Flowserve CPX, User Instructions

Page 1: ...n centrifugal chemical process pumps PCN 71569117 02 10 E Based on C937KH013 C937KH054 C961KH001 and C937KH067 Original instructions Installation Operation Maintenance These instructions must be read prior to installing operating using and maintaining this equipment ...

Page 2: ...ems 16 5 COMMISSIONING START UP OPERATION AND SHUTDOWN 16 5 1 Pre commissioning procedure 16 5 2 Pump lubricants 17 5 3 Open impeller clearance 18 5 4 Direction of rotation 18 5 5 Guarding 18 5 6 Priming and auxiliary supplies 18 5 7 Starting the pump 19 5 8 Running the pump 19 5 9 Stopping and shutdown 20 5 10 Hydraulic mechanical and electrical duty 20 Page 6 MAINTENANCE 21 6 1 General 21 6 2 Ma...

Page 3: ...5 2 5 17 Maintenance 6 21 Maintenance schedule 6 2 22 Name nomenclature 3 2 11 Nameplate 1 7 1 8 Operating limits 3 4 1 11 Ordering spare parts 6 3 1 22 Part assemblies 4 2 12 Parts interchangeability 8 5 39 Parts lists 8 33 Performance 3 4 11 Piping 4 6 13 Pre commissioning 5 1 16 Priming and auxiliary supplies 5 6 18 Protection systems 4 9 16 Page Reassembly 6 10 Assembly 26 Receipt and unpackin...

Page 4: ...pplicable the Directives and any additional Approvals cover important safety aspects relating to machinery and equipment and the satisfactory provision of technical documents and safety instructions Where applicable this document incorporates information relevant to these Directives and Approvals To confirm the Approvals applying and if the product is CE marked check the serial number plate markin...

Page 5: ...iate training and instruction must be provided If required the operator may commission the manufacturer supplier to provide applicable training Always coordinate repair activity with operations and health and safety personnel and follow all plant safety requirements and applicable safety and health laws and regulations 1 6 3 Safety action This is a summary of conditions and actions to help prevent...

Page 6: ...cal seal DO NOT RUN THE PUMP AT ABNORMALLY HIGH OR LOW FLOW RATES Operating at a flow rate higher than normal or at a flow rate with no back pressure on the pump may overload the motor and cause cavitation Low flow rates may cause a reduction in pump bearing life overheating of the pump instability and cavitation vibration 1 6 4 Products used in potentially explosive atmospheres Measures are requi...

Page 7: ...lity for compliance with the specified maximum liquid temperature is with the plant operator Temperature classification Tx is used when the liquid temperature varies and when the pump is required to be used in differently classified potentially explosive atmospheres In this case the user is responsible for ensuring that the pump surface temperature does not exceed that permitted in its actual inst...

Page 8: ...ed to have the correct corrosion resistance Avoid entrapment of liquid in the pump and associated piping due to closing of suction and discharge valves which could cause dangerous excessive pressures to occur if there is heat input to the liquid This can occur if the pump is stationary or running Bursting of liquid containing parts due to freezing must be avoided by draining or protecting the pump...

Page 9: ...mp only noise levels in the table should be combined with the level for the driver obtained from the supplier Consult Flowserve or a noise specialist if assistance is required in combining the values It is recommended that where exposure approaches the prescribed limit then site noise measurements should be made The values are in sound pressure level LpA at 1 m 3 3 ft from the machine for free fie...

Page 10: ...d steel there are no specific lifting points provided for this complete machine set unless so identified Any lifting points that can be seen are provided only for dismantling parts for servicing Slings ropes and other lifting gear should be positioned where they cannot slip and where a balanced lift is obtained Before lifting the driver alone refer to the manufacturer s instructions 2 4 Storage St...

Page 11: ...ng enables adjustment of impeller face clearance via the bearing carrier jacking screws 3 3 5 Pump bearings and lubrication The pump is fitted with ball and or roller type bearings which may be configured differently dependent on use The bearings may be oil or grease lubricated 3 3 6 Cover The cover has spigots between the pump casing and bearing housing for optimum concentricity A fully confined ...

Page 12: ...f pump and motor half coupling must be checked If this is incorrect it indicates that the baseplate has become twisted and should be corrected by re shimming e If not supplied guarding shall be fitted as necessary to meet the requirements of ISO 12100 and EN953 4 4 Grouting Where applicable grout in the foundation bolts After adding pipework connections and rechecking the coupling alignment the ba...

Page 13: ...and including section 5 Commissioning startup operation and shutdown before connecting driver and checking actual rotation 4 6 Piping Protective covers are fitted to the pipe connections to prevent foreign bodies entering during transportation and installation Ensure that these covers are removed from the pump before connecting any pipes 4 6 1 Suction and discharge pipework Never use pump as a sup...

Page 14: ... b It is recommended that the pump inlet pipe is no larger than the pump inlet bore or such that the suction velocity is in the range of 3 to 5 m sec 10 to 16 ft sec The piping should slope down towards the pump casing suction flange c Allow a minimum of two pipe diameters of straight section between the elbow and inlet flange d Fitting an isolation valve will allow easier maintenance e Never thro...

Page 15: ...oid seal damage it is recommended that any external flush cooling supply be continued after stopping the pump 4 6 4 3 Pumps fitted with heating cooling jackets Connect the heating cooling pipes from the site supply The top connection should be used as the outlet to ensure complete filling venting of the annulus with heating cooling liquids steam is usually in at the top out at the bottom 4 6 5 Fin...

Page 16: ...stalled To prevent excessive surface temperatures at bearings it is recommended that temperature or vibration monitoring is carried out 5 COMMISSIONING START UP OPERATION AND SHUTDOWN These operations must be carried out by fully qualified personnel 5 1 Pre commissioning procedure 5 1 1 Lubrication Determine the mode of lubrication of the pump set eg grease oil etc For oil lubricated pumps fill th...

Page 17: ...311 Z C3 3313 Z C3 6207 Z C3 6309 Z C3 6311 Z C3 6313 Z C3 7306 pair back to back 7309 pair back to back 7311 pair back to back 7313 pair back to back 6 0 2 13 0 5 18 0 6 20 0 7 14 0 5 25 0 9 35 1 2 46 1 6 Nilos ring fitted into bearing locknut 3712 2 Oil lubricated medium duty bearings Oil lubricated heavy duty bearings Oil lubricated optional heavy duty bearings Frame size Pump end Drive end Pum...

Page 18: ...ing element removed Ensure the direction of rotation of the motor is correct before fitting the coupling element Direction of rotation must correspond to the direction arrow If maintenance work has been carried out to the site s electricity supply the direction of rotation should be re checked as above in case the supply phasing has been altered 5 5 Guarding Guarding is supplied fitted to the pump...

Page 19: ...ing time is noted Priming times in excess of 5 minutes will indicate a pump or system fault Any noticeable increases in priming time on subsequent starts will also indicate a fault Irregular use could lead to the risk of evaporation of the priming fluid k Do not run the pump with the outlet valve closed for a period longer than 30 seconds l If the pump has to fill the system it may take a short ti...

Page 20: ...elocity unfiltered r m s Motor 15 kW mm sec in sec Motor 15 kW mm sec in sec Normal N 3 0 0 12 4 5 0 18 Alarm N x 1 25 3 8 0 15 5 6 0 22 Shutdown trip N x 2 0 6 0 0 24 9 0 0 35 Where a grease lubricated unit is utilized in a vertical shaft configuration with a duck foot bend onto the pump suction the following apply Vibration velocity unfiltered r m s Vertical configurations mm sec in sec Normal N...

Page 21: ...NANCE 6 1 General It is the plant operator s responsibility to ensure that all maintenance inspection and assembly work is carried out by authorized and qualified personnel who have adequately familiarized themselves with the subject matter by studying this manual in detail See also section 1 6 Any work on the machine must be performed when it is at a standstill It is imperative that the procedure...

Page 22: ...c seals and that any sealant systems if fitted are full and operating normally c Check that shaft seal leaks are within acceptable limits d Check the level and condition of oil lubricant On grease lubricated pumps check running hours since last recharge of grease or complete grease change e Check any auxiliary supplies eg heating cooling if fitted are functioning correctly Refer to the manuals of ...

Page 23: ...pendent on pump size Open ended spanners wrenches to suit up to M 24 screws nuts Socket spanners wrenches up to M 24 screws Allen keys up to 10 mm A F Range of screwdrivers Soft mallet More specialized equipment Bearing pullers Bearing induction heater Dial test indicator C spanner wrench for removing shaft nut If difficulties in sourcing are encountered consult Flowserve Coupling grip shaft spann...

Page 24: ... is obtained This is the zero clearance position e Set a dial indicator to zero on the shaft end or measure the bearing carrier to bearing housing gap and record the measurement f Slacken the jacking screws 6570 3 g Tighten bearing carrier screws 6570 2 evenly about one flat at a time until the dial indicator or feeler gauge shows the correct impeller clearance from the zero clearance position Thi...

Page 25: ...e cover screws d Loosen the grub screws used in most mechanical seals e Carefully pull off the gland and mechanical seal rotating element s f Remove the seal cover 1220 g Remove shaft sleeve 2400 if fitted h On non cartridge seals the stationary seat remains in the cover with its sealing member Remove only if damaged or worn out i On pumps fitted with gland packing the packing and lantern ring sho...

Page 26: ...and grip the shaft It is important that the temperature is not raised above 100 ºC 212 ºF Method 2 Press the bearing onto the shaft using equipment that can provide a steady even load to the inner race Take care to avoid damaging the bearing and shaft d Fit the thrust ball bearing 3013 on to shaft 2100 e The double row thrust bearing will not normally have a single filling slot as such bearings ar...

Page 27: ...ards the bearing housing and set with its clearance 0 5 to 2 mm 0 02 to 0 08 in 6 10 2 Cover and seal assembly a Extreme cleanliness is required The sealing faces and shaft or sleeve surface must be free from scratches or other damage b Refer to section 6 11 Seal arrangements for seal diagrams c Carefully press the stationary seat into the cover 1220 ensuring that the seating ring is not deformed ...

Page 28: ...the distance ring 2510 2 b Install the bearing housing assembly into the pump casing Coat the screws 6570 1 with anti galling compound and tighten into casing c Check impeller front clearance against original setting or process requirement and adjust as necessary See section 6 7 Setting impeller clearance d Ensure that all other items have been re attached and all fasteners tightened then follow t...

Page 29: ...12 5 0 160 12 5 0 5 5 9 5 200 17 5 5 0 5 5 9 5 250 10 6 4 4 18 3 4 3 315 10 6 4 4 18 3 4 3 4 7 32 3 400 27 0 4 3 3 5 24 0 500 10 6 4 4 18 3 4 3 4 7 32 3 6 11 2 Cartridge seal types 6 11 2a Cartridge seal in conical cover 6 11 2b Hooked sleeve cartridge seal For S see seal supplier s instructions 6 11 3 Tandem seal types 6 11 3a Tandem seal with Flowserve eccentric pumping annulus circulation BI Rp...

Page 30: ...irculation Setting dimension X mm Pump size Frame 1 Frame 2 Frame 3 Frame 4 125 11 0 160 11 0 17 5 200 6 0 17 5 250 12 4 14 4 315 12 4 14 3 32 3 400 5 7 24 0 500 12 4 14 3 32 3 6 11 5 External seal types 6 11 5a External seal D drain 6 11 6 Packed gland seal types 6 11 6a Packed gland with fibre packing 4120 4130 4134 F Rp in flush BI Rp in barrier liquid inlet BO Rp in barrier liquid outlet ...

Page 31: ...e Check suction pipe is airtight Air leaks into pump through mechanical seal sleeve joints casing joint or pipe lugs Check and replace faulty parts CONSULT FLOWSERVE Foot valve too small Investigate replacing the foot valve Foot valve partially clogged Clean foot valve Inlet of suction pipe insufficiently submerged Check out system design Speed too low CONSULT FLOWSERVE Speed too high CONSULT FLOW...

Page 32: ...tory check bearings for excessive wear Impeller out of balance resulting in vibration Abrasive solids in liquid pumped Internal misalignment of parts preventing seal ring and seat from mating properly Check and CONSULT FLOWSERVE Mechanical seal was run dry Check mechanical seal condition and source of dry running and repair Internal misalignment due to improper repairs causing impeller to rub Chec...

Page 33: ... ring 2540 1 Flinger liquid 2540 2 Flinger liquid 3011 Radial ball bearing 3013 Thrust ball bearing 3134 Support foot 3200 Bearing housing 3240 Bearing carrier 3712 1 Bearing locknut 3712 2 Bearing locknut 3855 Constant level oiler 3856 Oil sight gauge 4200 Mechanical seal 4330 Labyrinth ring 4590 1 Gasket 4590 2 Gasket 4610 1 O ring 4610 2 O ring 6544 Circlip 6569 1 Plug filler 6569 2 Plug 6569 3...

Page 34: ...d 3011 Radial ball bearing 3013 Thrust ball bearing 3134 Support foot 3200 Bearing housing 3240 Bearing carrier 3712 1 Bearing locknut 3712 2 Bearing locknut 3855 Constant level oiler 3856 Oil sight gauge 4200 Mechanical seal 4330 Labyrinth ring 4590 Gasket 4610 1 O ring 4610 2 O ring 6544 Circlip 6569 1 Plug filler 6569 2 Plug magnetic 6570 1 Screw 6570 2 Screw 6570 3 Screw 6570 4 Screw 6572 Stud...

Page 35: ...liquid 2540 2 Flinger liquid 3011 Radial ball bearing 3013 Thrust ball bearing 3134 Support foot 3200 Bearing housing 3240 Bearing carrier 3712 1 Bearing locknut 3712 2 Bearing locknut 3855 Constant level oiler oil lubrication only 3856 Oil sight gauge 4200 Mechanical seal 4330 Labyrinth ring 4590 1 Gasket 4590 2 Gasket 4610 1 O ring 4610 2 O ring 6544 Circlip 6569 1 Plug filler 6569 2 Plug 6569 3...

Page 36: ... 1 Flinger liquid 2540 2 Flinger liquid 3011 Radial ball bearing 3013 Thrust ball bearing 3134 Support foot 3200 Bearing housing 3240 Bearing carrier 3712 Bearing locknut 3855 Constant level oiler 3856 Oil sight gauge 4200 Mechanical seal 4330 Labyrinth ring 4590 1 Gasket 4590 2 Gasket 4610 1 O ring 4610 2 O ring 6544 Circlip 6569 1 Plug filler 6569 2 Plug 6569 3 Plug magnetic 6569 4 Plug filler 6...

Page 37: ...casing 1100 4590 3 6570 5 1410 6570 1 4590 1 4610 3 6569 2 4590 2 6569 4 Drawing taken from C665 001 sheet 9 rev C 8 3 4 CPXP diffuser casing parts list Item Description 1100 Casing 1410 Diffuser 4590 1 Gasket 4590 2 Gasket 4590 3 Gasket 4610 3 O ring 6569 2 Plug 6569 4 Plug filler 6570 1 Screw 6570 5 Screw Standard option ...

Page 38: ... key drive impeller option 2100 2400 6700 2 2200 4610 5 2912 1 4590 4 6570 6 2912 2 4610 4 includes heli coil 6589 SOLID SHAFT SHOWN BELOW CENTRE LINE SLEEVED SHAFT SHOWN ABOVE CENTRE LINE Key drive design for 304 316 stainless steel and above secure screw with PTFE sealant Loctite 577 Item Description 2100 Shaft 2200 Impeller 2400 Sleeve if fitted 2912 1 Impeller nut 2912 2 Impeller nut 4590 4 Ga...

Page 39: ...CPX CPXR CPXN and CPXP USER INSTRUCTIONS ENGLISH 71569117 02 10 Page 39 of 44 flowserve com 8 5 Parts interchangeability 8 5 1 CPX parts interchangeability ...

Page 40: ...ypical general arrangement drawing and any specific drawings required by the contract will be sent to the Purchaser separately unless the contract specifically calls for these to be included into the User Instructions If required copies of other drawings sent separately to the Purchaser should be obtained from the Purchaser and retained with these User Instructions ...

Page 41: ... obtained from the purchaser for retention with these User Instructions Where any pre printed set of User Instructions are used and satisfactory quality can be maintained only by avoiding copying these they are included at the end of these User Instructions such as within a standard clear polymer software protection envelope 10 2 Change notes If any changes agreed with Flowserve Pump Division are ...

Page 42: ...USER INSTRUCTIONS CPX CPXR CPXN and CPXP ENGLISH 71569117 10 09 Page 42 of 44 flowserve com Notes ...

Page 43: ...USER INSTRUCTIONS CPX CPXR CPXN and CPXP ENGLISH 71569117 10 09 Page 43 of 44 flowserve com Notes ...

Page 44: ... Service Fax 33 43 40 58 17 To find your local Flowserve representative please use the Sales Support Locator System found at www flowserve com FLOWSERVE REGIONAL SALES OFFICES USA and Canada Flowserve Corporation 5215 North O Connor Blvd Suite 2300 Irving Texas 75039 5421 USA Telephone 1 972 443 6500 Fax 1 972 443 6800 Europe Middle East Africa Worthing S P A Flowserve Corporation Via Rossini 90 9...