Pump Division

Worthington S.r.l.

INSTRUCTIONS FOR
INSTALLATION,OPERATION
AND MAINTENANCE
___________________________________________

Centrifugal pumps

Type HPX

CE-HPX-R-FLOW.DOC – rev. 0
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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 Safety
1.2 Installation, Operation and Maintenance Safety Procedures
1.3 Installation Safety Procedures
1.4 Operation Safety Procedures
1.5 Maintenance Safety Procedures
1.6 Construction
1.7 Parts description
1.8 Casing
1.9 Impeller
1.10 Casing cover
1.11 Shaft
1.12 Bearing housing
1.13 Bearings
1.14 Inducer
1.15 Coupling/Coupling guards
1.16 Baseplate
1.17 Check upon arrival
1.18 Care during storage
1.19 Long term storage
1.20 Inspection upon arrival
1.21 Storage
1.22 Inspection and maintenance
1.23 Painting and preservation
1.24 Associated equipment
1.25 Lifting equipment
1.26 To lift unit
1.27 To lift driver
1.28 To lift complete pump only

II INSTALLATION 15
2.1 Location
2.2 Foundation
2.3 Level the baseplate
2.4 Method of levelling baseplate using wedges or shims
2.5 Grouting
2.6 Shaft/Coupling alignment
2.7 Types of misalignment
2.8 Alignment using the Reverse Alignment method
2.9 Alignment using a graph (Reverse Alignment)
2.10 Assemble Coupling
2.11 Dowel Pump and Driver
2.12 Hot Alignment Check
2.13 Installation Check List
2.14 Piping
- Suction and Discharge Piping
- Bypass Line
2.15 Suction Strainer
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III OPERATION 32
3.1 Technical Data
3.2 Effects of Specific Gravity
3.3 Effect of Viscosity
3.4 Changing the Pump Speed
3.5 Net Positive Suction Head (NPSH)
3.6 Minimum Continuous Stable Flow
3.7 Minimum Flow Control
3.8 Control Notes
3.9 Thermal Control
3.10 Pressure and/or Flow Control
3.11 Continuous Bypass Control
3.12 Operating Precautions
3.13 Pre-Operational Checks
3.14 Initial Start Up Procedure
3.15 Operating Checks
3.16 Normal Start Up
3.17 Securing the Pump
3.18 General Maintenance
3.19 Routine Maintenance
3.20 Trouble Shooting
3.21 Trouble Shooting Chart

IV LUBRICATION 43
4.1 Preparing Bearing Housing
4.2 Inspection
4.3 Replenishment
4.4 Oil Change
4.5 Lubrication Specification
4.6 Trico Oiler Setting
4.7 Bearing Housing Oil Fill Capacities
4.8 Bearing Housing Oil Limitations

V MECHANICAL SEALS 47
5.1 Description
5.2 Servicing Mechanical Seal

VI MAINTENANCE, DISMANTLING 48
6.1 Dismantling – General
6.2 Pump Disassembly Instructions
6.3 Disassembly of Pull Out Element

VII INSPECTION AND RENEWAL OF PARTS 53

7.1 General
7.2 Wear Rings (Impeller)
7.3 Case Wear Ring (and Casing Cover Wear Ring when Fitted)
7.4 Mechanical Seal
7.5 Throat Bush (If Fitted)
7.6 Bearing Handling Information
7.7 Bearing handling
7.8 Bearing Installation
7.9 Bearing Removal
7.10 Bearing Cleaning
7.11 Assembly
7.12 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

Provision 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).
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1.19 Long term storage

General
During extended periods of storage prior to installation, precautions must be taken to protect the
pump from deterioration. The various parts of the pump are protected prior to shipment by
applying varying grades of preservative to the parts. However, during shipment and handling the
preservatives are subjected to conditions that can cause their removal. Also, during extended
periods of time the preservatives may deteriorate. The listed procedures should be followed to
prevent deterioration of the pump during the extended storage period. These procedures may also
be supplemented by the experience of the person(s) performing the tasks.

1.20 Inspection upon arrival

When the pump is received it should be inspected for damage or other signs of rough handling. If
any damage is found it should be reported to the carrier immediately.
Inspect the preservative coating on various parts. If necessary, renew preservative in areas where
it has been rubbed or scraped.
Inspect all painted surfaces. If necessary, touch up the areas where paint has been chipped or
scraped.
Inspect all covers over pump openings and piping connections. If covers or seals for the covers
are damaged or loose, they are to be removed, and a visual inspection made of the accessible
interior areas for accumulation of foreign materials or water. If necessary, clean and preserve the
interior parts as noted above to restore the parts to the "as shipped" condition. Install or replace
covers and fasten securely.

1.21 Storage

If at all possible, the pump and its component parts should be stored indoors where they will be
protected from the elements. In no case should any pump element be subjected to extended
periods of submergence or wetting prior to start up. If it is not possible to store the pump and its
components indoors, precautions must be taken to protect them from the elements. Regardless of
whether storage is indoors or outside, the storage area should be vibration free. All boxes marked
for indoor storage should be stored indoors. When stored outdoors the pump and its components
should be protected from dirt, dust, rain, snow, or other unfavourable conditions by heavy plastic
sheets, canvas, waterproof burlap or other suitable coverings.
All equipment must be placed upon skids or blocks to prevent contact with the ground and surface
contaminants. Equipment must be adequately supported to prevent distortion and bending.
The pump shaft should be rotated, in the direction of rotation, at least 11/4 turns each week during
the storage period and any other periods of stand by.
When selecting a storage area the following should be taken into
consideration.

1. The deterioration of the equipment will be proportionate to the class of storage provided.

2. The expenses involved in restoring the equipment at time of installation will be proportionate
to the class of storage provided.
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1.22 Inspection and maintenance

The stored equipment is to be placed on a periodic inspection schedule by the purchaser.

The responsibility for setting up an inspection schedule rests with the purchaser and will be
dependent upon the class of storage provided. It would be expected initially, inspection would
occur weekly, then depending upon the inspection reports being favourable or unfavourable,
inspection would continue weekly, monthly, or quarterly, as may be determined.
Each inspection should consist of a general surface inspection to assure that:

1. Pump supports are firmly in place.

2. Pump covers over openings are firmly in place.

3. Pump coverings, plastic or tarps are firmly in place. Any holes or tears must be repaired to
prevent entrance of dirt or water.

4. Pump covers are periodically removed from openings and interior accessible areas
inspected. If surface rusting has occurred, clean or coat with preservative.

5. If rusting occurs on exterior surfaces clean and repaint or coat with preservative.

6. Check individually wrapped parts for signs of deterioration. If necessary, renew preservative
and wrapping.

Six months prior to the scheduled installation date, an FLOWSERVE representative is to be

employed to conduct an inspection. This inspection may include, not necessarily in its entirety and
not limited to the following:

1. An inspection of all periodic inspection records as kept on file by the purchaser, and all
inspection reports that have been compiled during the storage period.

2. An inspection of the storage area to determine the "as stored" condition of the equipment
prior to any protection covers being removed.

3. An inspection of the equipment with protective covers and flange covers removed.

4. Depending upon the length of time the equipment was stored, the type of storage provided
(i.e. Indoor: heated, unheated, ground floor, concrete floor. Outdoors: under roof, no roof,
waterproof coverings, on concrete, on ground) and as a result of the inspection of 1,2 & 3
above the FLOWSERVE representative may require a partial or complete dismantling of the
equipment.

5. Dismantling may necessitate restoration of painted or preserved surfaces, and, or

replacement of gaskets, "O" rings, packing and bearings.

6. All costs involved during inspection, dismantling, restoration, replacement of parts and
reassembly will be to the account of the purchaser. All necessary labour, tools and cranes
will be supplied by the purchaser.
 13

Upon completion of the inspection the FLOWSERVE representative shall submit a report to the
purchaser, and to the Manager of Customer Service, stating in detail the results of the inspection.
One month prior to installation of the equipment, an FLOWSERVE representative is to be
employed to conduct a final inspection. This inspection will be made to assure that the
requirements of the six months inspection report were satisfactorily completed and that the
equipment is ready for installation.
Upon completion of this inspection the FLOWSERVE representative shall submit a final report to
the purchaser, and to the Manager of Customer Service, advising the results of the final
inspection.
All costs involved in conducting the final inspection will be to the account of the purchaser.
Prior to and during start up, any requirements for the services of an FLOWSERVE representative
will revert back to the original contract agreement for equipment purchased, with revised costing.

1.23 Painting and preservation

Paints and preservatives used are either FLOWSERVE standard or 'special' as required by the
contract specification. Refer to your branch office through which the order was placed, or
FLOWSERVE for the description of paints and preservatives used on this order.

1.24 Associated equipment

Motors, Turbines, Gears, etc., being supplied by FLOWSERVE.

Generally rotors of associated equipment should be blocked to relieve bearing loads. Storage
should be indoors and dry. See the specific manufacturers storage requirements.

1.25 Lifting equipment

WARNING

Make sure that any equipment used to lift the 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.

1.26 To Lift unit

Pump, driver and baseplate can be lifted as a unit. Sling from all four (4) eye bolts provided on
baseplate side rails. Failure to use all four (4) could result in permanent distortion of the baseplate.
Use as long a sling as possible, or use a spreader arrangement.

WARNING

Coupling bolting and spacer piece must be removed from between pump and driver half
couplings before lifting baseplate with pumping element.
To lift pump and baseplate, less driver, or baseplate alone, sling from all four (4) eye bolts.
 14

WARNING

Do not lift pump, motor, baseplate unit by slinging from pump casing and/or eye bolt on
motor.

1.27 To lift driver

Refer to Manufacturers Instructions.

1.28 To lift complete pump only

Rig lifting straps at coupling end of bearing housing and at stuffing box extension. Make sure
straps are adjusted to obtain an even lift.
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SECTION II

INSTALLATION

2.1 Location

Install the unit close to the source of the liquid to be pumped.

It is desired to have a straight length of suction pipe (approx. 8 to 10 times the pipe diameter) just
upstream of suction nozzle (No double turns).
When selecting the location, be sure to allow adequate space for operation as well as for
maintenance operations involving dismantling and inspections of parts.
Head room is an important consideration as an overhead lift of some type is required.

2.2 Foundation

The foundation should be sufficiently rigid and substantial to prevent any pump vibration and to
permanently support the baseplate at all points.
The most satisfactory foundations are made of reinforced concrete. These should be poured well
in advance of the installation to allow sufficient time for drying and curing.
The General Arrangement Drawing (In the last section of this manual) will furnish anchor bolt
locations, size of bolts, etc. See Figure 1 below.

ALLOW BOLTS TO PROJECT FOR

GROUTING UNDER BASEPLATE

BOLT
MAKE THIS DISTANCE
EQUAL TO LUG ON BASEPLATE

PIPE

WASHER

TEMPLATE FOR HANGING FOUNDATION BOLTS

Figure 1

Figure 2 below illustrates a recommended foundation bolt arrangement which can be used in lieu
of standard foundation bolts. Notice the large washer with lugs at the bottom. It should be welded
to the bolt and pipe sleeve to prevent turning.
Allow a little more than the specified threaded bolt length above the rail of the baseplate. The
excess can always be cut off if it is not needed.
A rough finish top surface is best when applying grout.
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ALLOW AMPLE THREADED

BOLT LENGTH ABOVE
ROUGH CONCRETE

ROUGH FINISH
FOR GROUT
STUFF WASTE AROUND
BOLT WHILE POURING
CONCRETE

PIPE SLEEVE TO BE
THREE TIMES DIAMETER
OF ANCHOR BOLT

WELD A LARGE WASHER

WITH LUGS TO THE
BOTTOM OF BOLT
AND PIPE SLEEVE TO
PREVENT TURNING

Fig. 2 Arrangement of foundation bolt in foundation

2.3 Level the baseplate

Before putting the unit on the foundation, thoroughly clean the top of the foundation. Break off any
loose pieces of cement and roughen the top with a chisel to afford a good hold for grout.

NOTE

Coupling bolting and spacer piece must be removed from between the pump and driver half
couplings before lifting baseplate with pumping element

NOTE

When lifting baseplate with pumping element, sling baseplate from all lifting eyes provided.
Refer to Section 1.26.

Prepare sufficient steel plates to be placed below each baseplate jacking screw furnished with the
baseplate. The purpose of the plate is to spread the load of the screw without crushing the
concrete below.
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Figure 3

2.4 Method of levelling baseplate using wedges or shims

Level the baseplate by using a machinist's level on the machined surfaces of the pump and driver
pads. Levelling is best achieved by adjusting the shim pack thickness under each holding bolt.
Carefully raise the baseplate by using either the baseplate jacking screws provided or by levering
with a suitable pinch bar or by installing a low level hydraulic jack.

Adjust the shim pack thickness and lower the baseplate.

Repeat this procedure in a logical manner at each bolt position until the baseplate is both straight
and level. A degree of 0.0035 inch per foot (.25mm per metre) length is achievable on most units
with a maximum of 0.005 inch per foot. (.40mm per metre length).

When the baseplate is level, pull down the foundation bolts so they are snug. This may have
disturbed the baseplate, so re-check the levels.

Ensure that shaft alignment per Section 2.6 can be achieved prior to grouting the baseplate.
 18

2.5 Grouting

Build a dam around the foundation as shown in Figure 4 after levelling the baseplate. It is a matter
of personal preference whether the levelling wedges under the baseplate should be removed after
grouting. If you do not want to remove the wedges, carefully mark their locations before pouring
grout.

CAUTION

Before grouting, level machined pads of baseplate in both directions and perform a rough
shaft/coupling alignment. Alignment after grout has set will not be possible if above is not
satisfactorily completed.

FINISHED GROUT

LEAVE TOP OF
FOUNDATION ROUGH
DO NOT FINISH
WITH TROWEL

DAM GROUTING 1 TO 2
INCHES DEEP

CONCRETE

Figure 4

Use a good, high strength, non shrink grout mix and install as per manufacturer's instructions.
Holes are provided in the baseplate to permit pouring the grout and stirring while acting as air
vents. Fill under the baseplate completely, stirring to assure correct distribution of the grout. Check
to see that the grout flows under the edges of the baseplate evenly.

NOTE

Do not vibrate baseplate when grouting, making sure baseplate is vented correctly and all areas
are thoroughly puddled to prevent any reasonant problems.
When the grout is thoroughly hardened, remove the dam and wedges, if desired, filling in the
holes they leave with grout.

NOTE

Pour grout until level reaches top of dam. Allow to dry sufficiently to prevent grout from overflowing
while completing the remaining grouting.
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2.6 Shaft/Coupling alignment

CAUTION

Shaft alignment must be correct for successful operation. Rapid wear, noise, vibration and
actual damage to the equipment may be caused by shaft misalignment. The shafts must be
aligned within the limits given within this section.

NOTE

Adjustment to correct the alignment in one direction may alter the alignment in another direction.
Always check in all directions after making any adjustment.
Coupled equipment must be aligned to minimize unnecessary stresses in shafts, bearings and
coupling. Flexible couplings will not compensate for appreciable misalignment. Foundation settling,
thermal expansion or nozzle loads resulting in baseplate/foundation deflection and vibration during
operation may require the full coupling misalignment capability.

2.7 Types of misalignment

There are two types of shaft misalignment: angular and offset. Therefore, two sets of
measurements and corrections are required. Both types of misalignment can occur in horizontal
and vertical planes and are present in most applications.

A. Angular misalignment

In angular misalignment, the centre line of the shafts intersect, but are not on the same axis.

ANGULAR MISALIGNMENT
 20

B. Offset misalignment

OFFSET MISALIGNMENT

COMBINATION OFFSET
AND
ANGULAR MISALIGNMENT

In offset misalignment, the shaft centre lines are parallel but do not intersect.

2.8 Alignment using the Reverse Alignment Method

The following practices are recommended when using the reverse method of alignment. These
should be carried out prior to main alignment.

CHECK FOR SOFT FOOT

This is a check to ensure that there is no undue

stress on the driver holding down bolts; owing
to non-level baseplate or twisting
To check, remove all shims and clean surfaces
and tighten down driver to 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”) is considered acceptable
but any more will have to be corrected by adding
shims, for example, if the Dial Test Indicator
shows the foot
lifting 0.15 mm (0.006") then this is the
thickness of shim to be placed under that foot.
Tighten down and repeat the same procedure
on all other feet until all are within tolerance.

NOTE

If the driver is an electric motor with sleeve bearings then the magnetic centre at which the rotor
will run must be set. This is usually done by lining up a groove in the shaft to a pointer fixed to the
motor body (refer to Motor Manufacture’s instructions).
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2.9 Alignment using a graph (Reverse Alignment)

CL CL

A B

F1
F2

FIGURE 1

NOTE

With reverse alignment there are certain points which must always be born in mind.

A) The pump coupling hub is referred to as A. The motor coupling hub is referred to as B.
The motor is aligned to the pump which is considered to be the datum.
B) The dial test indicator on hub A is secured to hub B and vice versa and both hubs are
rotated together to obtain readings. For vertical alignment the Dial Test Indicator's are
zeroed on the top and they are read at the bottom - 180 degrees.

For horizontal they are zeroed at the side away from the person doing the alignment and
called far in the text and read on the opposite side and called near in the text.

C) To plot the graph the above measurements must be recorded, A to B, this is the distance
between the Dial Test Indicator pointers which should be positioned halfway along the hub.

A to F1, this is the distance to the first foot centre or to the centre of the holding down bolt
hole.

A to F2, distance to second foot centre.

D) Acceptable tolerance for vertical and horizontal alignment is 0.05mm (0.002in). Total
indicator reading.
 22

NOTE

For shaft end gaps greater than 3in (75mm) check the rigidity of the Dial Test Indicator arm as
follows.
Clamp the arm with the Dial Test Indicator fitted to a rigid member (channel or bar). With the Dial
Test Indicator on top zero the clock, turn through 180 degrees, half the reading and record. If
reading is excessive, the arm should be stiffened.

PROCEDURE

Horizontal Plane

Step 1. Position Dial Test Indicator's on the far side and zero, rotate both hubs through 180
degrees and note readings. Halve readings and plot onto the graph Figure 2.

Move the motor over the required amounts, re-tighten and check again.
If the hubs are within tolerance proceed with step 2.

Vertical Plane

Step 2. Position Dial Test Indicator's on the top of the hubs and zero.
Rotate through 180 degrees and note the readings and halve the value. Plot onto the
graph to determine the shimming needed to be added or removed and when carried out
repeat step 1 and tighten down again.

Check top and bottom again and if outside tolerance repeat as necessary.

EXAMPLES
Number 1, See Figure 2
As can be seen from the graph (Figure 2) the measurements taken from Figure 1 are plotted by
vertical lines with a horizontal line drawn across which is the centre line of both machines (C - C)
when in perfect alignment.

NOTE

To interpret the readings the following is important

PUMP - a plus reading on A hub means that the value is plotted above C - C, a minus reading is
plotted below C - C.

MOTOR - a plus reading on B hub means that the value is plotted below C - C a minus reading is
plotted above C - C.
 23

HORIZONTAL
The following are examples of readings taken and plotted on the graph. First side to side and
represented by the line Y - Y. Hub A Total Indicator Reading (TIR) + 0.014in. Hub B total Indicator
Reading (TIR) - 0.008in.

As these are total readings they are first halved and so become A + 0.007in, and B - 0.004in.

Therefore as A is plus it is plotted above C - C and as B is minus it too is plotted above C - C.

These two points are connected by the line Y - Y. If this intersecting line when projected is below C
- C where it crossed the F1 and F2 lines then the required movement of the motor is towards the
FAR side. From the graph it can be seen that Y - Y intersects F1 0.002 in below and at F2 0.016in
below, so by moving the motor feet towards the FAR these amounts, front foot moved 0.002in and
the rear foot moved 0.015in we will achieve side to side alignment.

VERTICAL
The line X - X represents the reading taken from top to bottom which were, A minus 0.034in and B
plus 0.024in.

This means that A is minus so it is plotted below C - C 0.017in divisions, B is plus so it is also
plotted below C - C 0.012 divisions.

From the graph it can be seen that the intersecting line X - X passes through F1 0.002 in below C
- C which means that this is the thickness of shimming to be added to the front feet. However, at
F2 the line is 0.020" above C - C this means that the motor is high at the rear feet and this is the
thickness of shimming to be removed from these feet.

See also examples 2 and 3.

 24

FIGURE 2
EXAMPLE 1

A B F1 F2

0.07
0.06
0.05
0.04
0.03 X-X
0.02
Pump
Hub 0.01
Clock C 0 C
Readings 0.01 Y-Y
(in) 0.02
0.03
0.04
0.05
0.06
0.07

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40

Distance Over Motor Feet (in)

VERTICAL HORIZONTAL

TIR FOR TOP AND BOTTOM TIR FOR SIDE TO SIDE

A = - 0.034" Therefore Plot A above - 0.007” A = + 0.014" Therefore A above + 0.017”

B = + 0.024" Therefore Plot B above + 0.012” B = - 0.008" Therefore B above - 0.004”

MOTORS ALTERED AS FOLLOWS: MOTOR TO BE MOVED TO FAR SIDE

F1 Add 0.002" of Shims F1 = 0.002" and F1 = 0.0155".

F2 remove 0.0205" of Shims

 25

FIGURE 2
EXAMPLE 2

A B F1 F2

0.07
0.06
0.05
0.04
0.03
0.02 X-X
Pump
Hub 0.01
Clock C 0 C
Readings 0.01
(in) 0.02
0.03
0.04
Y-Y
0.05
0.06
0.07

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40

Distance Over Motor Feet (in)

VERTICAL X - X HORIZONTAL Y - Y

A = TIR - 0.04 = - 0.02 A = TIR +0.012 = 0.006

B = TIR + 0.032 = + 0.016 B = TIR 0 = 0
At F1 Add 0.008 Shim At F1 Move to Far 0.012
At F2 remove 0.010 Shim At F2 Move to Far 0.039
FIGURE 2
EXAMPLE 3

A B F1 F2

0.07
0.06
0.05
0.04 Y-Y
0.03
0.02
Pump
Hub 0.01
Clock C 0 C
Readings 0.01
(in) 0.02
X-X
0.03
0.04
0.05
0.06
0.07

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40

Distance Over Motor Feet (in)

VERTICAL X - X HORIZONTAL Y - Y

A = TIR + 0.036 = + 0.018 A = TIR - 0.060 = - 0.03

B = TIR - 0.024 = - 0.012 B = TIR + 0.046 = + 0.023
At F1 No Change At F1 Move to Far 0.009
At F2 Add 0.027 Shim At F2 Move to Near 0.0225
 SERIAL NO. PUMP TYPE ALIGNED BY DATE

0.07

0.06

0.05

0.04

0.03

0.02

0.01
PUMP HUB
CLOCK 0
READINGS
0.01

0.02

0.03

0.04

0.05

0.06

0.07
26

Distance Over Motor Feet

 27

The shims between the equipment feet and mounting surface should be clean and dry. This is
especially critical for pumps in service for sometime and need to be realigned. Water, dirt and rust
may change the height of the shim pack over a period of time. Shims should be made large
enough to support the weight of the equipment on its mounting foot. Do not use many thin shims
as this may result in a spongy mounting.

Recommended shim design

Move the equipment vertically by adding or removing the calculated thickness of shims. Torque
holding down bolts to required values.

NOTE

It is recommended, the complete "ALIGNMENT GRAPH SHEET" be retained as part of your

permanent maintenance file.

2.10 Assemble Coupling

1. Assemble coupling as per the manufacturer's instructions included in Appendix of this

manual.

2. Install coupling guard.

 28

2.11 Dowel Pump and Driver

Pump hold down bolts are to be torqued down and dowel pins are to be located in pump feet
as shown below.

Dowel pin location

2. Refer to driver outline drawing and/or driver instructions for driver dowelling information.

2.12 Hot Alignment Check

A hot check can only be made after the unit has been in operation a sufficient length of time to
assume its NORMAL operating temperature and conditions. If the unit has been correctly cold set,
the offset misalignment will be within .005" TIR (.12mm TIR) and the angular misalignment will be
within .0025" TIR (.06mm TIR) when in operation. If not make adjustments.

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.

WARNING

Before attempting any inspection or repair on the pump the driver controls must be in the
"off" position, locked and tagged to prevent restarting equipment and injury to personnel
performing service on the pump.
 29

2.13 Installation Check List

1. Level Baseplate?

2. Grout Baseplate - Check Foundation Bolts?

3. Alignment Shaft/Coupling?

4. Piping Installed - Correct Vent, Gauge, Valve, Suction Strainer Locations?

5. All Flange Bolting Correctly Torqued with appropriate gaskets in place?

6. Check Shaft/Coupling Alignment again.

7. Coupling guard correctly installed?

 30

2.14 Piping

2.14.1 Suction and Discharge Piping

These units are furnished for a particular service condition. Changes in the hydraulic system may
affect performance adversely. This is especially true if the changes reduce the pressure at the
suction or if the liquid temperature is increased. In case of doubt contact FLOWSERVE
Suction and discharge piping should be of ample size, be installed in direct runs, and have a
minimum of bends. Double bends must be avoided in suction line and a straight run of pipe, equal
8 to 10 times the pipe diameter is desired directly upstream of the suction nozzle.

NOTE

Provision must be made to support piping external to the pump to prevent excessive nozzle loads,
maintain pump/driver alignment and avoid pipe induced vibrations.

Install a check valve and a gate valve in the discharge pipe of the pump. When the pump is
stopped, the check valve will protect the pump against excessive pressure and will prevent the
pump from running backward. The check valve should be installed between the gate valve and the
pump nozzle in order to permit its inspection.

Keep the suction pipe from the source short and direct. Use a suction pipe equal to or one size
larger than the pump suction nozzle. Keep the suction pipe free of all air pockets. (Vent as
required).

IMPORTANT

A spool piece should be installed in suction line so that the suction strainer may be
installed and removed with a pressure gauge between the strainer and pump

2.14.2 Bypass Line

CAUTION

Operation at low flows results in pump horsepower heating the liquid. A bypass may be
required to prevent vaporization and subsequent pump damage. Refer to local
FLOWSERVE branch to determine if a bypass is required. Mechanical damage may result
from continuous operation at flows less than specified.
 31

2.15. Suction Strainer

In a new installation, great care should be taken to prevent dirt, scale, welding beads and other
items from entering the pump, as it is particularly important to protect the numerous close running
fits from abrasive matter present in new piping

The suction system should be thoroughly flushed before installing the suction strainer and making
up suction piping to the pump.
The suction strainer should be installed between 5 to 20 pipe diameters upstream from the pump
suction flange.

NOTE

The open area of the strainer should have a minimum of a 3 to 1 ratio to the area of the
pump suction

The FLOWSERVE standard for suction strainers consists of a conical shaped steel plate. The
plate has 1/16" perforations and is of sufficient size and thickness for the required flow. See Figure
above.

Other type of strainers may be used as long as they conform to the requirements stated above.

Pressure gauges should be installed on both sides of the screen so that the pressure drop across
the screen can be measured.

When the unit is being started, the gauges on each side of the screen should be carefully
watched. An increase in the differential pressure between the two gauges indicates that the screen
is becoming clogged with dirt and scale. At this point, the pump should be shut down, and the
screen cleaned and/or replaced.
 32

SECTION III

OPERATION

3.1 Technical Data

These pumps are furnished for a particular service condition. Changes in the hydraulic system
may affect the pump's performance adversely. This is especially true if the changes reduce the
pressure at the suction flange or if the liquid temperature is increased. In case of doubt, contact
the nearest FLOWSERVE office.

3.2 Effects of Specific Gravity

The capacity and total head in feet of liquid developed by a centrifugal pump are fixed for every
point on the curve and are always the same speed. Neither capacity not total head will be affected
by a change in the specific gravity of the liquid pumped. However, since the developed gauge
pressure and the power required to drive the pump are a function of the specific gravity of the
liquid, both will be affected in direct proportion by any change in the specific gravity. Therefore, a
change in specific gravity will affect the discharge gauge pressure. Any changes should be noted,
in that they may overload the pump's driver.

3.3 Effects of Viscosity

The pump is designed to deliver rated capacity and rated head for a liquid with a particular
viscosity. When contemplating operation at some viscosity other than for which the pump was
originally designed and/or applied, the changed conditions should be referred to FLOWSERVE for
our recommendations.

3.4 Changing the Pump Speed

Changing the speed of a centrifugal pump changes the capacity, total head and brake
horsepower. The capacity will vary in a direct ratio with the speed, whereas, the total head will vary
as the square of the speed The brake horsepower will vary in the ratio of the speed cubed except
in cases where the speed change also changes the efficiency of the pump. When contemplating
speeds other than of the original condition, refer to FLOWSERVE for recommendations.

3.5 Net Positive Suction Head (NPSH)

Any liquid, hot or cold, must be pushed into the impeller of the pump by absolute pressure, such
as the atmospheric or vessel pressure from which the pump takes its suction.
The head in feet of liquid necessary to push the required flow into the pump is called the Net
Positive Suction Head. This value, more commonly called NPSH, is measured above the vapour
pressure of the liquid at the pumping temperature.
There are two kinds of NPSH: the NPSHR is the head required by the pump to cover the losses in
the pump suction - that is shown on the pump characteristic curve. The second, NPSHA, is the
head available in the system, taking into account friction loss in suction piping, valves, fittings etc.
In all cases the NPSHA, measured above vapour pressure, must exceed the NPSHR in order to
push the liquid into the pump. Failure to have this will result in both bad performance and
mechanical damage to the pump, and in certain cases actual pump failure.
 33

3.6 Minimum Continuous Stable Flow

The Minimum Continuous Stable Flow for the pump is stated on the Data sheet.

3.7 Minimum Flow Control

In all cases, it is the customer's responsibility to supply a system and/or control which assures that
any pump within a system is not operated below its minimum flow condition.
In many cases, this is not a problem because the system is operating within its own flow range to
assure product delivery. A simple high pressure alarm, shut down and/or bypass control can be
used. However, in systems where product demand has high swings or where more than 100%
capacity units are desired to support a product system, additional care must be taken.

3.8 Control Notes

3.9 Thermal Control

The actual protection of the given unit is best provided by thermal sensors which read direct or
"related to" fluid temperatures and respond accordingly by opening additional flow paths until the
given unit re-establishes the acceptable temperature rise, and sets off alarms if not achieved
within reasonable/normal time periods. (High limit could actually shut down unit).

3.10 Pressure and/or Flow Control

Pressure and/or flow sensors can be used to hold the unit at higher flows by opening additional
flow paths once a "high pressure limit" or " low pressure limit" was indicated. Upon system
reaching increased flow a "low pressure limit" or "high pressure limit" setting would close the
bypass flow path. Care must be taken to allow for signal spread to avoid cyclic conditions.

3.11 Continuous Bypass Control

This is not a desired system, as it requires an oversize bypass system as dictated below with
excessive power losses and oversize pumping units, however, if used the following must be
considered.
Continuous Bypass Sizing for Parallel Units:
The limits and/or protection requirements of two or more units in parallel operation is dictated by
the minimum flow of each particular unit and the performance tolerances of the pump and system.
The following is required to provide unit protection.

1. Determine the minimum flow of one of the units. This will be the smallest flow allowed for
any of the units in the parallel system.
2. By general specification, while the rated head condition has a tolerance of +2% to -2% at
the guarantee point, the tolerance at "shutoff" (low flow = 0) is +5% to -5%.
Therefore: draw two head capacity curves; one at -2% head at rated capacity and fared to -
5% at shutoff, the other at 2% head at rated capacity fared to +5% at shutoff.
The lower curve represents the "weakest" pump in the system and the upper represents
the "strongest" pump or pumps in the system.
At the minimum flow from step 1 above, find the Total Developed Head (TDH) of the
Weakest pump. Draw a straight line at this TDH until it intersects the head-capacity curve
of the strongest pump. Read the corresponding "Strong Pump Flow".
 34

The minimum flow of the pumps within the system can now be defined and provisions must be
made in the system to assure the total capacity is not less than this.

Total Minimum Flow of = Minimum Flow of Weakest Pump + (total No.Pumps - 1)

Pumps in System (Strong Pump Flow)

Sample: (see Figure )

1. Assume the minimum flow for a single pump is 27 GPM.

2. Data for the head - capacity curve:

At the rated point:

[EQN "[Strongest pump head = 300 +(300x2) over 100 = 306]]

[EQN "[Weakest pump head = 300 - (300x2) over 100 = 294]]

At Shutoff:

[EQN "[Strongest pump head = 360 + (360 x 5) over 100 = 378]]

[EQN "[Weakest pump head = 360 - (360 x 5) over 100 = 342]]

From head capacity curve:

Minimum weakest pump flow = 27GPM

Minimum strongest pump flow = 65GPM

Total minimum flow of pumps in a typical application with 2 pumps operating in parallel.

Total Minimum Flow of Pumps in System = 27 + (2-1) (65) = 92 GPM

 35

FT

400
378 STRONGEST

342
WEAKEST
300

20 27 40 60 80 100

CAPACITY GPM
PARALLEL OPERATION
 36

3.12 Operating Precautions

WARNING
Do not clean pump in the vicinity of rotating parts when pump is operating. If unusual noise
or vibrations occur, secure pump as soon as possible.

1. Never operate the pump with suction valve closed.

2. Never operate the pump with the discharge valve closed.

3. Never operate the pump unless it is completely filled with liquid and vented.

4. Never operate the pump unless an adequate liquid source is available.

5. Never operate the pump on liquids other than the one specified on the pump data sheet.

3.13 Pre-Operational Checks

The following steps should be followed at initial start up and after the equipment has been
overhauled:

1. Prior to installing the pump, flush the suction side of the system to remove all deposit (slag,
bolts etc).

2. Ensure the pump and piping is clean. Before putting the pump into operation, the piping
should be thoroughly back flushed to remove any foreign matter which may have
accumulated during installation. Take all possible care not to contaminate your system.

3. Install suction strainer. (See Section 2.15).

4. Fill the bearing housing with the appropriate oil to the correct level.Bearing must receive a
small amount of oil prior to starting to ensure adequate lubrication at start up. (Refer to
Section 4).

5. Turn pump rotor by hand or with a strap wrench to make sure it turns smoothly.

6. Assure that correct seal piping has been installed and has not been damaged.

7. Prior to coupling installation, bump start motor to check for correct rotation. If rotation is not
correct refer to motor manual for appropriate connections to change rotation (Shut down all
power prior to change).

8. Ensure coupling is correctly aligned and lubricated, and pump and driver is satisfactorily
dowelled. (Refer to Section 2.6).

9. Ensure coupling guard is correctly installed.

WARNING
The unit must not be operated unless coupling guard is securely and completely bolted in
place. Failure to observe the warning could result in injury to operating personnel.

10. Check torque of all bolting and the plugs for tightness.
 37

3.14 Initial Start Up Procedure

1. Close discharge valve if valve is not already closed, and then crack open to assure minimal
flow. (Do not start unit with fully closed valve). On first starts care must be taken not to cause
a system water hammer.

2. Prepare the driver for start up in accordance with the driver manufacturer's instructions.

3. Warm up pump.

Avoid severe thermal shocks to the pump as the result of sudden liquid temperature
changes. The pump must be preheated prior to start up. Unless otherwise specified the
thermal temperature of the casing must be within 130 degrees F (55°C) of the temperature
of the liquid to be pumped at time of start up. Due to the heavy metal sections, the casing
will lag the liquid temperature during such changes, and severe temperature stresses and
subsequent misalignment of machined fits may result. Preheating is accomplished by
circulating a small amount of hot fluid through the casing by utilizing vents, drains or bypass
from discharge. Preheat pump slowly at a rate not to exceed 130 degrees F per hour (55°C
per hour).

4. Prime pump and ensure suction valve is open.

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.

5. Ensure pump recirculating line (if required) is open, clear and free of obstructions.

6. Check that pump is vented by observing leakage from casing vent (when fitted) and seal
piping vent. Close vent (if fitted) when liquid is emitted.
7. Turn on cooling liquid and assure correct flow exists (to cooler, insert gland etc.) as
specified.

8. Double check pump rotation by starting unit momentarily. The direction of input shaft rotation
is counter clockwise when facing pump shaft from coupling end. Ensure that the pump
coasts to a gradual stop.

CAUTION

If pump stops abruptly when driver is shut down, investigate for pump binding. take
necessary remedial action before resuming operation.

9. Start the driver and bring it up to speed quickly.

10. As soon as the pump is up to rated speed slowly open discharge valve.
This will avoid abrupt changes in velocity and prevent surging in the suction line.

11. Perform the operating checks

 38

3.15 Operating Checks

WARNING

In the interest of operator safety the unit must not be operated above the nameplate
conditions. Such operations 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.

CAUTION

Operation at low flows results in pump horsepower heating the liquid. A bypass may be
required to prevent vaporization and subsequent pump damage. Refer to local
FLOWSERVE branch to determine if a bypass is required. Mechanical damage may result
from continuous operation at flows less than the specified minimum continuous stable
flow.

Immediately after start up, and frequently during running check the following:

1. Check suction and discharge pressure gauges.

2. Check pressure gauges on each side of suction strainer.

3. Check for excessive leakage at seal areas.

4. Check for unusual noises.

5. Check oil level in bearing housing. (Refer to Section 4).

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 physical injury.

6. Check for adequate flow of cooling liquids.

7. After unit (Particular to services 130°F (55°C) above ambient) has been operated a sufficient
length of time to reach normal operating temperature and condition, the unit is to be shut
down and a "HOT" coupling alignment check must be made (Refer to Section 2.6).

3.16 Normal Start Up

The starting procedure to be followed for normal start up is the same as that for initial starting with
the exception that Step 8 "CHECK ROTATION" does not have to be repeated as long as driver
systems have not been changed since last pump operation.
 39

3.17 Securing the Pump

1. Shut down driver.

The pump should be shut down rapidly to protect the internal wearing parts which are
lubricated by the liquid being pumped.

NOTE

If pump stops abruptly when driver is shut down, investigate for pump binding. Take
necessary remedial action before restarting pump.

2. Close the pump suction and discharge valve.

3. Close valve in bypass line

4. Turn off cooling liquid.

5. If pump is subjected to freezing temperatures the pump must be drained of liquid to prevent
damage to the pump.

3.18 General Maintenance

These pumps have been designed to simplify maintenance and make service easy. Preventative
maintenance and overhauls before serious troubles occur will reduce operating costs. The
following section outlines the various steps necessary for the removal and replacement of all parts.
If an overhaul is required, follow the specific instructions carefully. Contact the factory if additional
information is needed.
 40

3.19 Routine Maintenance

Recommended Schedule
PARTS
DAILY Check Suction And Discharge Gauges.
Check For Abnormal Operating Conditions (High/Low Temperature,
Flows, Vibration, Pressures Etc.)
Check Motor Current/Driver Power.
Check For Leakage From Seals, Joints.
Check All Lubricant Levels Ie. Bearing Housing Oilers, Seal Plan 52/53,
Seal Supply Systems As Applicable.
Check For Free Flow Of Cooling Medium As Applicable.
Check Stand By Pump is At Applicable Temperature And Available To
Start As Required.

WEEKLY Check Unit Vibration.

Check Operators Log For Loss Of Unit Performance.

MONTHLY Check For Lubricant Contamination Whether Bearing Oil, Or Seal Oil (If
Applicable) By Sample Analysis.
Check All Paint Or Protective Coatings.
Check All Power/Instrument Cable Glands For Tightness.

6 MONTHLY Change Lubricants.

YEARLY Check Foundation Fixing, Bolting, Grouting For Looseness, Cracking Or

General Distress.
Check Unit Alignment Against Previous Inspection.
Check Calibration Of Instruments.

3 YEARLY Check Internal Condition of Pump And All AncillaryPipework For

Corrosion/Erosion.
Check Internal Pump Components For Wear.

NOTE

This schedule is a recommendation only and is intended to be amended by site experience

of the prevailing conditions. It outlines recommendations for the pump only and must be
supplemented by schedules for other equipment on the package
 41

3.20 Trouble Shooting

This chart presents the probable troubles that can occur to the pump along with the probable
causes and remedies for the troubles.

3.21 Trouble Shooting Chart

TROUBLE CAUSE REMEDY

Insufficient capacity Suction pressure or speed too Open suction valve wide. Check power
and/or pressure. low. supply for correct voltage.

Incorrect direction or rotation. Check driver instruction book.

Excessive amount of air or Check suction system for air leakage and
vapours in the liquid. correct. Vent air, Tighten flange bolts.

Foreign material in impeller.

Dismantle pump and remove any foreign
material.
Foreign material in suction Dismantle suction line and remove foreign
line. material.

Mechanical causes: Dismantle pump and correct.

Impeller damaged by foreign
material.
Broken or damaged coupling.

Pump loses prime after Insufficient liquid supply. Ensure that suction valve is wide open.
starting. Check for appropriate liquid level.
Blocked suction strainer.

Excessive amount of air or Check suction system for air leakage and
vapour in the liquid. correct.

Clogged impeller. Dismantle pump and correct.

Suction pipe clogged. Remove foreign material.

Pump vibration. Loose mounting or coupling Tighten bolts.

bolts.
Coupling. Check alignment and correct.

Air or gas in liquid. Vent air and check suction for leaks.
Tighten flange bolts.

Incorrect installation. Baseplate not correctly supported along

rails.

Foreign material in impeller Dismantle pump and remove any foreign

causing unbalance. material.

Mechanical causes: Shaft Dismantle pump and replace part or parts

bent. causing vibration.
 42

TROUBLE CAUSE REMEDY

Pump overloads driver False overload signal. Check starter controls.
Wire/connections faulty. Check for hot spots in lines.
Speed to high. Check driver instruction section.
Specific gravity too high. Check rated conditions.

Pump bearings seized or Dismantle pump and replace part or

rotating element binding. parts
causing seizure or binding.
Pump stops abruptly. Pump binding at running fits. Dismantle pump and realign rotor in
casing.

High pump thrust Incorrect lubrication, including Replenish oil with correct grade lubricant
bearing inadequate cooling. and assure cooling capacity.
temperature rise.
Insufficient oil. Add oil.

Contaminated oil Drain and refil with clean oil, change filter

Excessive seal leakage. Dirt across seal faces. Replace seal.

Pump is noisy. Cavitation. Check that pump is primed. Check for

high suction temperature, increase static
head. Check for obstruction in suction
line
Loose parts.
Noise in driver. Tighten or replace defective parts.
Check driver with stethoscope.

Check driver instruction section for trouble shooting instructions.

 43

SECTION IV

LUBRICATION

A "Trico" Oiler is normally furnished with the pump unless otherwise specified.

4.1 Preparing Bearing Housing

Before filling the bearing housing reservoir, flush out the housing thoroughly with safety solvent
and a leading grade of flushing oil, compatible with the lubricating oil that will be used. The
reservoir is to be filled to appropriate level as illustrated in section 4.6.

D1: oiler connection with slinger lubrication C1: overflow plug with slinger lubrication
D2: oiler connection with oil ring lubrication C2: overflow plug with oil ring lubrication

CONSTANT LEVEL OILER LUBRICATION

The oil level must be maintained at the correct level: oil lack may cause overheating and failure of
the bearings, while exceeding the correct level can result in leakage from the labyrinth seals. The
constant level oiler can be adjusted by changing the height of the cross arms which support the
glass reservoir, as illustrated for TRICO oiler in section 4.6.

4.2 Inspection

Inspect the oil level in the bearing housing at least once a day. Inspect the condition of the oil at
least weekly. Oil is always subject to gradual deterioration from use and contamination from dirt
and moisture which is the cause of premature bearing wear.

4.3 Replenishment

Replenish the oil in the oiler as required. More frequent replenishment at high temperatures may
be required.
 44

4.4 Oil Change

Frequency of oil change is dependent on pump service and environmental conditions. As a

general guide, oil in the bearing housing should be changed every 5000 operating hours, after the
initial change.

4.5 Lubrication Specification

The ideal bearing lubricant is a straight well refined, neutral mineral, preferably of the turbine type.
It should not contain free acid, chlorine sulphur or more than a trace of free alkali. It is suggested
that the oil conform to the following physical characteristics.

Type Mineral Oil (Petroleum based)

Lubrication Service Ball Bearing

Lube Oil Specification ISO VG 32

Make, Type and Grade See Table Below

Approx Consumption 0.12 litres, ¼ pint per month

Continuous operation

Quantity See following page

Flushing Requirements Low pour point mineral oil

Viscosity 210°F (99°C) 4.7 c/s min. at 210°F (99°C)

and 100°F (38°C) 29 c/s min - 43 c/s max at 100°F (38°C)

Type, Quantity As required

Pour Point Minus 20°F Max (-29°C max)

Flash Point 330°F Min. closed (165°C Min. closed)

Running in Period 500 hours

First Oil Change 500 hours

Further Oil Changes 5000 hours

One Years Consumption 1.44 litres approx. max

- Synthetic Lubricants
If a synthetic lubricant (fire resistant fluid) is to be used instead of the normal type oil for the
lubrication of bearings, gears etc., the material of all gaskets and "O" rings in contact with the
lubricant must be compatible with the lubricant. Normal gasket materials will usually swell and
deteriorate when immersed in synthetic lubricants: also normal paints will peel from internal walls
of reservoirs and bearing chambers.
 45

ISO VG 32
BP Energol THB 32 (ISO) Gulf Harmony 32
Castrol Perfecto T32 Mobil DTE Oil Light
Chevron OC Turbine Oil 32 Shell Turbo T32
Esso Nuto H32 Texaco Regal Oil R & O 32

4.6 Trico Oiler Setting

Initial fill via top of housing, using overflow plug to establish correct level (see Section 4.1
illustration).

Release thumb screw and remove bottle. Establish a measurement from the centre line of the oiler
connection in bearing housing to the upper cross arm of 6 mm (.24"); this can be obtained by
completely screwing down the lower arm as illustrated below.

TRICO OILER

Fill bottle with recommended oil and install on holder. Remove and fill bottle as many times as is
required to fill the bearing housing up to the cross arm level and no air bubbles appear in the
bottle.

Remove bottle and ascertain that the oil level is 6 mm (.24") from the centre line of oiler
connection. Adjust upper cross arm as required and lock in place with lower arm.
 46

4.7 Bearing Housing Oil Fill Capacities

Bearing Housing Number * Bearing Designation Oil Fill Capacities (litres)

Slinger Oil Ring
G040B159 7308 1.51 1.13

G050B159 7311 1.34 0.85

G070B159 7314 1.83 1.02

G090B159 7315 4.43 2.82

7316 4.17 2.60

* The bearing housing size can be identified from the identifying marks cast on the housing on the
horizontal centre line in the opposite side to the oiler.

4.8 Bearing Housing Oil Limitations

Maximum Oil Temperature 180°F

82°C
Minimum Oil Temperature At Start Up 60°F
15.6°C
Desirable Operating Temperature 140-160°F
60-71°C
Housing Capacity 3 Pints
1.42 Litres
Oil Level Above Oil Connection Centre line 6 mm

FOR MORE DETAILS REFER TO THE APPENDIX ON THE LAST PAGE OF THE IOM MANUAL
AND THE LUBRICANT LIST
 47

SECTION V

MECHANICAL SEALS

5.1 Description

Cartridge mechanical seals are provided, to seal the shaft against leakage. The seals used on the
"HPX" pump have internal design differences for sealing against specific liquids and conditions.

Long seal life with minimal leakage can only be obtained if the seals are provided with clean, cool
liquid. Even tiny solids that may be suspended in the liquid being pumped can damage the seal
faces and cause the seal to leak, making an external flush or a different seal arrangement
necessary. The seal balancing and flushing arrangement provided for each pump is designed and
fitted for the specific order requirements.

The "HPX" pump can be arranged with either a single, double or tandem mechanical pump seal.
Refer to the General Arrangement for piping connections to be used with your pump.

5.2 Servicing Mechanical Seal

Mechanical seal replacement or servicing requires that the pull out element be removed from the
casing.
For removal of pullout element refer to Manufacturer’s instructions.
 48

SECTION VI

MAINTENANCE, DISMANTLING

6.1 Dismantling - General

Avoid serious or troublesome problems by systematic maintenance checks. Study Section 3.10 as
an aid to your maintenance programme.

Your pump is a precision machine. Take every precaution to avoid damage or even slight burrs to
the shaft bearing areas, as well as any other ground finished surface when dismantling your 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.

Before performing any disassembly, maintenance and/or inspection on the unit, the following steps
should be taken and warnings observed.

1. Tag driver controls in the "off" position.

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 on the
pump.

2. Isolating Pump.

WARNING

Before attempting to disassemble pump, pump must be isolated from system, by closing
suction and discharge system valves, drained of liquid and cooled, if pump is handling hot
liquid.

3. Draining pump.

A. If handling hot liquids. WARNING

When the pump is handling "hot" liquid, extreme care must be taken to ensure the safety of
personnel when attempting to drain pump. Hot pumps must be allowed to cool before
draining.
 49

B. If handling caustic liquids WARNING

When pump is handling "caustic” liquid, extreme care must be taken to ensure safety of
personnel when attempting to drain pump. Protective devices of suitable protective
materials must be worn when draining pump.

C. If on vacuum service. WARNING

Before attempting any maintenance work on pumps in vacuum service. Pumps must be
isolated from suction and discharge system then carefully vented to return pressure in
pump casing to atmospheric pressure.

4. Draining lubricating oil WARNING

Use caution when draining hot oil from bearing housing to prevent burns/injury to
personnel.

5. Drain the pump casing. By removing the drain plug situated at the bottom of the casing.

6. Drain the bearing housing of oil. This can be done by removing the drain plug situated at the
bottom of the bearing housing.

7. Disconnect and remove seal flush pipework and allow to drain.

CAUTION

8. It is advisable to thoroughly drain and dry off the baseplate before attempting any
maintenance work on the pump. This could eliminate the risk of slipping on a wet
surface causing personal injury or mechanical damage.

9. Remove pump monitoring equipment, auxiliary services or other plant or equipment that may
interfere with safe dismantling of the pump.

10. Remove pump coupling hub, using an approved puller. Heat will be required to effect removal.
Heat to approximately 300 degrees F (149°C) in successive stages from periphery of hub
towards centre. If coupling is of the gear type then "NEVER APPLY AN OPEN FLAME TO
THE TEETH".
 50

6.2 Pump Disassembly Instructions

6.3 Disassembly of Pull Out Element

This is a pull from rear design, so it is not necessary to remove casing, or to detach suction or
discharge piping, coupling hubs or to remove driver.

1. Remove all seal piping, related instrumentation and electrical equipment that will interfere
with disassembly.

WARNING

Use extreme caution not to expose maintenance personnel to hot or caustic liquids when
removing auxiliary piping or when draining pump.

2. Disassemble and remove coupling guard and coupling spacer.

NOTE

Refer to sectional arrangement drawing and bill of material section for names of parts

3. Place lifting straps around pump at coupling end of bearing housing and at casing cover
bearing housing area. Take a slight strain on slings.

LOCATION OF LIFTING STRAPS FOR REMOVING PUMPING ELEMENT

4. When applicable remove bolting holding support plate to bearing housing and baseplate.
Remove support plate.

5. Remove casing cover to casing main flange bolting. Install two jack screws (provided) in
casing cover. Tighten jack screws evenly to separate joint between casing cover and
casing.

6. Carefully withdraw pumping element from casing until impeller (or inducer when fitted) is
clear of casing. Move pumping element to area where disassembly will be performed.
 51

7. Correctly support pumping element in horizontal position. For non-inducer machines

release impeller locking screws and locknut on impeller. For machines fitted with an
inducer, release cap nut then remove security washer.

Note - Locking devices have left hand throat form.

8. Remove inducer (if fitted) and impeller.

9. Remove and discard gasket from casing cover. Now rotate assembly so that the shaft axis
is in the vertical plane with coupling end uppermost.

10. Refer to mechanical seal drawing (in the Appendix of this manual) and identify the seal
setting plates on the front of the gland plate.

11. Rotate (or slide as appropriate for the design) the plates into the mechanical seal sleeve
setting groove and then secure.

12. Slacken the screws locking the collar/seal sleeve onto the pump shaft.

13. Unscrew any pipework from the tapped ports on the periphery of the gland plate.

14. Remove the cap screws which secure the casing cover to the bearing housing.

15. With the casing cover suitably supported carefully remove the bearing housing and place
horizontally on flat surface.

16. Remove the four nuts securing the gland plate to the casing cover. Returning to the casing
cover (with the gland plate uppermost). Note - When oil ring lubrication is provided an
additional ½" NPT plug is fitted in the top of the bearing housing adjacent to the mushroom
headed vent. Removal of the plug should enable the visual inspection of the ring.

17. Remove mechanical seal cartridge assembly.

18. Now, returning to the bearing housing, remove impeller key (and throat bush if fitted). If a
cooling fan is fitted, then remove the three locking screws securing the fan to the outboard
flinger.
Withdrawal the fan from the coupling end of the shaft.

19. Loosen clamping screws and remove flingers from pump shaft.

20. Remove cap screws from bearing end covers, securing cover to bearing housing.

21. Remove bearing end covers remove and discard gasket. Remove labyrinth from bore of
outboard end cover. Remove o-ring from labyrinth.

22. Place the bearing housing in a vertical position, (coupling end up) on blocking. Blocking
must be of sufficient height to prevent shaft end from contacting the floor.

To avoid damage to the oil rings, (when fitted) position them as shown.
 52

Oil

23. Remove the shaft assembly from coupling end of bearing housing.
Remove labyrinth from seal end of bearing housing.
Remove o-ring from labyrinth.

CAUTION

Take care not to damage the oil rings.

24. Release locking tab of lock washer. Remove locknut and lock washer.

25. Bearings can be removed by the use of a press or puller. Bearing must be installed in the
same manner as removed. It is suggested that each bearing be marked for sequence and
direction.

NOTE

When removing bearings exert pressure on inner race only. Do not exert any pressure on outer
bearing race. (See Section 7.6).

26. Remove oil rings and oil throwers from the shaft as appropriate.

This completes disassembly.

 53

SECTION VII

INSPECTION AND RENEWAL OF PARTS

7.1 General

Having dismantled the rotor, check the shaft for run out using "V" blocks or rollers placed under
the bearing areas. Run out of shaft is not to exceed .002" TIR (0.05mm TIR).

Wire brush the pump parts thoroughly. Clean off all scale, carbon, etc.
Examine parts for wear, corrosion and erosion.

7.2 Wear Rings (Impeller)

The impeller may be fitted with both front and rear wear rings or front ring only.
The impeller ring(s) are renewable and should be replaced when badly grooved, and/or when
pump performance does not meet the system requirements. Whenever it becomes necessary to
replace either wear ring, both rings involved (impeller and casing/casing cover) must be ordered
and replaced as a set as they are furnished standard size only (impeller ring oversize). Be sure to
re-establish the original running clearance between the two wear rings involved by machining the
fitted impeller ring.

To remove impeller wear rings, mutually remove wear ring set screws or ground off tack weld.
Rings can be machined off or grind two slots diametrically opposite across the width of the ring so
it can be split apart. Use caution if ring is removed by grinding so as not to damage impeller hubs.

IMPELLER

IMPELLER
HAND RING
GRINDER

IMPELLER RING REMOVAL

 54

Make sure ring fits on impeller are free of nicks or burrs. Heat new ring to 225 degrees F (107°C)
and install on impeller. Drill and tap new holes in impeller, located from clearance holes in ring for
No. 10-24 x ½" setscrews spaced half the circular distance from the previously used holes in the
impeller. See sketch below.

TYPICAL SCREW INSTALLATION FOR IMPELLER RINGS

NOTE

Impeller wear rings when installed must be machined to establish original diameter and running
clearance.

NOTE

Whenever an impeller has new wear rings fitted it must be dynamically balanced before being
reassembled.

7.3 Case Wear Ring (and Casing Cover Wear Ring When Fitted)

Each wear ring is locked against rotation with a cylindrical pin.

To remove the wear ring, press it out. If this method does not easily effect removal of the ring, it
can be split apart. First, however, drill one or more holes in the face of the worn ring.

New rings to be installed must be shrunk by freezing when installing in casing or casing cover. Fit
and secure with a locking pin.
Replacement wear rings are furnished standard size in the bore.
 55

7.4 Mechanical Seal

Mechanical seal stationary and rotating faces should be inspected for signs of wear or cracks and
replaced as necessary.

It is recommended that when reassembling mechanical seal new "O" rings and gaskets be used.

Refer to manufacturers drawing for assembly of mechanical seal.

Refer to mechanical seal section within this manual for further details.

7.5 Throat Bush (If Fitted)

Check the throat bush and replace if required. Note that the bush outside diameter should be the
same diameter as the adjacent impeller wear ring.

7.6 Bearing Handling Information

The ball bearings require correct handling and installation to ensure optimum performance. The
following information is intended as a minimum to ensure that the bearings are handled and
installed correctly.

7.7 Bearing Handling

1. Do not remove new bearings from their storage package except for inspection, when
stored for a long period of time or just prior to their installation

2. Work area must be clean to ensure that no dirt or other contaminates will enter the
bearings. Handle bearings with clean, dry hands and with clean, lint free rags. Lay bearings
on clean paper and keep covered. Never expose bearings on a dirty bench or floor.

3. Do not wash a new bearing. It is already clean and the preservative should not be
removed.

4. Before mounting, be sure shaft bearing areas are clean and free of nicks and burrs. Check
the dimensions of these areas to ensure correct fit of bearings.

7.8 Bearing Installation

1. There are two simple methods of providing a heat source for expanding the inner race of
the bearings to facilitate mounting. In the first method, bearings still wrapped in their
original intimate wrap are placed on a shelf in a temperature controlled oven, or in an
enclosure lined with foil and heated with electric light bulbs. A temperature of 150 Degrees
F (66°C) for one half hour should be sufficient.

A second method consists of locating a light bulb (100 to 150 watt) in the bore of the
bearing. The light bulb will heat, primarily, the inner ring and the bearing can usually be
handled by the outer ring without special gloves. Care must be taken to keep the bearing
clean and uncontaminated.
 56

NOTE

The old and once popular method of heating bearings in an oil bath is DEFINITELY
DISCOURAGED. HEATING INNER RING WITH A GAS TORCH IS PROHIBITED. In either case,
it is difficult to control the heating rate and final temperature and even more difficult to keep the oil
and/or bearing clean.

2. When bearings are installed on the shaft make sure the bearing is installed squarely and is
firmly seated. Hold bearing in place until it has cooled sufficiently so that it will not move
from position. Cover bearings to protect them from dirt.

NOTE

When installing the bearings the mounting pressure should never be applied in such a manner that
it is transmitted through the rolling element. Apply the mounting force directly against, and only
against, the inner ring.

7.9 Bearing Removal

If the bearing cannot be removed with the tools available never use a torch under any
circumstances. Split the outer ring with a small hand grinder, saw through the ball/roller retainer,
and split the inner ring about three quarters through with a grinder and break with a cold steel
chisel.

7.10 Bearing Cleaning

NOTE

Do not attempt to inspect condition of bearings until they have been cleaned.

1. Solvent for cleaning bearings should be in a clean container. Place bearings in solvent and
let soak for a short time. Agitate the bearing around near the top of the container, giving it a
turn now and then until it is clean. Rinse in a clean container of fresh solvent.

NOTE

Do not spin dirty bearings. Rotate them slowly while washing.

2. Dry thoroughly cleaned bearings. If an air hose is used for drying, make sure it is clean dry
air.

NOTE

Do not allow the bearings to spin by force of air. Hold the inner and outer rings to prevent
bearing from spinning.

3. Inspect bearings immediately. If there is any question as to the condition of a bearing do

not hesitate to replace it. There are many conditions that contribute to the deterioration of
the bearings. A qualified bearing representative should be consulted if there is any question
of bearing condition.
 57

4. Inspected bearings which will be reused should be packed with new grease or dipped in
clean lubricating oil, covered with clean lint free rags or other suitable covering and placed
in a clean box or carton until ready for installation.

NOTE

Under no circumstances are the bearings to be left exposed.

7.11 Assembly

1. Install thrower(s) and oil ring (if supplied) onto shaft. Secure thrower to shaft by tightening
set screws into the location groove in the shaft.

2. Install the thrust and radial bearings in the same sequence and direction as removed.

NOTE

INNER THRUST BEARING MUST BE ASSEMBLED AGAINST SHOULDER ON SHAFT WITH

THE WIDE FLANGE OF THE OUTER RACE TOWARDS THE COUPLING. THE OUTER
THRUST BEARINGS IS TO BE PLACED ON THE SHAFT WITH THE WIDE FLANGE OF THE
OUTER RACE TOWARDS THE INNER BEARING.

When installing bearings on shaft, a slight heat is required to expand the inner bearing race. The
use of a 150 watt light bulb with an aluminium foil cover to contain the heat is recommended.
Place bulb foil to cover over bearing and light bulb. Heat for approximately 20 - 30 minutes.

3. Install the lock washer and locknut.

4. Place the bearing housing in a vertical position on blocks in preparation for installation of
shaft assembly. Make sure blocking is of sufficient height so that shaft will not contact the
floor.

5. Suspend shaft vertically for installation into bearing housing. Position oil ring (if fitted) on
shaft to prevent damage it enters bearing housing.

6. Lower the shaft assembly into the bearing housing. Install gasket and end cover. Torque
bolts in accordance with Section 7.12.
 58

7. Place bearing housing in a horizontal position suitably supported. Fit new o-rings into the
grooves on each labyrinth. Working from the coupling end of the shaft the smaller labyrinth
over the shaft and press into the bearing housing until it locates against the machined
shoulder. It is held in place by the o-ring - no further fixing is required. Repeat the
operation for the other flinger, working from the impeller end of shaft.

8. Install coupling and pump end flingers onto shaft. Position flingers approximately 1mm
(.040") from their respective labyrinth and secure with appropriate clamping screws.

9. Fit new gasket in face of mechanical seal gland plate. Refit mechanical seal cartridge over
the 4 gland studs on the casing cover ensuring correct orientation of the gland tappings
(refer to mechanical seal assembly drawing). Secure with four nuts tightened to the torque
specified in section 7.12.

10. Rig bearing housing assembly to hoist impeller end and shaft downwards. Carefully lower
shaft end through seal sleeve until bearing housing locates on casing cover.

11. Secure bearing housing to cover.

12. Retighten mechanical seal drive collar set screws. Move setting plates from "transit" to
"run" position. Refit screwed piping into mechanical seal gland plates.

13. For non-inducer machines install key and impeller. Install locking nut - noting left hand
thread form. Torque nut to correct tightness. Fit and tighten lockscrew on end of locknut
throat bush (if fitted).

14. Install a new spiral wound gasket into position on casing cover.

15. Rig assembly with lifting straps to an overhead hoist and carefully install the assembled
pumping element into the casing.

NOTE

Use care when installing pumping element to avoid damage to the gasket.

Install nuts on casing cover to casing studs. Torque nuts evenly to correct tightness. (See Section
7.12).

16. Install coupling key and coupling hub onto the pump shaft.

NOTE

The coupling hub has a shrink fit to the pump shaft. The use of heat and an approved press/puller
will be required to install it. Install the pump half coupling hub by heating to approximately 300
degrees F (149°C) in successive stages from periphery of hub toward the centre. NEVER APPLY
AN OPEN FLAME TO THE COUPLING HUB TEETH.

17. If fitted install bolting holding to support plate to bearing housing and to baseplate.

18. Re-install drain plug and fill the bearing housing to the prescribed level with fresh
lubricating oil. (See Section 4).
 59

19. Check to see if rotor runs freely by turning the shaft with a strap wrench or by hand. Make
any corrections or adjustments.

20. Check driver rotation. Driver rotation must coincide with direction indicated by arrow on
pump.

21. Align pump - motor coupling per "ALIGNMENT" instructions and install spacer piece. Install
coupling guard.

22. Replace all auxiliary piping.

 60

7.12 Torque Value Supplement

Main Flange Studs/Nuts (Casing to Casing Cover)

Stud Size Torque Value
Inches ft-lbs (Nm)
¾ 166 - 195 (225 - 264)
7/8 264 - 310 (358 - 420)
1 404 - 475 (548 - 644)
1-1/8 642 - 755 (870 - 1024)

Bearing Housing To Casing Cover

Hex Head Screw Size Torque Value
Inches ft-lbs (Nm)
½ 13 - 16 (18 - 22)
5/8 27 - 33 (37 - 45)

Bearing Housing End Cover to Bearing Housing

Hex Head Screw Size Torque Value
Inches ft-lbs (Nm)
3/8 6-8 (8 - 11)

Mechanical Seal to Casing Cover

Stud/Nut Size Torque Value
Inches ft-lbs (Nm)
1/2 26 - 30 (35 - 41)
5/8 45 - 50 (58 - 68)

Thrust Bearing Locknut Torque Value

Bearing Size ft-lbs (Nm)
7307 27 - 29 (37 - 39)
7308 37 - 39 (50 - 53)
7309 48 - 50 (65 - 68)
7310 60 - 63 (81 - 85)
7311 73 - 77 (99 - 104)
7312 87 - 92 (118 - 125)
7313 102 - 107 (138 - 145)
7314 117 - 123 (159 - 167)

Inboard/Outboard Flingers Torque Value

& Oil Thrower
Socket Head Capscrews Size

Inches ft-lbs (Nm)

1/4 3-4 (4 - 5)

Torque Values listed above are selected to achieve the correct amount of pre-stress in the
threaded fastener. Maintenance personnel must ensure that threads are in good condition (free of
burrs, galling, dirt, etc.) and that commercial thread lubricant is used. Torque should be
periodically checked to ensure that it is at the recommended value.
 APPENDIX

PURE OIL MIST LUBRICATION

FOR HPX TYPE PUMPS

OIL MIST INSTALLATION

Pump bearing housing is arranged for pure oil mist lubrication. The following connections are
provided in the bearing housing

- A 1/4” NPT with adapter oil mist inlet connection in the top half of the bearing housing,
between line and thrust bearings.

- A 1/4” NPT vent connection in the space between the rolling element bearing and the
inboard/outboard bearing housing cover.

- A 1/2” NPT drain connection in the bottom half of the bearing housing.

Remove inlet and outlet pipe plugs from above connections. Install appropriate reclassifier in the
top opening, leave open vent connections, connect oil recovery trap to bottom opening or leave it
open to act as relief.

OIL SUPPLY

The lubricating oil should be rust and oxidation inhibited and stray mist suppressed, manufactured
in accordance with good commercial practice.
The viscosity should be ISO VG 100 (approx. 470 SUS at 100°F).
The following oils are recommended:

ESSO ENMIST
CHEVRON VISTAC
SHELL OMALA
TEXACO TEXAMIST

OIL MIST REQUIREMENTS

- Design manifold pressure : 20” H2O

- Oil consumption : 0.4 cubic inch/hour/CFM

- Mist consumption
7308 BG/6208 : 0.24 SCFM
7311 BG/6212 : 0.33 SCFM
7314 BG/6216 : 0.43 SCFM
7315 BG/6314 : 0.43 SCFM
7316 BG/6315 : 0.46 SCFM
7316 BG/6218 : 0.49 SCFM