USER INSTRUCTIONS
MHP-TN centrifugal pump
Installation
Operation
Maintenance
Single-stage, axial suction, vertical discharge type
centrifugal pump
PCN=71576313 – 02/07 (E)
These instructions must be read prior to installing,
operating, using and maintaining this equipment.
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MHP-TN USER INSTRUCTIONS ENGLISH 71576313 - 02/07
INDEX
Page
Page
Additional sources (10.3) .....................................27
Alignment of shafting (see 4.2, 4.4 and 4.7)
Sectional drawings (8.1)...................................... 26
Sound level (see 1.9, Noise level).......................... 9
Sources, additional information (10.3).................. 27
Spare parts (6.3) ................................................. 24
Specific machine performance (1.8) ...................... 8
Standard maintenance (6.2.1) ............................ 22
Starting the pump (5.4)........................................ 18
Stop/start frequency (5.5.5) ................................. 20
Stopping and shutdown (5.6)............................... 20
Storage, pump (2.4) ............................................ 11
Storage, spare parts (6.3.2)................................. 24
Suction piping (4.5.2) ......................................... 15
Supplementary manuals or information sources .. 27
Thermal expansion (4.4.1) .................................. 14
Transport and storage (2) ................................... 10
Trouble-shooting (see 7) ..................................... 25
Vibration (5.5.4)................................................... 19
ATEX marking (1.6.4.2) .........................................7
CE marking and approvals (1.2)............................. 4
Certification (9)....................................................27
Change notes (10.2)............................................27
Cleaning prior to operation (5.8.1) .......................21
Commissioning, start-up, operation (5).................17
Compliance, ATEX (1.6.4.1)................................... 6
Configurations (3.1) .............................................11
Copyright (1.4).......................................................4
Coverage charts (3.3)..........................................12
Direction of rotation (5.1)......................................17
Disassembly (6.5)................................................24
Discharge piping (4.5.3) ......................................16
Disclaimer (1.3)..................................................... 4
Dismantling (see 6.5, Disassembly) .....................24
Drawings (8.1).....................................................26
Duty conditions (1.5)..............................................4
Electrical connections (4.6)..................................16
End of product life (2.5)........................................11
Faults; causes and remedies (7)..........................25
Final checks (4.5.4) ............................................16
First pump start up (5.4.2) ................................... 18
Foundation (4.2)..................................................13
Forces and moments (see 4.5.1)..........................15
General arrangement drawing (8.3) .....................27
Gland packing (6.2.4)........................................... 23
Grouting (4.3) ......................................................14
Guarding (5.2).....................................................17
Handling (2.2)......................................................10
Hydraulic, mechanical and electrical duty (5.7).....20
Inspection (6.2.2 and 6.2.3) .................................22
Installation (4)......................................................13
Internal coating (6.2.5).........................................23
Lifting (2.3) ..........................................................10
Location (4.1).......................................................13
Maintenance (6)...................................................21
Maintenance schedule (6.2).................................22
Nomenclature (3.2)..............................................11
Nameplate (1.7.1)..................................................8
Operating limits (see 3.1).....................................12
Ordering spare parts (6.3.1).................................24
Parts lists (8.2).....................................................27
Piping (4.5)..........................................................15
Protection systems (4.8) ......................................17
Pump masses (2.2.2) ..........................................10
Receipt and unpacking (2.1) ................................10
Recommended spares (6.4).................................24
Recycling (2.5).....................................................11
Replacement parts (see 6.3 and 6.4) ...................24
Running the pump (5.5) .......................................19
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)
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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 INTRODUCTION AND SAFETY
1.1 General
1.3 Disclaimer
These instructions must always be kept
close to the product's operating location or
directly with the product.
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 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 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 removalof original components
may impair the safety of these products in their use.
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.
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.
These instructions must be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment must not be put into service until all
the conditions relating to safety noted in the
instructions, have been met.
1.5 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) and Equipment for Potentially Explosive
Atmospheres (ATEX).
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.
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
incorporates information relevant to these Directives
and Approvals.
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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1.6.3 Safety action
1.6 Safety
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.
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.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS OPERATIONAL
This symbol indicates safety instructions where
non-compliance would affect personal safety and
could result in loss of life.
DRAIN THE PUMP AND ISOLATE PIPEWORK
BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be taken
where the pumped liquids are hazardous.
This symbol indicates “hazardous substances
and toxic fluid” safety instructions where non-
compliance would affect personal safety and could
result in loss of life.
FLUORO-ELASTOMERS (When fitted.)
When a pump has experienced temperatures over
250 ºC (482 ºF), partial decomposition of fluoro-
elastomers (example: Viton) will occur. In this
condition these are extremely dangerous and skin
contact must be avoided.
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.
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.
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 non-
compliance in the hazardous area would cause the
risk of an explosion.
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.
This sign is not a safety symbol but indicates
an important instruction in the assembly process.
NEVER APPLY HEAT TO REMOVE
IMPELLER
Trapped lubricant or vapor could cause an explosion.
1.6.2 Personnel qualification and training
All personnel involved in the operation, installation,
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 (175 °F)
or below 5 °C (20 °F) in a restricted zone, or
exceeds local regulations, action as above shall
be taken.
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1.6.4 Products used in potentially explosive
atmospheres
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.
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.
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.
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:
ENSURE CORRECT LUBRICATION
(See section 5, Commissioning, startup, operation
and shutdown.)
Avoiding excessive surface temperature
Preventing build up of explosive mixtures
Preventing the generation of sparks
Preventing leakages
START THE PUMP WITH OUTLET
VALVE PART OPENED
Maintaining the pump to avoid hazard
(Unless otherwise instructed at a specific point in the
User Instructions.)
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.
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.)
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.
NEVER RUN THE PUMP DRY
INLET VALVES TO BE FULLY OPEN
WHEN PUMP IS RUNNING
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.
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.
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The responsibility for compliance with the
1.6.4.2 Marking
specified maximum liquid temperature is with the
plant operator.
An example of ATEX equipment marking is shown
below. The actual classification of the pump will be
engraved on the nameplate.
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.
II 2 GD c IIC 135 ºC (T4)
Equipment Group
I = Mining
II = Non-mining
If an explosive atmosphere exists during the
Category
2 or M2 = High level protection
3 = normal level of protection
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.
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)
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.
IIC – Hydrogen (typical)
Maximum surface temperature (Temperature Class)
(see section 1.6.4.3)
Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, temperature monitor or a
power monitor and make routine vibration monitoring
checks.
1.6.4.3 Avoiding excessive surface temperatures
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE
In dirty or dusty environments, regular checks must
be made and dirt removed from areas around close
clearances, bearing housings and motors.
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.
1.6.4.4 Preventing the build up of explosive
mixtures
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.
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.
The temperature rise at the seals, bearings and due
to the minimum permitted flow rate is taken into
account in the temperatures stated.
Temperature limit of liquid
Maximum
surface
temperature
permitted
handled (* depending on
material and construction
variant - check which is
lower)
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).
Temperature
class to
EN 13463-1
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) *
To avoid potential hazards from fugitive emissions of
vapor or gas to atmosphere the surrounding area
must be well ventilated.
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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
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.
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.
Avoid electrostatic charge: do not rub non-
metallic 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.
1.7.2 Safety labels
Additional requirements for metallic pumps on
non-metallic baseplates
When metallic components are fitted on a non-
metallic 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.
Oil lubricated units only:
Where there is the potential hazard of a loss of a
seal barrier fluid or external flush, the fluid must be
monitored.
If leakage of liquid to atmosphere can result in a
hazard, the installation of a liquid detection device is
recommended.
1.8 Specific machine performance
For performance parameters see section 1.5, Duty
conditions. When the contract requirement specifies
these to be incorporated into User Instructions these
are included here. Where performance data has
been supplied separately to the purchaser these
should be obtained and retained with these User
Instructions if required.
1.6.4.7 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.
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.
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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.
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.
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.
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.
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”.
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.
For estimating sound power level LWA (re 1 pW)
then add 17 dBA to the sound pressure value.
Typical sound pressure level LpA at 1 m reference 20 μPa, dBA
2 900 r/min 1 750 r/min
Motor size
and speed
kW (hp)
3 550 r/min
1 450 r/min
Pump
Pump and
motor
Pump
Pump and
motor
Pump
Pump and
motor
Pump
Pump and
motor
only
72
72
74
74
75
75
75
76
76
80
80
81
81
83
83
86
86
87
87
89
89
only
64
64
66
66
68
70
71
72
72
76
76
77
77
79
79
82
82
83
83
85
85
only
62
62
64
64
65
65
65
66
66
70
70
71
71
73
73
76
76
77
77
79
79
85
87
only
62
62
62
62
63
63
63
64
64
68
68
69
69
71
71
74
74
75
75
77
77
83
85
< 0.55 (< 0.75)
0.75 (1)
1.1 (1.5)
1.5 (2)
72
72
74
74
76
76
76
77
77
81
81
81
81
83
83
86
86
87
88
90
90
65
66
67
71
72
73
73
75
75
78
78
78
79
81
81
84
84
85
85
87
87
64
64
64
64
66
66
66
67
67
71
71
71
71
73
73
76
76
77
78
80
80
87
90
64
64
63
63
64
64
64
65
65
69
69
71
71
73
73
76
76
77
78
80
80
85
86
2.2 (3)
3 (4)
4 (5)
5.5 (7.5)
7.5 (10)
11 (15)
15 (20)
18.5 (25)
22 (30)
30 (40)
37 (50)
45 (60)
55 (75)
75 (100)
90 (120)
110 (150)
150 (200)
200 (270)
300 (400)
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.
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In areas where the staff has to intervene, remember
that when the level of the sound pressure is:
To lift machines or pieces with one or several
suspension rings, only use hooks and chains in
compliance with the local regulations concerning
safety.
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.
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.
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
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.
2.1 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.
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.
2.2.2 Pump masses
Pump mass
Pump type
kg
lb
MHP- TN 100-65-315
MHP- TN 125-100-315
134
152
295
335
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.
All motors (for masses see the motor
description plate) must be handled with a winch.
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.
For masses above 25 kg (55 lb), manual
handling is forbidden.
2.3 Lifting
2.2 Handling
2.3.1 Slinging of motor pumps units
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.
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 lift heavy pieces above 25 kg (55 lb), use a winch
adapted to the mass and in accordance with the
current local regulations.
To avoid distortion, the pump unit
should be lifted as shown.
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Motor pump unit
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
The centrifugal motor pump is designed for the
pumping of cold water or all clear liquids which are
not solid and liquid mixtures, non-corrosive, non-
abrasive when in contact with the pump motor unit
and its working parts (Important: for other liquids
consult Flowserve for beforehand advice).
Bareshaft pump
The MHP-TN pump is a centrifugal, single-stage
pump with axial inlet and outlet in the vertical axis.
The pump must be stored in a non explosive,
ventilated location, sheltered from bad weather, dust
and vibrations.
When handling always wear gloves, safety
boots and an industrial safety helmet.
For masses above 25 kg (55 lb), manual
handling is forbidden.
The reliability of the delivered machine can only be
ensured if it is used according to the conditions given
in this manual. The maximum values specified in this
manual must never be exceeded.
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.
Maximum working pressure at discharge
................................................. 16 bar (232 psi)
Maximum working pressure at suction
................................................. 10 bar (145 psi)
Maximum pumped fluid temperature
- Gland packing without cooling
Do not store pumps starting on the fan guard.
.............................................. 105 °C (221 °F)
Minimum pumped fluid temperature
The pump may be stored as above for up to 6
months. Consult Flowserve for preservative actions
when a longer storage period is needed.
.................................................... -10 °C (14 °F)
Maximum ambient temperature.... 40 °C (104 °F)
Maximum solid suspension
........................................50 g/m3 (0.003 lbm/ft3)
Density ..................................1
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.
2
Viscosity................................ 1 mm /s (31 SSU)
Maximum rotation speed (frequency 50 Hz)
....................................................... 2900 min-1
The maximum speed is shown on the
pump nameplate.
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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
Mass
Flow rate
Head
Maximum admissible
Pressure at 20 °C (68 °F)
Maximum / minimum
temperature
Radial/thrust bearing
Year of construction +
Manufacture number
Each pump unit is supplied with the following nameplate:
Mass of the set
3.3 Coverage charts
3.3.1 2900 min-1 (50 Hz): coverage charts (Q, H)
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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.
NF E 27 811
Provide sufficient space in the foundation to
accommodate the anchor bolts. If necessary,
provide concrete risers.
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.
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.
4.2.1 Setting the base plate for anchoring
a) Clean the foundation surface thoroughly.
b) Put shims on the foundation surface [approx
20-25 mm (0.79-0.98 in.) thick], one on each
side of the bolt hole (as an alternative, leveling
screws can be used).
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.
d) If anchor bolts have been pre-cast in the
foundation slightly tighten the anchor bolts.
Otherwise let them hang in the foundation
holes.
Particularly, this applies to individual plates where
the anchor bolts have to withstand the driving
torque.
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4.4.2 Alignment methods
4.3 Grouting
Ensure pump and driver are isolated
electrically and the half couplings are
disconnected. Ensure that the pump pipework,
suction and discharge, is disconnected.
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:
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:
b) Prepare grouting product (concrete, resin) in
accordance with manufacturers' instructions.
Check the alignment at three or
four points, before piping assembly.
with a rule
with a comparator
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:
= 0.02 in. parallel checking
= 0.05 in. angular checking
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.
f) After grout starts to cure, definitively tighten
anchor bolts.
Check the couplings manual for further details.
Angular checking:
g) Control the alignment such as described as
follows.
4.4 Initial alignment
with a sliding rule
with a caliper gauge
Before connecting the couplings
verify the motor rotation direction.
The alignment will be definitive only
after pipe connection (see § 4.5.4).
4.4.1 Thermal expansion
If necessary, improve the machine alignment:
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.
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).
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It is only necessary to rectify the adjustment under
base plate. If it proves to be insufficient, modify the
motor and the piping.
Forces
Fv Fh
max max
Discharge
DNR
Moments
Mt max
Suction
DNA
Pump type
mm
(in.)
100
(4”)
mm
(in.)
65
daN daN
m.daN
(lbf.ft)
27
(lbf)
(lbf)
Pump and motor mounted on individual base
plates:
MHP-TN
100-65-315
140
105
(2”1/2)
(315) (236)
180 125
(405) (281)
(199)
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.
MHP-TN
125-100-315
125
(5”)
100
(4”)
47
(347)
Never connect the electric motor
before the setting has been completely finished.
4.5 Piping
The user must verify that the equipment is
isolated from any external sources of vibration.
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.
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.
Ensure piping and fittings are
flushed before use.
4.5.1 Suction and discharge piping
The dimensions of the pipes do not directly
depend on suction and discharge diameters of the
pump:
Ensure piping for hazardous liquids is
arranged to allow pump flushing before removal 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.
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.
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.
Valve
Non return valve
Motor
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.
Continuous
flow valve
Baseplate Coupling guard
Coupling
Forces and moments applied to the pump flanges
must never exceed the values shown in the
following table:
Flooded suction configuration
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).
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c) If high points cannot be avoided in suction line,
If necessary, a control manometer (pressure
gauge) can be connected on the piping.
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.
Control manometer
Do not tighten flanges before the
final check (see § 4.5.4).
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.
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.
D
I
Sufficient
immersion
c) Check that holes of piping flanges are parallel
and correspond to those of the pump.
d) Tighten suction and discharge flanges.
I 3 x D
4.6 Electrical connections
Electrical connections must be made
by a qualified Electrician in accordance with
relevant local national and international
Sump suction configuration
regulations. This includes any grounding.
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.
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.
c) If a foot valve is necessary, do not oversize it
because it would generate pulsations (valve
beating).
Avoid mechanical, hydraulic or electrical
overload by using motor overload trips or a power
monitor and make routine vibration monitoring.
Do not tighten flanges before the
final check (see § 4.5.4).
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.
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 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 non-return valve will be set in the discharge
pipe to protect the pump from any excessive
pressure surge and from reverse rotation.
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Except when explicitly required by the customer in
The identification nameplate should be checked to
ensure the power supply is appropriate. A device
to provide emergency stopping shall be fitted.
the specifications, when a possibility of reverse
rotation exists the customer must install a reverse
rotation protection device.
Carry out the ground connections according to the
current local regulations.
The customer must install all equipment required
to avoid water hammer.
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).
5 COMMISSIONING, START-UP,
OPERATION AND SHUTDOWN
These operations must be carried out by
fully qualified personnel.
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.
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.
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.
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
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.
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.
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.
Ensure all electrical, hydraulic,
pneumatic, sealant and lubrication systems (as
applicable) are connected and operational.
To prevent excessive surface temperatures at
bearings it is recommended that temperature or
vibration monitoring are carried out. See sections
5.5.3 and 5.5.4.
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.
If a defect of cooling can lead to temperature
higher than those acceptable a system of cooling
surveillance must be installed.
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*Without foot valve:
5.3.1 Priming of a flooded pump
Priming may be accomplished by means of venting
system.
a) As discharge valve is closed, fill the pump by
opening the valve at suction. Let air escape by
removing the plugs located on the pump.
Foot valves are not recommended when
the pumped liquid has suspended solid particles.
They may lodge between foot valve seat and
shutter.
b) The discharge pipe is headed and there is a
by-pass 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.
5.4 Starting the pump
5.4.1 Bring controls and preparation before the
first starting and after each service call
Necessarily:
a) Check the tightening of the different plugs.
b) Check that the gland lightly tightens the
packing rings.
Air escape
c)
Risk of seal ring overheating.
d) Check the direction of rotation of the motor.
Refer to the rotation arrow of the pump.
e)
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.
Priming of a flooded 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 pump.
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.
c) When the pump is totally free of air bubbles,
replace the plugs.
a) Start motor and check outlet pressure.
b) 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.
External source
Air escape
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.
Never remove a plug when the pump is
running.
Priming of sump suction pump with foot valve
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SAFETY INSTRUCTIONS WHEN THE PUMP IS
RUNNING:
5.5 Running the pump
5.5.1 Venting the pump
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.
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.
If the temperature is greater than 80 °C (176
°F), a warning plate must be clearly placed on the
pump.
5.5.2 Pump fitted with a stuffing box
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
protection against electrical risks are used.
5.5.3 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.
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.
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]
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.
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.
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.
5.5.4 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.
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.
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.
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.
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The example (N) value is given for the preferred
5.6.3 Shutdown > 1 month
operating flow region (typically this may extend to
70 to 120 % of the pump best efficiency point);
outside the preferred flow region the actual
a) Isolate motor.
b) Avoid reverse rotation of the pump.
c) Make sure that the discharge line pressure
does not reach the foot valve.
vibration experienced may be multiplied by up to 2.
d) Close the outlet valve. Eventually close the
inlet valve.
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.
e) Switch off external power supply,
flushing/quench, cooling liquid.
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).
Horizontal
Configuration
mm/s (in./s) r.m.s.
Vibration Velocity - unfiltered
Normal
Alarm
N
5.6 (0.22)
7.1 (0.28)
11.2 (0.44)
N x 1.25
Shutdown Trip N x 2.0
When ambient temperatures are
likely to drop below freezing point, the pump and
any cooling and flushing arrangements must be
drained or otherwise protected.
5.5.5 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.
5.6.4 Restarting in continuous running
a) Ensure that the pump is completely full of
liquid.
Maximum stop/starts
Motor rating kW (hp)
per hour
b) Ensure a continuous supply with a sufficient
available NPSH.
c) Ensure a backpressure so that the motor
power is not in excess.
Up to 15 (20)
Between 15 (20) and 90 (120)
90 (120) to 150 (200)
Above 150 (200)
15
10
6
Refer
d)
e)
Respect the starting frequency
imposed by the motor manufacturer.
Where duty and standby pumps are installed it is
recommended that they are run alternately every
week.
Protect the pump against water hammer
when stopping or starting.
5.6 Stopping and shutdown
5.7 Hydraulic, mechanical and
electrical duty
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:
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.
5.6.1 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.
5.7.1 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 over-
pressurize the pump.
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.
5.7.2 Viscosity
For a given flow rate the total head reduces with
increased viscosity and increases with reduced
viscosity.
e) Switch off external power supply,
flushing/quench, cooling liquid.
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Also for a given flow rate the power absorbed
5.8.1 Cleaning prior to operation
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.
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.
5.7.3 Pump speed
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.
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.
6 MAINTENANCE
6.1 General
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.
If a belt drive is used, the assembly and
tension of the belts must be verified during regular
maintenance procedure.
In dirty or dusty environments, regular checks
must be made and dirt removed from areas around
close clearances, bearing housings and motors.
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.
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).
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.
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.
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.
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.
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
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.
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.
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.
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When air or compressed inert gas is used in the
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.
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.
m) Verify the correct operation of the system.
Do not direct an air or gas jet towards other
people.
The equipment used for maintenance and
disassembly in an ATEX zone must be in
conformity with the requirements zone.
Never use air or compressed inert gas to clean
clothes.
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".
If any problems are found the following sequence
of actions should take place:
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".
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.
Never clean equipment with inflammable solvents
or carbon tetrachloride.
6.2.1 Standard maintenance
Protect yourself against toxic fumes when using
cleaning agents.
Roller bearing
The bearing housings are provided with sealed for
life ball bearings. No maintenance is required.
6.2 Maintenance schedule
6.2.2 Routine inspection (daily/weekly)
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.
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.
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 packings 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.
6.2.3 Periodic inspection (six monthly)
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.
a)
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.
j) Check the tightness of the connections.
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SETTING OF PACKING
If a check shows a bad running of the
motor pump unit, the user must:
Follow the instructions:
a) Assemble of the packing in S.
b) Stagger by about 90° between two rings.
c) Assemble packing after packing.
a)
Refer to the "fault finding chart" chapter
7 of this leaflet to apply the recommended
solutions.
After setting the last packing ring, secure the
packing with the gland and tighten the nut by
hand.
b) Ensure that your equipment corresponds to
the arrangements of this leaflet.
c) Contact Flowserve after-sales Department if
the problem persists.
After tightening, the shaft should turn by hand as
easily as before the setting of the packing.
6.2.4 Gland packing
6.2.4.1 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.
6.2.4.2 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
D1
A x A
Nb x length
in mm
mm
(in.)
mm
(in.)
mm
(in.)
(in.)
d) Inspect the state of the sleeve surface; the
presence of many marked grooves will
indicate that it must be replaced.
55
(2.17)
76
(2.99)
10
(0.39)
4 x 207
(4 x 8.15)
e) Carefully clean the different pieces of the
packing gland.
6.2.5 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.
6.2.4.3 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.
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.
For that purpose, wind the packing helically around
the shaft sleeve or a chuck of the same diameter.
(Take precautions to avoid damaging sleeve).
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.
Example of straight cut
Example of bevel cut
Ensure a tightening on the stuffing
box housing and not on the sleeve.
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6.3 Spare parts
FLOWSERVE
6.3.1 Ordering of spares
After-sales Service
Flowserve keeps records of all pumps that have
been supplied. When ordering spares the following
information should be quoted:
1) Pump serial number.
Tel.: 02 43 40 57 57
(33) 2 43 40 57 57
Fax.: 02 43 40 58 17
(33) 2 43 40 58 17
2) Pump size.
3) Part name
4) Part number
5) Number of parts required.
According to the After-sales Service instructions,
disassembly will be limited to the dismantling of
the pump.
The pump size and serial number are shown on
the pump nameplate.
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.
To ensure continued satisfactory operation,
replacement parts to the original design
specification should be obtained from Flowserve.
d)
DRAIN PUMP.
Any change to the original design specification
(modification or use of a non-standard part) will
invalidate the pump’s safety certification.
e) Dismantle inlet and outlet pipeworks as well as
all pipeworks.
f)
REMOVE PUMP TAKING INTO
ACCOUNT SAFETY (§ 1) AND HANDLING
(§ 2.2) PROCEDURES.
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.
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
6.4 Recommended spares and
consumable items
[1500], [2250], [3011], [4130], [4590-01], [4590-
02], [4590-03]
ADDRESSES AND TELEPHONE NUMBERS
WILL BE GIVEN ON REQUEST.
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.
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:
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7 FAULTS; CAUSES AND REMEDIES
Insufficient flow rate
Irregular pump running
Driver overloaded
Mechanical seal leak
Equipment vibration
Excessive pump casing temperature
SOLUTIONS
POSSIBLE CAUSES
Pump or suction pipe not completely filled
- Check and complete filling
Air bubbles in pipes
Suction level too low
- 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
Wrong rotation
- Reverse 2 phases on motor terminal boxes
The motor is running on 2 phases only
Motor running too low
- Check and control the motor electrical power supply
- Check the connection in the terminal box according to the
voltage
Total manometric head system higher than
pump differential head
- 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
Total manometric head system lower than
pump differential head
-Throttle at discharge valve or trim the impeller (contact our
local agent): CONSULT FLOWSERVE
Pipes (valves, filter...)
Insufficient flow rate
- Control, dismantle and clean
- Check the suction and discharge pipes (valves, back
pressure)
Worn wear-ring surfaces
Seizure, jamming
- Foresee pump mending. CONSULT FLOWSERVE
- CONSULT FLOWSERVE
Excessive strains on flanges
- Check the flange connections and eliminate strains (pipe
positioning or elastic sleeves mounting)
Defective gland packing on the shaft
- Check and replace all the gland-packing parts.
- Mechanical seal: CONSULT FLOWSERVE
- CONSULT FLOWSERVE
Defective motor bearings
Specific gravity or viscosity of liquid too high
Misalignment
- Consult our local agent to analyze the problem
- Check the alignment of the pump and of its driver
Foundations not sufficiently rigid
- Check the setting of base plates: tightening, bad adjustment,
seal
Insufficient pressure
Pump looses prime after starting
POSSIBLE CAUSES
SOLUTIONS
Rotation speed too low (check the driver)
- Check the connection in the terminal box according to the
voltage
Presence of air
- Check and de-aerate
Suction pressure insufficient
Mechanical defects
- Check: the available NPSH > the required NPSH
- CONSULT FLOWSERVE
- Check suction pipe is airtight
- Check diameter of suction pipe
Air leak in the suction pipe
Restriction in suction pipe
Suction level too low
- 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
- Check condition of pipe
Defective gland packing on the shaft
- Check and replace all the gland packing.
- Mechanical seal: CONSULT FLOWSERVE
Defective gasket
- CONSULT FLOWSERVE
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8 PARTS LIST AND DRAWINGS
8.1 Sectional drawings
9331
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8.2 Sectional drawings part list
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.
ITEM
DESIGNATION
Pump casing
1110
1221
1500
2110
2250
2450
2540
2905
2912
Casing cover with stuffing box
Wear ring
Pump shaft
9 CERTIFICATION
Radial flow impeller
Shaft sleeve
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.
Thrower
Plain washer
Self-braked nut
10 OTHER RELEVANT
DOCUMENTATION AND MANUALS
3011
3134
3200
3260
3300
4120
Radial ball bearing
Support foot
Bearing housing
Bearing cover
Bearing bush
Gland
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.
4130
4132
Gland packing
Stuffing box neck bush
Gasket
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.
4590-01
4590-02
4590-03
6511
Gasket
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.
Special ring
Priming plug
Drain plug
Bore circlip
Screwed plug
Stud
6515
6544
Reference 2:
Pumping Manual, 9th edition, T.C. Dickenson,
Elsevier Advanced Technology, United Kingdom, 1995.
6569
6572
Reference 3:
Pump Handbook, 2nd edition, Igor J. Karassik et al,
McGraw-Hill Inc., New York, 1993.
6577-01
6577-02
6577-03
6581
Hexagon bolt
Hexagon bolt
Hexagon bolt
Hexagon nut
Key
Reference 4:
ANSI/HI 1.1-1.5, Centrifugal Pumps - Nomenclature,
Definitions, Application and Operation.
6700-01
6700-02
9331
Reference 5:
ANSI B31.3 - Process Piping.
Key
Cover plate
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MHP-TN USER INSTRUCTIONS ENGLISH 71576313 - 02/07
FLOWSERVE REGIONAL
SALES OFFICES:
Your Flowserve factory contacts:
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
Worthing S.P.A.
Flowserve Corporation
Via Rossini 90/92
Flowserve Pompes
13, rue Maurice Trintignant
72234 Arnage Cedex, France
20033 Desio (Milan) Italy
Telephone 39 0362 6121
Fax 39 0362 303396
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
Latin America and Caribbean
Flowserve Corporation
6840 Wynnwood Lane
Houston, Texas 77008 USA
Telephone 1 713 803 4434
Fax 1 713 803 4497
Local Flowserve factory representatives:
North America:
Flowserve Pump Division
5310 Taneytown Pike, PO Box 91
Taneytown, MD 21787-0091, USA
Asia Pacific
Flowserve Pte. Ltd
200 Pandan Loop #06-03/04
Pantech 21
Telephone:
Customer Service FAX: +1 (410) 756 2615
Parts inquiry/Order PH: +1 (800) 526 3569
+1 (410) 756 2602
Singapore 128388
Telephone 65 6775 3003
Fax 65 6779 4607
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
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