71576283

USER INSTRUCTIONS
DS centrifugal pump Installation

Operation
Single-stage, horizontal end suction, double volute type Maintenance
centrifugal pump
PCN=71576283 – 03/07 (E)
These instructions must be read prior to installing,

operating, using and maintaining this equipment.
DS USER INSTRUCTIONS ENGLISH 71576283 - 03/07
CONTENTS
Page Page
1 INTRODUCTION AND SAFETY ......................... 4 6 MAINTENANCE................................................ 22
1.1 General ........................................................4 6.1 General ......................................................22
1.2 CE marking and approvals............................4 6.2 Maintenance schedule ................................23
1.3 Disclaimer.....................................................4 6.3 Spare parts ................................................. 27
1.4 Copyright......................................................4 6.4 Recommended spares and consumable
1.5 Duty conditions.............................................4 items ................................................................27
1.6 Safety...........................................................5 6.5 Disassembly ...............................................27
1.7 Nameplate and safety labels .........................8 7 FAULTS; CAUSES AND REMEDIES................. 29
1.8 Specific machine performance ......................8
1.9 Noise level....................................................9 8 PARTS LIST AND DRAWINGS ......................... 30
2 TRANSPORT AND STORAGE ......................... 10 8.1 Sectional drawings......................................30
2.1 Consignment receipt and unpacking ...........10 8.2 Sectional drawing parts list ......................... 31
2.2 Handling .....................................................10 8.3 General arrangement drawing.....................31
2.3 Lifting..........................................................11 9 CERTIFICATION .............................................. 31
2.4 Storage.......................................................11
2.5 Recycling and end of product life ................11 10 OTHER RELEVANT DOCUMENTATION AND
MANUALS ........................................................... 31
3 PUMP DESCRIPTION ...................................... 12
10.1 Supplementary User Instructions...............31
3.1 Configurations ............................................12 10.2 Change notes ...........................................31
3.2 Nomenclature .............................................12 10.3 Additional sources of information...............31
3.3 Design of major parts..................................13
3.4 Guide to store “vulcanized rubber” ..............13
4 INSTALLATION................................................. 14
4.1 Location......................................................14
4.2 Foundation .................................................14
4.3 Grouting .....................................................15
4.4 Initial alignment...........................................15
4.5 Piping .........................................................16
4.6 Electrical connections .................................18
4.7 Final shaft alignment check.........................18
4.8 Protection systems .....................................18
5 COMMISSIONING, START-UP, OPERATION AND
SHUTDOWN ....................................................... 18
5.1 Direction of rotation.....................................18
5.2 Guarding.....................................................19
5.3 Priming and auxiliary supplies .....................19
5.4 Starting the pump........................................19
5.5 Running the pump ......................................20
5.6 Stopping and shutdown...............................21
5.7 Hydraulic, mechanical and electrical duty....22
Page 2 of 32 flowserve.com
INDEX
Page Page
Additional sources (10.3) .....................................31 Safety, protection systems (see 1.6 and 4.8)
Alignment of shafting (see 4.2, 44 and 4.7) Sectional drawings (8.1) ...................................... 30
ATEX marking (1.6.4.2) ......................................... 7 Sound level (see 1.9, Noise level).......................... 9
CE marking and approvals (1.2)............................. 4 Sources, additional information (10.3) .................. 31
Certification (9)....................................................31 Spare parts (6.3).................................................. 27
Change notes (10.2)............................................31 Specific machine performance (1.8).......................8
Commissioning, start-up, operation (5)................. 18 Starting the pump (5.4) ........................................ 19
Compliance, ATEX (1.6.4.1)................................... 6 Stop/start frequency (5.5.6).................................. 21
Configurations (3.1) .............................................12 Stopping and shutdown (5.6) ............................... 21
Copyright (1.4).......................................................4 Storage, pump (2.4)............................................. 11
Design of major parts (3.3)................................... 13 Storage, spare parts (6.3.2) ................................. 27
Direction of rotation (5.1)......................................18 Suction piping (4.5.2) .......................................... 16
Disassembly (6.5)................................................27 Supplementary manuals or information sources ... 31
Discharge piping (4.5.3) ......................................17 Thermal expansion (4.4.1) .................................. 15
Disclaimer (1.3) ..................................................... 4 Transport and storage (2) ................................... 10
Dismantling (see 6.5, Disassembly) .....................27 Trouble-shooting (see 7)...................................... 29
Drawings (8.1) .....................................................30 Vibration (5.5.5) ................................................... 21
Duty conditions (1.5)..............................................4
Electrical connections (4.6).................................. 18
End of product life (2.5)........................................ 11
Faults; causes and remedies (7).......................... 29
Final checks (4.5.4) ............................................17
First pump start up (5.4.2) ................................... 20
Foundation (4.2) .................................................. 14
General arrangement drawing (8.3) .....................31
Gland packing (6.2.5)........................................... 26
Grouting (4.3) ......................................................15
Guarding (5.2) .....................................................19
Handling (2.2) ......................................................10
Hydraulic, mechanical and electrical duty (5.7).....22
Inspection (6.2.1 and 6.2.2) ................................. 23
Installation (4)......................................................14
Internal coating (6.2.6)......................................... 27
Lifting (2.3) .......................................................... 11
Location (4.1).......................................................14
Maintenance (6)................................................... 22
Maintenance schedule (6.2)................................. 23
Nomenclature (3.2) ..............................................12
Nameplate (1.7.1).................................................. 8
Operating limits (see 3.1).....................................12
Ordering spare parts (6.3.1)................................. 27
Parts lists (8.2).....................................................31
Piping (4.5).......................................................... 16
Protection systems (4.8) ......................................18
Pump masses (2.2.2) .......................................... 11
Receipt and unpacking (2.1) ................................10
Recommended fill quantities (see 6.2.3 and 6.2.4)
............................................................................24
Recommended grease lubricants (see 6.2.3) .......24
Recommended oil lubricants (see 6.2.4) ..............26
Recommended spares (6.4)................................. 27
Recycling (2.5).....................................................11
Replacement parts (see 6.3 and 6.4) ................... 27
Routine inspection (6.2.1) ................................... 23
Running the pump (5.5) .......................................20
Safety action (1.6.3)...............................................5
Safety labels (1.7.2) ...............................................8
Safety markings (1.6.1).......................................... 5
1 INTRODUCTION AND SAFETY To confirm the Approvals applying and if the product is
CE marked, check the serial number plate markings
1.1 General and the Certification. (See section 9, Certification.)
These instructions must always be kept 1.3 Disclaimer

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
Flowserve products are designed, developed and Corporation to provide sound and all necessary
manufactured with state-of-the-art technologies in information the content of this manual may appear
modern facilities. The unit is produced with great insufficient and is not guaranteed by Flowserve as
care and commitment to continuous quality control, to its completeness or accuracy.
utilizing sophisticated quality techniques, and safety
requirements. Flowserve manufactures products to exacting
International Quality Management System Standards
Flowserve is committed to continuous quality as certified and audited by external Quality Assurance
improvement and being at service for any further organizations. Genuine parts and accessories have
information about the product in its installation and been designed, tested and incorporated into the
operation or about its support products, repair and products to help ensure their continued product quality
diagnostic services. and performance in use. As Flowserve cannot test
parts and accessories sourced from other vendors the
These instructions are intended to facilitate incorrect incorporation of such parts and accessories
familiarization with the product and its permitted use. may adversely affect the performance and safety
Operating the product in compliance with these features of the products. The failure to properly select,
instructions is important to help ensure reliability in install or use authorized Flowserve parts and
service and avoid risks. The instructions may not accessories is considered to be misuse. Damage or
take into account local regulations; ensure such failure caused by misuse is not covered by the
regulations are observed by all, including those Flowserve warranty. In addition, any modification of
installing the product. Always coordinate repair Flowserve products or removal of original components
activity with operations personnel, and follow all may impair the safety of these products in their use.
plant safety requirements and applicable safety and
health laws and regulations. 1.4 Copyright
All rights reserved. No part of these instructions may
These instructions must be read prior to be reproduced, stored in a retrieval system or
installing, operating, using and maintaining the transmitted in any form or by any means without
equipment in any region worldwide. The prior permission of Flowserve.
equipment must not be put into service until all
the conditions relating to safety noted in the 1.5 Duty conditions
instructions, have been met. This product has been selected to meet the
specifications of your purchaser order. The
1.2 CE marking and approvals acknowledgement of these conditions has been sent
It is a legal requirement that machinery and separately to the Purchaser. A copy should be kept
equipment put into service within certain regions of with these instructions.
the world shall conform with the applicable CE
Marking Directives covering Machinery and, where The product must not be operated beyond
applicable, Low Voltage Equipment, Electromagnetic the parameters specified for the application. If
Compatibility (EMC), Pressure Equipment Directive there is any doubt as to the suitability of the
(PED) and Equipment for Potentially Explosive product for the application intended, contact
Atmospheres (ATEX). Flowserve for advice, quoting the serial number.
Where applicable the Directives and any additional If the conditions of service on your purchase order
Approvals cover important safety aspects relating to are going to be changed (for example liquid
machinery and equipment and the satisfactory pumped, temperature or duty) it is requested that the
provision of technical documents and safety user seeks the written agreement of Flowserve
instructions. Where applicable this document before start up.
incorporates information relevant to these Directives
and Approvals.
1.6 Safety 1.6.3 Safety action
1.6.1 Summary of safety markings This is a summary of conditions and actions to

These User Instructions contain specific safety prevent injury to personnel and damage to the
markings where non-observance of an instruction environment and to equipment. For products
would cause hazards. The specific safety markings used in potentially explosive atmospheres
are: section 1.6.4 also applies.
NEVER DO MAINTENANCE WORK

This symbol indicates electrical safety
WHEN THE UNIT IS CONNECTED TO POWER
instructions where non-compliance will involve a
high risk to personal safety or the loss of life.
GUARDS MUST NOT BE REMOVED WHILE
THE PUMP IS OPERATIONAL
This symbol indicates safety instructions where
non-compliance would affect personal safety and DRAIN THE PUMP AND ISOLATE
could result in loss of life. PIPEWORK BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be taken
This symbol indicates “hazardous substances where the pumped liquids are hazardous.
and toxic fluid” safety instructions where non-
compliance would affect personal safety and could FLUORO-ELASTOMERS (When fitted.)
result in loss of life. When a pump has experienced temperatures over
250 ºC (482 ºF), partial decomposition of fluoro-
elastomers (example: Viton) will occur. In this
This symbol indicates safety condition these are extremely dangerous and skin
instructions where non-compliance will involve some contact must be avoided.
risk to safe operation and personal safety and would
damage the equipment or property.
HANDLING COMPONENTS
Many precision parts have sharp corners and the
This symbol indicates explosive atmosphere wearing of appropriate safety gloves and equipment
zone marking according to ATEX. It is used in safety is required when handling these components. To lift
instructions where non-compliance in the hazardous heavy pieces above 25 kg (55 lb) use a crane
area would cause the risk of an explosion. appropriate for the mass and in accordance with
current local regulations.
This symbol is used in safety instructions to THERMAL SHOCK

remind not to rub non-metallic surfaces with a dry Rapid changes in the temperature of the liquid within
cloth; ensure cloth is damp. It is used where non- the pump can cause thermal shock, which can result
compliance in the hazardous area would cause the in damage or breakage of components and should
risk of an explosion. be avoided.
This sign is not a safety symbol but indicates NEVER APPLY HEAT TO REMOVE
an important instruction in the assembly process. IMPELLER
Trapped lubricant or vapor could cause an explosion.
1.6.2 Personnel qualification and training
All personnel involved in the operation, installation, HOT (and cold) PARTS
inspection and maintenance of the unit must be If hot or freezing components or auxiliary heating
qualified to carry out the work involved. If the supplies can present a danger to operators and
personnel in question do not already possess the persons entering the immediate area action must be
necessary knowledge and skill, appropriate training taken to avoid accidental contact. If complete
and instruction must be provided. If required the protection is not possible, the machine access must
operator may commission the manufacturer/supplier be limited to maintenance staff only, with clear visual
to provide applicable training. warnings and indicators to those entering the
immediate area. Note: bearing housings must not be
Always coordinate repair activity with operations and insulated and drive motors and bearings may be hot.
health and safety personnel, and follow all plant If the temperature is greater than 68 °C (175 °F)
safety requirements and applicable safety and health or below 5 °C (20 °F) in a restricted zone, or
laws and regulations. exceeds local regulations, action as above shall
be taken.
1.6.4 Products used in potentially explosive

HAZARDOUS LIQUIDS atmospheres
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
appropriate sitting of the pump, limiting personnel units when installed in potentially explosive
access and by operator training. If the liquid is atmospheres must be followed to help ensure
flammable and/or explosive, strict safety procedures explosion protection.
must be applied.
The terminology and procedures ensure that the
Gland packing must not be used when pumping installed pump is in compliance with the European
hazardous liquids. 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
PREVENT EXCESSIVE EXTERNAL non-electrical equipment must meet the requirements
PIPE LOAD 94/9/EC.
Do not use pump as a support for piping. Do not
mount expansion joints, unless allowed by Even if the installation is in a region where ATEX is not
Flowserve in writing, so that their force, due to the applicable regulation, the general measures
internal pressure, acts on the pump flange. described shall be followed to ensure safe operation.
ENSURE CORRECT LUBRICATION The measures are explained under the headings of:
(See section 5, Commissioning, startup, operation  Avoiding excessive surface temperature
and shutdown.)  Preventing build up of explosive mixtures
 Preventing the generation of sparks
 Preventing leakages
START THE PUMP WITH OUTLET
 Maintaining the pump to avoid hazard
VALVE PART OPENED
(Unless otherwise instructed at a specific point in the 1.6.4.1 Scope of compliance
User Instructions.)
This is recommended to minimize the risk of Use equipment only in the zone for which it is
overloading and damaging the pump motor at full or appropriate. Always check that the driver, drive
zero flow. Pumps may be started with the valve coupling assembly, seal and pump equipment are
further open only on installations where this situation suitably rated and/or certified for the classification of
cannot occur. Pump outlet valve shall may need to the specific atmosphere in which they are to be
be adjusted to comply with the duty following the installed.
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
NEVER RUN THE PUMP DRY select the coupling, driver and any additional
equipment, with the necessary CE Declaration of
INLET VALVES TO BE FULLY OPEN Conformity establishing it is suitable for the area in
WHEN PUMP IS RUNNING which it is to be installed.
Running the pump at zero flow or below the
recommended minimum flow continuously will cause The output from a variable frequency drive (VFD) can
damage to the seal. 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
DO NOT RUN THE PUMP AT electrical supply is from the VFD. This particular
ABNORMALLY HIGH OR LOW FLOW RATES requirement still applies even if the VFD is in a safe
Operating at a flow rate higher than normal or at a area.
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.
1.6.4.2 Marking The responsibility for compliance with the

An example of ATEX equipment marking is shown specified maximum liquid temperature is with the
below. The actual classification of the pump will be plant operator.
engraved on the nameplate.
Temperature classification “Tx” is used when the
liquid temperature varies and the pump could be
II 2 GD c IIC 135 ºC (T4) installed in different hazardous atmospheres. In this
case the user is responsible for ensuring that the
Equipment Group pump surface temperature does not exceed that
I = Mining permitted in the particular hazardous atmosphere.
II = Non-mining
If an explosive atmosphere exists during the
Category installation, do not attempt to check the direction of
2 or M2 = High level protection rotation by starting the pump unfilled. Even a short
3 = normal level of protection run time may give a high temperature resulting from
Gas and/or Dust contact between rotating and stationary
G = Gas; D= Dust components. Furthermore, confinement of liquid in
the pump and pipes must be avoided (valve closed).
c = Constructional safety If the liquid heats up this may cause excessive
(in accordance with EN 13463-5) pressure and lead to bursting of pump components.
Gas Group (Equipment Category 2 only) Where there is any risk of the pump being run against
IIA – Propane (typical) a closed valve generating high liquid and casing
IIB – Ethylene (typical) external surface temperatures it is recommended that
IIC – Hydrogen (typical) users fit an external surface temperature protection
Maximum surface temperature (Temperature Class) device.
(see section 1.6.4.3)
Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, temperature monitor or a
1.6.4.3 Avoiding excessive surface temperatures power monitor and make routine vibration monitoring
checks.
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
Pumps have a temperature class as stated in the clearances, bearing housings and motors.
ATEX Ex rating on the nameplate. These are based
on a maximum ambient of 40 °C (104 °F); refer to 1.6.4.4 Preventing the build up of explosive
Flowserve for higher ambient temperatures. mixtures
The surface temperature on the pump is influenced ENSURE PUMP IS PROPERLY FILLED AND
by the temperature of the liquid handled. The VENTED AND DOES NOT RUN DRY.
maximum permissible liquid temperature depends
on the temperature class and must not exceed the Ensure pump and relevant suction and discharge
values in the table that follows. pipeline system is totally filled with liquid at all times
during the pump operation, so that an explosive
The temperature rise at the seals, bearings and due atmosphere is prevented. In addition it is essential to
to the minimum permitted flow rate is taken into make sure that seal chambers, auxiliary shaft seal
account in the temperatures stated. systems and any heating and cooling systems are
properly filled.
Temperature limit of liquid
Maximum
Temperature surface
handled (* depending on If the operation of the system cannot avoid this
class to material and construction condition the fitting of an appropriate dry run
temperature variant - check which is
EN 13463-1 permitted protection device is recommended (eg liquid
lower)
detection or power monitor).
T6 85 °C (185 °F) Consult Flowserve
T5 100 °C (212 °F) Consult Flowserve To avoid potential hazards from fugitive emissions of
T4 135 °C (275 °F) 115 °C (239 °F) * vapor or gas to atmosphere the surrounding area
T3 200 °C (392 °F) 180 °C (356 °F) * must be well ventilated.
T2 300 °C (572 °F) 275 °C (527 °F) *
T1 450 °C (842 °F) 400 °C (752 °F) *
1.6.4.5 Preventing sparks Where there is a risk from such tools or materials;
maintenance must be conducted in a safe area.
To prevent a potential hazard from mechanical It is recommended that a maintenance plan and
contact, the coupling guard must be non-sparking. schedule is adopted. (See section 6, Maintenance.)
To avoid the potential hazard from random induced
current generating a spark the ground contact on the 1.7 Nameplate and safety labels
baseplate must be used.
1.7.1 Nameplate
Avoid electrostatic charge: do not rub non- For details of nameplate, see the Declaration of
metallic surfaces with a dry cloth, ensure cloth is Conformity, or separate documentation included with
damp. these User Instructions.
Where applicable the coupling must be selected to
comply with 94/9/EC and correct alignment must be 1.7.2 Safety labels
maintained.
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 Oil lubricated units only:
and ancillary systems.
Where there is the potential hazard of a loss of a

seal barrier fluid or external flush, the fluid must be
monitored.
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
1.6.4.7 Maintenance to avoid the hazard conditions. When the contract requirement specifies
these to be incorporated into User Instructions these
CORRECT MAINTENANCE IS REQUIRED are included here. Where performance data has
TO AVOID POTENTIAL HAZARDS WHICH GIVE A been supplied separately to the purchaser these
RISK OF EXPLOSION should be obtained and retained with these User
Instructions if required.
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.
1.9 Noise level Similarly the motor noise assumed in the “pump and
Attention must be given to the exposure of motor” noise is that typically expected from standard
personnel to the noise, and local legislation will and high efficiency motors when on load directly
define when guidance to personnel on noise driving the pump. Note that a motor driven by an
limitation is required, and when noise exposure inverter may show an increased noise at some
reduction is mandatory. This is typically 80 to 85 speeds.
dBA. If a pump unit only has been purchased for fitting
with your own driver then the “pump only” noise
The usual approach is to control the exposure time levels in the table should be combined with the level
to the noise or to enclose the machine to reduce
for the driver obtained from the supplier. Consult
emitted sound. Flowserve or a noise specialist if assistance is
required in combining the values.
You may have already specified a limiting noise
level when the equipment was ordered, however if It is recommended that where exposure approaches
no noise requirements were defined, then attention the prescribed limit, then site noise measurements
is drawn to the following table to give an indication of should be made.
equipment noise level so that you can take the
appropriate action in your plant. The values are in sound pressure level L pA at 1 m
(3.3 ft) from the machine, for “free field conditions
Pump noise level is dependent on a number of over a reflecting plane”.
operational factors, flow rate, pipework design and
acoustic characteristics of the building, and so the For estimating sound power level LWA (re 1 pW)
values given are subject to a 3 dBA tolerance and then add 17 dBA to the sound pressure value.
cannot be guaranteed.
Typical sound pressure level LpA at 1 m reference 20 μPa, dBA

Motor size
and speed 3 550 r/min 2 900 r/min 1 750 r/min 1 450 r/min
kW (hp) Pump Pump and Pump Pump and Pump Pump and Pump Pump and
only motor only motor only motor only motor
< 0.55 (< 0.75) 72 72 64 65 62 64 62 64
0.75 (1) 72 72 64 66 62 64 62 64
1.1 (1.5) 74 74 66 67 64 64 62 63
1.5 (2) 74 74 66 71 64 64 62 63
2.2 (3) 75 76 68 72 65 66 63 64
3 (4) 75 76 70 73 65 66 63 64
4 (5) 75 76 71 73 65 66 63 64
5.5 (7.5) 76 77 72 75 66 67 64 65
7.5 (10) 76 77 72 75 66 67 64 65
11 (15) 80 81 76 78 70 71 68 69
15 (20) 80 81 76 78 70 71 68 69
18.5 (25) 81 81 77 78 71 71 69 71
22 (30) 81 81 77 79 71 71 69 71
30 (40) 83 83 79 81 73 73 71 73
37 (50) 83 83 79 81 73 73 71 73
45 (60) 86 86 82 84 76 76 74 76
55 (75) 86 86 82 84 76 76 74 76
75 (100) 87 87 83 85 77 77 75 77
90 (120) 87 88 83 85 77 78 75 78
110 (150) 89 90 85 87 79 80 77 80
150 (200) 89 90 85 87 79 80 77 80
200 (270)     85 87 83 85
300 (400) 87 90 85 86
 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.
In areas where the staff has to intervene, remember To lift heavy pieces above 25 kg (55 lb), use a winch
that when the level of the sound pressure is: adapted to the mass and in accordance with the
 below 70 dBA: it is not necessary to take special current local regulations.
precautions.
 above 70 dBA: people working continuously in To lift machines or pieces with one or several
the machine room must be supplied with suspension rings, only use hooks and chains in
protective devices against noise. compliance with the local regulations concerning
 below 85 dBA: no particular measures need to safety.
be taken for casual visitors staying in the room
during a limited period. Never put cables, chains or ropes directly on or in
 above 85 dBA: the room must be considered as the suspension rings. Cables, chains or lifting ropes
a dangerous area because of the noise and a must never present excessive bending.
warning sign must be fixed at each entry
warning the people coming into the room, even Never bend the lifting hooks, suspension rings,
for a short period, that they must wear hearing chains, etc., which should only be made to endure
protection. stresses within, calculated limits.
 above 105 dBA: special hearing protection
adapted to this noise level and to the spectral Remember that the capacity of a lifting device
noise components must be installed and a decreases when the direction of the lifting force
warning sign to this effect erected at each entry. direction makes an angle with the device axis.
The staff in the room must wear ear protection.
To increase the safety and the efficiency of the lifting
Make sure that the noise, which travels through the device, all the lifting elements must be as
walls and windows, does not generate too high perpendicular as possible. If necessary a lifting
noise levels in the machine room's surroundings. beam can be placed between the winch and the
load.
2 TRANSPORT AND STORAGE When heavy pieces are lifted up, never stay or work
under the load or in the area, which could be in the
2.1 Consignment receipt and unpacking path of the load if it were to swing or fall away.
Immediately after receipt of the equipment it must be
checked against the delivery and shipping Never leave a load hanging from a winch. The
documents for its completeness and that there has acceleration or the slowing-down of lifting equipment
been no damage in transportation. must stay in the safety limits for the staff.
Any shortage and or damage must be reported A winch must be positioned in such a way that the
immediately to Flowserve and received in writing load will be raised perpendicularly. Where possible
within one month of receipt of the equipment. Later necessary precautions must be taken to avoid the
claims cannot be accepted. swing of the load, using for example two winches
making approximately the same angle, below 30°,
Check any crate, boxes and wrappings for any with the vertical.
accessories or spare parts that may be packed
separately with the equipment or attached to
sidewalls of the box or equipment.
Each product has a unique serial number. Check

that this number corresponds with that advised and
always quote this number in correspondence as well
as when ordering spare parts or further accessories.
2.2 Handling
2.2.1 General instructions concerning handling
Boxes, crates, pallets or cartons may be unloaded
using forklift vehicles or slings dependent on their
size and construction. See 2.3.1 for positioning of
slings.
2.2.2 Pump m asses Bareshaft pump
PUMP MASS
PUMP TYPE
kg lb
200 DS 401 320 706
200 DS 451 340 750
200 DS 552 470 1036
250 DS 401 340 750
250 DS 452 360 794
250 DS 552 500 1102
300 DS 401 500 1102
300 DS 452 575 1268
300 DS 553 670 1477
350 DS 703 990 2183
350 DS 854 1150 2535 When handling always wear gloves, safety
400 DS 553 1010 2227 boots and an industrial safety helmet.
400 DS 603 1160 2558
400 DS 704 1250 2756
For masses above 25 kg (55 lb), manual
handling is forbidden.
400 DS 855 1550 3417
500 DS 704 1280 2822 2.4 Storage
600 DS 604 1590 3505
Store the pump in a clean, dry
All motors (for masses see the motor location away from vibration. Leave piping
description plate) must be handled with a winch. connection covers in place to keep dirt and other
foreign material out of pump casing. Turn pump at
2.3 Lifting intervals to prevent brinelling of the bearings and the
seal faces, if fitted, from sticking.
2.3.1 Slinging of motor pumps units
Do not store pumps starting on the fan guard.
Use handling means in accordance with motor
pump unit mass mentioned on the CE plate. For the The pump may be stored as above for up to 6
masses of the pumps bare end of shaft see table § months. Consult Flowserve for preservative actions
2.2.2 and nameplate. when a longer storage period is needed.
To avoid distortion, the pump unit 2.5 Recycling and end of product life
should be lifted as shown. At the end of the service life of the product or its
parts, the relevant materials and parts should be
Motor pump unit recycled or disposed of using an environmentally
acceptable method and local regulations.
If the product contains substances which are harmful

to the environment, these should be removed and
disposed of in accordance with current regulations.
This also includes the liquids and or gases in the
"seal system" or other utilities.
Make sure that hazardous substances or toxic

fluid are disposed of safely and that the correct
personal protective equipment is used. The safety
specifications must be in accordance with the
current regulations at all times.
3 PUMP DESCRIPTION
3.1 Configurations
The pump is mounted on a common base plate and consists of a WORTHINGTON centrifugal pump type DS
and an E-motor connected by an adequate coupling.
MAXIMUM PRESSURE
Maximum working pressure Maximum test pressure
Maxi. NODU- NODU-
CAST CAST
PUMP pressure IRON NI LAR STEEL IRON NI LAR STEEL
CAST CAST
RESIST IRON X2CrNiM RESIST IRON X2CrNiM
suction EN-GJL-
(D2) EN-GJS- o17-12-2
STEEL EN-GJL-
(D2) EN-GJS- o17-12-2
STEEL
250 250
400-15 400-15
bar psi bar psi bar psi bar psi bar psi bar psi bar psi bar psi bar psi bar psi bar psi
200 DS 401 4 58 8 116 10 145 12 174 13 188 15 218 12 174 15 218 18 261 19 276 22 319
200 DS 451 5 72 10 145 13 188 15 218 16 232 18 261 15 218 19 276 22 319 24 348 27 392
200 DS 552 6 87 15 218 20 290 23 334 25 363 27 392 23 334 30 435 35 508 37 537 41 595
250 DS 401 3 43 8 116 10 145 12 174 13 188 15 218 12 174 15 218 18 261 19 276 22 319
250 DS 452 4 58 10 145 13 188 15 218 16 232 18 261 15 218 19 276 22 319 24 348 27 392
250 DS 552 5 72 15 218 20 290 23 334 25 363 27 392 23 334 30 435 35 508 37 537 41 595
300 DS 401 8 116 8 116 10 145 12 174 13 188 15 218 12 174 15 218 18 261 19 276 22 319
300 DS 452 3 43 10 145 13 188 15 218 16 232 18 261 15 218 19 276 22 319 24 348 27 392
300 DS 553 3 43 15 218 20 290 23 334 25 363 27 392 23 334 30 435 35 508 37 537 41 595
350 DS 703 6 87 10 145 13 188 15 218 16 232 18 261 15 218 19 276 18 261 19 276 22 319
350 DS 854 6 87 15 218 20 290 23 334 25 363 27 392 23 334 30 435 35 508 37 537 41 595
400 DS 553 3 43 8 116 10 145 12 174 13 188 15 218 12 174 15 218 18 261 19 276 22 319
400 DS 603 7 101 8 116 10 145 12 174 13 188 15 218 12 174 15 218 18 261 19 276 22 319
400 DS 704 3 43 10 145 13 188 15 218 16 232 18 261 15 218 19 276 22 319 24 348 27 392
400 DS 855 4 58 15 218 20 290 23 334 25 363 27 392 23 334 30 435 35 508 37 537 41 595
500 DS 704 2.6 38 10 145 13 188 15 218 16 232 18 261 15 218 19 276 22 319 24 348 27 392
600 DS 604 3 43 8 116 10 145 12 174 13 188 15 218 12 174 15 218 18 261 19 276 22 319
 Minimum pumped fluid temperature

.............................................. - 10 °C (14 °F)
 Maximum ambient temperature
.............................................. 40 °C (104 °F)
 Maximum solid suspension 3
..................................... 50 g/m (0.003 lbm/ft3)
 Density............................... 1
 Viscosity............................. 1 mm²/s (31 SSU)
The maximum speed is shown on

the pump nameplate.
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 Maximum admissible
Pressure at 20 °C (68 °F)
Head
Maximum / minimum
Radial/thrust bearing temperature
Year of construction +
Manufacture number
Each pump unit is supplied with the following 3.3.4 Wearing rings
nameplate: Pump casing and stuffing box head are furnished
with shrunk in wearing rings.
Mass of the set:
3.3.5 Shaft and shaft sleeve
The pump shaft is provided with a shaft sleeve
axially, secured by the impeller and a shaft shoulder.
3.3.6 The impeller

The single suction impeller is keyed to the shaft.
Axial movement is prevented by a cap with lock
screw and the shaft sleeve.
3.3.7 The bearing bracket

3.3 Design of major parts The bearings are mounted in the bearing bracket.
For grease: lubrication grease nipples are provided.
3.3.1 Pump casing
The double volute type casing is centerline 3.3.7.1 The bearing
supported and provided with drain and seal
connections. The thrust bearing
The thrust bearing consists of two angular contact
Suction and discharge nozzles are cast integrally, ball bearings mounted "face to face".
permitting inspection and repair of the pump without
disturbing the suction and discharge piping. The inner races are secured axially by the shaft
shoulder and the lock nut. The outer races are
The suction and discharge nozzles are horizontally contained between the circlips and the outer cover.
or vertically arranged refer to elevation drawing.
The line bearing
All casings are provided with stop pieces in the The line bearing is a cylinder roller bearing with its
suction nozzle to prevent pre-rotation of the liquid as inner race mounted against a shaft shoulder. The
it enters the impeller. outer race is contained between the circlips and the
inner cover.
3.3.2 Stuffing box head
The stuffing box head is supplied with the shaft 3.3.8 The couplings
sealing equipment consisting of a packing seal or a For details about the fitted coupling refer to
mechanical seal. Furthermore it is supplied with a manufacturer's instructions.
bore for gland seal.
3.3.9 The driver
3.3.3 Shaft sealing For details about the installed driver refer to
The sealing against leakage along the shaft sleeve manufacturer's instructions.
at this point where it passes through the casing is
accomplished by a packing seal or a mechanical 3.4 Guide to store “vulcanized rubber”
seal. (Max. time of storage 2 years)
Packing seal 3.4.1 Introduction

The seal is equipped with packing rings and a Most vulcanized rubbers change in physical
lantern ring. The packing ring quality has been properties during storage and may become
chosen in accordance with the service conditions. unserviceable because of excessive hardening,
To prevent corrosion the pumps will be shipped softening, cracking, crazing or other surface
without packing rings. degradation caused by the action of oxygen, ozone,
light, heat and humidity or improper storage.
Sealing liquid
Normally the liquid seal connection is piped from the The deleterious effects of these factors may,
discharge side to the lantern ring. If the pumped however, be minimized by careful choice of storage
liquid cannot be used for sealing inpended clean condition.
sealing liquid should be supplied with a pressure
slightly higher than the pump suction pressure. 3.4.1.1 Storage room
The storage room should be cool, dry, dust free and
moderately aired.
3.4.2 Temperature 4.1 Location

The storage temperature should not exceed 25 °C Fulfill the following requirements:
(77 °F) and should not. Drop below -10 °C (14 °F)  Accessibility for operation and inspection and
[Neoprene +12 °C (53.6 °F)]. Adhesives and space for maintenance
solutions should not be stored below 0 °C (32 °F).  Simple piping layout, no pipe bends immediately
Not keeping these limits will result in detoriation and preceding suction nozzle
affect the service life.
The effects of low temperature are not permanently

deleterious, but care should be taken to avoid
destroying them during handling. When articles are
taken from low temperature storage for immediate
use, their temperature should be raised to about 20
°C (68 °F) throughout.
3.4.3 Humidity
Moist condition should be avoided; storage
conditions should be such that condensation does
not occur. Favorable humidity should be about 65
per cent.
3.4.4 Light
The articles should be protected from light, in  Suction line as short as possible for minimum
particular direct sunlight and strong artificial light with suction losses
a high ultra-violet content. Unless the articles are  Ample headroom to lift components for
packing in opaque containers, it is advisable to maintenance
cover the windows of storage rooms with a red or
orange coating or screen. 4.2 Foundation
3.4.5 Oxygen and Ozone There are many methods of installing

As ozone is particularly deleterious, storage rooms pump units to their foundations. The correct method
should not contain equipment that is capable of depends on the size of the pump unit, its location
generating ozone, such as electrical equipment, and noise vibration limitations. Non-compliance with
electric motors or other equipment which may give the provision of correct foundation and installation
rise to electric sparks or silent electrical discharges. may lead to failure of the pump and, as such, would
be outside the terms of the warranty.
Combustion gases and organic vapors should be
excluded, as they may give rise to ozone via
petrochemical processes. Solvents, fuels, lubricants,
chemicals, acid, etc. should not be stored in this
room.
3.4.6 Deformation
The articles should be stored in a relaxed condition
free from tension, compression or other deformation.
(O-rings should not be stored hanging up on a
hook). The base plate should be mounted onto a firm
foundation, either an appropriate thickness of quality
4 INSTALLATION concrete or sturdy steel framework. It should NOT
be distorted or pulled down onto the surface of the
Equipment operated in hazardous locations foundation, but should be supported to maintain the
must comply with the relevant explosion protection original alignment.
regulations. See section 1.6.4, Products used in
potentially explosive atmospheres. Anchor bolts must be in accordance with the foot
bolt holes. Use anchor bolts of accepted standards
All equipment must be grounded. and sufficient to ensure a secure fitting in the
foundation. Particularly, this applies to individual
plates where the anchor bolts have to withstand the
driving torque.
b) Prepare grouting product (concrete, resin) in

accordance with manufacturers' instructions.
NF E 27 811
Provide sufficient space in the foundation to

accommodate the anchor bolts. If necessary,
provide concrete risers.
Usually the pump and its drive are mounted on a

common base plate. If not, individual base plates
underneath each machine foot shall be installed.
Base plates are to be fully grouted.
4.2.1 Setting the base plate for anchoring

a) Clean the foundation surface thoroughly. c) Use grouting products with anti-shrinking
b) Put shims on the foundation surface [approx 20- components.
25 mm (0.79-0.98 in.) thick], one on each side of d) To grout up to the required level. Polish
the bolt hole (as an alternative, leveling screws surfaces. Take necessary precautions to avoid
can be used). 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.
c) Lay the base plate and level in both directions g) Control the alignment such as described as
with extra shims. The base plate should be level follows.
to within 0.5 mm per 1 m (0.02 in. per 3.3 ft).
. 4.4 Initial alignment
Before connecting the couplings

verify the motor rotation direction.
4.4.1 Thermal expansion
The pump and motor will normally

have to be aligned at ambient temperature and
d) If anchor bolts have been pre-cast in the
should be corrected to allow for thermal expansion
foundation slightly tighten the anchor bolts. at operating temperature. In pump installations
Otherwise let them hang in the foundation holes.
involving high liquid temperatures, the unit should be
run at the actual operating temperature, shut down
4.3 Grouting and the alignment checked immediately.
4.3.1 Base plate grouting 4.4.2 Alignment methods
a) Prepare the site for grouting. Before grouting
clean the foundation surface thoroughly and Ensure pump and driver are isolated
provide external barriers as shown. The base electrically and the half couplings are disconnected.
plate is provided with holes to be filled with the Ensure that the pump pipework, suction and
concrete. discharge, is disconnected.
The alignment MUST be checked.
Although the pump will have been aligned at the

factory it is most likely that this alignment will have
been disturbed during transportation or handling. If
necessary, align the motor to the pump, not the
pump to the motor.
b a rrie rs
Alignment 4.5 Piping

Parallelism and concentricity check:
The user must verify that the equipment is
Check the alignment at three or four isolated from any external sources of vibration.
points, before piping assembly.
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.
with a rule with a comparator
4.5.1 Suction and discharge piping
Admissible margin for a motor with roller bearings The dimensions of the pipes do not directly depend
with European couplings: on suction and discharge diameters of the pump:
= 0.15 mm parallel checking a) First, choose a flow speed < 2 m/s (7 ft/s) at
= 0.1 mm angular checking suction, and about 3 m/s (10 ft/s) at discharge.
b) Take into account the available NPSH, which
For US supplied couplings values to be used are: must be superior to the required NPSH of the
= 0.02 in. parallel checking pump.
= 0.05 in. angular checking
Check the couplings manual for further details. Never use pump as a support for
piping.
Angular checking:
Do not mount expansion joints in
such a way that their force, due to internal pressure,
may act on the pump flange.
Maximum forces and moments allowed on the pump

flanges vary with the pump size and type.
with a sliding rule with a caliper gauge These external strains may cause misalignment, hot
bearings, worn couplings, vibrations and the
The alignment will be definitive only possible failure of the pump casing.
after pipe connection (see § 4.5.1).
When designing the pipes (§ 4.5.2.1, § 4.5.2.2, §
In case of DSV with cardan shaft drive refer to 4.5.3.1) take necessary precautions in order not to
respective instruction. exceed maximum allowed strains.
If necessary, improve the machine alignment: Forces and moments applied to the pump flanges
must never exceed the values shown in the overall
 Complete unit mounted on common base plate: dimension.
The machines are first aligned accurately in our
workshops. Usually, any misalignment observed on Ensure piping and fittings are flushed
site is due to a wrong adjustment under the base before use.
plate (disturbed during transport or because of
forces exerted by the piping). It is only necessary to Ensure piping for hazardous liquids is
rectify the adjustment under base plate. If it proves arranged to allow pump flushing before removal of
to be insufficient, modify the motor and the piping. the pump.
 Pump and motor mounted on individual base 4.5.2 Suction piping

plates:
Machines are (or must be) first mounted on their 4.5.2.1 Design of a flooded suction line
own base plate in the workshop. Once the pump is The suction line must be as short and direct as
set, it will be regarded as the fixed piece. Any possible, never mount an elbow directly on the inlet
alignment necessary shall be carried out on the flange of the pump.
motor.
Never connect the electric motor

before the setting has been completely finished.
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
Valve are no peaks.
c) If a foot valve is necessary, do not oversize it
Non return valve because it would generate pulsations (valve
beating).
Motor
Do not tighten flanges before the final

check (see § 4.5.4).
4.5.3 Discharge piping
Continous 4.5.3.1 Design of a discharge line

flow valve a) If discharge line is provided with a divergent, its
total angle will be between 7° and 12°.
Baseplate Coupling guard Coupling b) Install the discharge valve after the non-return
valve downstream.
Flooded suction configuration
The non-return valve will be set in the discharge
a) Avoid sharp elbows or sudden narrowing. Use pipe to protect the pump from any excessive
convergent 20° (total angle). pressure surge and from reverse rotation.
b) Arrange the piping so that there are no air
pockets (no bulges). If necessary, a control manometer (pressure gauge)
c) If high points cannot be avoided in suction line, 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
Manometer
with direct crossing.

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.
Installation of the control manometer

D 4.5.4 Final checks
a) Check the tightening of anchor bolts. Tighten
them if necessary.
I Sufficient b) Check that protective covers on suction and
Immersion discharge flanges are removed.
c) Check that holes of piping flanges are parallel
and correspond to those of the pump.
I 3 x D d) Tighten suction and discharge flanges.
4.6 Electrical connections 4.8 Protection systems

Electrical connections must be made The following protection systems are
by a qualified Electrician in accordance with relevant recommended particularly if the pump is installed in
local national and international regulations. This a potentially explosive area or is handling a
includes any grounding. hazardous liquid. If in doubt consult Flowserve.
It is important to be aware of the EUROPEAN If there is any possibility of the system allowing the
DIRECTIVE on potentially explosive areas where pump to run against a closed valve or below
compliance with IEC60079-14 is an additional minimum continuous safe flow a protection device
requirement for making electrical connections. should be installed to ensure the temperature of the
liquid does not rise to an unsafe level.
Avoid mechanical, hydraulic or electrical
overload by using motor overload trips or a power If there are any circumstances in which the system
monitor and make routine vibration monitoring. can allow the pump to run dry, or start up empty, a
power monitor should be fitted to stop the pump or
It is important to be aware of the EUROPEAN prevent it from being started. This is particularly
DIRECTIVE on electromagnetic compatibility when relevant if the pump is handling a flammable liquid.
wiring up and installing equipment on site. Attention
must be paid to ensure that the techniques used during If leakage of product from the pump or its associated
wiring/installation do not increase electromagnetic sealing system can cause a hazard it is
emissions or decrease the electromagnetic immunity of recommended that an appropriate leakage detection
the equipment, wiring or any connected devices. If in system is installed.
doubt, contact Flowserve for advice.
To prevent excessive surface temperatures at
The motor must be wired up in bearings it is recommended that temperature or
accordance with the motor manufacturer's vibration monitoring are carried out. See sections
instructions (normally supplied within the terminal 5.5.4 and 5.5.5.
box) including any temperature, earth leakage,
current and other protective devices as appropriate. If a defect of cooling can lead to temperature higher
The identification nameplate should be checked to than those acceptable a system of cooling
ensure the power supply is appropriate. surveillance must be installed.
A device to provide emergency stopping shall be Except when explicitly required by the customer in
fitted. the specifications, when a possibility of reverse
rotation exists the customer must install a reverse
Carry out the ground connections according to the rotation protection device.
current local regulations.
The customer must install all equipment required to
To avoid any risk of jamming, the avoid water hammer.
direction of rotation will be checked after priming of
the pump (§ 5.3.1, 5.3.2) and before the first start (§ 5 COMMISSIONING, START-UP,
5.4.2). OPERATION AND SHUTDOWN
4.7 Final shaft alignment check These operations must be carried out by
a) Check the alignment pump-motor according to fully qualified personnel.
the procedure § 4.4.2. Rectify if necessary by
adjusting the motor only. 5.1 Direction of rotation
b) Check by hand that the pump turns freely.
A binding indicates a distortion of the pump, Starting or operating pumps with the
which is due to excessive pipe strain. If wrong direction of rotation can be harmful to the
necessary the pipe design must be re-examined. pumps. Ensure that the pump rotation is the same
c) If it provided, connect auxiliary pipe systems as the arrow on the pump casing.
(hydraulic, pneumatic, sealing system).
d) Control tightness and functionality of auxiliary It is preferable to check the direction of rotation
piping. before installing the coupling. If not, the pump must
be filled in with the liquid before start-up.
5.3.2 Priming of a sump suction pump

If maintenance work has been carried * With foot valve:
out to the site's electricity supply, the direction of a) Fill suction pipe and casing with liquid from an
rotation should be re-checked as above in case the independent source (pressure 1 to 2 bars or 15
supply phasing has been altered. to 30 psi).
b) Let air escape by removing the plugs located on
5.2 Guarding the piping.
c) When the pump is totally free of air bubbles,
Guarding is supplied fitted to the pump set. replace the plugs.
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 External source Air escape
Where there is any risk of the pump being run

against a closed valve generating high liquid and
casing external surface temperatures it is
recommended that users fit an external surface
temperature protection device.
Ensure all electrical, hydraulic,

pneumatic, sealant and lubrication systems (as
applicable) are connected and operational.
Ensure the inlet pipe and pump

casing are completely full of liquid before starting
continuous duty operation. Priming of a sump suction configuration with
foot valve
These operations must be carried out by personnel
with approved qualifications. * Without foot valve:
Priming may be accomplished by means of venting
5.3.1 Priming of a flooded pump system.
a) Close the discharge valve, fill the pump by
opening the suction valve. Let air escape by Foot valves are not recommended when
removing the plug located on the piping. the pumped liquid has suspended solid particles.
b) The discharge pipe is headed and there is a by- They may lodge between foot valve seat and
pass valve on the check valve, open slightly the shutter.
discharge valve and the by-pass of the check
valve. 5.4 Starting the pump
c) When the pump is totally free of air bubbles,
replace the plugs. 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 of the bearing.
f) Open all suction valves (if existing).
g) Close the outlet valve and the bypass valve.
Priming of a flooded suction pump
h) Ensure inlet pipe and pump casing are The pump should be run for ten minutes with steady
completely full of liquid. leakage and the gland nuts tightened by 10 degrees
i) If stuffing box sealing/quenching from a remote at a time until leakage is reduced to an acceptable
source is required make sure there is liquid level.
supply.
j) Check for sufficient lube oil. The temperature of the gland should be checked
after each round of tightening. If the temperature
5.4.2 First pump start-up starts to climb rapidly then back off the gland nuts
until the temperature drops down. Wait for the
Suction valves must be fully open temperature to stabilize before tightening again.
when pump is running. Never run the pump dry, it
will cause damage. The leakage must not be reduced below a rate of 20
drops per minute. Bedding in of the packing may
a) Start motor and check outlet pressure. take several hours.
b) If pressure is satisfactory, slowly OPEN outlet
valve. Shield grids being removed during installation
c) Do not run the pump with the outlet valve closed of the gland packing, it must be ensured that they
for a period longer than 30 seconds. are replaced as soon as this operation is completed.
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.
5.5 Running the pump

5.5.1 Venting the pump 5.5.3 Pump fitted with mechanical seal
A mechanical seal ensures a seal without leakage
Vent the pump to enable all trapped air to and does not need any adjustment. Nevertheless if a
escape taking due care with hot or hazardous light leakage occurs during start-up, it should
liquids. disappear after the initial running in of the friction
faces.
Under normal operating conditions, after the pump
has been fully primed and vented, it should be
unnecessary to re-vent the pump. NEVER RUN A MECHANIC AL SEAL
DRY, EVEN FOR A SHORT WHILE.
5.5.2 Pump fitted with a stuffing box
If the pump has a packed gland there must be some SAFETY INSTRUCTIONS WHEN THE PUMP IS
leakage from the gland. Gland nuts should initially RUNNING:
be finger tight only. Leakage should take place soon
after the stuffing box is pressurized. If no leakage If hot or freezing components of the machine
takes place the packing will begin to overheat. If can present a danger to operators, they must be
overheating takes place the pump should be shielded to avoid accidental contact. If a 100 %
stopped and allowed to cool before being restarted. protection is not possible, the machine access must
When the pump is restarted it should be checked to be confined to the maintenance staff only.
ensure leakage is taking place at the packed gland.
If the temperature is greater than 80 °C (176
When adjusting an operating stuffing box °F), a warning plate must be clearly placed on the
(shield grids removed for this operation) the operator pump.
must be very careful. Safety gloves are compulsory
and loose clothes are not allowed (above all to the It is strictly forbidden to open switch
arms) to avoid being caught by the pump shaft. cupboards, switch boxes, or all other live electric
equipment.
If it is necessary to open them in order to take Vibration Velocity - unfiltered Horizontal Configuration
readings, to carry out tests or adjustments for mm/s (in./s) r.m.s.
example, only a skilled technician may do them with Normal N 5.6 (0.22)
adapted tools. Make sure that physical protection Alarm N x 1.25 7.1 (0.28)
against electrical risks is used. Shutdown Trip N x 2.0 11.2 (0.44)
5.5.4 Bearings 5.5.6 Stop/start frequency

Pump sets are normally suitable for the number of
If the pumps are working in a potentially equally spaced stop/starts per hour shown in the
explosive atmosphere, temperature or vibration table below. Check actual capability of the driver and
monitoring at the bearings is recommended. If control/starting system before commissioning.
bearing temperatures are to be monitored it is
essential that a benchmark temperature is recorded Maximum stop/starts
Motor rating kW (hp) per hour
at the commissioning stage and after the bearing Up to 15 (20) 15
temperature has stabilized.
Between 15 (20) and 90 (120) 10
 Record the bearing temperature (t) and the 90 (120) to 150 (200) 6
ambient temperature (ta) Above 150 (200) Refer
 Estimate the likely maximum ambient Where duty and standby pumps are installed it is
temperature (tb) recommended that they are run alternately every
 Set the alarm at (t+tb-ta+5) C [(t+tb-ta+10)  F] week.
and the trip at 100 C (212  F) for oil lubrication
and 105  C (220  F) for grease lubrication 5.6 Stopping and shutdown
It is important, particularly with grease lubrication, to
keep a check on bearing temperatures. After start up According to hydraulic conditions of
the temperature rise should be gradual, reaching a the installation and its automation degree, stop and
maximum after approximately 1.5 to 2 hours. This restart procedures can have different forms.
temperature rise should then remain constant or Nevertheless all of them must respect imperatively
marginally reduce with time. the following rules:
5.5.5 Normal vibration levels, alarm and trip 5.6.1 Stopping < 1 hour
a) Isolate motor.
For guidance, pumps generally fall under a
b) Avoid reverse rotation of the pump.
classification for rigid support machines within the c) Make sure that the discharge line pressure does
International rotating machinery standards and the not reach the foot valve.
recommended maximum levels below are based on
those standards. 5.6.2 Stopping < 1 month
a) Isolate motor.
Alarm and trip values for installed b) Avoid reverse rotation of the pump.
pumps should be based on the actual c) Make sure that the discharge line pressure does
measurements (N) taken on site on the bearing not reach the foot valve.
housings of the pump in the fully commissioned as d) Close the outlet valve. Eventually close the inlet
new condition. valve.
e) Switch off external power supply,
The example (N) value is given for the preferred flushing/quench, cooling liquid.
operating flow region (typically this may extend to 70
to 120 % of the pump best efficiency point); outside 5.6.3 Shutdown > 1 month
the preferred flow region the actual vibration a) Isolate motor.
experienced may be multiplied by up to 2. b) Avoid reverse rotation of the pump.
c) Make sure that the discharge line pressure does
These standard values can vary with the rotational not reach the foot valve.
speed and the power absorbed by the pump. For d) Close the outlet valve. Eventually close the inlet
any special case, do not hesitate to consult us. valve.
e) Switch off external power supply,
Measuring vibration at regular intervals will then flushing/quench, cooling liquid.
show any deterioration in pump or system operating f) Keep the pump fully filled with water. In case of
conditions. 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 If increasing the speed, it is important therefore to
verifications recommended before starting (see ensure the maximum pump working pressure is not
§ 5.4.1). exceeded, the driver is not overloaded, NPSHA >
NPSHR, and that noise and vibration are within local
When ambient temperatures are requirements and regulations.
likely to drop below freezing point, the pump and any
cooling and flushing arrangements must be drained 5.7.4 Net positive suction head (NPSHA)
or otherwise protected. NPSH available (NPSHA) is the head available at the
impeller inlet, above the vapor pressure of the
5.6.4 Restarting in continuous running pumped liquid.
a) Ensure that the pump is completely full of liquid.
b) Ensure a continuous supply with a sufficient NPSH required (NPSHR) is the minimum head required
available NPSH. at the impeller inlet, above the vapor pressure of the
c) Ensure a backpressure so that the motor power pumped liquid, to avoid excessive cavitation and
is not in excess. extreme performance degradation.
d) Respect the starting frequency It is important that NPSHA > NPSHR. The margin
imposed by the motor manufacturer. between NPSHA > NPSHR should be as large as
possible.
e) Protect the pump against water hammer
when stopping or starting. If any change in NPSHA is proposed, ensure these
margins are not significantly eroded. Refer to the
5.7 Hydraulic, mechanical and electrical pump performance curve to determine exact
requirements particularly if flow has changed. If in
duty doubt please consult your nearest Flowserve office
This product has been supplied to meet the for advice and details of the minimum allowable
performance specifications of your purchase order, margin for your application.
however it is understood that during the life of the
product these may change. The following notes may 5.7.5 Pumped flow
help the user decide how to evaluate the Flow must not fall outside the minimum and
implications of any change. If in doubt contact your maximum continuous safe flow shown on the pump
nearest Flowserve office.
performance curve and or data sheet.
5.7.1 Specific gravity (SG)
Pump capacity and total head in meters (feet) do not 6 MAINTENANCE
change with SG, however pressure displayed on a
pressure gauge is directly proportional to SG. Power 6.1 General
absorbed is also directly proportional to SG. It is
therefore important to check that any change in SG If a belt drive is used, the assembly and
will not overload the pump driver or over-pressurize tension of the belts must be verified during regular
the pump. maintenance procedure.
5.7.2 Viscosity In dirty or dusty environments, regular checks
For a given flow rate the total head reduces with must be made and dirt removed from areas around
increased viscosity and increases with reduced close clearances, bearing housings and motors.
viscosity. Also for a given flow rate the power
absorbed increases with increased viscosity, and It is the plant operator's responsibility to
reduces with reduced viscosity. It is important that ensure that all maintenance, inspection and
checks are made with your nearest Flowserve office assembly work is carried out by authorized and
if changes in viscosity are planned. qualified personnel who have adequately
familiarized themselves with the subject matter by
5.7.3 Pump speed studying this manual in detail (see also section
Changing pump speed effects flow, total head, 1.6.2).
power absorbed, NPSHR, noise and vibration. Flow
varies in direct proportion to pump speed, head Any work on the machine must be performed when it
varies as speed ratio squared and power varies as is at a standstill. It is imperative that the procedure
speed ratio cubed. The new duty, however, will also for shutting down the machine is followed; as
be dependent on the system curve. described in section 5.6.
On completion of work all guards and safety devices e) Gland packing must be adjusted correctly to give
must be re-installed and made operative again. visible leakage and concentric alignment of the
gland follower to prevent excessive temperature
Before restarting the machine, the relevant of the packing or follower. Mechanical seals
instructions listed in section 5, Commissioning, start should present no leakage.
up, operation and shut down must be observed. f) Check for any leaks from gaskets and seals.
The correct functioning of the shaft seal must be
Oil and grease leaks may make the ground checked regularly.
slippery. Machine maintenance must always g) Check bearing lubricant level, and if the hours
begin and finish by cleaning the ground and the run show a lubricant change is required.
exterior of the machine. h) Check that the duty condition is in the safe
operating range for the pump.
If platforms, stairs and guardrails are required for i) Check vibration, noise level and surface
maintenance, they must be placed for easy access temperature at the bearings to confirm
to areas where maintenance and inspection are to satisfactory operation.
be carried out. The positioning of these accessories j) Check the tightness of the connections.
must not limit access or hinder the lifting of the part k) Check dirt and dust is removed from areas
to be serviced. around close clearances, bearing housings and
motors.
When air or compressed inert gas is used in the l) Check coupling alignment and re-align if
maintenance process, the operator and anyone in necessary.
the vicinity must be careful and have the appropriate m) Verify the correct operation of the system.
protection.
The equipment used for maintenance and
Do not spray air or compressed inert gas on skin. disassembly in an ATEX zone must be in conformity
with the requirements zone.
Do not direct an air or gas jet towards other people.
Our specialist service personnel can help with
Never use air or compressed inert gas to clean preventative maintenance records and provide
clothes. 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 If any problems are found the following sequence of
on the starting device with the words: actions should take place:
"Machine under repair: do not start". a) Refer to section 7, Faults; causes and remedies,
for fault diagnosis.
With electric drive equipment, lock the main switch b) Ensure equipment complies with the
open and withdraw any fuses. Put a warning board recommendations in this manual.
on the fuse box or main switch with the words: c) Contact Flowserve if the problem persists.
"Machine under repair: do not connect".
6.2.1 Routine inspection (daily/weekly)
Never clean equipment with inflammable solvents or
carbon tetrachloride. Protect yourself against toxic The following checks should be made
fumes when using cleaning agents. and the appropriate action taken to remedy any
deviations:
6.2 Maintenance schedule a) Check operating behavior. Ensure noise,
vibration and bearing temperatures are normal.
It is recommended that a maintenance plan b) Check that there are no abnormal fluid or
and schedule is adopted, in line with these User lubricant leaks (static and dynamic seals) and
Instructions. It should include the following: that any sealant systems (if fitted) are full and
a) The pump must be completely vented and operating normally.
drained and rendered inert before any c) Pump fitted with a stuffing box: leakage of 20
disassembly operation. drops per minute.
b) Any auxiliary systems installed must be d) Pump fitted with a mechanical seal: no leakage.
monitored, if necessary, to ensure they function e) Check the level and condition of oil lubricant. On
correctly. grease lubricated pumps, check running hours
c) During cleaning of the pump ensure the since last recharge of grease or complete
compatibility between the cleaning products and grease change.
the gaskets.
d) Verify the condition of the gaskets.
6.2.2 Periodic inspection (six monthly) b) Connect grease gun to the nipple.
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.
If a check shows a bad running of the

c) Press grease into bearing housing until the first
motor pump unit, the user must:
signs of it appear in the gap between housing
a)  Refer to the "fault finding chart" chapter 7
and shaft. Then stop greasing.
of this leaflet to apply the recommended

solutions.
b) Ensure that your equipment corresponds to the
arrangements of this leaflet.
c) Contact Flowserve after-sales Department if the
problem persists.
6.2.3 Grease lubricated anti-friction bearings
Grease lubricated anti friction

bearings are factory lubricated to prevent rusting for
a short period of time only. The maximum allowable operating temperatures for
a) Before starting the pump, the bearings must be anti friction bearings will differ from unit to unit.
properly greased. Depending on ambient and fluid temperature, the
b) Check the bearings for the first hour or so after difference to the bearing housing temperature
the pump was started to insure proper function. should not exceed 50 °C (122 °F).
c) Proper grease lubrication is very important. Anti
friction bearings can be over greased as well as Continuously rising temperatures and an abrupt
under greased. The characteristics of the temperature rise are indicative for trouble.
installation and severity of the service will These symptoms require immediate stopping of the
determine the frequency of lubrication. pump and a thorough investigation to determine the
cause of trouble. V-rings should be seated at the
Type of grease: proper distance from the sealing surface to avoid
 At ordinary room temperatures: Grease N° 2 overheating.
 At low ambient temperatures: Grease N° 1
 For specific recommendations consult a
reputable grease manufacturer.
 Do not use graphite
a) Move the axial seal ring back so the gap

TEMP
between pump shaft and bearing cover can be

seen.
TIME
REGULAR GREASE CHANGE:

Change the grease every 4000 operating hours.
COMPLETE CLEANING DURING A MAJOR

OVERHAUL:
a) Remove bearing housing from the rotor
assembly .
b) Brush bearing housing with hot kerosene (100-
115 °C) [(212-239 °F)] or other non-toxic
solvent.
c) Flush out the housing with a light mineral oil. The bearing housing is provided with a constant
level oiler. It feeds enough oil to maintain the
d) Do not use waste oil to clean the required level. The control operates on the liquid
housing. seal principle, feeding only when the level is lowered
and breaks the liquid seal at the shank end, thus
To clean the bearings: permitting air to enter the bottle. It will not feed as
a) Wipe off as much grease as possible with clean long as the oil covers the hole in the shank end.
nonlinting cloth.
b) Brush bearings with hot kerosene (80-90 °C) The constant level oiler has a fixed level, which is 7
[(176-194 °F)] while gently spinning the outer mm (0.28 in.) above connection centerline. If it is
bearing ring. replaced by another model make sure that this
c) Spin each ball to insure that it is clean. distance is maintained. As long as oil is visible in the
glass dome there is no need to refill.
To remove badly oxidized grease, which refuses to

come off:
a) Support rotor in vertical position and immerse
bearing in hot kerosene or a mixture of alcohol IF OIL NEEDS TO BE REFILLED:
a) Turn the dome out at its hinge.
and light mineral solvent. b) Screw the glass dome off.
b) Gently spin bearing outer ring.
c) Fill the glass dome with oil.
c) Reflush bearing with clean light oil and force d) Screw it back and swing the dome in upward
fresh grease into it. operating position.
OIL CHANGE
Operating conditions and severity of service will
6.2.4 Oil lubricated anti friction bearings determine the intervals between oil changes.
The bearing housing is filled with oil to a defined
level, which is maintained during operation by a Normal intervals are 4000 operating hours. If
constant level oiler. A breather filter connects the bearings maintain their normal temperature and no
housing space with the atmosphere. The correct oil contamination is observed in the oil the intervals
level is very important. may be prolonged.
At too low oil level the bearing will run dry and wear If bearing temperature increases, check immediately
out fast. At too high oil level the bearing may run hot for improper lubrication, a faulty bearing or improper
and oil will leak past the V-rings. V-ring seat.
OIL QUANTITY: OIL GRADE:

Oil volume  Use high quality turbine or circulating oil with
Pump type
liter (fl.oz.)) rust and oxidation inhibitors
200 DS 401  Recommended viscosity grade: VSO VG32, 46
200 DS 451
250 DS 401
1.0 (33.8) or 68
300 DS 401  For abnormal conditions, refer to a reputable
200 DS 552 lubricant supplier for recommendations
250 DS 552 1.5 (50.7)  Oil must be clean and free of any abrasive
300 DS 452 matter and foreign liquid (i.e. water)
300 DS 553
350 DS 703 4.0 (135.3)
400 DS 553
400 DS 603
350 DS 854
400 DS 704 3.5 (118.3)
600 DS 604
500 DS 704
400 DS 855 5.0 (169.1)
Viscosity grade ISO 46

TABLE OF EQUIVALENCE AND CHARACTERISTICS
Ambient temperature OF RECOMMENDED OILS
Bearings temperature 80 °C (176 °F) maximum
BP ELF ESSO MOBIL SHELL TOTAL TOTAL
MANUFACTURER TYPE
ENERGOL TURBELF TERESSO DTE TELLUS PRESLIA AZOLLA
CHARACTERISTICS
HLP 46 SA 46 46 MEDIUM T 37 46 ZS 46
Density at 15 °C (59 °F) 0.885 0.881 0.868 0.878 0.87 0.872 0.877
Viscosity at 40 °C (104 °F).cSt 45 48.6 43 43 46 46 46
Viscosity at 50 °C (122 °F).cSt 30 31.5 29.4 28 30 29.5 30
Viscosity at 100 °C (212 °F).cSt 6.9 7.1 6.7 7 6.9 6.9 6.8
Pour-point °C / °F - 30 - 22 - 27 - 17 - 12 10.4 - 15 5 - 30 - 22 - 12 10 - 21 -6
Flash-point °C / °F 210 410 220 428 220 428 220 428 214 417 230 446 230 446
Fire-point °C / °F 240 464 252 486 280 536 240 464 245 473
Aniline point °C / °F 99 210 102 216 110 230 102 216 109 228 101 214 101 214
Viscosity index 105 106 109 105 113 100 100
Acid value 0.2 0.6 0.2 0.13 0.7 0.1 0.7 to 1.2
Color 1½ 2 1 2 2 1½ 1
Antierosion additives yes yes yes yes yes

Foam inhibitors yes yes yes yes yes yes yes
Anticorrosion additives yes yes yes yes yes yes yes
Antioxidant yes yes yes yes yes yes yes
Conradson carbon residue 0.01 0.2
- 12 to - 21 to
Limits on temperature °C / °F 120 °C (10 110 °C (- 6
to 248 °F) to 230 °F)
Saponification < 0.5 1.2
6.2.5 Gland packing 6.2.5.2 Gland packing inspection and removal

a) Remove the shield guards .
6.2.5.1 Pump fitted with a packed gland b) Slide back the gland.
A well run in and correctly adjusted packing gland c) Remove the packing rings with an extractor
requires little maintenance. If, after some time, the designed for this purpose (including the lantern
leakage becomes too great, the gland should be ring if it exists; note its position and its direction
tightened again in order to return these to a normal of rotation).
level. d) Inspect the state of the sleeve surface; the
presence of many marked grooves will indicate
If re-tightening is not possible, new packing must be that it must be replaced.
installed e) Carefully clean the different pieces of the
packing gland.
6.2.5.3 Gland packing fitting Flowserve has applied the coatings according to the
If the packing is supplied as cord the packing must supplier's instructions but will not be held
be cut so that the external diameter is lightly responsible for coating wear or cracks that may
tightened and there is an initial gap between the develop over time.
sleeve and the packing ring.
6.3 Spare parts
For that purpose, wind the packing helically around
the shaft sleeve or a chuck of the same diameter. 6.3.1 Ordering of spares
(Take precautions to avoid damaging sleeve). Flowserve keeps records of all pumps that have
been supplied. When ordering spares the following
information should be quoted:
1) Pump serial number
2) Pump size
3) Part name
4) Part number
Example of straight cut Example of bevel cut 5) Number of parts required
The pump size and serial number are shown on the

Ensure a tightening on the stuffing pump nameplate.
box housing and not on the sleeve.
To ensure continued satisfactory operation,
SETTING OF PACKING replacement parts to the original design specification
should be obtained from Flowserve. Any change to
Follow the instructions: the original design specification (modification or use
a) Assemble of the packing in S. of a non-standard part) will invalidate the pump’s
b) Stagger by about 90° between two rings. safety certification.
c) Assemble packing after packing.
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 are
recommended at 6 monthly intervals.
6.4 Recommended spares and

consumable items
[4610-01], [1500-01], [1500-02], [3011], [3012],
After setting the last packing ring, secure the [2250], [4130], [4200]
packing with the gland and tighten the nut by hand.
a) Destroy all the gaskets after dismantling, replace
After tightening, the shaft should turn by hand as them when reassembling.
easily as before the setting of the packing.
b) It is recommended that bearings
6.2.6 Internal coating are not reused after any removal from the shaft.
If the pump has an internal coating, this coating
must be inspected periodically. Any wear or cracks c) After serving during two years, replace the gland
of the coating found must be immediately repaired. packing.
Failure to do this may lead to accelerated wear of 6.5 Disassembly

the coating during operation and corrosion of the
exposed base metal, depending on the material and Refer to section 1.6, Safety, and section 6
pumped liquid. Maintenance, before dismantling the pump.
Special attention must be paid to the coating edges. Before dismantling the pump for
Any loss of coating material is considered to be overhaul, ensure genuine Flowserve replacement
normal wear and tear on the pump and is not parts are available. Refer to sectional drawings for
part numbers and identification.
considered as warranty.
REPAIR OF THE PUMP
If the pump presents abnormalities or a

persistent malfunction, contact immediately:
FLOWSERVE
After-sales Service
Tel.: 02 43 40 57 57
(33) 2 43 40 57 57
Fax.: 02 43 40 58 17
(33) 2 43 40 58 17
According to the After-sales Service instructions,

disassembly will be limited to the dismantling of the
pump:
a) DISCONNECT THE UNIT FROM

POWER.
b) Close the inlet valve (if fitted) and outlet valve.
c) Wait for the moment when the pump casing is
cooled and at ambient temperature.
d) DRAIN PUMP.
e) Dismantle inlet and outlet pipeworks as well as
all pipeworks.
f) REMOVE PUMP TAKING INTO

ACCOUNT SAFETY (§ 1) AND HANDLING (§
2.2) PROCEDURES.
ANY DISASSEMBLY, REPAIR OR

REASSEMBLY WILL BE CARRIED OUT UNDER
FLOWSERVE' RESPONSABILITY, EITHER
DIRECTLY BY THE AFTER-SALES SERVICE OR
BY OTHER FLOWSERVE-AGENTS WHO WILL
GET THE REQUIRED INSTRUCTIONS AND
APPROVALS. THIS IS THE CASE OF
AUTHORIZED REPAIRERS WHOSE ADDRESSES
AND TELEPHONE NUMBERS WILL BE GIVEN
ON REQUEST.
7 FAULTS; CAUSES AND REMEDIES

Insufficient flow rate
Irregular pump running
Driver overloaded
Mechanical seal leak
Equipment vibration
Excessive pump casing temperature
POSSIBLE CAUSES SOLUTIONS
    Pump or suction pipe not completely filled - Check and complete filling
   Air bubbles in pipes - Check and desecrate the pipes
   Suction level too low - 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 - Check and control the motor electrical power supply
 Motor running too low - Check the connection in the terminal box according to the
voltage
  Total manometric head system higher than - Check the discharge head
pump differential 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 - Throttle at discharge valve or trim the impeller (contact our
pump differential head local agent): CONSULT FLOWSERVE
   Pipes (valves, filter...) - Control, dismantle and clean
  Insufficient flow rate - Check the suction and discharge pipes (valves, back pressure)
 Worn wear-ring surfaces - Foresee pump mending: CONSULT FLOWSERVE
    Seizure, jamming - 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
    Defective motor bearings - CONSULT FLOWSERVE
  Specific gravity or viscosity of liquid too high - Consult our local agent to analyze the problem
 Misalignment - 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 - Check: the available NPSH > the required NPSH
 Mechanical defects - CONSULT FLOWSERVE
 Air leak in the suction pipe - Check suction pipe is airtight
 Restriction in suction pipe - Check diameter of 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
8 PARTS LIST AND DRAWINGS
8.1 Sectional drawings
Cartridge seal
Grease bearing
Oil bearing
Joint filler
Joint filler
8.2 Sectional drawing parts list 8.3 General arrangement drawing

The typical general arrangement drawing and any
Item Designation specific drawings required by the contract will be sent
1110 Pump casing to the Purchaser separately unless the contract
1221 Casing cover specifically calls for these to be included into the
1500-01 Wear ring
1500-02 Wear ring User Instructions. If required, copies of other
2110 Shaft drawings sent separately to the Purchaser should
2250 Impeller be obtained from the Purchaser and retained with
2450-01 Shaft sleeve these User Instructions.
2450-02 Shaft sleeve
2540-01 Deflector
2540-02 Deflector 9 CERTIFICATION
2900 Washer Certificates determined from the Contract
2905 Washer requirements are provided with these instructions
3011 Radial ball bearing where applicable. Examples are certificates for CE
3012 Radial roller bearing
3126 Shim
marking, ATEX marking etc. If required, copies of
3134 Support foot other certificates sent separately to the Purchaser
3200 Bearing housing should be obtained from the Purchaser for
3260-01 Bearing cover retention with these User Instructions.
3260-02 Bearing cover
3712 Bearing nut
3852 Constant level oiler 10 OTHER RELEVANT
3853 Grease nipple DOCUMENTATION AND MANUALS
3863 Grease regulator
4120 Gland
4130 Gland packing 10.1 Supplementary User Instructions
4134 Lantern ring Supplementary instructions such as for a driver,
4200 Mechanical seal instrumentation, controller, seals, sealant system
4213 Carrier for mechanical seal etc are provided as separate documents in their
4590-01 Gasket
4590-02 Gasket
original format. If further copies of these are
4590-03 Gasket required they should be obtained from the supplier
4590-04 Gasket for retention with these User Instructions.
4590-05 Gasket
10.2 Change notes
Item Designation If any changes, agreed with Flowserve, are made to
4590-06 Gasket
4590-07 Gasket
the product after its supply, a record of the details
4590-08 Gasket should be maintained with these User Instructions.
4590-09 Gasket
4610-01 O-ring 10.3 Additional sources of information
4610-02 O-ring
6515 Drain plug Reference 1:
6521 Vent plug NPSH for Rotor dynamic Pumps: a reference
6541 Lock washer guide, Euro pump Guide No. 1, Euro pump &
6544 Circlips World Pumps, Elsevier Science, United Kingdom,
6569-01 Screwed plug 1999.
6569-02 Screwed plug
6569-03 Screwed plug Reference 2:
6569-04 Screwed plug Pumping Manual, 9th edition, T.C. Dickenson,
6569-05 Screwed plug Elsevier Advanced Technology, United Kingdom,
6569-06 Screwed plug
6570-01 Hexagon socket grub screw
1995.
6570-02 Hexagon socket grub screw Reference 3:
6572-01 Stud Pump Handbook, 2nd edition, Igor J. Karassik et al,
6572-02 Stud McGraw-Hill Inc., New York, 1993.
6572-03 Stud
6577-01 Hexagon bolt Reference 4:
6577-02 Hexagon bolt ANSI/HI 1.1-1.5, Centrifugal Pumps -
6577-03 Hexagon bolt Nomenclature, Definitions, Application and
6577-04 Hexagon bolt Operation.
6581-01 Hexagon nut
6581-02 Hexagon nut Reference 5:
6581-03 Hexagon nut ANSI B31.3 - Process Piping.
6810 Grooved pin
6700-01 Key
6700-02 Key
9331 Cover plate
FLOWSERVE REGIONAL
Your Flowserve factory contacts: SALES OFFICES:
USA and Canada

Flowserve Corporation
5215 North O’Connor Blvd.,
Suite 2300
Irving, Texas 75039-5421 USA
Telephone 1 972 443 6500
Fax 1 972 443 6800
Europe, Middle East, Africa

Worthing S.P.A.
Flowserve Pompes
Via Rossini 90/92
13, rue Maurice Trintignant
20033 Desio (Milan) Italy
72234 Arnage Cedex, France
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
Latin America and Caribbean
Repair & Service Fax: +33 2 43 40 58 17
6840 Wynnwood Lane
Houston, Texas 77008 USA
Local Flowserve factory representatives: Telephone 1 713 803 4434
Fax 1 713 803 4497
North America:
Flowserve Pump Division Asia Pacific
5310 Taneytown Pike, PO Box 91 Flowserve Pte. Ltd
Taneytown, MD 21787-0091, USA 200 Pandan Loop #06-03/04
Pantech 21
Telephone: +1 (410) 756 2602 Singapore 128388
Customer Service FAX: +1 (410) 756 2615 Telephone 65 6775 3003
Parts inquiry/Order PH: +1 (800) 526 3569 Fax 65 6779 4607
South America:
Flowserve do Brasil Ltda
Av. Don Helder Camara, 5451
20771-001 Rio de Janerio, Brasil
Telephone: +55-21-2108-4000
Fax: +55-21-2108-4184
To find your local Flowserve representative please

use the Sales Support Locator System found at
www.flowserve.com

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USER INSTRUCTIONS

DS centrifugal pump Installation

PCN=71576283 – 03/07 (E)

These instructions must be read prior to installing,

These instructions must always be kept 1.3 Disclaimer

1.6 Safety 1.6.3 Safety action

1.6.1 Summary of safety markings This is a summary of conditions and actions to

NEVER DO MAINTENANCE WORK

This symbol is used in safety instructions to THERMAL SHOCK

1.6.4 Products used in potentially explosive

1.6.4.2 Marking The responsibility for compliance with the

Additional requirements for metallic pumps on

1.6.4.6 Preventing leakage

The pump must only be used to handle liquids

Avoid entrapment of liquid in the pump and associated

Bursting of liquid containing parts due to freezing

Where there is the potential hazard of a loss of a

If leakage of liquid to atmosphere can result in a

To avoid potential explosion hazards during

Typical sound pressure level LpA at 1 m reference 20 μPa, dBA

Each product has a unique serial number. Check

2.2.2 Pump m asses Bareshaft pump

If the product contains substances which are harmful

Make sure that hazardous substances or toxic

 Minimum pumped fluid temperature

The maximum speed is shown on

Each pump is supplied with the following nameplate:

3.3.6 The impeller

3.3.7 The bearing bracket

Packing seal 3.4.1 Introduction

3.4.2 Temperature 4.1 Location

The effects of low temperature are not permanently

3.4.5 Oxygen and Ozone There are many methods of installing

b) Prepare grouting product (concrete, resin) in

Provide sufficient space in the foundation to

Usually the pump and its drive are mounted on a

4.2.1 Setting the base plate for anchoring

Before connecting the couplings

4.4.1 Thermal expansion

The pump and motor will normally

The alignment MUST be checked.

Although the pump will have been aligned at the

Alignment 4.5 Piping

Maximum forces and moments allowed on the pump

 Pump and motor mounted on individual base 4.5.2 Suction piping

Never connect the electric motor

a) Avoid sharp elbows or sudden narrowing. Use

Do not tighten flanges before the final

4.5.3 Discharge piping

Continous 4.5.3.1 Design of a discharge line

Do not tighten flanges before the final

4.5.2.2 Design of a suction lift line

Installation of the control manometer

Do not tighten flanges before the final

4.6 Electrical connections 4.8 Protection systems

5.3.2 Priming of a sump suction pump

5.3 Priming and auxiliary supplies External source Air escape

Where there is any risk of the pump being run

Ensure all electrical, hydraulic,

Ensure the inlet pipe and pump

e) Install all protection systems and more

The pump should run smoothly and without

The pump must never run at a capacity of less than