇓ Mechanical seal has short life
⇓ Mechanical seal leaks excessively
⇓ Pump requires excessive power
⇓ Pump loses prime after starting
⇓ Insufficient pressure developed
⇓ Insufficient capacity delivered
⇓ Pump does not deliver liquid
⇓ PROBABLE CAUSES POSSIBLE REMEDIES
Incorrect type of mechanical seal for operating
Consult Flowserve
conditions.
Check misalignment and correct if necessary.
Shaft running off centre because of worn
If alignment satisfactory check bearings for
bearings or misalignment.
excessive wear
Impeller out of balance resulting in vibration. Check and consult Flowserve
Abrasive solids in liquid pumped. Check and consult Flowserve
Check mechanical seal condition and source
Mechanical seal was run dry.
of dry running and repair
Internal misalignment due to improper repairs Check method of assembly, possible damage
causing impeller to rub. or state of cleanliness during assembly
Excessive thrust caused by a mechanical Check wear condition of Impeller, its
failure inside the pump. clearances and liquid passages
Excessive grease in ball bearings. Check method of regreasing
Check hours run since last change of lubricant,
Lack of lubrication for bearings.
the schedule and its basis
Check method of assembly, possible damage
Improper installation of bearings or state of cleanliness during assembly and
type of bearing used
Check contamination source and replace
Damaged bearings due to contamination.
damaged bearings
C. ELECTRICAL TROUBLES
Wrong direction of rotation. Reverse 2 phases on motor terminal box
Motor running too slow, Check motor terminal box connections
Page 38 of 42
ECPJ USER INSTRUCTIONS ENGLISH - 05/16
9.0 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.
Reference 2:
Pump Handbook, 2nd edition, Igor J. Karassik et al,
McGraw-Hill Inc., New York, 1993.
Reference 3:
ANSI/HI 1.1-1.5
Centrifugal Pumps - Nomenclature, Definitions,
Application and Operation.
Reference 4:
ANSI B31.3 - Process Piping.
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ECPJ USER INSTRUCTIONS ENGLISH - 05/16
10.4 Abbreviations
ISO unit Multiplication US unit
Quantity ISO unit US unit
abbreviation Factor 1 Abbreviation
millimetre/ inches/
Vibration 3
second mm/s 0.03937 second in./sec
1
multiply the ISO unit by the multiplication factor to obtain US units
2 where pressure is not stated to be absolute it is gauge
3 where not stated to be peak it is r.m.s.
4 sound pressure level LpA, re 1m - 20microPa, or sound power level LwA re 1 pW when sound power is
applicable
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ECPJ USER INSTRUCTIONS ENGLISH - 05/16
AFTERMARKET DIRECTORY
OUR ADDRESS
Flowserve (Austria) GmbH Tel: +43 / 2236 / 31530
Industriestraße B/6 Fax: +43 / 2236 / 33430
A-2345 Brunn/Geb., AUSTRIA Mail: flowserve-brunn@flowserve.com
IMPORTANT NOTES:
RECOMMENDATION:
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ECPJ USER INSTRUCTIONS ENGLISH - 05/16
FLOWSERVE REGIONAL
Your Flowserve factory contacts: SALES OFFICES:
Latin America
Flowserve Corporation
Martín Rodriguez 4460
B1644CGN-Victoria-San
Fernando
Buenos Aires, Argentina
Telephone: +54 11 4006 8700
Telefax: +54 11 4714 1610
Asia Pacific
Flowserve Pte. Ltd.
10 Tuas Loop
Singapore 637345
Telephone: +65 6771 0600
Telefax: +65 6862 2329