Flowserve HPX Programming manual

INSTRUCTIONS FOR
INSTALLATION,OPERATION
AND MAINTENANCE
___________________________________________
Centrifugal pumps
Type HPX
CE-HPX-R-FLOW.DOC – rev. 0
Pump Division
Worthington S.r.l.

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FOREWORD
FLOWSERVE products are the result of more than a century of progressive study and
development. Advanced design, proper selection of materials, and precision construction reflect
this wide experience. FLOWSERVE products will give trouble-free efficient operation with
minimum maintenance and repair.
This instruction book will familiarize management and operating personnel with pertinent details
and proper procedures for the installation, operation and maintenance of one of these products.
Designate below your identification of the equipment for which this book applies.
Unit Size
Identification No.
STUDY THIS INSTRUCTION BOOK
The descriptions and instructions included in this book cover the standard design of the equipment
and any common deviations when possible. This book does not cover all design details and
variations nor does it provide for every possible contingency which may be encountered. When
information can not be found in this book, contact the nearest FLOWSERVE Service Centre.
WARNING
Do not operate this equipment in excess of its rated capacity, speed, pressure and
temperature, nor otherwise than in accordance with the instructions contained in this
Manual.
This equipment has been shop tested and found satisfactory for the conditions for which it
was sold, but its operation in excess of these conditions will subject it to stresses and
strains which it was not designed to withstand.
Failure to heed this warning may result in an accident causing personal injury.

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TABLE OF CONTENTS
I INTRODUCTION 5
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18
1.19
1.20
1.21
1.22
1.23
1.24
1.25
1.26
1.27
1.28
Safety
Installation, Operation and Maintenance Safety Procedures
Installation Safety Procedures
Operation Safety Procedures
Maintenance Safety Procedures
Construction
Parts description
Casing
Impeller
Casing cover
Shaft
Bearing housing
Bearings
Inducer
Coupling/Coupling guards
Baseplate
Check upon arrival
Care during storage
Long term storage
Inspection upon arrival
Storage
Inspection and maintenance
Painting and preservation
Associated equipment
Lifting equipment
To lift unit
To lift driver
To lift complete pump only
II INSTALLATION 15
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
Location
Foundation
Level the baseplate
Method of levelling baseplate using wedges or shims
Grouting
Shaft/Coupling alignment
Types of misalignment
Alignment using the Reverse Alignment method
Alignment using a graph (Reverse Alignment)
Assemble Coupling
Dowel Pump and Driver
Hot Alignment Check
Installation Check List
Piping
- Suction and Discharge Piping
- Bypass Line
Suction Strainer

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III OPERATION 32
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20
3.21
Technical Data
Effects of Specific Gravity
Effect of Viscosity
Changing the Pump Speed
Net Positive Suction Head (NPSH)
Minimum Continuous Stable Flow
Minimum Flow Control
Control Notes
Thermal Control
Pressure and/or Flow Control
Continuous Bypass Control
Operating Precautions
Pre-Operational Checks
Initial Start Up Procedure
Operating Checks
Normal Start Up
Securing the Pump
General Maintenance
Routine Maintenance
Trouble Shooting
Trouble Shooting Chart
IV LUBRICATION 43
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
Preparing Bearing Housing
Inspection
Replenishment
Oil Change
Lubrication Specification
Trico Oiler Setting
Bearing Housing Oil Fill Capacities
Bearing Housing Oil Limitations
V MECHANICAL SEALS 47
5.1
5.2
Description
Servicing Mechanical Seal
VI MAINTENANCE, DISMANTLING 48
6.1
6.2
6.3
Dismantling – General
Pump Disassembly Instructions
Disassembly of Pull Out Element
VII INSPECTION AND RENEWAL OF PARTS 53
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
General
Wear Rings (Impeller)
Case Wear Ring (and Casing Cover Wear Ring when Fitted)
Mechanical Seal
Throat Bush (If Fitted)
Bearing Handling Information
Bearing handling
Bearing Installation
Bearing Removal
Bearing Cleaning
Assembly
Torque Value Supplement

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SECTION I
INTRODUCTION
This manual contains instructions for installation, operation and maintenance for your
FLOWSERVE Centrifugal Pump. The instructions are written for the use of personnel with a
general training in the operation and maintenance of Centrifugal Pumps.
Your pump has been designed to provide safe and reliable service. However, it is both a pressure
vessel and a piece of rotating machinery so that operators must exercise good judgement and
observe correct safety practices to avoid damage to the equipment and surroundings and to
prevent personal injury.
The pump has been designed for the duty specified in the customers order. F.P.D should be
consulted prior to any significant change of duty.
1.1 Safety
It is assumed that your safety department has established a safety programme based upon a
thorough analysis of industrial hazards. Before installing and operating or performing maintenance
on the pump and associated components in this manual, it is suggested that the safety
programme be reviewed to ensure that it covers the hazards arising from high speed rotating
machinery.
It is also important that due consideration be given to those hazards which arise from the presence
of electrical power, hot oil, high pressure and temperature liquids, toxic liquids and gases,
flammable liquid and gases. Correct installation and care of protective guards, shut down devices
and over pressure protection equipment should also be considered an essential part of any safety
programme.
Also essential are special precautionary measures to prevent the possibility of applying power to
the equipment at any time when maintenance work is in progress. The prevention of rotation due
to reverse flow should not be overlooked.
In general, all personnel should be guided by all the basic rules of safety associated with the
equipment and the process.
1.2 Installation, Operation and Maintenance Safety Procedures
In the following safety procedures you will encounter the words WARNING, CAUTION and NOTE.
These are intended to emphasize certain areas in the interest of personal and satisfactory pump
operation and maintenance. The definitions are as follows:
WARNING: An operating procedure, practice, etc, which if not correctly followed, could result in
personal injury, or loss of life.
CAUTION: An operating procedure, practice, etc, which, if not correctly observed, could result
in damage to, or destruction of equipment.
NOTE: An operating procedure, etc, which is essential to highlight.
These safety procedures are to be used in conjunction with the installation, operation and
maintenance instructions contained in the pump manual.

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1.3 Installation Safety Procedures
1. Lifting equipment
Make sure that any equipment used to lift pump or any of its components is capable of supporting
the weights encountered. Make sure that all parts are correctly rigged before attempting to lift.
2. Coupling alignment CAUTION
Coupling alignment must be correct for successful operation. Flexible couplings will not
compensate for any appreciable misalignment, and rapid wear, noise, vibration and actual
damage to the equipment may be caused by misalignment. Therefore, the coupling must be
aligned within the limits given.
3. Driver rotation WARNING
The driver rotation must be checked before making up coupling. Actual damage to the
equipment and personal injury could result from operating the unit with incorrect rotation.
4. Suction and discharge piping
Provisio
n must be made to support suction and discharge piping to the pump to prevent excessive
nozzle loads and maintain pump to driver alignment.
1.4 Operation Safety Procedures
1. Operating conditions WARNING
In the interest of operator safety the unit must not be operated above the nameplate
conditions. such operation could result in unit failure causing injury to operating
personnel. Consult instruction book for correct operation and maintenance of the pump
and its supporting components.
2. Pumps handling heavy viscous liquids CAUTION
When pump is handling heavy viscous liquid, the temperature of the liquid must allow it to
be pumped easily. Liquid may have to be heated prior to pump start-up.

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3. Pump priming CAUTION
Before starting or while operating the pump, the casing and suction line must be
completely filled with the liquid being pumped. The rotating parts depend on this liquid for
lubrication and the pump may seize if operated without liquid.
4. Pump by pass line CAUTION
When operating for some time at reduced capacity, much of the pump horsepower will go
into the liquid in the form of heat. A by pass must be provided under these conditions to
prevent the liquid in the pump from becoming hot enough to vaporize.
5. Operation at reduced capacity CAUTION
Damage to pump may result from prolonged operations at capacities less than 25% of the
best efficiency point
6. Bearing lubrication WARNING
Operation of the unit without correct lubrication can result in overheating of the bearings,
Bearing failures, pump seizures and actual breakup of the equipment, exposing operating
personnel to injury.
7. Operation inspections WARNING
Do not attempt any maintenance, inspection, repair or cleaning in the vicinity of rotating
equipment. Such action could result in injury to operating personnel.
8. Coupling guards WARNING
The unit must not be operated unless coupling guard is in place. Failure to observe this
warning could result in injury to operating personnel.
1.5 Maintenance safety procedures
1. Tagging for inspection or repair WARNING
Before attempting any inspection or repair on the pump the driver controls must be in the
"off" position, locked and tagged to prevent injury to personnel performing service to the
pump.

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2. Isolating the pump WARNING
Before attempting to disassemble the pump, the pump must be isolated from the system,
by closing suction and discharge system valves, drained of liquid and cooled, if pump is
handling hot liquid.
3. Draining pump handling hot liquids WARNING
When pump is handling "hot" liquid extreme care must be taken to ensure safety of
personnel when attempting to drain pump. Hot pumps must be allowed to cool before
draining.
4. Draining pump handling caustic liquid WARNING
When pump is handling "caustic" liquid extreme care must be taken to ensure safety of
personnel when attempting to drain the pump. Protective devices of suitable protective
materials must be worn when draining the pump.
It should be understood that the information contained in this manual does not relieve
operating and maintenance personnel of the responsibility of exercising normal good
judgement in operation and care of the pump and its components.
5. Pumps on vacuum service WARNING
Before attempting any maintenance work on pumps in vacuum service, the pumps must be
isolated from suction and discharge system then carefully vented to return pressure in
pump casing to atmospheric pressure.
6. Oil ring inspection (where applicable) CAUTION
Remove the pipe plug(s) from the top of the bearing housing(s) and check to see that oil
rings are riding free on the pump shaft and are not hung up. Failure to observe this caution
could result in damage to or destruction of equipment.

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1.6 Construction
1.7 Parts description
The type 'HPX' are horizontally mounted, vertically split, back pull out single stage, single suction
overhung process pumps, constructed to the requirements of API 610 specifications, for
continuous duty service in all process industries and industrial application within the pressure and
temperature limitations.
1.8 Casing
The casing is centre line supported with end suction and top discharge. It provides for the
immediate containment of liquid being pumped as the liquid is directed from the suction nozzle
through the impeller and then through the volute to the discharge nozzle. The casing also provides
the centre line attachment to the baseplate or support. A wear ring is mounted in the casing to
provide a close running clearance with the impeller wear ring.
1.9 Impeller
The impeller is a single suction, radial flow, closed design. The impeller is dynamically balanced,
keyed to the shaft and secured by locknut and lockscrew. Renewable wear rings are a press fit
onto the impeller hub and positively secured with radial screws.
1.10 Casing cover
The casing cover is designed to accommodate single, tandem or double elastomer and metal
bellow cartridge seals to the dimensional requirements of API 682. On certain models a wear ring
may be mounted in the cover to provide a close running clearance with the impeller back wear
ring.
1.11 Shaft
A high strength shaft is of stiff shaft design, machined over its entire length to close tolerances.
The shaft transmits the required power without vibration.
1.12 Bearing housing
The bearing housing is air cooled with fan type flingers provided at inboard and outboard ends.
The bearing housing contains the thrust and radial bearings and, for other than pure mist type
lubrication, serves as the oil reservoir for the bearing lubricating oil. For other than pure mist
applications, a constant level oiler is provided for maintaining required oil level. Labyrinth type
flingers help to seal the bearing housing to prevent contamination of the lubricating oil.
A finned type cooling insert is available as an option for the cooling of the lubricating oil. Provision
for purge oil mist is standard whilst pure oil mist lubrication is optional.

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1.13 Bearings
Heavy duty, single row radial bearing and duplex angular contact thrust bearings arranged back to
back ensure long life under the most severe operating conditions. The bearings are a sliding fit in
the bearing housing and a light interference fit on the shaft in accordance with AFBMA
recommendations.
Lubrication of the bearings is provided by oil rings, thrower, purge mist or pure mist as a customer
option.
1.14 Inducer
Inducers are available on most pump models for low NPSH conditions. The inducer replaces the
standard impeller locknut and lockscrew. It is secured by proper cap nut and security washer.
1.15 Coupling/Coupling guards
Flexible spacer couplings are provided in various makes and models to suit customer preference.
(Fabricated heavy gauge sheet metal, or aluminium hinged or non- hinged guards are provided)
1.16 Baseplate
Standard baseplates are welded steel, drain pan type in conformance with API 610 standardized
dimensions, forces and moments. Horizontal driver alignment screws and vertical baseplate
levelling screws are provided as an option.
Special baseplates can be supplied to suit individual installation circumstances.
1.17 Check upon arrival
Your pump was carefully checked at the factory prior to shipment to assure its meeting the
requirements of your order.
It is suggested that the pump be inspected upon arrival and that any irregularities arising due to
shipping be reported immediately to the carrier and FLOWSERVE
1.18 Care During Storage
If the equipment is not to be installed immediately it should be stored in a clean, dry, vibration free
area and covered. Add "disessicant" between the covering and the pump.
Replace nozzle covers. Turn rotor in direction of rotation once a week.
Secure coverings after each check.
Electric Motors (Pump Driver) should not be stored in damp places without special protection
(Refer to Motor manufacturers instructions).