Flowserve SVCN 7, Installation Operation & Maintenance

Page 1: ...5 API 610 7th Ed dated Feb 1989 SUBJECT Instruction Operation and Maintenance IOM Manual Notes The SVCN7 design was the same for both API 610 7th and 8th Editions During 1993 IDP transitioned to the HPX NOTE This information is intended for the use of Flowserve Employees The information provided is based on standard catalogue price book information Details for specific units or serial numbers may ...

Page 2: ...SVCN 7 PUMP INSTALLATION OPERATION MAINTENANCE 1 ...

Page 3: ...fting Complete Unit 1 5 1 6 2 Lifting Driver 1 5 1 6 3 Lifting Pump 1 5 1 7 Storage 1 6 1 7 1 Preparation For Storage 1 7 1 7 2 Storage Area 1 7 1 7 3 Inspection and Maintenance 1 7 1 7 3 1 Six Months Prior to Installation 1 8 1 7 3 2 One Month Prior to Installation 1 8 1 7 4 Painting and Preservation 1 8 1 7 5 Associated Equipment 1 9 1 8 Preparation For Installation Operation 1 9 2 Installation ...

Page 4: ...thetic Lubricants 3 5 3 3 2 Bearing Housing Preparation 3 6 3 3 3 Oiler Adjustment 3 6 3 3 4 Inspection 3 6 3 3 5 Replenishment 3 7 3 3 6 Oil Change 3 7 3 4 Pump Operation 3 7 3 4 1 Operating Precautions 3 7 3 4 2 Pre Operational Checks 3 7 3 4 3 Initial Start Up Procedure 3 8 3 4 4 Normal Start Up 3 9 3 4 5 Operating Checks 3 10 3 4 6 Securing the Pump 3 11 3 5 General Maintenance 3 11 3 5 1 Rout...

Page 5: ... Wear Rings or Bushings 4 7 4 4 7 Replacing Impeller Wear Rings 4 8 4 5 Assembly 4 9 4 5 1 Head Rotor Assembly 4 9 4 5 2 Head Rotor Installation 4 12 5 PARTS ORDERING AND SERVICING INFORMATION 5 1 5 1 REGIONAL Sales OFFICES 5 1 5 2 SERVICE Centers North America 5 1 5 3 INTERNATIONAL OFFICES 5 4 v DO2604 13 ...

Page 6: ...p and associated components covered by this manual Correct installation and care of protective guards shut down devices and over pressure protection equipment are essential to any safety program and must be included If applicable to your operating environment your safety program must also cover hazards which arise from the presence of electrical power hot oil high pressure and temperature liquids ...

Page 7: ...e with a 3 in 75 mm or smaller discharge nozzle Vent drain and gauge connections are optional Those incorporated in the case are shown by the pump and motor driver OUTLINE drawing Drains are drilled through the inner volute of the double volute pump With any case design all major parts of the pump can be removed as a unit once the coupling spacer is removed without disturbing the position of the c...

Page 8: ...are used with both packing and the mechanical seal and can only be removed by disassembling the pump Cartridge seals may also used 1 3 7 HEAD The head on the SVCN 7 pump has a packing gland or a seal plate and it is installed from outside the head Only packing can be replaced without disassembling the pump The head with packing gland incorporates a passageway and tapped boss for piping a lubricant...

Page 9: ...igned for installation from the inside In either event it is tack welded or secured with set screws which are staked 1 4 3 BEARING LUBRICATION The automatic oiler on the side of the housing maintains the oil level below the lowest balls of the bearings The basic system is supplemented by oiling rings that turn with the pump shaft splashing oil on unsubmerged balls The purge mist if installed is bl...

Page 10: ...IT WARNING Do not lift the complete unit by slinging from pump case and or eye bolt on motor The coupling spacer must be removed from between pump and driver half couplings before lifting the complete unit To lift the pump and baseplate without the driver or the baseplate alone sling from all four eye bolts The pump driver and baseplate can be lifted as a complete unit Sling from all four eye bolt...

Page 11: ...e agreed full responsibility and cost associated with the storage and inspection of this equipment rests with the purchaser 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 DO2604 13 1 6 ...

Page 12: ...If the pump was shipped in a sealed plastic covering then the covering should be reinstalled prior to placing the pump in storage 1 7 2 STORAGE AREA 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 po...

Page 13: ...he removal of any protective coverings 3 An inspection of the equipment with the protective coverings removed 4 A partial or complete dismantling of the equipment may be required depending on the length of storage the class type of storage provided and the results of steps 1 through 3 above 5 Restoration of painted or preserved surfaces and or replacement of gaskets O rings packing or mechanical s...

Page 14: ...e from a spark Ensure that the area where they are used is well ventilated and has a fire extinguisher nearby After the equipment has been inspected and unpacked after receipt or storage the pump surfaces must be cleaned and prepared for operation before installing the pump Internal and unpainted external surfaces of the pump as well as items ordered separately are protected with a petroleum based...

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Page 16: ...ouble turns 5 that the piping slopes in the correct direction 6 that no high spots or pockets are present in which air or vapor can collect 7 that piping supports valves and fittings are properly located and all eccentric reducers or increasers are properly installed 8 that the piping is installed to avoid excessive loads on the pump nozzles from poor alignment of piping or improper location of pi...

Page 17: ...n pump horsepower heating the liquid A bypass may be required to prevent vaporization and subsequent pump damage Refer to your local Flowserve office to determine if a bypass is required Mechanical damage may result from continuous operation at flows less than specified 2 1 3 FOUNDATION The foundation should be sufficiently rigid and substantial to prevent any pump vibration and to permanently sup...

Page 18: ...bolt while pouring concrete Pipe sleeve to be three times the diameter of the anchor bolt Weld a large washer with lugs to the bottom of the bolt and pipe sleeve to prevent turning Rough finish concrete for grout Figure 2 3 Foundation Bolt 2 1 4 LEVELING THE BASEPLATE Before putting the unit on the foundation thoroughly clean the top of the foundation Break off any loose pieces of cement and rough...

Page 19: ...urfaces of the pump and driver pads Adjust the baseplate level by adjusting the leveling screws or by adjusting the shim packs under the baseplate To adjust the shim pack thickness 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 basep...

Page 20: ...uctions Holes are provided in the baseplate to permit pouring the grout and to act 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 Make sure the baseplate is vented correctly and all areas are thoroughly filled to prevent any resonant problems Pour grout until level reach...

Page 21: ...o the pump 2 after the first run with the pump still hot from several hours of operation with incoming liquid at its normal temperature and before the pump goes on line for an extended period 3 after the first slight increase in vibration appears following a long period in service or after a sudden increase in vibration 2 2 2 ALIGNMENT PRECONDITIONS To simplify shaft alignment and prevent inaccura...

Page 22: ...ure distance between pencil marks the distance or total lateral movement should be at least 0 5 in 13 mm d Set end space by pushing shaft back in toward sleeve bearing 0 13 in 3 mm see Figure 2 6 At this setting there will be adequate end space between thrust collars and bearing faces For example if total lateral movement is 0 5 in 13 mm and the shaft is pushed back in toward bearing face 0 13 in ...

Page 23: ...ling or driver shaft as shown in Figure 2 8 PUMP OR OTHER UNIT HALF COUPLING SPACER INSTALLED DRIVER OR OTHER UNIT HALF COUPLING DIAL INDICATORS NOTE TO PREVENT DEFLECTION OF INDICATORS THE BRACKETS MUST BE RIGID IN CONSTRUCTION AND SECURELY FIXED IN POSITION Figure 2 8 Dial Indicator Setup For Alignment 2 Set the bracket to the horizontal 9 o clock position Zero the indicator then rotate both sha...

Page 24: ...ount pads 3 Check both pump and driver for soft foot at each hold down bolt as follows a Tighten all hold down bolts to the torque recommended by the equipment manufacturer b Install a dial indicator to read the vertical motion of a equipment foot Loosen the hold down bolt for that foot until it is finger tight The vertical motion should not exceed 0 002 in 0 05 mm If the vertical motion is excess...

Page 25: ...ng This is the amount of bar sag 8 Rotate the pipe again so that indicator is facing up It must return to 0 9 Repeat steps 7 and 8 to confirm reading NOTE All indicator readings must be taken on the periphery or rim of the coupling hub or shaft or on the opposite bracket They must be recorded as viewed from the fixed unit pump see Figure 2 10 FIXED UNIT 3 12 3 6 9 1 2 4 3 12 3 6 9 1 2 4 MOVABLE UN...

Page 26: ...s Horizontal Movement Calculations Movable Unit Scale Fixed Unit Scale 50 40 30 20 10 0 10 20 30 40 50 60 60 50 40 30 20 10 0 10 20 30 40 50 60 60 180 0 90 270 3 Indicator 2 4 1 Set Bar Sag 2 2 2 4 180 0 90 270 3 Indicator 2 4 1 Set Bar Sag 2 2 2 4 50 cm 20 in 100 cm 40 in 150 cm 60 in 200 cm 80 in 0 0 SHAFT ALIGNMENT CALCULATOR Cold º Hot Pump Shop Order Movable Unit Fixed Unit Measurement 1 Meas...

Page 27: ...ot exceed 0 001 inch per 12 inches 0 03 mm per 305 mm 19 Check hold down bolt positions on the graph or otherwise determine the amount of shims to be added for the vertical correction and the movement required for the horizontal correction if either exceeds maximums If maximums are exceeded a release driver hold down bolts if installed b using lifting equipment lift driver and shim under feet for ...

Page 28: ...ection in which the pump is designed to turn 26 Remove flat strap 27 Secure coupling spacer between half couplings if not done previously 28 Install coupling guard 2 2 6 HOT ALIGNMENT CAUTION Gear type couplings must be lubricated before running pump see coupling manufacturer s instructions After completing a cold alignment of driver and pump but before the pump is allowed to operate for an extend...

Page 29: ...rwise determine the amount of shims to be added or subtracted for the vertical correction and the movement required for the horizontal correction If maximums are exceeded in this hot alignment a allow units to cool down b complete steps 19a through 19e 20 and 21 of paragraph 2 2 5 starting on page 2 12 above c repeat hot alignment procedure until TIR is within specifications DO2604 13 2 14 ...

Page 30: ...d be referred to Flowserve for our recommendations 3 1 3 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 ch...

Page 31: ...low for this pump is listed on your pump data sheet 0 6 0 7 0 8 0 9 1 0 1 0 1 5 2 0 2 5 3 0 3 5 4 0 Km Figure 3 1 Minimum Flow Correction Factor for NPSHA Margin 0 20 40 60 80 100 120 20 40 80 1 00 1 20 60 Percent of Design R P M KS Figure 3 2 Correction of MCSF for Speeds Other Than Design Speed DO2604 13 3 2 ...

Page 32: ...en to allow for signal spread to avoid cyclic conditions 3 2 4 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 3 2 4 1 Continuous Bypass Sizing for Parallel Units The limits and or protection requirements of two or more units in p...

Page 33: ...akest pump head 3600 3600 2 100 3420 From head capacity curve Minimum weakest pump flow 27 gpm Minimum strongest pump flow 65 gpm 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 4000 3780 3420 3000 20 27 40 60 80 100 CAPACITY GPM STRONGEST PUMP WEAKEST PUMP Figure 3 3 Parallel Operation 3 3 LUBRICATION A...

Page 34: ... 600 700 800 F Pure Oil Mist ISO 68 315 SSU Frame B C Pumpage Temperature ISO 68 315 SSU Ambient Temperature C 130 120 110 100 90 80 70 60 50 400 350 300 250 200 150 100 50 0 40 50 40 30 20 10 C F 100 200 300 400 500 600 700 800 Figure 3 4 Recommended Viscosity at Specified Pumping and Ambient Temperature Frame A Frame B Frame C 1 7 1 5 10 5 6 13 6 18 1 5 7 2 10 5 8 13 8 18 2 7 3 10 5S 3 15 10 18 ...

Page 35: ...ng nut so that the rim of the reservoir is 0 47 to 0 50 in 11 9 to 12 7 mm above the centerline of the side port Fill reservoir with recommended oil and install on oiler body Remove fill and reinstall reservoir as many times as required to fill the bearing housing up to the rim of the reservoir with no air bubbles in the reservoir Remove reservoir and ensure that the oil level is 0 47 to 0 50 in 1...

Page 36: ...on which is compliant with your organization s local safety procedures Do not allow sparking flames or hot surfaces in the vicinity of equipment which handles volatile or flammable liquids Do not perform any maintenance on or around the pump when it is rotating If unusual noise or vibrations occur secure the pump as soon as possible 1 Never operate the pump with the suction valve closed 2 Never op...

Page 37: ...inimal flow Do not start pump with a fully closed discharge 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 Check the oil level in the bearing housing to ensure sufficient oil is available for bearing lubrication Replenish oil as necessary in accordance with section 3 3 Lubrica...

Page 38: ...ter 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 10 Start the driver in accordance with the manufacturer s instructions and bring it up to speed quickly 11 As soon as the pump is up to rated speed slowly op...

Page 39: ... 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 CAUTION Excessive tightening of the packing gland increases packing wear which in turn is apt to result in burned packing and a scored shaft sleeve 3 After ru...

Page 40: ...discharge valve The pump suction valve should be closed only if required by system operation or maintenance 3 Close valve in bypass line 4 Turn off cooling liquid 5 If pump is subjected to freezing temperatures it must be drained of liquid to prevent damage to the pump Before being put on the line that is started the pump requires an external inspection for operational readiness and lube oil servi...

Page 41: ...le glands for tightness Every Six Months Change all lubricants Yearly Check foundation fixing bolting grouting for looseness cracking or general distress Check unit alignment against previous inspection Check calibration of instruments Every Three Years Check internal condition of pump and all auxiliary piping for corrosion erosion Check internal pump components for wear 3 5 2 TROUBLESHOOTING This...

Page 42: ...pump and remove any foreign material Mechanical Causes Shaft bent Dismantle pump and replace part or parts causing vibration Pump overloads driver False overload signal Check starter controls Wire connections faulty Check for hot spots in lines Speed too high Check driver instruction manual Specific gravity too high Check rated conditions Pump bearings seized or rotating element binding Dismantle ...

Page 43: ...N OPERATION MAINTENANCE TROUBLE CAUSE REMEDY Loose parts Tighten or replace defective parts Noise in driver Check driver with stethoscope Check driver instruction section for trouble shooting instructions DO2604 13 3 14 ...

Page 44: ...rawing or the Parts List both located in the back of this manual Before performing any disassembly maintenance and or inspection on the unit the following steps should be taken WARNING When in the vicinity of caustic corrosive volatile flammable hot cold or otherwise hazardous liquids wear protective clothing which is compliant with your organization s local safety procedures When in the vicinity ...

Page 45: ... packing removal hook 4 2 2 PACKING INSTALLATION To install packing if installed proceed as follows 1 Clean shaft sleeve and packing gland thoroughly with a petroleum base agent such as kerosene or dry cleaning solvent and allow to dry 2 Dip packing in a lubricating liquid which is compatible with your pumpage 3 Slide first packing ring into box as far as possible by hand 4 Slide a split sleeve or...

Page 46: ...ion Secure the head rotor to prevent tipping or rolling 2 Using a torch heat the pump half coupling to about 300 F 149 C Then use a coupling puller to remove it from the shaft 1 Remove the coupling key 2966B NOTE The impeller nut 238 or inducer 3186 has left handed threads 3 Bend back the ear of the impeller lock washer 3151 then remove the impeller nut 238 or inducer 3186 and lock washer Then rem...

Page 47: ...otherwise continue to disassemble pump as outlined 10 Pull the outboard fan 2719 off of the shaft with its O rings 1259E 11 Loosen lock screw and remove inboard fan 2744 from shaft 1 12 Remove end cover cap screws and bearing housing end cover 2999B Remove the bearing isolator rotor 3043B Remove and discard the O ring 1259D If installed remove the outer oiling ring 2889B 13 Using a wooden mandrel ...

Page 48: ...nd may ignite from a spark Ensure that the area where they are used is well ventilated and has a fire extinguisher nearby When the pump is used in a steam or water circuit all internal parts of the pump should be cleaned with a non petroleum based cleaning agent such as alcohol or acetone or a steam cleaner that uses steam from demineralized water Petroleum based agents such as dry cleaning solven...

Page 49: ...facturer s instructions located in the back of this manual Specifically the stationary and rotating seal faces should be inspected for wear or cracking and replaced as necessary When reassembling the seal all old gaskets and O rings should be discarded and replaced with new parts 4 4 3 CHECKING SHAFT STRAIGHTNESS CAUTION Application of heat to straighten shaft will cause more distortion When makin...

Page 50: ... 610 proceed as follows CAUTION Ensure that the parent part is not damaged during removal of the wear ring 1 Remove the wear ring retainers 2 Remove the old wear ring by placing the parent part in a lathe and turning out the wear ring If this is not feasible grind through the wear ring in two places and break the ring out of the parent part CAUTION Do not bind or distort the wear ring Ensure that ...

Page 51: ...nd break the ring off of the impeller CAUTION Do not bind or distort the wear ring 4 Heat the new wear ring to 225 F 107 C using a torch or induction heater then slip the wear ring into place on the impeller Ensure that the set screw holes in the wear ring line up with the set screw holes in the impeller 5 Verify trueness of wear ring to impeller fit as outlined below or by an equivalent technique...

Page 52: ...uter race in contact in between the two bearings Figure 4 3 Thrust Bearing Assembly 2 Heat radial bearing 3036A and thrust bearing 3036B to 200 230 F 95 110 C and slide them up against their shoulders on the shaft 1 3 Install the thrust bearing lock washer 3150 and lock nut 453 as follows a Slide thrust bearing lock washer onto shaft then thread lock nut onto shaft hand tight b Spin outer races of...

Page 53: ...ing end cover and evenly tighten cap screws CAUTION If you have oil mist lubrication make sure that the oil drain holes are plugged on the thrust and radial sides of the bearing housing to allow oil mist to pass through bearings Use 3 8 16U NC X 0 38 long setscrew for thrust side and 20UNC X 0 25 long set screw for radial side 8 Carefully lift bearing housing 2998 and place it in a horizontal posi...

Page 54: ...ads f Install impeller lock washer 3151 then install and tighten lock nut 238 or inducer 3186 but do not bend an ear on the lock washer The impeller must be tight against the shaft shoulder with no play g Fix dial indicator to bearing housing register face or another point so that it is rigid and touch indicator button to either wear ring 200A B h Slowly rotate shaft and record readings at 12 3 6 ...

Page 55: ...reads 19 Install the impeller lock washer 3151 then install and tighten the impeller nut 238 or inducer 3186 and bend a lock washer tab to secure the nut 20 Using a dry heat convection oven or an induction heater heat the pump half coupling to about 300 F 149 C Install the coupling key 2966B and the pump half coupling on the shaft 1 21 Transport the head rotor to the case or to storage as required...

Page 56: ... fill the bearing housing 2998 to the prescribed level with fresh lubricating oil see paragraph 3 3 Lubrication on page 3 4 7 Reinstall the coupling spacer and coupling guard 8 Reinstall all auxiliary piping or equipment which was removed for disassembly 9 If the pump case and driver were not disturbed during the disassembly or assembly of the pump then perform a hot alignment check in accordance ...

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Page 58: ...he impeller wearing surfaces have been refaced the wearing ring on the mating stationary part can be supplied in undersize In such a case the required undersize diameter must be stated in the order 5 1 REGIONAL SALES OFFICES USA and Canada Flowserve Corporation Pump Division Millennium Center 222 Las Colinas Blvd 15th Floor Irving TX 75039 5421 USA Phone 972 443 6500 Fax 972 443 6800 Latin America...

Page 59: ...45 Fax 630 762 8994 Vancouver Service Center 10400 NE 13th Avenue Vancouver WA 98686 Phone 360 573 5211 Fax 360 574 7656 Rancho Dominguez Service Center 1909 East Cashdan Dominguez Hills CA 90220 Phone 310 608 4500 Fax 310 608 4540 Fairfield Service Center 142 Clinton Road Fairfield NJ 07004 Phone 973 227 4565 Fax 973 227 6615 Greer Service Center 2431 South Highway 14 Greer SC 29650 Phone 864 879...

Page 60: ...SVCN 7 INSTALLATION OPERATION MAINTENANCE 5 3 DO2604 13 ...

Page 61: ...e 39 0931 511326 Fax 39 0931 511304 Italy Caserta S S 87 Km 19 81025 Marcianise Caserta Augusta Italy Phone 39 0823 634232 Fax 39 0823 634218 Italy Desio Via Rossini 90 92 20033 Desio Milan Italy Phone 39 0362 612251 Fax 39 0362 628882 The Netherlands Etten Leur Parallelweg 6 4878 AH Etten Leur Netherlands Phone 31 76 5028360 Fax 31 76 5028359 Spain Arganda Cía Ingersoll Dresser Pump S A Ctra NIII...

Page 62: ... 61 362653 Fax 58 61 361771 Venezuela Punto Fijo AV Raul Leoni Edif Trattoria D Enzo 1er Piso Oficina 5 Punto Fijo Estado Falcon Venezuela Phone 58 69 46 7744 Fax 58 69 46 5544 Venezuela Puerta La Cruz AV Las Flores Centro Profesional Fabian Piso 9 Oficina 94 Puerta La Cruz Edo Anzoategui Venezuela Phone 58 81 67402 Fax 58 81 673677 MIDDLE EAST United Arab Emirates Flowserve AL Mansoori Services C...