Mark 3 Darco

USER INSTRUCTIONS
FLOWSERVE
MARK 3 GROUP 4 Installation
Operation
Horizontal, end suction, centrifugal pumps for chemical
process, water and general service
Maintenance
PCN= 71569286 08-12 (E)
Original Instructions
These instructions must be read prior to installing,

operating, using, and maintaining this equipment.
MARK 3 GROUP 4 USER INSTRUCTIONS ENGLISH 71569286 08-12
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CONTENTS
PAGE PAGE
6.4 Recommended spares and consumable items

1 INTRODUCTION AND SAFETY ...................... 4
33
1.1 General ....................................................... 4
6.5 Tools required ............................................33
1.2 CE marking and approvals .......................... 4
6.6 Fastener torques .......................................34
1.3 Disclaimer ................................................... 4
6.7 Renewal clearances ..................................34
1.4 Copyright ..................................................... 4
6.8 Disassembly ..............................................34
1.5 Duty conditions ............................................ 4
6.9 Examination of parts ..................................35
1.6 Safety .......................................................... 5
6.10 Assembly ...................................................36
If leakage of liquid to atmosphere can result in a
6.11 Impeller axial clearance adjustment ..........39
hazard, install a liquid detection device. ..... 8
1.7 Nameplate and warning labels .................... 9 7 FAULTS; CAUSES AND REMEDIES ............ 41
1.8 Specific machine performance.................. 10
8 PARTS LIST AND DRAWINGS ..................... 43
1.9 Noise level ................................................. 10
8.1 Mark 3 Group 4 chemical pump sectional and
2 TRANSPORT AND STORAGE...................... 11 parts list .....................................................43
2.1 Consignment receipt and unpacking......... 11 8.2 Mark 3 Group 4 chemical pump- liquid end
2.2 Handling .................................................... 11 exploded view ............................................45
2.3 Lifting ......................................................... 11 8.3 Mark 3 Group 4 chemical pump frame
2.4 Storage ...................................................... 12 exploded view ............................................46
2.5 Recycling and end of product life .............. 12 8.4 General arrangement drawing ...................47
3 PUMP DESCRIPTION ................................... 12 9 CERTIFICATION ............................................ 47
3.1 Configurations ........................................... 12
10 OTHER RELEVANT DOCUMENTATION AND
3.2 Name nomenclature .................................. 13
MANUALS ................................................................ 47
3.3 Design of major parts ................................ 13
10.1 Supplementary User Instruction manuals .47
3.4 Performance and operating limits ............. 13
10.2 Change notes ............................................47
3.5 Table Of Engineering Data ....................... 15
10.3 Additional sources of information ..............47
3.6 Table of Engineering Data ........................ 16
3.7 Materials of Construction .......................... 17
4 INSTALLATION ............................................. 18
4.1 Location ..................................................... 18
4.2 Part assemblies ......................................... 18
4.3 Foundation ................................................ 18
4.4 Baseplate installation ................................ 18
4.5 Initial alignment ......................................... 19
4.6 Grouting .................................................... 22
4.7 Piping ........................................................ 23
4.8 Final shaft alignment check ...................... 25
4.9 Electrical connections ............................... 26
4.10 Protection systems .................................... 26
5 COMMISSIONING, START-UP, OPERATION
AND SHUTDOWN ................................................... 27
5.1 Pre-commissioning procedure .................. 27
5.2 Pump lubricants ........................................ 28
5.3 Direction of rotation ................................... 29
5.4 Guarding ................................................... 29
5.5 Priming and auxiliary supplies .................. 29
5.6 Starting the pump ...................................... 29
5.7 Running the pump ..................................... 29
5.8 Stopping and shutdown ............................ 30
5.9 Hydraulic, mechanical and electrical duty . 31
6 MAINTENANCE ............................................. 31
6.1 General ..................................................... 31
6.2 Maintenance schedule .............................. 32
6.3 Spare parts ................................................ 33
Page 2 of 48 flowserve.com
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INDEX
PAGE
Alignment of shafting (see 4.3, 4.5and 4.7) ............. 19
CE marking and approvals (1.2) ................................ 4
Clearances (see 6.7, Renewal clearances) ............. 34
Clearance setting (6.11) .......................................... 39
Commissioning and operation (see 5) ..................... 27
Configurations (3.1) ................................................. 12
Direction of rotation (5.3) ......................................... 29
Dismantling (see 6.8, Disassembly) ........................ 34
Duty conditions (1.5) .................................................. 4
Electrical connections (4.9)...................................... 26
Examination of parts (6.9)........................................ 35
Faults; causes and remedies (see 7) ...................... 41
General assembly drawings (see 8) ........................ 43
Grouting (4.6) ........................................................... 22
Guarding (5.4) .......................................................... 29
Handling (2.2) .......................................................... 11
Hydraulic, mechanical and electrical duty (5.9) ....... 31
Lifting (2.3) ............................................................... 11
Location (4.1) ........................................................... 18
Lubrication schedule (see 5.2, Pump lubricants)..... 29
Maintenance schedule (6.2) .................................... 32
Piping (4.7)............................................................... 23
Priming and auxiliary supplies (5.5) ......................... 29
Reassembly (see 6.10, Assembly) .......................... 36
Replacement parts (see 6.3 and 6.4) ...................... 33
Safety, electrical (see 4.9) ....................................... 26
Safety, protection systems (see 4.10) ..................... 26
Sound level (see 1.9, Noise level) ........................... 10
Specific machine performance (1.8) ........................ 10
Starting the pump (5.6) ............................................ 29
Stopping and shutdown (5.8) ................................... 30
Storage (2.4) ............................................................ 12
Supplementary manuals or information sources ..... 47
Tools required (6.5) ................................................. 33
Torques for fasteners (6.6) ...................................... 34
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provision of technical documents and safety

1 INTRODUCTION AND SAFETY instructions. Where applicable this document
1.1 General incorporates information relevant to these Directives
and Approvals.
These instructions must always be kept close To confirm the Approvals applying and if the product is
to the product's operating location or directly with CE marked, check the serial number platemarkings and
the product. the Certification. (See section 9, Certification.)
Flowserve products are designed, developed and 1.3 Disclaimer
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great care Information in these User Instructions is believed
and commitment to continuous quality control, utilising to be complete and reliable. However, in spite of all
sophisticated quality techniques, and safety of the efforts of Flowserve Corporation to provide
requirements. comprehensive instructions, good engineering and
safety practice should always be used.
Flowserve is are committed to continuous quality
improvement and being at your service for any further Flowserve manufactures products to exacting
information about the product in its installation and International Quality Management System Standards
operation or about its support products, repair and as certified and audited by external Quality Assurance
diagnostic services. organisations. Genuine parts and accessories have
been designed, tested and incorporated into the
These instructions are intended to facilitate products to help ensure their continued product quality
familiarization with the product and its permitted use. and performance in use. As Flowserve cannot test
Operating the product in compliance with these parts and accessories sourced from other vendors the
instructions is important to help ensure reliability in incorrect incorporation of such parts and accessories
service and avoid risks. The instructions may not take may adversely affect the performance and safety
into account local regulations; ensure such regulations features of the products. The failure to properly select,
are observed by all, including those installing the install or use authorised Flowserve parts and
product. Always coordinate repair activity with accessories is considered to be misuse. Damage or
operations personnel, and follow all plant safety failure caused by misuse is not covered by the
requirements and applicable safety and health laws and Flowserve warranty. In addition, any modification of
regulations. Flowserve products or removal of original components
may impair the safety of these products in their use.
These instructions must be read prior to
installing, operating, using and maintaining the 1.4 Copyright
equipment in any region worldwide. The
All rights reserved. No part of these instructions may
equipment must not be put into service until all the
be reproduced, stored in a retrieval system or
conditions relating to safety noted in the
transmitted in any form or by any means without prior
instructions, have been met. Failure to follow and
permission of Flowserve.
apply the present user instructions is considered to
be misuse. Personal injury, product damage, delay 1.5 Duty conditions
or failure caused by misuse are not covered by the
Flowserve warranty. 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
separately to the Purchaser. A copy should be kept
It is a legal requirement that machinery and equipment
with these instructions.
put into service within certain regions of the world shall
conform with the applicable CE Marking Directives
The product must not be operated beyond the
covering Machinery and, where applicable, Low
parameters specified for the application. If there is
Voltage Equipment, Electromagnetic Compatibility
any doubt as to the suitability of the product for the
(EMC), Pressure Equipment Directive (PED) and
application intended, contact Flowserve for advice,
Equipment for Potentially Explosive Atmospheres
quoting the serial number.
(ATEX).
If the conditions of service on your purchase order are
Where applicable, the Directives and any additional
going to be changed (for example liquid pumped,
Approvals, cover important safety aspects relating to
temperature or duty) it is requested that you/the user
machinery and equipment and the satisfactory
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seek the written agreement of Flowserve before start 1.6.3 Safety action
up. This is a summary of conditions and actions to
prevent injury to personnel and damage to the
1.6 Safety environment and to equipment. (For products used
1.6.1 Summary of safety markings in potentially explosive atmospheres section 1.6.4
These user instructions contain specific safety also applies.)
markings where non-observance of an instruction
would cause hazards. The specific safety markings NEVER DO MAINTENANCE WORK
are: WHEN THE UNIT IS CONNECTED TO POWER
This symbol indicates electrical safety
instructions where non-compliance will involve a high GUARDS MUST NOT BE REMOVED WHILE
risk to personal safety or the loss of life THE PUMP IS OPERATIONAL
would affect personal safety.
DRAIN THE PUMP AND ISOLATE PIPEWORK
This symbol indicates safety instructions where BEFORE DISMANTLING THE PUMP
non-compliance would affect personal safety and could The appropriate safety precautions should be taken
result in loss of life.. where the pumped liquids are hazardous.
This symbol indicates “hazardous and toxic fluid” FLUORO-ELASTOMERS (When fitted.)
safety instructions where non-compliance would affect When a pump has experienced temperatures over
personal safety and could result in loss of life. 250 ºC (482 ºF), partial decomposition of fluoro-
elastomers (eg Viton) will occur. In this condition these
This symbol indicates safety instructions are extremely dangerous and skin contact must be
where non-compliance will involve some risk to safe avoided.
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 is
zone marking according to ATEX. It is used in safety 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
remind not to rub non-metallic surfaces with a dry cloth; THERMAL SHOCK
ensure the cloth is damp. It is used in safety Rapid changes in the temperature of the liquid within
instructions where non-compliance in the hazardous the pump can cause thermal shock, which can result in
area would cause the risk of an explosion. damage or breakage of components and should be
avoided.
This sign is not a safety symbol but indicates
an important instruction in the assembly process. NEVER APPLY HEAT TO REMOVE IMPELLER
Trapped lubricant or vapour 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 and taken to avoid accidental contact. If complete
instruction must be provided. If required the operator protection is not possible, the machine access must be
may commission the manufacturer/supplier to provide limited to maintenance staff only, with clear visual
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 safety If the temperature is greater than 80°C (176 °F) or
requirements and applicable safety and health laws below - 5 °C (23 °F) in a restricted zone, or excee ds
and regulations. local regulations, action as above shall be taken.
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HAZARDOUS LIQUIDS 1.6.4 Products used in potentially explosive

When the pump is handling hazardous liquids care atmospheres
must be taken to avoid exposure to the liquid by
appropriate sitting of the pump, limiting personnel Measures are required to:
access and by operator training. If the liquid is • Avoid excess temperature
flammable and/or explosive, strict safety procedures • Prevent build up of explosive mixtures
must be applied. • Prevent the generation of sparks
• Prevent leakages
Gland packing must not be used when pumping • Maintain the pump to avoid hazard
hazardous liquids. The following instructions for pumps and pump units
when installed in potentially explosive atmospheres
must be followed to help ensure explosion protection.
PREVENT EXCESSIVE EXTERNAL
For ATEX Both electrical and non-electrical equipment
PIPE LOAD
must meet the requirements of European Directive
Do not use pump as a support for piping. Do not mount
94/9/EC. Always observe the regional legal Ex
expansion joints, unless allowed by Flowserve in
requirements eg Ex electrical items outside the EU may
writing, so that their force, due to internal pressure, acts
be required certified to other than ATEX eg IECEx, UL.
on the pump flange.
1.6.4.1 Scope of compliance
NEVER RUN THE PUMP DRY
Use equipment only in the zone for which it is
ENSURE CORRECT LUBRICATION appropriate. Always check that the driver, drive coupling
(See section 5, Commissioning, start-up, operation and assembly, seal and pump equipment are suitably rated
shutdown.) and/or certified for the classification of the specific
atmosphere in which they are to be installed.
START THE PUMP WITH OUTLET
VALVE PART OPENED
Where Flowserve has supplied only the bare shaft
(Unless otherwise instructed at a specific point in the
pump, the Ex rating applies only to the pump. The party
user instructions.)
responsible for assembling the ATEX pump set shall
This is recommended to minimize the risk of
select the coupling, driver and any additional equipment,
overloading and damaging the pump or motor at full or
with the necessary CE Certificate/ Declaration of
zero flow. Pumps may be started with the valve further
Conformity establishing it is suitable for the area in which
open only on installations where this situation cannot
it is to be installed.
occur. The pump outlet control valve may need to be
adjusted to comply with the duty following the run-up
The output from a variable frequency drive (VFD) can
process. (See section 5, Commissioning start-up,
cause additional heating affects in the motor and so, for
operation and shutdown.)
pumps sets with a VFD, the ATEX Certification for the
motor must state that it is covers the situation where
INLET VALVES TO BE FULLY OPEN
electrical supply is from the VFD. This particular
WHEN PUMP IS RUNNING
requirement still applies even if the VFD is in a safe
Running the pump at zero flow or below the
area.
recommended minimum flow continuously will cause
damage to the pump and mechanical seal.
DO NOT RUN THE PUMP AT

ABNORMALLY HIGH OR LOW FLOW RATES
Operating at a flow rate higher than normal or at a flow
rate with no back pressure on the pump may overload
the motor and cause cavitation. Low flow rates may
cause a reduction in pump/bearing life, overheating of
the pump, instability and cavitation/ vibration.
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1.6.4.2 Marking
The operator is responsible to ensure that the
An example of ATEX equipment marking is shown specified maximum liquid temperature is not
below. The actual classification of the pump will be exceeded.
engraved on the nameplate.
Temperature classification “Tx” is used when the liquid
II 2 GD c IIC 135 ºC (T4) temperature varies and when the pump is required to be
used in differently classified potentially explosive
Equipment Group atmospheres. In this case the user is responsible for
I = Mining ensuring that the pump surface temperature does not
II = Non-mining exceed that permitted in its actual installed location.
Category
2 or M2 = High level protection If an explosive atmosphere exists during the
3 = normal level of protection installation, do not attempt to check the direction of
rotation by starting the pump unfilled. Even a short run
Gas and/or Dust time may give a high temperature resulting from
G = Gas; D= Dust contact between rotating and stationary components.
c = Constructional safety
(in accordance with En13463-5) Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, temperature monitors or a
Gas Group power monitor and make routine vibration monitoring
IIA – Propane (typical) checks.
IIB – Ethylene (typical)
IIC – Hydrogen (typical) In dirty or dusty environments, make regular checks and
Maximum surface temperature (Temperature Class) remove dirt from areas around close clearances, bearing
(See section 1.6.4.3.) housings and motors.
1.6.4.3 Avoiding excessive surface temperatures Where there is any risk of the pump being run against a
closed valve generating high liquid and casing external
ENSURE THE EQUIPMENT TEMPERATURE surface temperatures fit an external surface temperature
CLASS IS SUITABLE FOR THE HAZARD ZONE protection device.
Pumps have a temperature class as stated in the ATEX 1.6.4.4 Preventing the build up of explosive
Ex rating on the nameplate. These are based on a mixtures
maximum ambient of 40 °C (104 °F); refer to Flowser ve
for higher ambient temperatures. ENSURE THE PUMP IS PROPERLY FILLED
AND VENTED AND DOES NOT RUN DRY
The surface temperature on the pump is influenced by
the temperature of the liquid handled. The maximum Ensure the pump and relevant suction and discharge
permissible liquid temperature depends on the ATEX pipeline system is totally filled with liquid at all times
temperature class and must not exceed the values in during the pump operation, so that an explosive
the table that follows. atmosphere is prevented. In addition it is essential to
make sure that seal chambers, auxiliary shaft seal
Maximum permitted liquid temperature for pumps systems and any heating and cooling systems are
Maximum surface Temperature limit of properly filled.
Temperature class
to EN13463-1 temperature permitted liquid handled
T6 85 °C (185 °F) 65 °C (149 °F) *
If the operation of the system cannot avoid this
T5 100 °C (212 °F) 80 °C (176 °F) * condition install an appropriate dry run protection
T4 135 °C (275 °F) 115 °C (239 °F) * device (eg liquid detection or a power monitor).
T3 200 °C (392 °F) 180 °C (356 °F) *
T2 300 °C (572 °F) 275 °C (527 °F) * To avoid potential hazards from fugitive emissions of
T1 450 °C (842 °F) 400 °C (752 °F) * vapour or gas to atmosphere the surrounding area
must be well ventilated.
The temperature rise at the seals and bearings and due
to the minimum permitted flow rate is taken into
account in the temperatures stated.
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1.6.4.5 Preventing sparks

1.6.4.7 Maintenance to avoid the hazard
To prevent a potential hazard from mechanical
CORRECT MAINTENANCE IS REQUIRED TO
contact, the coupling guard must be non-sparking.
AVOID POTENTIAL HAZARDS WHICH GIVE A RISK
OF EXPLOSION
To avoid the potential hazard from random induced
current generating a spark, the baseplate must be The responsibility for compliance with maintenance
properly grounded. instructions is with the plant operator.
To avoid potential explosion hazards during

Avoid electrostatic charge: do not rub non-metallic maintenance, the tools, cleaning and painting materials
surfaces with a dry cloth; ensure cloth is damp. used must not give rise to sparking or adversely affect
the ambient conditions. Where there is a risk from
For ATEX, the coupling must be selected to comply with such tools or materials, maintenance must be
94/9/EC. Correct coupling alignment must be conducted in a safe area.
maintained.
It is recommended that a maintenance plan and
Additional requirement for metallic pumps on non- schedule is adopted. (See section 6, Maintenance.
metallic baseplates
When metallic components are fitted on a non-metallic
baseplate they shall be individual grounded.
1.6.4.6 Preventing leakage
The pump must only be used to handle liquids for

which it has been approved to have the correct
corrosion resistance.
Avoid entrapment of liquid in the pump and associated

piping due to closing of suction and discharge valves,
which could cause dangerous excessive pressures to
occur if there is heat input to the liquid. This can occur
if the pump is stationary or running.
Bursting of liquid containing parts due to freezing must

be avoided by draining or protecting the pump and
ancillary systems.
Where there is the potential hazard of a loss of a seal
barrier fluid or external flush, the fluid must be
monitored.If leakage of liquid to atmosphere can result
in a hazard, install a liquid detection device.
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1.7 Nameplate and warning labels

1.7.1 Nameplate
For details of nameplate, see the Declaration of
Conformity or separate documentation included with
these User Instructions
1.7.2 Safety labels
MECHANICAL SEAL WARNING ROTATION WARNING

P/N 2113931-001 P/N 2113932-001
GROUT WARNING LIFTING WARNING

P/N 2113934-001 P/N 9901701-001
LUBRICATION WARNING – QF-440-R01 (2124841)

Oil lubricated units only:
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1.8 Specific machine performance capacity, pipework design and acoustic

characteristics of the building. The levels specified in
For performance parameters see section 1.5, Duty
the table below are estimated and not guaranteed.
conditions. When the contract requirement specifies
these to be incorporated into User Instructions these The dBA values are based on the noisiest ungeared
are included here. Where performance data has electric motors that are likely to be encountered.
been supplied separately to the purchaser these They are Sound Pressure levels at 1 m (3.3 ft) from
should be obtained and retained with these User the directly driven pump, for "free field over a
Instructions if required. reflecting plane". For estimating LwA sound power
level (re 1 pW) add 14dBA to the sound pressure
1.9 Noise level value.
When pump noise level exceeds 85 dBA attention If a pump unit only has been purchased, for fitting
must be given to prevailing Health and Safety with your own driver, then the "pump only" noise
Legislation, to limit the exposure of plant operating levels from the table should be combined with the
personnel to the noise. The usual approach is to level for the driver obtained from the supplier. If the
control exposure time to the noise or to enclose the motor is driven by an inverter, it may show an
machine to reduce emitted sound. You may have increase in noise level at some speeds. Consult a
already specified a limiting noise level when the Noise Specialist for the combined calculation.
equipment was ordered, however if no noise
requirements were defined then machines above a
certain power level will exceed 85 dBA. In such
For units driven by equipment other than
electric motors or units contained within enclosures,
situations consideration must be given to the fitting of
see the accompanying information sheets and
an acoustic enclosure to meet local regulations.
manuals.
Pump noise level is dependent on a number of
factors, the type of motor fitted, the operating
Typical sound pressure level LpA at 1 m reference 20 µPa, dBA

Motor size
and speed 1 750 r/min 1 450 r/min 1180 r/min 980 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) 62 64 62 64 60 62 60 64
0.75 (1) 62 64 62 64 60 62 60 64
1.1 (1.5) 64 64 62 63 62 64 60 63
1.5 (2) 64 64 62 63 62 64 60 63
2.2 (3) 65 66 63 64 63 66 61 64
3 (4) 65 66 63 64 63 66 61 64
4 (5) 65 66 63 64 63 66 61 64
5.5 (7.5) 66 67 64 65 64 67 63 65
7.5 (10) 66 67 64 65 64 67 63 65
11(15) 70 71 68 69 68 71 67 69
15 (20) 70 71 68 69 68 71 67 69
18.5 (25) 71 71 69 71 69 71 68 70
22 (30) 71 71 69 71 69 71 68 70
30 (40) 73 73 71 73 71 73 70 72
37 (50) 73 73 71 73 71 73 70 72
45 (60) 76 76 74 76 74 76 72 75
55 (75) 76 76 74 76 74 76 72 75
75 (100) 77 77 75 77 75 77 73 76
90 (120) 77 78 75 78 75 78 73 76
110 (150) 79 80 77 80 77 78 75 78
150 (200) 79 80 77 80 77 78 76 78
200 (270) 85 87 83 85 81 83 80 82
300 (400) 87 90 85 86 83 85 82 84
1 The noise level of machines in this range will most likely be of values which require noise exposure control, but typical values are
inappropriate.
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Note: For 880 and 720 r/min reduce 980 r/min values by 2 dBA.
2 TRANSPORT AND STORAGE

2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be
checked against the delivery/shipping documents for
its completeness and that there has been no damage
in transportation. Any shortage and/or damage must
be reported immediately to Flowserve Pump Division
and must be received in writing within one month of
receipt of the equipment. Later claims cannot be
accepted.
Check any crate, boxes or wrappings for any

accessories or spare parts that may be packed
separately with the equipment or attached to side
walls 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
Boxes, crates, pallets or cartons may be unloaded
using fork-lift vehicles or slings dependent on their
size and construction.
The pump should be lifted with suitably sized and

located slings. Do not use the shaft for lifting and take
special care to prevent the pump from rotating in the
slings due to unbalanced weight distribution.
2.3 Lifting
A crane must be used for all pump sets or

components in excess of 25 kg (55 lb). Fully trained
personnel must carry out lifting, in accordance with
local regulations. The driver and pump weights are
recorded on the general arrangement drawing for the
specific project. The table of engineering data in
section 3.5 is for bare pump only and does not
include the weight of the base, driver or auxiliary
equipment.
The pump unit should be lifted as shown. Do not Use

the driver, bare shaft pump or component lifting
points to lift the complete machine.
Before lifting the driver alone, refer to the

manufacturer’s instructions
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The pump half coupling and key should be removed

2.4 Storage from the shaft, coated with rust preventative and
wrapped to prevent metal-to-metal contact. Exposed
surfaces of the pump shaft should be protected with
2.4.1 Short-Term Storage a rust preventative. All dismantled parts should be
When it is necessary to store a pump for a short time wrapped and tagged according to pump serial
before it can be installed, place it in a dry, cool number and a record kept of their location.
location. Protect it thoroughly from moisture and
Pumps covered with plastic
condensation. Protective flange covers should not be
should not be stored in a cool environment
removed until the pump is being installed.
because resulting condensation can cause
Wrap the exposed portions of the shaft and coupling
rusting.
to protect against sand, grit or other foreign matter.
Oil lubricated units should be lubricated (refer to 2.5 Recycling and end of product life
Section III) to protect the bearings. Grease
At the end of the service life of the product or its
lubricated units are lubricated at the factory during
parts, the relevant materials and parts should be
assembly. Turn the rotor over by hand at least once
recycled or disposed of using an environmentally
a week to maintain a protective film on the bearing
acceptable method and in accordance with local
components.
regulations. If the product contains substances that
2.4.2 LONG-TERM STORAGE are harmful to the environment, these should be
More than precautions are required if long-term removed and disposed of in accordance with current
storage in excess of 90 days from factory shipment is local regulations. This also includes the liquids
unavoidable. and/or gases that may be used in the "seal system"
or other utilities.
The internal surfaces of the pump should be sprayed
with a rust preventative such as a water soluble oil or Make sure that hazardous substances are
other suitable alternative. Particular attention should disposed of safely and that the correct personal
be given to the impeller, wear plate and stuffing box. protective equipment is used. The safety
specifications must be in accordance with the current
An optional method of protection is to suspend bags local regulations at all times.
of desiccant material inside casing and completely 3 PUMP DESCRIPTION
seal all openings from the surrounding atmosphere.
The stuffing box should be packed with clean, dry 3.1 Configurations
rags. Use of this method requires that the casing be Flowserve "MARK 3" pumps are single stage, end
initially free of liquid. The desiccant material should suction centrifugal pumps specifically designed for
be checked at regular intervals to ensure that it has the chemical process industry and consequently are
not absorbed excessive water vapour. A warning ideally suited to many process fluids. A volute type
instruction, advising that the desiccant must be casing with integrally cast feet and top centerline
removed prior to installation should be wired to the discharge nozzle is standard. The semi-open
pump. impeller with rear pump-out vanes is designed for
high efficiency and prevents clogging. Sealing is
A rust inhibitor should be added to the lubricating oil provided at the impeller to shaft fit to prevent
of oil lubricated units to give additional protection corrosion and thereby facilitate impeller removal.
without destroying the lubricating properties of the oil. The thrust bearing housing uses a threaded
For specific recommendations, consult your adjustment that will permits precision bearing
lubrication dealer. Grease lubricated units, which alignment and impeller setting. The back pull-out
can be identified by the grease fitting at each bearing feature, typical of all MARK 3 pumps, permits quick
location, should be well lubricated prior to placing in removal of the entire rotor/frame assembly without
storage. Small amounts of additional grease should disturbing the casing or driver.
be added at regular intervals during storage. Refer
to Section III for additional information related to The pump is sealed using non-asbestos packing in
grease lubrication. the stuffing box, various mechanical seal designs as
specified by the customer may be installed at the
Storage of pumps in areas of high ambient vibration factory or retrofitted in the field.
should be avoided to prevent bearing damage due to
brinelling. The risk of such damage can be reduced All pumps are carefully inspected and prepared for
by frequent rotation of the shaft. shipment. All exterior machined surfaces are coated
®
with a rust preventative compound and openings are 3.3.6 Stuffing box housing
provided with covers or plugs. Shaft packing, when The stuffing box housing has a spigot (rabbet) fit
required, is shipped with the pump and should not be between the pump casing and bearing housing for
installed until the pump is ready to run. Mechanical optimum concentricity. The design enables a
seals, when provided, are factory installed and number of sealing options to be fitted.
adjusted prior to shipment. The axial impeller
running clearance is preset at the factory but should 3.3.7 Shaft seal
be checked prior to final alignment in case of The mechanical seal(s), attached to the pump shaft,
tampering. seals the pumped liquid from the environment.
Gland packing may be fitted as an option.
3.2 Name nomenclature
3.3.8 Driver
The pump size will be engraved on the nameplate.
The following example explains how the pump name The driver is normally an electric motor. Different
identifies the construction features and options. drive configurations may be fitted such as internal
combustion engines, turbines, hydraulic motors etc
driving via couplings, belts, gearboxes, drive shafts
4K10x6-18OP etc.
Group size 3.3.9 Accessories
Accessories may be fitted when specified by the
Power end customer.
Nominal suction branch size 3.4 Performance and operating limits

This product has been selected to meet the
Nominal discharge branch size specifications of your purchase order see section 1.5.
The following data is included as additional
Nominal maximum impeller diameter information to help with your installation. It is typical,
and factors such as temperature, materials, and seal
Open impeller type may influence this data. If required, a definitive
statement for your particular application can be
3.3 Design of major parts obtained from Flowserve.
3.3.1 Pump casing 3.4.1 Operating limits
The pump casing is a volute type casing with
integrally cast feet and top centerline discharge Pumped liquid temperature limits up to+177 ºC (350 ºF)
nozzle. It is a one piece pressure retaining casting Minimum ambient temperature -20 ºC (-4 ºF)
with gasket connections to the stuffing box head and Maximum ambient temperature +50 ºC (122 ºF)
Maximum soft solids in suspension up to 7 % by volume
the suction and discharge flanges. Maximum pump speed Refer to the nameplate
3.3.2 Impeller
The impeller is semi-open design, keyed to the shaft 3.4.2 Speed torque curves
and secured with a contoured impeller nut. The To bring a centrifugal pump up to rated speed, the
vanes of the impeller are Francis type. driver must be capable of providing more torque at
3.3.3 Shaft each speed than required by the pump. The margin
between the available and required torque affects the
The large diameter stiff shaft, mounted on bearings,
time it takes the unit to reach full speed. If the torque
has a keyed drive end.
required by the pump exceeds the torque capability
3.3.4 Pump bearings and lubrication of the drive at any run-up speed, the unit will not
Ball bearings are fitted as standard and may be accelerate to full speed. Normally, this is not a
either oil or grease lubricated. Oil lubrication is only problem with standard induction or synchronous
available where the pump shaft is horizontal. motors provided the proper voltage is supplied at the
motor.
3.3.5 Bearing housing
For oil lubricated bearings, a bulls eye level gauge is For pumps started at shut valve conditions, 100
supplied. Constant level oilers can also be fitted. Two percent full speed torque can be calculated by using
grease nipples enable grease lubricated bearings to the formula:
be replenished between major service intervals.
Torque (Nm) = 9545 Shutoff Power (kW)
r/min
®
Torque (lbfx ft) = 5250 Shutoff Power (hp) pressures shall be derated.
r/min
Do not conduct a hydro test on the
Torque required by the pump at any other speed namplete pump set without the specific approval of
during start-up can be determined from the curve. Flowserve. While the duty requirement will have been
Note that the driver manufacturer usually bases 100 covered, auxiliary items, flange drillings and suction
percent torque on the design power of the driver and pressure limits may impose a reduced static and
consequently the speed-torque curves should be dynamic pressure rating compared to that of the
plotted in torque units (e.g. Nm) instead of pump casting rating itself.
percentage torque to avoid confusion.
Note: all flanges are ANSI 125 (Cast Iron or Ductile
Iron-flat faced) or ANSI 150 (Stainless-raised face)
unless otherwise stated. All flange facings on the
casings are 250 rms – circular finish
3.4.3 MAXIMUM WORKING PRESSURES -bar

(psi).
Above ambient temperature these maximum
STAINLESS STEEL
CONSTRUCTION CAST IRON AND C.I.S.S. FITTED
316,317L, WORTHITE, ETC.
TEMPERATURE UP TO 12” 14 TO 16” UP TO 16”
°C ( °F) DISCHARGE DISCHARGE DISCHARGE
-30 to 38 (-20 to100) 10.3 (150) 10.3 (150) 13.8 (200)
65 (150) 10.3 (150) 9.7 (140) 13.8 (200)
95 (200) 10.3 (150) 9.3 (135) 13.4 (195)
120 (250) 10.3 (150) 9.0 (130) 12.6 (185)
150 (300) 12.1 (175)

Consult factory for applications in this range. Cast
iron not recommended due to thermal shock risks.
175 (350) 11.0 (160)
®
3.5 Table Of Engineering Data

3.5.1 (GROUP 4 - LIQUID END)
4K12X10-18OP
4K14X12-18OP
4K14X14-18OP
4K16X16-18OP
4K10X8-18OP
4K10X6-18OP
4K8x4-18OP
ENGINEERING DATA
PUMP DATA
SUCTION DIAMETER mm (in.) 200 (8) 250 (10) 300 (12) 250 (10) 350 (14) 350 (14) 400 (16)
DISCHARGE DIAMETER mm (in.) 100 200 (8) 250 (10) 150 (6) 300 (12) 350 (14) 400 (16)
C.I. mm (in.) 16 (0.63) 21 (0.82) 21 (0.82) 18 (0.69) 19 (0.75) 21 (0.82) 21 (0.82)

CASINGTHICK
NESS
S.S.mm (in.) 12 (0.50) 16 (0.63) 18 (0.69) 14(0.56) 16 (0.63) 18 (0.69) 18 (0.69)
CASING TYPE SV DV SV DV-DUAL VOLUTE

GAUGE CONNECTION 1 / 2 NPT
DRAIN CONNECTION 3/4 NPT 1 NPT 1 - 1 / 4 NPT
NO. OF VANES 4 6 5
2 2
0.020 0.036 0.043 0.029 0.076 0.083 0.108
IMPELLER EYE AREA m (in. ) (31.0) (55.6) (66.0) (45.2) (117) (130) (169)
MAX. SPHERE DIA. mm (in.) 28 (1.1) 56 (2.2) 68 (2.7) 48 (1.9) 97 (3.8) 41 (1.6) 41 (1.6)
2 2 2
0.57 1.00 1.32 0.83 0.93 1.57 1.39
WK kg•m (lb•ft. ) (13.6) (23.9) (31.3) (19.8) (22.0) (37.2) (33.0)
473 555 718 644 816 902 1021
PUMP WT. kg (lb.)
(1040) (1220) (1580) (1420) (1800) (1990) (2250)
Max. BACK PULLOUT WT kg (lb.) 340 (750)
IMPELLER AXIAL mm (in.) 0.38/0.50
FRONT CLEARANCE (0.015 /0.020)
NO COOLING 120 °C (250 °F)

MAXIMUMTEM
PERATURE
WITH COOLING 176 °C (350 °F)
STUFFING BOX DATA – CBS

O.D. SLEEVE mm (in.) 76.20 (3.000) 95.25 (3.750)
STUFFING BOX BORE mm (in.) 101.6 (4.000) 127.0 (5.000)
DEPTH OF BOX mm (in.) 99.0 (3.90) 122.2 (4.81)
PACKING SIZE (in.) 1 /2 X 1 /2 5/8 X 5/8

PACKING STD. 2L3
ARRANGEMENT ALT. 3L2
DISTANCE TO FIRST mm (in.)
130 (5.11) 107 (4.21)
OBSTRUCTION (gland)
®
3.6 Table of Engineering Data

3.6.1 (GROUP 4 - FRAME DETAILS)
4K12X10-18OP
4K14X12-18OP
4K14X14-18OP
4K16X16-18OP
4K10X8-18OP
4K10X6-18OP
4K8x4-18OP
ENGINEERING DATA
SHAFT AND BEARING DATA
Dia. at Impeller mm (in.) 50.8 (2.000) 69.9 (2.750)
Dia. Under Sleeve mm (in.) 66.68 (2.625) 82.55 (3.250)
Dia. Between Brgs mm (in.) 114.3 (4.50)
Dia. at Coupling mm (in.) 73.03 (2.875)
Line Bearing 6220
Thrust Bearing 7318 BUA (PAIRED BACK-TO-BACK)
BEARING SPAN mm (in.) 293.4 (11.55)
Nom. Impeller Overhang mm (in.) 312.2 (12.29)
B10 Bearing Life MINIMUM 3 YEARS
Oil Sump Capacity* l (US gal.) 5 (1.3)

* Standard construction is oil lubrication.
®
3.7 Materials of Construction

3.7.1 (LIQUID END)
IRON CASING
BASIC ALL IRON ALL 316 SS WORTHITE
SS FITTED 317L SS CD4MCUN
CONSTRUCTION AIF (SS) W
(SSF)
Casing, ASTM A48 ASTM A743 ASTM A48 ASTM A743 ASTM A890 ASTM A743
Stuff Box Head CL35A CF8M CL35A CG3M CD4MCUN CN7MS
ASTM A48 ASTM A743 ASTM A743 ASTM A743 ASTM A890 ASTM A743
Impeller
CL30A CF8M CF8M CG3M CD4MCUN CN7MS
Impeller Nut
CG3M CG3M CG3M CG3M CD4MCUN CN7M
Throat Bushing
CF8M CF8M CF8M CG3M CD4MCUN CN7M
Shaft Sleeve
CG3M * CG3M * CG3M * CG3M * CD4MCUN CN7M
Shaft AISI 1045 AISI 1045 AISI 1045 AISI 1045 AISI 1045 AISI 316
Gland Halves
CF8M CF8M CF8M CN7M CD4MCUN CN7M
Pipe Plugs (Liquid End) C.I. AISI 316 C.I. A-20 A-20 A-20
Gland Studs And Nuts AISI 316
Impeller Key AISI 316
Packing Synthetic Fibre
ASTM A743
Seal Cage Halves ASTM A743 CG8M
CN7M
Gaskets Synthetic Fibre
o
O-Rings (Liquid End) BUNA-N (120 C MAX.)**
Misc. Fastners,Parts Steel
* Nickel-Chrome-Boron Coated, except for units with mechanical seals.

o
** Viton will be used for all applications operating above 120 C.
®
4 INSTALLATION
Equipment operated in hazardous locations

must comply with the relevant explosion protection
regulations. See section 1.6.4, Products used in
potentially explosive atmospheres.
4.1 Location
The pump should be located to allow room for
access, ventilation, maintenance and inspection with
ample headroom for lifting and should be as close as
practicable to the supply of liquid to be pumped.
Allow sufficient room to facilitate the back pull-out
4.4 Baseplate installation
feature on V-belt driven units.
Position the baseplate and pump next to the
Refer to the general arrangement drawing for the foundation and clean the foundation surface
pump set. thoroughly. Remove the rag packing from the pipe
sleeves and place wedges or ships as close to the
4.2 Part assemblies foundation bolts as possible. These may be omitted
Motors may be supplied loose on MARK 3 pumps, if a jacking nut on the foundation anchor bolts is
typically on frame sizes 400 and above. It is the preferred for levelling.
responsibility of the installer to ensure that the motor
is assembled to the pump and lined up as detailed in Remove the flange covers and check inside the
section 4.5.2. pump nozzles for cleanliness. Kerosene is
recommended as the best solvent for removing
4.3 Foundation factory applied rust preventative. Ensure that all
traces of rust preventative are removed from the
The foundation may consist of any discharge and suction flange faces, the exposed
material that will afford permanent, rigid support to shafting and all coupling surfaces. Flush the pump
the full area of the pump or driver supporting internals of any rust preventative applied for long-
member. It should be of sufficient size and mass to term storage.
absorb expected strains and shocks that may be
encountered in service. Concrete foundations built Lift the baseplate assembly, remove the shipping
on solid ground are desirable. Use a concrete grade skids and clean the underside of the baseplate.
with a strength of approximately 20MPa (2900 PSI). Position the baseplate over the foundation and lower
the unit over the foundation bolts and onto the
The purpose of foundation bolts is to anchor the wedges, shims or jacking nuts.
pump unit securely to the foundation such that the
foundation and pump assembly become a single a) Level the pump baseplate assembly. If the
structural unit. High strength steel foundation bolts baseplate has machined coplanar mounting
(SAE Gr. 5 or equal) of the specified diameter should surfaces, these machined surfaces are to be
be located according to the elevation drawing referenced when leveling the baseplate. This
provided. Each bolt should be surrounded by a pipe may require that the pump and motor be
sleeve which is two or three times the diameter of the removed from the baseplate in order to reference
bolt. The sleeves should be securely anchored and the machined faces. If the baseplate is without
designed to allow the bolts to be moved to conform machined coplanar mounting surfaces, the pump
with the holes in the baseplate. The bolts should be and motor are to be left on the baseplate. The
sufficiently long to allow for wedges or shims or proper surfaces to reference when leveling the
levelling nuts under the baseplate, and a washer, pump baseplate assembly are the pump suction
heavy hex nut and hex jam nut for retention. Since and discharge flanges. DO NOT stress the
baseplate levelling is performed after the foundation baseplate.
has cured, it is best to use extra long bolts that can b) Do not bolt the suction or discharge flanges of
be shortened after the installation is complete. the pump to the piping until the baseplate
foundation is completely installed. If equipped,
use leveling jackscrews to level the baseplate. If
®
jackscrews are not provided, shims and wedges removed from under the baseplate at this time. If
should be used. (See Figure 4-5.) Check for they were to be left in place, they could rust,
levelness in both the longitudinal and lateral swell, and cause distortion in the baseplate.
directions. Shims should be placed at all base h) Run piping to the suction and discharge of the
anchor bolt locations. Do not rely on the bottom pump. There should be no piping loads
of the baseplate to be flat. Standard baseplate transmitted to the pump after connection is
bottoms are not machined and it is not likely that made. Recheck the alignment to verify that there
the field mounting surface is flat. are no significant loads.
c) After leveling the baseplate, tighten the anchor Check the impeller axial clearance and that the rotor
bolts. If shims were used, make sure that the turns freely by hand.
baseplate was shimmed near each anchor bolt
before tightening. Failure to do this may result in Note: Grout is not poured until an initial
a twist of the baseplate, which could make it alignment of the pump and driver has been
impossible to obtain final alignment. performed. See section 4.5
d) Check the level of the baseplate to make sure
that tightening the anchor bolts did not disturb
the level of the baseplate. If the anchor bolts did
change the level, adjust the jackscrews or shims
as needed to level the baseplate.
e) Continue adjusting the jackscrews or shims and
tightening the anchor bolts until the baseplate is
level.
f) Check initial alignment. If the pump and motor
were removed from the baseplate proceed with
step g) first, then the pump and motor should be
reinstalled onto the baseplate using Flowserve’s
factory preliminary alignment procedure as
described in section 4.5, and then continue with
the following. As described above, pumps are
given a preliminary alignment at the factory. This
preliminary alignment is done in a way that
ensures that, if the installer duplicates the factory
conditions, there will be sufficient clearance 4.5 Initial alignment
between the motor hold down bolts and motor The purpose of factory alignment is to ensure that the
foot holes to move the motor into final alignment. user will have sufficient clearance in the motor holes
If the pump and motor were properly reinstalled for final job-site alignment. To achieve this, the
to the baseplate or if they were not removed from factory has designed the mounting holes with
the baseplate and there has been no transit additional clearance to allow the pump to be aligned
damage, and also if the above steps where done in the horizontal plane to the motor, There should be
properly, the pump and driver should be within at least 1/16 clearance around the bolt. The coupling
0.38 mm (0.015 in.) FIM (Full Indicator has been designed to have some overhang of the
Movement) parallel, and 2.5 mm/m coupling hub (in most cases 1 or both hubs may be
(0.0025 in./in.) FIM angular. If this is not the overhung between 0.0 and 3 mm (0 and 0.12 in)
case, first check to see if the driver mounting unless otherwise stated. This procedure ensures that
fasteners are centered in the driver feet holes. If there is sufficient clearance in the motor holes for the
not, re-center the fasteners and perform a customer to field align the motor to the pump, to zero
preliminary alignment to the above tolerances by tolerance. This philosophy requires that the customer
shimming under the motor for vertical alignment, be able to place the base in the same condition as
and by moving the pump for horizontal the factory. Thus the factory alignment will be done
alignment. with the base sitting in an unrestrained condition on a
g) Grout the baseplate. A non-shrinking grout flat and level surface. This standard also emphasizes
should be used. Make sure that the grout fills the the need to ensure the shaft spacing is adequate to
area under the baseplate. After the grout has accept the specified coupling spacer.
cured, check for voids and repair them.
Jackscrews, shims and wedges should be
®
The factory alignment procedure is summarized necessary, align the motor to the pump, not the pump
below: to the motor.
4.5.2.1 Direct Driven Units
a) The baseplate is placed on a flat and level
workbench in a free and unstressed position. The importance of accurate alignment of pump
and driver shafts cannot be overemphasized.
b) The baseplate is leveled as necessary. Leveling IMPROPER ALIGNMENT IS THE PRIMARY
is accomplished by placing shims under the rails CAUSE OF VIBRATION PROBLEMS AND
of the base at the appropriate anchor bolt hole REDUCED BEARING LIFE.
locations. Levelness is checked in both the
longitudinal and lateral directions.
A flexible coupling is used to compensate for slight
c) The pump is put onto the baseplate, aligned and changes in alignment that occur during normal
leveled. The rear foot piece under the bearing operation and is not used to correct for installation
housing is adjustment as necessary by adding or errors. Install the pump and driver half couplings in
removing shims [3126.1] between the foot piece accordance with the coupling manufacturer's
and the bearing housing or at the baseplate. instructions. Note that the coupling hub faces are not
d) The motor and appropriate motor mounting always mounted flush with the ends of the shafts.
hardware is placed on the baseplate and the Place the driver on the baseplate such that the
motor is checked for any planar soft-foot correct spacing is obtained between the two half
condition. If any is present it is eliminated by couplings. In the case of electric motors, such as
shimming. those with sleeve bearings, it may be necessary to
e) The motor is fastened in place by tightening two run the motor to establish the rotor magnetic center.
diagonal motor mounting bolts. Consult the manufacturer's instruction manual for
details.
f) The spacer coupling gap is verified. As indicated
the gap may be adjusted to ensure adequate The purpose of the alignment procedure is to ensure
axial bolt clearance. that the pump and driver shafts are in parallel and
g) The parallel and angular vertical alignment is angular alignment under the normal operating
made by shimming under the motor. conditions of load and temperature.
h) The pump and motor shafts are then aligned
horizontally, both parallel and angular, by moving When the pump coupling and driver are assembled
the pump to the fixed motor. The pump feet are at the factory, the units are aligned prior to shipment.
tightened down. However, baseplates can be sprung or distorted
i) Both horizontal and vertical alignment is again during shipment or installation and the alignment
final checked as is the coupling spacer gap. must be checked before the unit is put in service. The
coupling spacer must be removed to make this
See section 4.8, Final shaft alignment. check.
4.5.1 Thermal expansion
For pumps and drivers that operate at different
The pump and motor will normally temperatures compensation must be made at the
have to be aligned at ambient temperature and initial alignment stage (when the units are at the
should be corrected to allow for thermal expansion at same temperature) to allow for thermal expansion
operating temperature. In pump installations during operation. Consult the instruction manual
involving high liquid temperatures, the unit should be supplied with the driver for the manufacturer's
run at the actual operating temperature, shut down recommendations.
and the alignment checked immediately.
Shaft alignment is greatly simplified by the use of a
4.5.2 Alignment methods dial indicator, or with extension rods and a magnetic
base. Before taking readings, ensure that the pump
Ensure pump and driver are isolated and driver mounting bolts are secure, and that the
electrically and the half couplings are disconnected. thrust bearing housing is properly aligned in the
bearing frame or cartridge
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
®
4.5.3 Parallel Alignment:

4.5.2.2 V-Belt Drive Units:
Check that both sheaves are free of grease, rust,

nicks or burrs. Install the correct size sheave on the
pump shaft and locate the sheave axially to minimize
overhang. Re-check the impeller axial clearance and
ensure that the pump is properly secured to the
baseplate. Install the driver on the adjustable base
provided and install the driver sheave in line with the
pump sheave. Ensure that the sheaves are tight on
the shafts. With a dial indicator, check the runout on
the periphery and face of each sheave to ensure that
each is running true. Tighten the adjustable base and
check that the driver rotation in the correct direction
and that vibration levels are not unacceptable.
Mount the magnetic base on the pump half coupling
hub, either the face or O.D. as shown in the sketch.
Place the dial indicator button on the outside
diameter of the driver half coupling hub.
The length of extension rods should be kept

at a minimum to reduce deflection.
Rotate the pump shaft and record the dial reading at

the top, bottom and each side. Correct the parallel
alignment by adding or removing shims under the
Checking V-Belt Sheave Alignment driver and/or moving the driver horizontally. Repeat
this procedure until the maximum total indicator
reading (T.I.R.) is within 0.08 mm (0.003 inch.)
Before starting the driver, refer to the
manufacturer’s instruction manual. The correct 4.5.4 Angular Alignment:
rotation of the pump shaft is marked on the pump
casing or frame.
Check that all belts making up one drive set have

matched code numbers. Loosen the adjustable base
and install the belts in their proper grooves. Adjust
the center distance between the sheaves to obtain
proper belt tension. Check the alignment of the pump
and driver sheaves with a taught string or straight
edge. For proper alignment and the sheave faces
must be parallel to each other and in line.
Adjustments are made by slackening the belts,
moving and retightening the drive or driver sheave,
and repeating the above procedure.
When the sheaves are aligned that the shafts rotate

freely by hand and install safety guard. Mount the magnetic base mounted on the pump half
coupling hub, either face or O.D. as shown. Move the
dial indicator button to indicate on the face of the
Belt drives must not be used in ATEX driver half coupling hub as close to the outside
Potentially explosive environments; refer to diameter as possible. When convenient the indicator
Flowserve. can be placed on the inside face to keep spans short.
Turn both shafts 360° and record the dial readings at
90° intervals. Adjust the shims under the motor as
®
required and repeat the procedure until the angular acceptable but any more will have to be corrected by
alignment is within 0.0005 mm (T.I.R.) per mm adding shims. For example, if the dial test indicator
(0.0005 in. per in.) of maximum hub diameter. shows the foot lifting 0.15 mm (0.006 in.) then this is
the thickness of shim to be placed under that foot.
Repeat the checks on parallel and angular alignment, Tighten down and repeat the same procedure on all
ensuring the mounting bolts are secure, until the unit other feet until all are within tolerance.
is properly aligned. Note that correction in one
direction may affect the alignment in another
direction. Re-check the gap between the coupling Complete piping as below and see sections
hubs. 4.8, Final shaft alignment check up to and including
section 5, Commissioning, start-up, operation and
If any difficulty is encountered in achieving the shutdown before connecting driver and checking
recommended alignment tolerances, the run-out of actual rotation.
the pump and driver shafts and each coupling hub
diameter and face should be checked. Occasionally, 4.6 Grouting
due to practical and unavoidable manufacturing The purpose of grouting is to provide rigid support to
tolerance build-up associate with the pump, coupling the pump and driver by increasing the structural
and driver, it may be necessary to match up the two rigidity of the baseplate and making it an integral
coupling hubs in the most advantageous relative mass with the foundation. Grouting should only be
angular position in order to achieve an acceptable completed after baseplate has been levelled (4.4)
alignment. and initial pump alignment (4.5).
Do not install the coupling spacer or sleeve until Clean the roughed foundation surface and build a
grouting is complete and cured and the alignment is wooden form around the baseplate. For initial
re-checked. grouting forms should be placed to isolate shims and
levelling nuts. The foundation surface should be
When the electric motor has sleeve bearings it is thoroughly saturated with water before grouting. A
necessary to ensure that the motor is aligned to run typical mixture for grouting-in a pump base is
on its magnetic centreline. A button (screwed into composed of one part pure Portland cement and two
one of the shaft ends) is normally fitted between the parts of clean building sand with sufficient water to
motor and pump shaft ends to fix the axial position. provide the proper consistency. The grout should
flow freely but not be so wet as to cause the sand
and cement to separate.
If the motor does not run in its
magnetic centre the resultant additional axial force Thoroughly puddle the grout while pouring to
may overload the pump thrust bearing. eliminate air pockets and low spots. Pour sufficient
grouting to ensure that the bottom surface of the
4.5.5 Check for soft foot
baseplate is completely submerged. Do not fill
isolated areas around the shims or levelling nuts.
Once the grout has set sufficiently, remove the
wooden forms and finish off the sides and top as
desired. At the same time, roughen the grout surface
inside the baseplate. Cover with wet burlap and
allow the grout to cure for at least 40 hours.
After grouting has cured, shims and levelling nuts

should be removed or backed off. Tighten down
baseplate to the new grout to put bolts in tension and
ensure rigidity of structure. Install jam nuts and cut
This is a check to ensure that there is no undue the bolts to the desired length. Finish grouting
stress on the driver holding down bolts; due to non- isolated areas. Fill the baseplate including pump and
level baseplate or twisting. To check, remove all driver support pedestals with concrete. Trowel and
shims and clean surfaces and tighten down driver to slope the surface to give suitable drainage.
the baseplate. Set a dial indicator as shown in
sketch and loosen off the holding down bolt while
noting any deflection reading on the dial test Indicator
- a maximum of 0.05 mm (0.002 in.) is considered
®
Maximum forces and moments allowed on the pump

4.7 Piping flanges vary with the pump size and type. To
minimize these forces and moments that may, if
Protective covers are fitted to the pipe excessive, cause misalignment, hot bearings, worn
connections to prevent foreign bodies entering during couplings, vibration and the possible failure of the
transportation and installation. Ensure that these pump casing, the following points should be strictly
covers are removed from the pump before followed:
connecting any pipes. • Prevent excessive external pipe load
4.7.1 Suction and discharge pipework • Never draw piping into place by applying force to
pump flange connections
In order to minimize friction losses and hydraulic
noise in the pipework it is good practice to choose • Do not mount expansion joints so that their force,
pipework that is one or two sizes larger than the due to internal pressure, acts on the pump flange
pump suction and discharge. Typically main
pipework velocities should not exceed 2 m/s (6 ft/sec) The table in 4.7.2 summarizes the maximum forces
suction and 3 m/s (9 ft/sec) on the discharge. and moments allowed on MARK 3 Group 4 pump
casings. Refer to Flowserve for other configurations.
Take into account the available NPSH that must be
higher than the required NPSH of the pump. Ensure piping and fittings are flushed
before use.
Never use the pump as a support for
Ensure piping for hazardous liquids is arranged
piping.
to allow pump flushing before removal of the pump.
4.7.2 Maximum forces and moments allowed on MARK 3, Group 4 pump flanges
Introduction: Flowserve Mark 3, Group 4 pumps are larger than those contained in ANSI/HI 9.6.2 and have been
designed around the FRBH process pump. API 610 has been used as a reference for these pumps to establish the
allowable forces and moments. Typically values are 2X API. The values shown in the table 4.7.2.2 are based on
pumps mounted on grouted baseplates. These values should be factored based on material of construction and
temperature. The table 4.7.2.1 has been adopted from Mark 3 manual (PCN 71569102) that uses data from
ANSI/HI 9.6.2.6.
Table 4.7.2.1: Casing Material Correction Factors

Material Group No.
1.0 2.2 2.8 3.8 3.17 Ti
Temp. °C Temp °F CI/DI 316/317L CD4MCU Hast. C Wort h/A20 Titanium
-29 -20 0.89 1.00 1.00 1.00 0.83 0.89
38 100 0.89 1.00 1.00 1.00 0.83 0.89
93 200 0.78 0.86 1.00 1.00 0.72 0.86
150 300 0.73 0.78 0.92 1.00 0.65 0.81
®
Table 4.7.2.2
Maximum forces (F) in N (lbf) and moments (M) in Nm (lbf•ft)
Pump Size Suction Discharge
Mx My Mz Fx Fy Fz Mx My Mz Fx Fy Fz
3530 1760 2580 4890 3780 3100 1330 680 1000 1420 1160 1780
4K8x4x18
(2600) (1300) (1900) (1100) (850) (700) (980) (500) (740) (320) (260) (400)
10040 4880 7200 13340 10680 8900 4600 2360 3560 4980 4100 6220
4K10x6x18
(7400) (3600) (5600) (3000) (2400) (2000) (3400) (1740) (2600) (1120) (920) (1400)
10040 4880 7200 13340 10680 8900 7060 3520 5160 7560 6220 9780
4K10x8x18
(7400) (3600) (5600) (3000) (2400) (2000) (5200) (2600) (3800) (1700) (1400) (2200)
12200 5960 9220 16000 13340 10680 10040 4880 7600 10680 8900 13340
4K12x10x18
(9000) (4400) (6800) (3600) (3000) (2400) (7400) (3600) (5600) (2400) (2000) (3000)
12740 6240 9500 16900 14240 11560 12200 5960 9220 13340 10680 16000
4K14x12x18
(9400) (4600) (7000) (4000) (3200) (2600) (9000) (4400) (7200) (3000) (2400) (3600)
12740 6240 9500 16900 14240 11560 12740 6240 9500 14240 11560 17800
4K14x14x18
(9400) (4600) (7000) (4000) (3200) (2600) (9400) (4600) (7000) (3200) (2600) (4000)
14640 7320 10840 20460 16900 13340 14640 7320 10840 16900 13340 20460
4K16x16x18
(10800) (5400) (8000) (4600) (3800) (1500) (10800) (5400) (8000) (3800) (3000) (4600)
Notes:
1) F = External force (tension or compression) M = External moment, clockwise or counter-clockwise
2) Forces and moments may be applied simultaneously in any direction
3) Correct values by material factor
4) Higher loads may be applicable, if direction and magnitude of individual loads are known, but these need written approval from Flowserve
5) Pumps must be on rigid foundations and baseplates must be fully grouted
6) Pump/baseplate should not used as pipe anchor. Expansion joints must be properly tied
7) The pump mounting bolt torques specified must be used to prevent relative movement between the pump casing and baseplate. (See
section 6.6, Fastener torques.) The bolt material must have a minimum yield strength of 600 N/mm 2 (87 000 lb/in.2)
d) On positive suction, the inlet piping must have a

4.7.3 Suction piping
constant fall towards the pump.
a) The inlet pipe should be one or two sizes larger
than the pump inlet bore and pipe bends should e) Flow should enter the pump suction with uniform
be as large a radius as possible. flow, to minimize noise and wear. This is
particularly important on large or high-speed
b) Pipework reducers should have a maximum total pumps that should have a minimum of four
angle of divergence of 15 degrees. diameters of straight pipe on the pump suction
c) On suction lift the piping should be inclined up between the elbow and inlet flange. See section
towards the pump inlet with eccentric reducers 10.3, Reference 1 for more detail.
incorporated to prevent air locks.
®
f) Inlet strainers, when used, should have a net If the seal requires an auxiliary quench then a
`free area' of at least three times the inlet pipe connection must be made to a suitable source of
area. liquid flow, low pressure steam or static pressure
g) Do not install elbows at an angle other than from a header tank. Recommended pressure is 0.35
perpendicular to the shaft axis. Elbows parallel bar (5 psi) or less. Check General arrangement
to the shaft axis will cause uneven flow. drawing.
h) Except in unusual circumstances strainers are
Special seals may require different auxiliary piping to
not recommended in inlet piping. If considerable
that described above. Consult separate User
foreign matter is expected a screen installed at
Instructions and/or Flowserve if unsure of correct
the entrance to the wet well is preferable.
method or arrangement.
i) Fitting an isolation valve will allow easier
maintenance. For pumping hot liquids, to avoid seal damage, it is
j) Never throttle pump on suction side and never recommended that any external flush/cooling supply
place a valve directly on the pump inlet nozzle. be continued after stopping the pump.
4.7.4 Discharge piping 4.7.6 Final checks
A non-return valve should be located in the discharge Check the tightness of all bolts in the suction and
pipework to protect the pump from excessive back discharge pipework. Check also the tightness of all
pressure and hence reverse rotation when the unit is foundation bolts.
stopped.
4.8 Final shaft alignment check
Pipework reducers should have a maximum total After connecting piping to the pump, rotate the shaft
angle of divergence of 15 degrees. Fitting an several times by hand to ensure there is no binding
isolation valve will allow easier maintenance. and all parts are free.
4.7.5 Auxiliary piping The baseplate should be levelled and grouted by this
4.7.5.1 Drains stage.
Pipe pump casing drains and gland leakage to a
convenient disposal point. Recheck the coupling alignment, as previously
described, to ensure no pipe strain. If pipe strain
4.7.5.2 Pumps fitted with gland packing exists, correct piping.
It is required that a clean water flush be provided to
the packing to provide lubrication and to prevent the a) Mount and level pump if appropriate. Level the
ingress of air. When the product is clean and free of pump by putting a level on the discharge flange.
solids this can be achieved with a supply from the It may be necessary to adjust the bearing frame
pump discharge volute to the stuffing box (Plan 11). foot by adding or deleting shims [3126.1]
A control valve or orifice may be fitted in the line to between the foot piece and the bearing housing
enable the pressure to the gland to be controlled. (or baseplate).
b) Check initial alignment. If pump and driver have
If the pumped liquid is dirty and cannot be used for been remounted or the specifications given
sealing, a separate clean compatible liquid supply to below are not met, perform an initial alignment as
the gland at a pressure equal to the estimated described in section 4.5. This ensures there will
stuffing box pressure, Ps (psig). be sufficient clearance between the motor hold
Ps = 0.6 x TDH X S.G. + Suction Pressure down bolts and motor foot holes to move the
2.31 motor into final alignment. The pump and driver
TDH = total developed head at shut valve (feet) should be within 0.38 mm (0.015 in.) FIM (full
S.G. = Specific Gravity of pump liquid indicator movement) parallel, and 2.5 mm/m
Suction Pressure = maximum suction pressure (0.0025 in./in.) FIM angular.
corrected for specific gravity (psig).
c) Run piping to the suction and discharge to the
4.7.5.3 Pumps fitted with mechanical seals pump. There should be no piping loads
Single seals requiring re-circulation will normally be transmitted to the pump after connection is
provided with the auxiliary piping from pump casing made. Recheck the alignment to verify that there
already fitted. are no significant changes.
®
d) Perform final alignment. Check for soft-foot under If not supplied pre-wired to the pump unit, the
the driver. An indicator placed on the coupling, controller/starter electrical details will also be
reading in the vertical direction, should not supplied within the controller/starter.
indicate more than 0.05 mm (0.002 in.) For electrical details on pump sets with controllers
movement when any driver fastener is loosened. see the separate wiring diagram.
Align the driver first in the vertical direction by
shimming underneath its feet. See section 5.3, Direction of rotation
e) When satisfactory alignment is obtained the before connecting the motor to the electrical supply.
number of shims in the pack should be 4.10 Protection systems
minimized. It is recommended that no more than
five shims be used under any foot. Final
The following protection systems are
horizontal alignment is made by moving the
recommended particularly if the pump is installed in a
driver. Maximum pump reliability is obtained by
potentially explosive area or is handling a hazardous
having near perfect alignment. Flowserve
liquid. If in doubt consult Flowserve.
recommends no more than 0.05 mm (0.002 in.)
parallel, and 0.5 mm/m (0.0005 in./in.) angular
If there is any possibility of the system allowing the
misalignment. (See section 6.9.6)
pump to run against a closed valve or below
f) Operate the pump for at least an hour or until it minimum continuous safe flow a protection device
reaches final operating temperature. Shut the should be installed to ensure the temperature of the
pump down and recheck alignment while the liquid does not rise to an unsafe level.
pump is hot. Piping thermal expansion may
change the alignment. Realign pump as If there are any circumstances in which the system
necessary. can allow the pump to run dry, or start up empty, a
4.9 Electrical connections power monitor should be fitted to stop the pump or
prevent it from being started. This is particularly
relevant if the pump is handling a flammable liquid.
Electrical connections must be made
by a qualified Electrician in accordance with relevant If leakage of product from the pump or its associated
local national and international regulations. sealing system can cause a hazard it is
recommended that an appropriate leakage detection
It is important to be aware of the EUROPEAN
system is installed.
DIRECTIVE on potentially explosive areas where
compliance with IEC60079-14 is an additional
To prevent excessive surface temperatures at
requirement for making electrical connections.
bearings it is recommended that temperature or
It is important to be aware of the EUROPEAN vibration monitoring are carried out. See sections
DIRECTIVE on electromagnetic compatibility when 5.7.4 and 5.7.5.
wiring up and installing equipment on site. Attention
must be paid to ensure that the techniques used
during wiring/installation do not increase
electromagnetic emissions or decrease the
electromagnetic immunity of the equipment, wiring or
any connected devices. If in any doubt contact
Flowserve for advice.
The motor must be wired up in

accordance with the motor manufacturer's
instructions (normally supplied within the terminal
box) including any temperature, earth leakage,
current and other protective devices as appropriate.
The identification nameplate should be checked to
ensure the power supply is appropriate.
A device to provide emergency stopping must

be fitted.
®
5.1.4.2 Pure Oil Mist

5 COMMISSIONING, START-UP, In this method all oil is drained from the oil sump, this
OPERATION AND SHUTDOWN is sometimes referred to as a dry sump. Oil is
injected outboard at each bearing. To use this
These operations must be carried method some modifications must be made to the
out by fully qualified personnel. pump. If pumps are shipped for standard oil or
grease lubrication the pumps must be dismantled
and reworked. All oil return grooves that permit
5.1 Pre-commissioning procedure movement of oil from outboard of each bearing back
5.1.1 Lubrication Methods to the sump shall be blocked. These passages may
be blocked using epoxy filler or other compounds
Determine the mode of lubrication of the pump set, compatible with the mist oil. Pressure inside the
eg grease, oil, product lubrication etc. center of the bearing frame must be controlled,
recommended pressure to be 25mm - 50mm (1”-2”)
For oil lubricated pumps, fill the
H2O. Excessive will cause fogging and venting of oil
bearing housing with correct grade of oil to the
through the bearing seals. High inboard pressures
correct level, ie sight glass or constant level oiler
could result in poor mist distribution and could result
bottle.
in bearing failure as mist is not forced through the
bearing. It is recommended that mist system operate
Other drivers and gearboxes, if appropriate, should
for 24 hrs before starting of the pump to ensure
be lubricated in accordance with their manuals.
bearing surfaces have been properly misted. Testing
In the case of product lubricated completed has used an oil viscosity of 100 cSt. For
bearings the source of product supply should be additional information refer to TR-3326, Pure Oil Mist
checked against the order. There may be lubrication of FRBH and R/M Slurry Pumps. Contact
requirements for an external clean supply, particular Flowserve engineering for copy or additional
supply pressure or the commencement of lubrication information such as reclassifier sizing.
supply before pump start-up.
5.1.2 Oil Bath Lubrication
When fitted with a constant level oiler, the bearing
housing should be filled by unscrewing or hinging
back the transparent bottle and filling the bottle with
oil. Where an adjustable body Trico oiler is fitted this
should be set to the proper height.
The oil filled bottle should then be refitted so as to

return it to the upright position. Filling should be
repeated until oil remains visible within the bottle.
Approximate oil volumes are shown in section 5.2.3,

Pump and impeller data.
5.1.3 Grease Lubrication
Grease lubricated pumps and electric motors are
supplied pre-greased.
5.1.4 Oil Mist Lubrication
Mk3 Group 4 pumps may be lubricated by pure or
purge oil mist. See comments below.
5.1.4.1 Purge Mist
In the case of purge mist an oil level is maintained in
the bearing frame. No changes are required to be
made to the pump, however, the oil level must be
maintained at site glass center. Excess oil must be
removed. Oil is injected outboard of each bearing.
®
5.2 Pump lubricants

5.2.1 Recommended oil lubricants
Centrifugal
lubrication
pump
Oil Splash / force feed / purge oil mist lubrication Pure oil mist
Viscosity cSt
32 46 68 100
@ 40 ºC
Oil temperature range * -5 to 65 -5 to 78 -5 and above -30 and above
ºC (ºF) (-23 to 149) (-23 to 172) (-23 and above) (59 and above)
Designation to ISO ISO VG 32 ISO VG 46 ISO VG 68 ISO VG 100
3448 and DIN51502 32 HL/HLP 46 HL/HLP 68 HL/HLP –
BP Energol HL32 BP Energol HL46 BP Energol HL68
BP –
BP Energol HLP32 BP Energol HLP46 BP Energol HLP68
Castrol Perfecto T32 Perfecto T46 Perfecto T68 –
Anstron HL32 Anstron HL46 Anstron HL68
DEA –
Anstron HLP32 Anstron HLP46 Anstron HLP68
OLNA 32
HYDRELEF 32 TURBELF SA46 TURBELF SA68
Elf –
Oil companies and lubricants
TURBELF 32
ELFOLNA DS32 ELFOLNA DS46 ELFOLNA DS68
TERESSO 32 TERESSO 46 TERESSO 68
Esso –
NUTO H32 NUTO H46 NUTO H68
LSC LSO 32 LSO 46 LSO 68 LSO 100
(for oil mist) Synthetic oil Synthetic oil Synthetic oil Synthetic oil
Mobil DTE oil light Mobil DTE oil medium
Mobil DTE oil heavy medium
Mobil Mobil DTE13M Mobil DTE15M –
Mobil DTE26
MobilDTE24 Mobil DTE25
Q8 Verdi 32 Q8 Verdi 46 Q8 Verdi 68
Q8 –
Q8 Haydn 32 Q8 Haydn 46 Q8 Haydn 68
Shell Tellus 32 Shell Tellus 01 C 46 Shell Tellus 01 C68
Shell Shell Tellus 37 Shell Tellus 01 46 Shell Tellus 01 68 –
Shell Turbo T32 Shell Turbo T46 Shell Turbo T68
Rando Oil HD 32 Rando Oil 46 Rando Oil 68
Texaco –
Rando Oil HD-AZ-32 Rando Oil HD B-46 Rando Oil HD C-68
Total Azolla ZS32 Azolla ZS46 Azolla ZS68 –
Wintershall Wiolan HN32 Wiolan HN46 Wiolan HN68
–
(BASF Group) Wiolan HS32 Wiolan HS46 Wiolan HS68
* Note that it normally takes 2 hours for bearing temperature to stabilize and the final temperature will depend on the ambient, r/min, pumpage temperature and pump size.
Also some oils have a greater Viscosity Index than the minimum acceptable of 95 (eg Mobil DTE13M) which may extend the minimum temperature capability of the oil. Always
check the grade capability where the ambient is less than -5 ºC (-23 ºF).
5.2.2 Recommended fill quantities

Most oils recommended for wet sump bearing
housings contain foam inhibitors as well as U.S. GAL. 1.3
OIL SUMP CAPACITY
antioxidants and anticorrosion additives normally LITRES 5
unsuitable for oil misting. Compounded oils CANNOT
be used for oil mist and anti-foam additives are to be Where the pump is lubricated by oil mist
avoided. The above LSC grades are recommended the amount of oil mist supplied (m³/h) is normally
by Flowserve where Oil mist. calculated to be at least the bearing bore diameter
(mm) x the number of bearing rows / 25. The oil mist
should consist of at least 0.025 - 0.04 % oil content.
Where oil mist is utilized to lubricate bearings the
pressure in the bearing housing must not exceed
0.01 barg (0.15 psi).
®
5.5.1 Suction pressure above atmospheric

5.2.3 Lubrication schedule pressure
Open vent connection (6521] on top of the pump
5.2.3.1 Oil lubricated bearings upper casing to allow the trapped air to escape. Let
Normal oil change intervals are 4 000 operating hours liquid run out until free from air bubbles.
or at least every 6 months. For pumps on hot service
5.5.2 Suction lift with foot valve fitted
or in severely damp or corrosive atmosphere, the oil
will require changing more frequently. Lubricant and Fill suction pipe and casing with liquid at a pressure
bearing temperature analysis can be useful in of 1 to 2 bar from an external source. Vent as
optimizing lubricant change intervals. described in section 5.5.1.
5.5.3 Suction lift without foot valve
The lubricating oil should be a high quality mineral oil
Pump casing vents on the suction volute must be
having foam inhibitors. Synthetic oils may also be
connected to an external vacuum pump priming
used if checks show that the rubber oil seals will not
system. If in doubt please consult Flowserve.
be adversely affected.
The bearing temperature may be allowed to rise to 5.6 Starting the pump
50 ºC (90 ºF).above ambient, but should not exceed
82 ºC (180 ºF). A continuously rising temperature, or a) Ensure flushing and/or cooling/
an abrupt rise, indicate a fault. heating liquid supplies are turned ON before
5.3 Direction of rotation starting the pump.
b) CLOSE the outlet valve.
c) OPEN all inlet valves.
Ensure the pump is given the same
d) Prime the pump.
rotation as the pump direction arrow cast on the
pump casing. Rotation is clockwise when the pump is e) Ensure all vent connections are closed
viewed from the driver. before starting.
f) Start motor and check outlet pressure.
To avoid dry running the pump must either be filled g) If the pressure is satisfactory, SLOWLY open
with liquid or have the flexible coupling disconnected outlet control valve.
before driver is switched on.
h) Do not run the pump with the
If maintenance work has been carried outlet valve closed for a period longer than 10
out to the site's electricity supply, the direction of seconds.
rotation should be re-checked as above in case the i) If NO pressure, or LOW pressure, STOP the
supply phasing has been altered. pump. Refer to section 7, Faults; causes and
5.4 Guarding remedies, for fault diagnosis.
5.7 Running the pump
Guarding is supplied fitted to the pump set. If
this has been removed or disturbed ensure that all the 5.7.1 Venting the pump
protective guards around the pump coupling and
exposed parts of the shaft are securely fixed. Vent the pump to enable all trapped air to
escape taking due care with hot or hazardous liquids.
5.5 Priming and auxiliary supplies
Under normal operating conditions, after the pump
Ensure all electrical, hydraulic, has been fully primed and vented, it should be
pneumatic, sealant and lubrication systems (as unnecessary to re-vent the pump.
applicable) are connected and operational. 5.7.2 Pumps fitted with packed gland
If the pump has a packed gland there must be some
Ensure the inlet pipe and pump leakage from the gland. Gland nuts should initially
casing are completely full of liquid before starting be finger-tight only. Leakage should take place soon
continuous duty operation. after the stuffing box is pressurised.
The gland must be adjusted evenly to give

visible leakage and concentric alignment of the gland
ring [4120) to avoid excess temperature. If no
®
leakage takes place the packing will begin to It is important, particularly with grease lubrication, to
overheat. If overheating takes place the pump keep a check on bearing temperatures. After start up
should be stopped and allowed to cool before being the temperature rise should be gradual, reaching a
re-started. Loosen the gland when the pump is re- maximum after approximately 1.5 to 2 hours. This
started; check to ensure leakage is taking place at temperature rise should then remain constant or
the packed gland. marginally reduce with time. Refer to section 6.2.3.1
for further information.
If hot liquids are being pumped it may be necessary
5.7.5 Normal vibration levels, alarm and trip
to slacken the gland nuts to achieve leakage.
For guidance, pumps generally fall under a
The pump should be run for 30 minutes with steady classification for rigid support machines within the
leakage and the gland nuts tightened by 10 degrees International rotating machinery standards and the
at a time until leakage is reduced to an acceptable recommended maximum levels below are based on
level, normally a minimum of 120 drops per minute is those standards.
required. Bedding in of the packing may take
another 30 minutes. Alarm and trip values for installed
pumps should be based on the actual measurements
Care must be taken when adjusting the gland (N) taken on the pump in the fully commissioned as
on an operating pump. Safety gloves are essential. new condition. Measuring vibration at regular
Loose clothing must not be worn to avoid being intervals will then show any deterioration in pump or
caught up by the pump shaft. Shaft guards must be system operating conditions.
replaced after the gland adjustment is complete.
Vibration velocity – unfiltered MARK 3
mm/s (in./s) r.m.s.
Never run gland packing dry, even for
a short time. Normal N ≤ 5.6 (0.22)
Alarm N x 1.25 ≤ 7.1 (0.28)
5.7.3 Pumps fitted with mechanical seal Shutdown trip N x 2.0 ≤ 11.2 (0.44)
Mechanical seals require no adjustment. Any slight
initial leakage will stop when the seal is run in. 5.7.6 Stop/start frequency
Pump sets are normally suitable for the number of
Before pumping dirty liquids it is advisable, if equally spaced stop/starts per hour shown in the
possible, to run in the pump mechanical seal using table below. Check actual capability of the driver and
clean liquid to safeguard the seal face. control/starting system before commissioning.
Maximum stop/starts
Motor rating kW (hp)
External flush or quench should be per hour
started before the pump is run and allowed to flow for Up to 15 (20) 15
a period after the pump has stopped. Between 15 (20) and 90 (120) 10
Above 90 (120) 6
Never run a mechanical seal dry,
even for a short time. Where duty and standby pumps are installed it is
5.7.4 Bearings recommended that they are run alternately every
week.
If the pumps are working in a potentially 5.8 Stopping and shutdown
explosive atmosphere temperature or vibration
monitoring at the bearings is recommended.
a) Close the outlet valve, but ensure
that the pump runs in this condition for no more
If bearing temperatures are to be monitored it is
than a few seconds.
essential that a benchmark temperature is recorded
b) Stop the pump.
at the commissioning stage and after the bearing
c) Switch off flushing and/or cooling/heating liquid
temperature has stabilized. Record the bearing
supplies at a time appropriate to the process.
temperature (t) and the ambient temperature (ta).
Estimate the likely maximum ambient temperature d) For prolonged shut-downs and
(tb). Set the alarm at (t+tb-ta+5)°C [(t+tb-ta+10)°F] especially when ambient temperatures are likely
and the trip at 100 °C (212 °F) for oil lubrication and to drop below freezing point, the pump and any
105 °C (220 °F) for grease lubrication. cooling and flushing arrangements must be
drained or otherwise protected.
®
5.9 Hydraulic, mechanical and electrical requirements particularly if flow has changed. If in
duty doubt please consult your nearest Flowserve office
for advice and details of the minimum allowable
This product has been supplied to meet the margin for your application.
performance specifications of your purchase order,
however it is understood that during the life of the 5.9.5 Pumped flow
product these may change. The following notes may Flow must not fall outside the minimum and
help the user decide how to evaluate the implications maximum continuous safe flow shown on the pump
of any change. If in doubt contact your nearest performance curve and/or data sheet.
Flowserve office.
6 MAINTENANCE
5.9.1 Specific gravity (SG)
Pump capacity and total head in metres (feet) do not 6.1 General
change with SG, however pressure displayed on a
pressure gauge is directly proportional to SG. Power It is the plant operator's responsibility to ensure
absorbed is also directly proportional to SG. It is that all maintenance, inspection and assembly work
therefore important to check that any change in SG is carried out by authorized and qualified personnel
will not overload the pump driver or over-pressurize who have adequately familiarized themselves with
the pump. the subject matter by studying this manual in detail.
(See also section 1.6.2.)
5.9.2 Viscosity
For a given flow rate the total head reduces with Any work on the machine must be performed when it
increased viscosity and increases with reduced is at a standstill. It is imperative that the procedure
viscosity. Also for a given flow rate the power for shutting down the machine is followed, as
absorbed increases with increased viscosity, and described in section 5.8.
reduces with reduced viscosity. It is important that
checks are made with your nearest Flowserve office On completion of work all guards and safety devices
if changes in viscosity are planned. must be re-installed and made operative again.
5.9.3 Pump speed Before restarting the machine, the relevant
instructions listed in section 5, Commissioning, start
Changing pump speed effects flow, total head, power
up, operation and shut down must be observed.
absorbed, NPSHR, noise and vibration. Flow varies
in direct proportion to pump speed, head varies as
Oil and grease leaks may make the ground
speed ratio squared and power varies as speed ratio
slippery. Machine maintenance must always
cubed. The new duty, however, will also be
begin and finish by cleaning the ground and the
dependent on the system curve. If increasing the
exterior of the machine.
speed, it is important therefore to ensure the
maximum pump working pressure is not exceeded,
the driver is not overloaded, NPSHA > NPSHR, and If platforms, stairs and guard rails are required for
maintenance, they must be placed for easy access to
that noise and vibration are within local requirements
areas where maintenance and inspection are to be
and regulations.
carried out. The positioning of these accessories
5.9.4 Net positive suction head (NPSHA) must not limit access or hinder the lifting of the part to
NPSH available (NPSHA) is a measure of the head be serviced.
available in the pumped liquid, above its vapour
pressure, at the pump suction branch. When air or compressed inert gas is used in the
maintenance process, the operator and anyone in the
NPSH required (NPSHR) is a measure of the head vicinity must be careful and have the appropriate
required in the pumped liquid, above its vapour protection.
pressure, to prevent the pump from cavitating. It is
important that NPSHA > NPSHR. The margin Do not spray air or compressed inert gas on skin.
between NPSHA > NPSHR should be as large as
possible. Do not direct an air or gas jet towards other people.
If any change in NPSHA is proposed, ensure these Never use air or compressed inert gas to clean
margins are not significantly eroded. Refer to the clothes.
pump performance curve to determine exact
®
Before working on the pump, take measures to

6.2.1 Routine inspection (daily/weekly)
prevent an uncontrolled start. Put a warning board
on the starting device with the words:
"Machine under repair: do not start". The following checks should be made
and the appropriate action taken to remedy any
With electric drive equipment, lock the main switch deviations:
open and withdraw any fuses. Put a warning board a) Check operating behaviour. Ensure noise,
on the fuse box or main switch with the words: vibration and bearing temperatures are normal.
"Machine under repair: do not connect". b) Check that there are no abnormal fluid or
lubricant leaks (static and dynamic seals) and
Never clean equipment with inflammable solvents or that any sealant systems (if fitted) are full and
carbon tetrachloride. Protect yourself against toxic operating normally.
fumes when using cleaning agents. c) Check that shaft seal leaks are within acceptable
limits.
6.2 Maintenance schedule d) Check the level and condition of oil lubricant. On
grease lubricated pumps, check running hours
It is recommended that a maintenance plan since last recharge of grease or complete grease
and schedule is adopted, in line with these User change.
Instructions, to include the following: e) Check any auxiliary supplies eg heating/cooling
a) Any auxiliary systems installed must be (if fitted) are functioning correctly.
monitored, if necessary, to ensure they function Refer to the manuals of any associated
correctly. equipment for routine checks needed.
b) Gland packings must be adjusted correctly to 6.2.2 Periodic inspection (six monthly)
give visible leakage and concentric alignment of
the gland follower to prevent excessive a) Check foundation bolts for
temperature of the packing or follower. security of attachment and corrosion.
c) Check for any leaks from gaskets and seals. b) Check pump running records for hourly usage to
The correct functioning of the shaft seal must be determine if bearing lubricant requires changing.
checked regularly. c) The coupling should be checked for correct
d) Check bearing lubricant level, and if the hours alignment and worn driving elements.
run show a lubricant change is required. Refer to the manuals of any associated
e) Check that the duty condition is in the safe equipment for periodic checks needed.
operating range for the pump.
f) Check vibration, noise level and surface 6.2.3 Re-lubrication
temperature at the bearings to confirm Lubricant and bearing temperature analysis can be
satisfactory operation. useful in optimizing lubricant change intervals. In
g) Check dirt and dust is removed from areas general however, the following is recommended.
around close clearances, bearing housings and
motors.
6.2.3.1 Oil lubrication
h) Check coupling alignment and re-align if
necessary.
Our specialist service personnel can help with Maintaining the correct oil level is very
preventative maintenance records and provide important.
condition monitoring for temperature and vibration to
identify the onset of potential problems. If the pump is supplied with a constant level oiler the
oil level will be automatically maintained and as long
If any problems are found the following sequence of as oil is visible in the glass bottle there is no need to
actions should take place: refill. If however a sight glass has been fitted then
a) Refer to section 7, Faults; causes and remedies, regular checks should be made to ensure the level is
for fault diagnosis. maintained at the centre of the glass window.
b) Ensure equipment complies with the
recommendations in this manual. Refer to section 5.1.1 for methods of oil fill, section
c) Contact Flowserve if the problem persists. 5.2.1 for oil grade recommendations and 5.2.3 for the
schedule and temperature limits.
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6.2.4 Mechanical seals

No adjustment is possible. When leakage reaches
6.4 Recommended spares and
an unacceptable level the seal will need replacement. consumable items
For start-up purposes:
1 - complete set of gland packing
6.2.5 Gland packing
2 - shaft sleeves
The stuffing box split gland can be completely 1 - set of gaskets and seals
removed for re-packing or to enable the addition of (optional: 2 - mechanical seals)
extra rings of packing.
For 2 years operation:
The stuffing box is normally supplied with a lantern 1 - set of bearings (line and thrust)
ring to enable a clean or pressurised flush to the 2 - sets of gland packing
centre of the packing. If not required, this can be 2 - shaft sleeves
replaced by an extra 2 rings of packing. 2 - sets of gaskets and seals
There must always be a small leakage; normally a 2 - lantern rings
minimum of 120 drops per minute to atmosphere to 2 - casing wear rings
lubricate and cool the packing is required. (optional: 2 - mechanical seals
2 - impeller wear rings)
Gland packing must not be used when pumping
hazardous liquids. For 4 years operation:
1 - set of bearings (line and thrust)
6.3 Spare parts 2 - sets of gland packing
2 - shaft sleeves
6.3.1 Ordering of spares 2 - sets of gaskets and seals
Flowserve keep records of all pumps that have been 2 - lantern rings
supplied. When ordering spares the following 2 - casing wear rings
information should be quoted: 1 – impeller (optional: 2 - mechanical seals)
1) Pump serial number
2) Pump size 6.5 Tools required
3) Part name – taken from section 8 A typical range of tools that will be required to
4) Part number – taken from section 8 maintain these pumps is listed below.
5) Number of parts required
Readily available in standard tool kits, and dependent
The pump size and serial number are shown on the on pump size:
pump nameplate.
All pumps are built with inch fasteners:
To ensure continued satisfactory operation,
replacement parts to the original design specification • Open ended spanners (wrenches) to suit up to
should be obtained from Flowserve. 1-7/8” screws/nuts
Any change to the original design specification • Socket spanners (wrenches), up to 1-7/8” screws
(modification or use of a non-standard part) will • Allen keys, up to 3/8” (A/F)
invalidate the pump’s safety certification. • Range of screwdrivers
6.3.2 Storage of spares • Soft mallet
Spares should be stored in a clean dry area away More specialized equipment:
from vibration. Inspection and re-treatment of
• Bearing pullers
metallic surfaces (if necessary) with preservative is
• Bearing induction heater
recommended at 6 monthly intervals.
• Dial test indicator
• C-spanner (wrench) - for removing shaft nut.
(If difficulties in sourcing are encountered,
consult Flowserve.)
®
6.6 Fastener torques To disassemble the pump consult the sectional

drawings, see section 8, Parts list and drawings.
Non-metallic gaskets incur creep
relaxation – retighten to the tightening torques
provided. 6.8.1 Rotor unit
The following procedure is recommended for
All torques specified subject to a tolerance of +/- 10% removing and disassembling the back pull-out
Torque Nm (lbft) element (rotating assembly).
Bolt size
Pump feet All other fasteners
fasteners Note that the replacement gaskets and
M 16 (⅝ in.) 170 (125) 84 (62) similar consumable materials should be available
M 20 (¾ in.) 340 (250) 165 (120) since they will be required for reassembly.
M 24 (⅞ in.) 590 (435) 285 (210)
M 27 (1 in.) 770 (570) 375 (275) a) Isolate motor and lock off electrical supply in
M 30 (1⅛ in.) 1 100 (810) 540 (400) accordance with local regulations.
M 36 (1⅜ in.) 1 840 (1 350) 900 (660)
b) Isolate suction and discharge valves.
M 42 (1⅝ in.) 2 000 (1 475) 1 410 (1 040)
M 48 (1⅞ in.) 2 240 (1 650) 2 060 (1 500)
c) Remove coupling guards and disconnect the
coupling halves.
IMPELLER NUT d) Drain pump casing. Remove any auxiliary piping
TIGHTENING TORQUE if applicable.
Nm lbf.ft. e) Disconnect stuffing box, cooling water and
FRAME 4K auxiliary piping.
400 300
f) Drain the oil from the bearing frame [3130] if
bearing frame is being dismantled.
TIGHTENING TORQUE FOR STAINLESS STEEL g) Place the sling around the bearing frame [3130]
STUDS and carefully take up the weight without straining
WITH LUBRICATED THREADS the casing. Refer to Section 3 to determine hoist
and sling requirements.
THREAD SIZE TIGHTENING TORQUE h) Release the thrust bearing housing [3240] hold
Nm ft. lb.
down bolts and jam nuts. While rotating the
pump shaft [6] by hand, tighten the three jacking
M10x1.5 (3/8–16UNC) 13 10 screws evenly until the impeller [2200] lightly
M12x1.75 (1/2–13UNC) 27 20 clamps the stuffing box head [4110] in place.
M16X2 (5/8-11UNC) 60 45 This will simplify withdrawal of the rotating
M20x2.5 (¾-10UNC) 100 75 element from the casing.
Excessive clamping force could

6.7 Renewal clearances damage bearing races.
Rotating the shaft helps to clear away solids
As wear takes place between the impeller and casing which may be trapped between the impeller and
the overall efficiency of the pump set will decrease. stuffing box head.
To maintain optimum efficiency it is recommended i) Remove the bolts connecting the rear support
that the impeller be adjusted to maintain the impeller foot [3134] to the baseplate.
axial clearance as detailed in section 6.11 to j) Remove the frame to casing bolts
clearance as detailed in table 3.5. Typically doubling k) Withdraw the rotating element from the casing.
the clearance can reduce performance by 5%
depending on pump size and operating condition.
6.8.2 Stuffing box
6.8 Disassembly
6.8.2.1 Shaft seal - mechanical seal
Refer to section 1.6, Safety, before dismantling Refer to any special instructions supplied with the
the pump. mechanical seal.
a) Remove seal cover screws and pull off seal cover
Before dismantling the pump for complete with the stationary seal ring which is
overhaul, ensure genuine Flowserve replacement held in place by the O-ring seal.
parts are available.
®
b) The mechanical seal cover can also be removed 6.9 Examination of parts
by placing a wedge into the gland chamfer, as
below: Used parts must be inspected before
assembly to ensure the pump will subsequently run
6.8.2.2 Impeller and stuffing box properly.
a) While preventing the shaft from rotating, remove
the impeller nut [2912] that has a right hand In particular, fault diagnosis is essential to enhance
thread. pump and plant reliability.
b) Remove the impeller [2200] and impeller key 6.9.1 Casing, seal housing and impeller
[6700]. Normally, a slight tightening of the thrust a) Inspect for excessive wear, pitting, corrosion,
gearing jacking screws will free the impeller and erosion or damage and any sealing surface
allow it to be removed. Except on the smaller irregularities.
sizes, there is a facility on the impeller hub to b) Replace as necessary.
assist removal in difficult cases. c) Inspect the impeller [2200] for excessive wear or
6.8.3 Shaft sleeve damage. Inspect the casing [1112] and stuffing
a) Remove the shaft sleeve gasket [4590.3]. box head [4110] for damage or excessive
b) Remove the shaft sleeve [2445] if scored or thinning of wall sections due to wear or
worn. corrosion. Clean the internal surfaces to
maintain pump efficiency.
6.8.4 Bearing housing d) Clean the internal bore of the stuffing box.
a) Remove the line bearing seal.
6.9.2 Shaft and sleeve [if fitted)
b) Remove the pump half coupling and coupling key
[6710]. a) Replace sleeve if grooved, pitted or worn.
c) Remove the bearing frame support [3134]. b) Clean the shaft and inspect for evidence of
d) Lift the bearing frame assembly into a vertical corrosion, evidence of cracking, fatigue or
position with the thrust bearing housing [3240] mechanical damage. Remove all burrs or nicks
up. Rest the bearing frame flange on heavy paying particular attention to the areas under the
wooden blocks sufficiently high to ensure end of lip seals. Check that the shaft is straight within
the shaft does not come into contact with the 0.002 inch (0.050 mm).
floor or table. 6.9.3 Gaskets and O-rings
e) Remove the thrust bearing hold down bolts and After dismantling, discard and replace.
remove shaft assembly for the bearing frame
[3130]. 6.9.4 Bearings
a) It is recommended that bearings are not re-used
6.8.5 Line bearing
after any removal from the shaft.
a) Lay the shaft [2110] horizontal and support with b) The plain liquid lubricated bearings may be re-
wooden ‘V’ Blocks. used if both the bearing bush and bearing sleeve
b) Only if necessary remove the line bearing [3011] show no sign of wear, grooving or corrosion
from the shaft. Bearings removed and reused attack. (It is recommended that both the bush
can easily be damaged and undetected until and sleeve are replaced at the same time.)
pump is put back in operation.
6.9.5 Bearing isolators, labyrinths or lip seals
6.8.6 Thrust bearings (if fitted)
a) Lay the shaft [2110] horizontal and support with a) The lubricant, bearings and bearing housing
wooden ‘V’ Blocks. seals are to be inspected for contamination and
b) Remove the thrust bearing clamp ring [2542] damage. If oil bath lubrication is utilised, these
from the thrust bearing housing [3240]. provide useful information on operating
c) Bend up the locking tab on the bearing conditions within the bearing housing.
lockwasher [6542] and remove the bearing b) If bearing damage is not due to normal wear and
locknut [3712] and lockwasher [6542]. the lubricant contains adverse contaminants, the
d) Only if necessary remove the thrust bearings cause should be corrected before the pump is
[3031] from the shaft. Bearings removed and returned to service.
reused can easily be damaged and undetected c) Labyrinth seals and bearing isolators should be
until pump is put back in operation inspected for damage but are normally non-
wearing parts and can be re-used.
®
d) Bearing seals are not totally leak free devices. See section 4.8 for recommended final shaft
Oil from these may cause staining adjacent to alignment limits.
the bearings.
Vibration analysis
6.9.6 Installed pump
Vibration analysis is a type of condition monitoring
Complete pump installed. where a pump’s vibration “signature” is monitored on
a regular, periodic basis. The primary goal of
Shaft movement caused by pipe strain vibration analysis is extension on MTBPM. By using
Pipe strain is any force put on the pump casing by this tool Flowserve can often determine not only the
the piping. Pipe strain should be measured as shown existence of a problem before it becomes serious,
below. Install the indicators as shown before but also the root cause and possible solution.
attaching the piping to the pump. The suction and
discharge flanges should now be bolted to the piping Modern vibration analysis equipment not only detects
separately while continuously observing the if a vibration problem exists, but can also suggest the
indicators. Indicator movement should not exceed cause of the problem. On a centrifugal pump, these
0.05 mm (0.002 in.). causes can include the following: unbalance,
misalignment, defective bearings, resonance,
Pipe strain movement hydraulic forces, cavitation and recirculation. Once
identified, the problem can be corrected, leading to
increased MTBPM for the pump.
Flowserve does not make vibration analysis

equipment, however Flowserve strongly urges
customers to work with an equipment supplier or
consultant to establish an on-going vibration analysis
program. See 5.7.5 regarding acceptance criteria.
6.10 Assembly
Alignment
To assemble the pump consult the sectional
Misalignment of the pump and motor shafts can
drawings, see section 8, Parts list and drawings.
cause the following problems:
Ensure threads, gasket and O-ring mating faces are
• Failure of the mechanical seal
clean. Apply thread sealant to non-face sealing pipe
• Failure of the motor and/or pump bearings thread fittings.
• Failure of the coupling
• Excessive vibration/noise
The schematics below show the technique for a 6.10.1 Bearing housing
typical rim and face alignment using a dial indicator. a) Lubricate the internal bores of the bearing frame
It is important that this alignment be done after the [3130] with the same oil or grease used to
flanges are loaded, and at typical operating lubricate the bearings.
temperatures. b) Install the thrust bearing housing [3240] in the
bearing frame [3130] to ensure a good sliding fit.
Remove the thrust bearing housing from the
frame.
c) Install the oil sight gauge [3856] and the drain lug
in the bearing frame [3130] using Teflon pipe
thread sealant. Install the vent plug [6521].
6.10.2 Line bearing

Many companies today are using laser alignment a) Pack the line bearing with grease if the bearings
which is a more sophisticated and accurate are being grease lubricated.
technique. With this method a laser and sensor b) Lightly lubricate the shaft [2110] at the line
measure misalignment. This is fed to a computer with bearing position. Install the line bearing [3011]
a graphic display that shows the required adjustment on the shaft. Use an induction heated or hot oil
for each of the motor feet. bath to first heat the bearing [250° F
®
recommended], press the bearing on shaft with Loctite 242 or equivalent.

the aid of a sleeve designed to push the inner
race only. Note that the bearing must remain The thrust bearing clamp ring [2542] is
square to the shaft during assembly and that the provided with one extra hole midway between two
inner race must seat on the shaft shoulder. adjacent bolt holes to permit free oil flow. On oil
Protect the bearing by wrapping with a clean, lint lubricated units, this hole must align with the cast oil
free cloth. return at the bottom of the thrust bearing housing
bore. For grease lubricated units, this hole should be
6.10.3 Thrust bearing oriented away from the cast oil return slot at the
a) Pack thrust bearing with grease if the bearings bottom the thrust bearing housing bore.
are being grease lubricated.
b) Place the thrust bearing clamp ring [2542] Tighten the capscrews evenly ensuring that the
loosely over the shaft on the largest diameter. clamp ring is not distorted and gap to the bearing
c) Install the angular contact bearings [3031] on the housing is even all around. Tighten in accordance
shaft [2110] using the same procedure as with section 6.6.
described in step 6.10.2. The bearings are
mounted back to back as shown. 6.10.4 Frame assembly
a) Place the bearing frame in a vertical position with
the large flange resting on wooden support
blocks sufficiently high to allow the shaft from
contacting the floor when it is installed.
b) Lift the shaft assembly into a vertical position and
lower it into the bearing frame [3130].
c) Screw the thrust bearing housing into bearing
frame housing at least 7 revolutions to prevent
the assembly from coming apart when lifting.
d) Place the bearing frame assembly into a
horizontal position.
e) Install the setscrews [6577].
f) Carefully install the INPRO seal [4300.2] in the
Bearing arrangement line bearing frame [3130] by pressing it squarely
into the bore. A small amount of sealant may be
d) Slide the bearing lockwashers [6541] on the shaft applied on the O-ring of the seal prior to its'
and fit the bearing locknut [3712]. Tighten the installation.
locknut snugly and allow to cool. Check the g) Install the coupling key [6700] and tape to the
tightness and bend one tab on the lockwasher shaft.
into a slot in the locknut. Protect the bearings h) Mount a dial indicator to the bearing frame [3130]
from contamination. and indicate shaft under bearing frame flange
e) Carefully install the IN seal [4300.2] in the thrust (approx. mid way between impeller mounting face
and end of sleeve area. Rotate shaft and check that
bearing housing [3240] by pressing it squarely
run-out does not exceed 0.050 mm (0.002 in.).
into the bore. The primary sealing lip [spring
loaded] on seal should be installed facing the 6.10.5 Stuffing box
bearing. A small amount of sealant may be
6.10.5.1 All
applied on the O.D. of the seal prior to its'
installation. a) Install the gland studs [6572] using Loctite grade
f) Lubricate the O-rings [4610.3] with the bearing A or equivalent. The gland studs [6572] on water
lubricant and assemble it into the groove of the cooled stuffing boxes must be sealed with pipe
outer circumference of the thrust bearing housing sealant. If only two gland studs are used, the
[3240]. remaining two tapped holes must be plugged
g) Lubricate the inside bore of the thrust bearing with set screws or short capscrews. To ensure
housing [3240] and assemble it over the thrust proper sealing, the chamber can be tested to a
bearings. Care must be taken to prevent design pressure of 75psi.
damage of the seal on the shaft. b) Press the stuffing box neck bush [4132] into the
h) Using capscrews and lockwashers, attach the stuffing box [4110], ensuring that it seats squarely
on the shoulder.
thrust bearing clamp ring [2542] to the thrust
c) Lubricate the shaft [2110] at the impeller position,
bearing housing [3240]. Lock the threads using
®
check the fit of the impeller key [6710] in the as to balance the weight, lift the frame/impeller
shaft keyway and install the impeller [2200] onto assembly keeping the shaft horizontal.
the shaft to ensure that there is a good sliding fit. b) Install the frame/impeller assembly into the
Remove the impeller [2200] and the impeller key casing [1112] by guiding the stuffing box head
[6710]. and bearing frame spigots squarely into the
d) Install the O-ring [4610.2] into the impeller nut casing recess. Ensure that the gasket [4590.3]
[2912] using grease or anti-seize compound to stays in position. If the fit becomes snug, use 4
hold it in place during assembly. equally spaced bolts to draw the assembly into
e) Install the shaft sleeve [2445] onto the shaft the casing.
[2110] and orientate the sleeve such that the c) Install the casing frame bolts with washers and
keyways are aligned. Install the impeller key tighten in accordance with section 6.6.
[6710] in the shaft. d) Using the thrust bearing housing adjustment
feature [Figure 1], move the impeller forward
6.10.5.2 Standard Packing
away from the stuffing box head [4110].
a) Assemble the stuffing box head [4110] over the e) Attach the bearing frame support [3134] to the
shaft sleeve [2445] and orientate the lantern ring bearing frame [3130] using the capscrews and
connections to auxiliary piping (Refer to Figure 6).
washers. Ensure that thread engagement is at
These connections are normally placed on the
least 1 diameter. Use Loctite 242 thread sealant.
vertical centerline for proper venting and draining as
well as providing optimum gland stud access.
f) Set the impeller front clearance in accordance
b) Push the stuffing box head [4110] back against the with instruction earlier in this section of the
bearing frame flange face. Back off the thrust manual.
bearing housing to line up with the stuffing box with 6.10.9 Shaft seal
shaft sleeve. The shaft sleeve should be lined up
with the stuffing box or fairly proud off the stuffing 6.10.9.1 Gland packing
box by 0.060” [1.50mm].
c) Install the shaft gasket [4590.3] onto the shaft,
ensuring that the outside diameter is no larger than
the sleeve.
6.10.6 Impeller Installation
a) Install impeller [2200].
b) Apply a small quantity of Loctite 242 or
equivalent to the exposed thread on the end of
the shaft, and thread the impeller nut [2912]
complete with O-ring [4610.2] onto the shaft.
For units with mechanical seals, do not

apply thread locking compound until seal axial
setting has been established.
c) Tighten the impeller nut [2912] in accordance
with the specific Impeller torque specified, see Standard Packed Box Arrangement
section 6.6. This is an essential step to properly a) Insert one packing ring at a time into the stuffing
seat the sleeve [2445] and compress the gasket box. Push the packing as far as possible into the
[4590.3] to provide a seal and to prevent packing bore.
loosening of the impeller on the shaft. b) Install additional rings as required, staggering the
d) Release the thrust bearing housing set screws joints.
[6577] and index the bearing housing [3240] to c) Once the first two or three rings of packing have
move the impeller in or out. been inserted, the two piece lantern ring [4134]
must be installed. Push the lantern ring and
6.10.7 All pumps previously installed packing. The ports in the lantern
a) Smear anti-seize compound on the casing [1112] ring do not need to be aligned with the inlet/outlet
and stuffing box head [4110] rabbit fit (spigot) ports.
diameters to ease assembly and future d) Ensure that the shaft can be turned by hand.
disassembly. e) Install the remaining rings of packing, alternating
the joints.
6.10.8 Rotor unit
a) With a sling around the bearing frame placed so It may not be possible to insert the last ring in
®
the box and still insert the gland. In this case, omit position the casing feet over the tapped holes in
the last ring of packing and install the gland. The the baseplate and clamp them.
last ring of packing should be installed after the b) Loosen the bolts that attach the rear support foot
pump has been in service and sufficient space is [3134] to the bearing frame [3130]. The rear
available. support foot is designed with shim allowance
f) Install the gland halves [4120], tighten the gland measured vertically. Level the unit and align with
nuts [6581] only finger tight. the piping. Tighten the bolts attaching the casing
feet to the baseplate in accordance with the
New packing has to be run-in and it is specific torque specified, see section 6.6. Do not
good practice to start the pump with the stuffing box
distort casing or frame.
gland quite loose. Packing that is too tight in the
c) Install the pump coupling or sheave as required.
box will cause undue friction, creating heat which
will glaze the packing and possible score the shaft
d) Refer to Section 4, Installation and Section 5,
sleeves. To be effective, the packing must remain Preparation for Operation.
soft and pliable. If stuffing box friction is so great e) It is recommended that the pump not be packed
that the pump shaft cannot be turned by hand, the until required. Refer to stuffing box packing
box is not properly packed. procedure in this section. Protect the stuffing box
bore and seal area with clean dry rags.
6.10.9.2 Mechanical Seal
Refer to any special instructions supplied with the Gland packing must not be used when pumping
mechanical seal. hazardous liquids.
a) Before the mechanical seal can be installed, the
pump must be assembled with the correct 6.11 Impeller axial clearance adjustment
impeller running clearances (ie: all assembly
steps above). A scribe mark is then placed on This procedure should not be used on units
the circumference of the sleeve to mark the end with mechanical seals if the design is such that a
of the box. This mark is used to locate the seal liquid seal cannot be maintained when the rotor is
position referenced by the mechanical seal moved axially against the wear plate.
drawing provided.
b) After scribing the sleeve, remove the rotating Unless seal is a cartridge design it may not be
element from the casing. Do not adjust the possible to adjust the shaft unless the pump is
bearing housing. dismantled.
c) Remove the impeller nut [2912], impeller [2200],
impeller key [6710] and stuffing box head [4110]. Refer to any special instructions supplied with
Assemble the mechanical seal components, the mechanical seal
including gland plates, gaskets and rotating parts
over the sleeve. Locate the seal relative to the NEVER ATTEMPT TO CHANGE THE
scribed markings on the shaft sleeve [2445] as CLEARANCE WHEN THE PUMP IS RUNNING.
indicated by the seal manufacturers’ instruction.
d) Remove lubricating compound from the impeller If the coupling has limited axial adjustment capability,
nut and shaft threads. Re-assemble components the pump and driver must be uncoupled prior to
in accordance with original assembly procedure adjusting the clearance in order to permit free
with the exception that Loctite 242 is applied to movement.
the impeller nut [2912] threads. Torque the
impeller nut to the specified value, see section A new impeller gasket [4590.3] must be installed
6.6. whenever the impeller has been removed from the
e) Assemble the mechanical seal gland plate and shaft.
gasket and fasten using gland studs [6572]. 6.11.1 Installation and clearance setting for
Secure with nuts [6581] and tighten each by impellers on Mark 3 Group 4 pump
hand. Further tighten the nuts in accordance with
section 6.6. Rotate the shaft to ensure that it
turns freely without rubbing or binding.
The impeller could have sharp edges, which
f) Re-assemble the rotating element into the could cause an injury. It’s very important to wear
casing. Do not adjust the thrust bearing housing. heavy gloves.
6.10.10 Final assembly
a) Lift the assembled pump onto the baseplate, a) Install impeller [2200], see section 6.10.6.
®
b) Set the impeller clearance by loosening the set considered when setting the impeller clearance.
screws [6577] and rotating the thrust bearing Rotate the thrust bearing housing clockwise the
housing [3240] to obtain the clearance. Turn the required amount to get the desired clearance to
thrust bearing housing counter-clockwise until the casing. Lastly, tighten the set screws [6577]
the impeller comes into light rubbing contact with to lock the thrust bearing housing in place.
the casing [1112]. Rotating the shaft at the same
time will accurately determine this zero setting.
Now, rotate the thrust bearing housing clockwise
to get the proper clearance. Rotating the thrust
bearing housing the width of one of the indicator
patterns cast into the thrust bearing housing
moves the impeller axially 0.1 mm (0.004 in).
(Figure 2).
It is recommended that two

people install an impeller. The weight of an impeller
greatly increases the chance of thread damage and
subsequent lock-up concerns.
c) Determine how far to rotate the thrust bearing

housing by dividing the desired impeller
clearance by 0.10 (one indicator pattern).
Tightening the set screws [6577] will cause the
impeller to move 0.005 mm (0.002 in) closer to
the casing because of the internal looseness in
the thrust bearing housing threads. This must be
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7 FAULTS; CAUSES AND REMEDIES

FAULT SYMPTOM
Pump overheats and seizes
⇓ Bearings have short life
⇓ Pump vibrates or is noisy
⇓ Mechanical seal has short life
⇓ Mechanical seal leaks excessivel y
⇓ Pump requires excessive power
⇓ Pump loses prime after starting
⇓ Insufficient pressure developed
⇓ Insufficient capacity delivered
⇓ Pump does not deliver liquid

⇓
POSSIBLE CAUSES POSSIBLE REMEDIES
A. System troubles
Pump not primed.
Check complete filling. Vent and/or prime.
Pump or suction pipe not completely filled with
liquid.
Suction lift too high or level too low.
Check NPSHa>NPSHr, proper submergence,
Insufficient margin between suction pressure and losses at strainers/fittings.
vapour pressure.
Excessive amount of air or gas in liquid. Check and purge pipes and system.
Air or vapour pocket in suction line. Check suction line design for vapour pockets.
Air leaks into suction line. Check suction pipe is airtight.
Air leaks into pump through mechanical seal, Check and replace faulty parts.
sleeve joints, casing joint or pipe plugs. CONSULT FLOWSERVE.
Foot valve too small. Investigate replacing the foot valve.
Foot valve partially clogged. Clean foot valve.
Inlet of suction pipe insufficiently submerged. Check out system design.
Speed too low. CONSULT FLOWSERVE.
Speed too high. CONSULT FLOWSERVE.
Total head of system higher than differential head

of pump. Check system losses.
Total head of system lower than pump design Remedy or CONSULT FLOWSERVE.

head.
Specific gravity of liquid different from design.
Check and CONSULT FLOWSERVE.
Viscosity of liquid differs from that for which
designed.
Operation at very low capacity. Measure value and check minimum permitted.
Remedy or CONSULT FLOWSERVE.
Operation at high capacity. Measure value and check maximum permitted.

Remedy or CONSULT FLOWSERVE.
B. Mechanical troubles
Misalignment due to pipe strain. Check the flange connections and eliminate strains
using elastic couplings or a method permitted.
Improperly designed foundation. Check setting of baseplate: tighten, adjust, grout

base as required.
Shaft bent. Check shaft run-outs are within acceptable values.
®
FAULT SYMPTOM
Pump overheats and seizes
⇓ Bearings have short life
⇓ Pump vibrates or is noisy
⇓ Mechanical seal has short life
⇓ Mechanical seal leaks excessivel y
⇓ Pump requires excessive power
⇓ Pump loses prime after starting
⇓ Insufficient pressure developed
⇓ Insufficient capacity delivered
⇓ Pump does not deliver liquid

⇓
POSSIBLE CAUSES POSSIBLE REMEDIES
CONSULT FLOWSERVE.
Rotating part rubbing on stationary part internally. Check and CONSULT FLOWSERVE, if necessary.
Bearings worn Replace bearings.
Wearing ring surfaces worn. Replace worn wear ring/surfaces.
Impeller damaged or eroded. Replace or CONSULT FLOWSERVE for improved

material selection.
Leakage under sleeve due to joint failure. Replace joint and check for damage.
Shaft sleeve worn or scored or running off centre. Check and renew defective parts.
Mechanical seal improperly installed. Check alignment of faces or damaged parts and
assembly method used.
Incorrect type of mechanical seal for operating CONSULT FLOWSERVE.

conditions.
Shaft running off centre because of worn bearings Check misalignment and correct if necessary. If
or misalignment. alignment satisfactory check bearings for excessive
wear.
Impeller out of balance resulting in vibration.
Abrasive solids in liquid pumped. Check and CONSULT FLOWSERVE.
Internal misalignment of parts preventing seal ring
and seat from mating properly.
Mechanical seal was run dry. Check mechanical seal condition and source of dry
running and repair.
Internal misalignment due to improper repairs Check method of assembly, possible damage or
causing impeller to rub. state of cleanliness during assembly.
Remedy or CONSULT FLOWSERVE, if necessary.
Excessive thrust caused by a mechanical failure Check wear condition of impeller, its clearances and
inside the pump. liquid passages.
Lack of lubrication for bearings. Check hours run since last change of lubricant, the
schedule and its basis.
Improper installation of bearings (damage during Check method of assembly, possible damage or
assembly, incorrect assembly, wrong type of state of cleanliness during assembly and type of
bearing etc). bearing used. Remedy or CONSULT
FLOWSERVE, if necessary.
Damaged bearings due to contamination. Check contamination source and replace damaged
bearings.
C. MOTOR ELECTRICAL PROBLEMS
Wrong direction of rotation. Reverse 2 phases at motor terminal box.
Motor running on 2 phases only. Check supply and fuses.
Motor running too slow. Check motor terminal box connections and voltage.
®
8 PARTS LIST AND DRAWINGS

8.1 Mark 3 Group 4 chemical pump sectional and parts list
®
Euro. Description Euro. Description Euro. Description

1112 Casing 3856 Plug, Level Sight 6515 Plug, Drain
1230 Handhole Cover 4110 Stuffing Box 6521 Breather Plug
2110 Shaft 4120 Gland Halves 6541 Lockwasher
2200 Impeller 4130 Packing 6542 Lockwasher
2445 Shaft Sleeve 4132 Throat Bushing 6572 Stud
2542 Clamp Ring 4134 Seal Cage Halves 6577.1 Cap Screw Hex Head
2905.1 Washer 4200 Mechanical Seal 6577.2 Cap Screw Hex Head
2905.2 Washer 4300.1 Inpro Seal 6577.3 Cap Screw Hex Head
2912 Impeller Nut 4300.2 Inpro Seal 6577.4 Cap Screw Hex Head
3011 Radial Ball Bearing 4590.1 Gasket 6578.1 Plug, Pipe
3031 Thrust Bearing 4590.2 Gasket, Hand-hole 6578.2 Square Head Pipe Plug
3130 Bearing Frame 4590.3 Gasket, Sleeve 6578.3 Square Head Pipe Plug
3134 Support Foot 4610.1 O-Ring 6581 Hex Nut
3240 Thrust Brg.Hsg. 4610.2 O-Ring 6700 Key
3712 Lock Nut 4610.3 O-Ring 6710 Key, Sleeve
®
8.2 Mark 3 Group 4 chemical pump- liquid end exploded view
®
8.3 Mark 3 Group 4 chemical pump frame exploded view
®
8.4 General arrangement drawing 10.3 Additional sources of information

The typical general arrangement drawing and any
specific drawings required by the contract will be sent Reference 1:
to the Purchaser separately unless the contract NPSH for Rotordynamic Pumps: a reference guide,
specifically calls for these to be included into the Europump Guide No. 1, Europump & World Pumps,
User Instructions. If required, copies of other Elsevier Science, United Kingdom, 1999.
drawings sent separately to the Purchaser should be
obtained from the Purchaser and retained with these Reference 2:
th
User Instructions. Pumping Manual, 9 edition, T.C. Dickenson,
Elsevier Advanced Technology, United Kingdom,
1995.
9 CERTIFICATION
Certificates, determined from the contract Reference 3:
nd
requirements will be provided with this manual. Pump Handbook, 2 edition, Igor J. Karassik et al,
Examples are certificates for CE marking and ATEX McGraw-Hill Inc., New York, 1993.
marking. If required, copies of other certificates sent
separately to the Purchaser should be obtained from Reference 4:
Purchaser for retention with the User Instructions. ANSI/HI 1.1-1.5
See section 1.9, Noise level, for details of typical Centrifugal Pumps - Nomenclature, Definitions,
noise certification. Application and Operation.
Reference 5:
10 OTHER RELEVANT ANSI B31.3 - Process Piping.
DOCUMENTATION AND MANUALS
10.1 Supplementary User Instruction

manuals
Supplementary instruction determined from the
contract requirements for inclusion into User
Instructions such as for a driver, instrumentation,
controller, sub-driver, seals, sealant system,
mounting component etc. are included under this
section. If further copies of these are required they
should be obtained from the purchaser for retention
with these User Instructions.
Where any pre-printed set of User Instructions are

used, and satisfactory quality can be maintained only
by avoiding copying these, they are included at the
end of these User Instructions such as within a
standard clear polymer software protection envelope.
10.2 Change notes

If any changes, agreed with Flowserve Pump
Division, are made to the product after its supply, a
record of the details should be maintained with these
User Instructions.
®
Your Flowserve factory contacts:
Flowserve Pump FLOWSERVE REGIONAL

SALES OFFICES:
5310 Taneytown Pike
PO Box 40
Taneytown, Md, USA USA and Canada
21787 Flowserve Corporation
5215 North O’Connor Blvd.,
Telephone +1 (410) 756 2602 Suite 2300
Fax +1 (410) 756 2615 Irving, Texas 75039-5421, USA
Telephone +1 972 443 6500
Flowserve Pump Fax +1 972 443 6800
15 Worthington Dr.
PO Box 40 Europe, Middle East, Africa
Brantford, Ontario, Canada Flowserve FSG – Italy
N3T 5M5 Worthing S.r.l.
Via Rossini 90/92
Telephone +1 (519) 753 7381 20033 Desio (Milan), Italy
Fax +1 (519) 753 0845
Telephone +39 0362 6121
Fax +39 0362 628 882
Latin America and Caribbean

Flowserve Corporation
Local Flowserve factory representatives: 6840 Wynnwood Lane
Houston, Texas 77008, USA
In Europe: Telephone +1 713 803 4434
Fax +1 713 803 4497
Flowserve Pumps Limited
PO Box 17, Newark Asia Pacific
Notts NG24 3EN Flowserve Pte. Ltd
United Kingdom
10 Tuas Loop
Telephone (24 hours): +44 (0)1636 494 600 Singapore 637345
Sales & Admin Fax: +44 (0)1636 705 991 Telephone +65 6771 0600
Repair & Service Fax : +44 (0)1636 494 833 Fax +65 6862 2329
E.mail [email protected]

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USER INSTRUCTIONS

These instructions must be read prior to installing,

6.4 Recommended spares and consumable items

provision of technical documents and safety

HAZARDOUS LIQUIDS 1.6.4 Products used in potentially explosive

DO NOT RUN THE PUMP AT

1.6.4.5 Preventing sparks

To avoid potential explosion hazards during

The pump must only be used to handle liquids for

Avoid entrapment of liquid in the pump and associated

Bursting of liquid containing parts due to freezing must

1.7 Nameplate and warning labels

1.7.2 Safety labels

MECHANICAL SEAL WARNING ROTATION WARNING

GROUT WARNING LIFTING WARNING

LUBRICATION WARNING – QF-440-R01 (2124841)

1.8 Specific machine performance capacity, pipework design and acoustic

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

2 TRANSPORT AND STORAGE

Check any crate, boxes or wrappings for any

Each product has a unique serial number. Check

The pump should be lifted with suitably sized and

A crane must be used for all pump sets or

The pump unit should be lifted as shown. Do not Use

Before lifting the driver alone, refer to the

The pump half coupling and key should be removed

Nominal suction branch size 3.4 Performance and operating limits

3.4.3 MAXIMUM WORKING PRESSURES -bar

-30 to 38 (-20 to100) 10.3 (150) 10.3 (150) 13.8 (200)

65 (150) 10.3 (150) 9.7 (140) 13.8 (200)

95 (200) 10.3 (150) 9.3 (135) 13.4 (195)

120 (250) 10.3 (150) 9.0 (130) 12.6 (185)

150 (300) 12.1 (175)

3.5 Table Of Engineering Data

C.I. mm (in.) 16 (0.63) 21 (0.82) 21 (0.82) 18 (0.69) 19 (0.75) 21 (0.82) 21 (0.82)

CASING TYPE SV DV SV DV-DUAL VOLUTE

NO COOLING 120 °C (250 °F)

STUFFING BOX DATA – CBS

STUFFING BOX BORE mm (in.) 101.6 (4.000) 127.0 (5.000)

DEPTH OF BOX mm (in.) 99.0 (3.90) 122.2 (4.81)

PACKING SIZE (in.) 1 /2 X 1 /2 5/8 X 5/8

3.6 Table of Engineering Data

SHAFT AND BEARING DATA

Dia. at Impeller mm (in.) 50.8 (2.000) 69.9 (2.750)

Dia. Under Sleeve mm (in.) 66.68 (2.625) 82.55 (3.250)

Dia. Between Brgs mm (in.) 114.3 (4.50)

Dia. at Coupling mm (in.) 73.03 (2.875)

Line Bearing 6220

Thrust Bearing 7318 BUA (PAIRED BACK-TO-BACK)

BEARING SPAN mm (in.) 293.4 (11.55)

Nom. Impeller Overhang mm (in.) 312.2 (12.29)

B10 Bearing Life MINIMUM 3 YEARS

Oil Sump Capacity* l (US gal.) 5 (1.3)

3.7 Materials of Construction

Gland Studs And Nuts AISI 316

Impeller Key AISI 316

Packing Synthetic Fibre

Gaskets Synthetic Fibre

Misc. Fastners,Parts Steel

* Nickel-Chrome-Boron Coated, except for units with mechanical seals.