Flowserve IJ Owner's manual

VINTAGE PARTS MARKETING
PRODUCT LINE: IJ - IJDS
HERITAGE COMPANY: Pacific Pumps
CONFIGURATION: Barrel pump - diffuser
TYPICAL APPLICATION: Refinery, Pipeline
VINTAGE: 1958 - 1994
PRODUCT LIFESPAN: API 610, 3rd – 8th
SUBJECT: Installation and Operations
Manual (IOM)
Note: The IJ was specifically geared for the API refinery
market. The BFI was the boilerfeed version of the IJ.
Pacific did not publish price book curves for these
pumps. The IJDS is the double suction version. The IJ
was officially made passive in 1994 as part of the IDP
integration, but is still sold today in some applications,
or as a duplicate. The stiff shaft successor of the IJ is
the WIK, mainly sold in decoker applications.
NOTE: This information is intended for the use of Flowserve Employees.
The information provided is based on standard catalogue / price book
information. Details for specific units or serial numbers may be different as
a result of non-standard construction, and parts, repairs and upgrades
provided by Flowserve or third parties.

IJ PUMP
INSTALLATION
OPERATION &
MAINTENANCE

IJ PUMP OPERATION AND MAINTENANCE MANUAL
iii BO2660-01
READ THIS BEFORE PROCEEDING
It should be understood that the information contained in this manual does not relieve
operating and maintenance personnel from the responsibility of exercising normal good
judgment in the installation, operation, and maintenance of the pump and its components.
Only qualified personnel should work on this equipment, and only after reading this manual
and becoming familiar with all of the safety notices and procedures contained herein. Safe
and successful operation of this equipment is dependent upon its proper handling,
installation, operation, and maintenance as described in this manual.
It should be understood that the contents of this manual do not add to or modify any prior or
existing warranty, agreement, commitment, and/or relationship between Flowserve and the
purchaser. The sales contract between the parties contains the sole warranty for this
equipment.
During initial start-up of the equipment, it is recommended that the services of an Flowserve
service representative be obtained to assure trouble-free operation. In some cases, the
presence of a Flowserve service representative may be a contractual requirement for
continuation of warranty. Check your contract for details.
To schedule a service representative, contact your local Flowserve sales office.
SAFETY NOTICES
Throughout this manual, you will encounter the words WARNING, CAUTION, and NOTE. These
are intended to emphasize certain areas in the interest of operator safety and satisfactory pump
operation/maintenance. The importance of these words is as follows:
WARNING
A procedure, which, if not strictly observed, could result
in personal injury, or loss of life.
CAUTION
A procedure, which, if not correctly followed, could result in
damage to, or destruction of, equipment.
NOTE
An operating procedure, condition, etc., which is essential to
highlight.

IJ PUMP OPERATION AND MAINTENANCE MANUAL
BO2660-01 iv

IJ PUMP OPERATION AND MAINTENANCE MANUAL
v BO2660-01
TABLE OF CONTENTS
PREFACE .............................................................................................................................................xi
OPERATING SPECIFICATIONS......................................................................................................xiii
TORQUE PROCEDURE...................................................................................................................xvii
1. DESCRIPTION .............................................................................................................................1-1
1.1 PHYSICAL DESCRIPTION.....................................................................................................1-1
1.1.1 GENERAL FEATURES....................................................................................................1-1
1.1.1.1 Intermediate Cover-Diffuser .......................................................................................1-1
1.1.1.2 Suction Spacer and Discharge Diffuser-Spacer...........................................................1-1
1.1.1.3 Wearing Rings and Bushings ......................................................................................1-1
1.1.1.4 Impellers......................................................................................................................1-2
1.1.1.5 Bearings.......................................................................................................................1-2
1.1.1.6 Shaft Seals...................................................................................................................1-2
1.1.1.7 Lube Oil System..........................................................................................................1-2
1.1.1.8 Seal Piping...................................................................................................................1-2
1.1.1.9 Baseplates....................................................................................................................1-2
1.1.1.10 Drivers.......................................................................................................................1-2
1.1.2 SPECIAL TOOLS..............................................................................................................1-2
1.1.3 INTERFERENCE FIT .......................................................................................................1-2
1.2 OPERATING PRINCIPLES.....................................................................................................1-3
1.2.1 PUMP FLOW.....................................................................................................................1-3
1.2.2 BALANCE.........................................................................................................................1-3
1.2.2.1 Radial Balance.............................................................................................................1-3
1.2.2.2 Axial Balance ..............................................................................................................1-3
1.2.3 BALANCING DRUM PIPING..........................................................................................1-3
1.2.4 MINIMUM FLOW.............................................................................................................1-4
1.2.5 MINIMUM FLOW ORIFICE............................................................................................1-4
1.2.6 NET POSITIVE SUCTION HEAD...................................................................................1-4
1.2.7 SHAFT SEAL ....................................................................................................................1-4
1.2.8 COOLING WATER SYSTEM..........................................................................................1-4
1.2.9 LUBE OIL SYSTEM.........................................................................................................1-4
1.2.9.1 Auxiliary Oil Pump.....................................................................................................1-4
1.2.9.2 Pressure Switch ...........................................................................................................1-5
1.2.9.3 Pressure Relief Valve..................................................................................................1-5
1.2.10 THERMAL EXPANSION...............................................................................................1-5
2. RECEIVING, STORAGE, AND PREINSTALLATION ..........................................................2-1
2.1 RECEIVING..............................................................................................................................2-1
2.1.1 SHIPMENT INSPECTION................................................................................................2-1
2.1.2 INBOARD AND OUTBOARD BEARING SHIPPING SHIMS ......................................2-1
2.1.3 LIFTING ............................................................................................................................2-1
2.1.3.1 Baseplate-Mounted Pump and Driver .........................................................................2-2
2.1.3.2 Soleplate-Mounted Barrel Pump.................................................................................2-3
2.1.3.3 Multistage Internal Assembly: Barrel Pump...............................................................2-3
2.1.3.4 Multistage Rotor..........................................................................................................2-4
2.1.3.5 Multistage Shaft ..........................................................................................................2-4

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BO2660-01 vi
TABLE OF CONTENTS
(CONTINUED)
2.2 STORAGE................................................................................................................................ 2-5
2.2.1 PUMP PRESERVATIVE STANDARDS......................................................................... 2-6
2.2.1.1 Precautions At Job Site............................................................................................... 2-6
2.2.1.2 Short-Term Indoor Storage......................................................................................... 2-6
2.2.1.3 Short-Term Outdoor Storage ...................................................................................... 2-6
2.2.1.4 Long-Term Indoor Storage......................................................................................... 2-7
2.2.1.5 Long-Term Outdoor Storage....................................................................................... 2-7
2.2.2 ROTOR PRESERVATIVE STANDARDS....................................................................... 2-8
2.2.2.1 Rotor Storage.............................................................................................................. 2-8
2.2.3 DEPRESERVING ............................................................................................................. 2-8
2.3 PREINSTALLATION .............................................................................................................. 2-9
2.3.1 SELECTING A LOCATION ............................................................................................ 2-9
2.3.2 PREPARING THE FOUNDATION ................................................................................. 2-9
3. INSTALLATION AND COUPLING.......................................................................................... 3-1
3.1 RECOMMENDATIONS AND NOTES FOR PIPING CONNECTS...................................... 3-1
3.1.1 CONNECTING TO FLANGED NOZZLES..................................................................... 3-1
3.1.2 WELDING TO NOZZLES................................................................................................ 3-3
3.1.3 AUXILIARY PIPING ....................................................................................................... 3-3
3.2 INSTALLING BASEPLATES AND SOLEPLATES.............................................................. 3-3
3.2.1 TOOLS AND EQUIPMENT............................................................................................. 3-3
3.2.2 ONE BASEPLATE FOR ENTIRE TRAIN OF UNITS.................................................... 3-4
3.2.3 BASEPLATES (OR SOLEPLATES) IN TRAIN. ............................................................ 3-8
3.2.4 BASEPLATE FOR PUMP OR SINGLE UNIT.............................................................. 3-15
3.2.5 LEVELING SOLEPLATES............................................................................................ 3-15
3.3 INSTALLING NOZZLE EXTENSIONS AND GROUTING ............................................... 3-16
3.3.1 GROUTING WITH CEMENT AND SAND .................................................................. 3-16
3.3.2 GROUTING WITH EPOXY........................................................................................... 3-17
3.3.3 INSTALLING NOZZLE EXTENSIONS........................................................................ 3-18
3.4 COUPLING PUMP AND DRIVER....................................................................................... 3-18
3.4.1 TOOLS AND EQUIPMENT........................................................................................... 3-19
3.4.2 ALIGNMENT ACCURACY........................................................................................... 3-19
3.4.3 REASONS FOR FIELD ALIGNMENT OF PUMP AND DRIVER.............................. 3-19
3.4.4 ALIGNMENT PRECONDITIONS................................................................................. 3-20
3.4.5 INSTALLING COUPLING............................................................................................. 3-20
3.4.6 SETTING DRIVER SHAFT ENDSPACE...................................................................... 3-20
3.4.7 TAPPING DRIVER MOUNT PADS.............................................................................. 3-22
3.4.8 COLD ALIGNMENT...................................................................................................... 3-23
3.4.9 HOT ALIGNMENT......................................................................................................... 3-26
3.5 FLUSHING LUBE OIL SYSTEM, CLEANING AND PRESERVING SEAL PIPING....... 3-27
3.5.1 LUBE OIL SYSTEM....................................................................................................... 3-27
3.5.1.1 Flushing Lube Oil System Using Auxiliary Lube Oil Pump.................................... 3-27
3.5.1.2 Flushing Lube Oil System Without Using Auxiliary Lube Oil Pump...................... 3-28

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TABLE OF CONTENTS
(CONTINUED)
3.5.2 SEAL PIPING..................................................................................................................3-29
3.5.2.1 Carbon Steel Piping...................................................................................................3-29
3.5.2.2 Stainless Steel Piping ................................................................................................3-29
4. OPERATION, MAINTENANCE, AND INSPECTION............................................................4-1
4.1 STARTUP .................................................................................................................................4-1
4.1.1 READYING AND SERVICING DRIVER .......................................................................4-1
4.1.2 READYING AND SERVICING PUMP AND AUXILIARY SYSTEMS........................4-1
4.1.2.1 Initial Steps in Preparing Brand-New or Factory-Overhauled Pump and Auxiliary
Systems for Operation.............................................................................................................4-1
4.1.2.2 Initial Steps in Preparing for Operation of Old Pump That Has Been off-line for
Extended Period ......................................................................................................................4-2
4.1.2.3 Following Fabrication and Rework of Piping.............................................................4-2
4.1.2.4 Servicing Empty Lube Oil System..............................................................................4-2
4.1.2.5 Checking and Replenishing Lube Oil Reservoir.........................................................4-3
4.1.2.6 Inspecting Components...............................................................................................4-3
4.1.2.7 Inspecting Pump, Driver, and Piping ..........................................................................4-3
4.1.2.8 Warming Up Pump......................................................................................................4-3
4.1.3 STARTING PUMP ............................................................................................................4-5
4.2 OPERATION ............................................................................................................................4-7
4.2.1 CHECKS AND MINOR ADJUSTMENTS.......................................................................4-7
4.2.2 ADJUSTING PACKING LEAKAGE RATE....................................................................4-9
4.2.3 OPERATING AT REDUCED CAPACITY ......................................................................4-9
4.3 STOPPING..............................................................................................................................4-10
4.3.1 FROM ON-LINE OPERATION TO COLD SHUTDOWN............................................4-10
4.3.2 FROM ON-LINE OPERATION TO HOT STANDBY...................................................4-11
4.4 MAINTENANCE AND INSPECTION TIPS.........................................................................4-12
4.4.1 PERIODIC SEAL REPLACEMENT...............................................................................4-12
4.4.2 BEARING HOUSING GASKET MATERIAL AND THICKNESS ..............................4-12
4.4.3 LUBE OIL CHANGE RECOMMENDATIONS.............................................................4-12
4.4.4 ACID OR CAUSTIC WASH...........................................................................................4-12
5. TROUBLESHOOTING................................................................................................................5-1
5.1 TROUBLES AND THEIR ORIGINS.......................................................................................5-1
5.1.1 FIRST LISTING ................................................................................................................5-1
5.1.2 SECOND LISTING ...........................................................................................................5-3
6. REPLACEMENT AND REPAIR................................................................................................6-1
6.1 GENERAL INSTRUCTIONS...................................................................................................6-1
6.1.1 ITEMS AND DETAILS EXCLUDED FROM INSTRUCTIONS....................................6-1
6.1.2 DISTURBING AN INSTALLATION...............................................................................6-1
6.1.3 GASKETS REQUIRE CONSIDERATION ......................................................................6-1
6.1.4 WHEN TO REPLACE WORN PARTS ............................................................................6-1
6.1.5 PARTS ORDERING INFORMATION.............................................................................6-1
6.1.6 SETSCREWS.....................................................................................................................6-1
6.1.7 WEAR PARTS...................................................................................................................6-1

IJ PUMP OPERATION AND MAINTENANCE MANUAL
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TABLE OF CONTENTS
(CONTINUED)
6.1.8 LIFTING............................................................................................................................ 6-2
6.1.9 INSTALLATION SCHEDULES ...................................................................................... 6-2
6.2 LUBE OIL SYSTEM COMPONENT MAINTENANCE........................................................ 6-4
6.2.1 REPLACEMENT LUBE OIL SYSTEM COMPONENT................................................. 6-4
6.2.2 REPAIRING AND ADJUSTING LUBE OIL SYSTEM COMPONENT........................ 6-4
6.2.3 BASEPLATE MOUNTED RESERVOIR......................................................................... 6-4
6.2.3.1 Removal...................................................................................................................... 6-4
6.2.3.2 Cleaning...................................................................................................................... 6-4
6.2.3.3 Installation .................................................................................................................. 6-4
6.3 TOOLS AND EQUIPMENT.................................................................................................... 6-5
6.3.1 COUPLING....................................................................................................................... 6-5
6.3.2 BEARINGS ....................................................................................................................... 6-5
6.3.3 HEAD ................................................................................................................................ 6-5
6.3.4 INTERNAL ASSEMBLY................................................................................................. 6-5
6.4 PUMP DISASSEMBLY........................................................................................................... 6-7
6.4.1 COUPLING REMOVAL................................................................................................... 6-7
6.4.2 MAIN LUBE OIL PUMP REMOVAL............................................................................. 6-7
6.4.3 BEARING DISASSEMBLY............................................................................................. 6-8
6.4.4 MECHANICAL SEAL...................................................................................................... 6-9
6.4.4.1 Removing Seal Unit.................................................................................................... 6-9
6.4.4.2 Removing Seal Housing ........................................................................................... 6-10
6.4.5 HEAD .............................................................................................................................. 6-10
6.4.5.1 Removing Head Using Carriage............................................................................... 6-10
6.4.5.2 Removing Head Without Using Carriage................................................................. 6-11
6.4.5.3 Disassembly.............................................................................................................. 6-11
6.4.6 INTERNAL ASSEMBLY............................................................................................... 6-12
6.4.6.1 Removing Internal Assembly.................................................................................... 6-12
6.4.6.2 Disassembling Internal Assembly............................................................................. 6-13
6.4.6.2.1 Interference Fit Part Removal............................................................................ 6-13
6.4.6.2.2 Stage Number System And Balanced Parts ....................................................... 6-14
6.4.6.2.3 Vertical Disassembly ......................................................................................... 6-15
6.4.6.2.4 Horizontal Disassembly..................................................................................... 6-16
6.5 PART CLEANING, INSPECTION, AND REPAIR.............................................................. 6-17
6.5.1 CLEANING..................................................................................................................... 6-18
6.5.2 INSPECTION AND REPAIR ......................................................................................... 6-18
6.5.2.1 General...................................................................................................................... 6-18
6.5.2.2 Main Lube Oil Pump ................................................................................................ 6-18
6.5.2.3 Bearings .................................................................................................................... 6-18
6.5.2.4 Mechanical Seal........................................................................................................ 6-18
6.5.2.4.1 Disassembling Seal Unit.................................................................................... 6-18
6.5.2.4.2 Inspection and Repair......................................................................................... 6-19
6.5.2.4.3 Assembling Seal Unit......................................................................................... 6-19
6.5.2.4.4 Replacing Seal Housing Bushing....................................................................... 6-19
6.5.2.5 Head.......................................................................................................................... 6-19

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TABLE OF CONTENTS
(CONTINUED)
6.5.2.6 Internal Assembly......................................................................................................6-19
6.5.2.6.1 Visual Inspection................................................................................................6-19
6.5.2.6.2 Checking Running Clearances............................................................................6-20
6.5.2.6.3 Checking Shaft Straightness...............................................................................6-21
6.5.2.6.4 Checking Fit Of Impellers And Balancing Drum With Shaft ............................6-21
6.5.2.6.5 Checking Concentricity Of Rotating Assembly.................................................6-22
6.5.2.6.6 Renewing Impeller Wearing Surfaces................................................................6-23
6.5.2.6.7 Replacing Stationary Wearing Rings .................................................................6-23
6.5.2.6.8 Replacing Bushings............................................................................................6-24
6.5.2.6.9 Replacing Impeller Wearing Rings ....................................................................6-26
6.6 PUMP ASSEMBLY................................................................................................................6-27
6.6.1 INTERNAL ASSEMBLY................................................................................................6-27
6.6.1.1 Assembling Internal Assembly..................................................................................6-27
6.6.1.1.1 Interference Fit Part Installation.........................................................................6-27
6.6.1.1.2 Vertical Assembly ..............................................................................................6-28
6.6.1.2 Installing Internal Assembly......................................................................................6-30
6.6.2 HEAD...............................................................................................................................6-32
6.6.2.1 Assembling Head.......................................................................................................6-32
6.6.2.2 Installing Head Using Carriage.................................................................................6-32
6.6.2.3 Installing Head Without Using Carriage...................................................................6-33
6.6.3 ROTOR ALIGNMENT....................................................................................................6-33
6.6.3.1 Rotor Radial Alignment ............................................................................................6-33
6.6.3.2 Rotor Axial Alignment..............................................................................................6-34
6.6.4 MECHANICAL SEAL ....................................................................................................6-35
6.6.4.1 Installing Seal Housing .............................................................................................6-35
6.6.4.2 Installing Seal Unit....................................................................................................6-36
6.6.5 BEARING ASSEMBLY..................................................................................................6-36
6.6.6 MAIN LUBE OIL PUMP INSTALLATION ..................................................................6-38
6.6.6.1 Installing Half-Couplings..........................................................................................6-38
6.6.6.2 Installing Lube Oil Pump ..........................................................................................6-38
6.6.7 COUPLING INSTALLATION........................................................................................6-39
6.6.8 FINAL ASSEMBLY TASKS ..........................................................................................6-40
7. PARTS ORDERING AND SERVICING INFORMATION .....................................................7-1
7.1 REGIONAL SALES OFFICES……………………………………………………………….7-1
7.2 SERVICE CENTERS (NORTH AMERICA)………………………………………………...7-2
7.3 INTERNATIONAL OFFICES………………………………………………………………..7-3