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I.O.M.
Installation,
Operation and
Maintenance
Pump Division
TABLE OF CONTENTS
1.0 Introduction .....................................................................1
2.0 Safety considerations .....................................................2
3.0 Overview
3.1 Warranty statement................................................4
3.2 Nameplate ..............................................................4
3.3 Storage
Short term..............................................................4
Long term ..............................................................5
3.4 Lifting pumps and assemblies................................5
4.0 Mark III ANSI Standard Pump
4.1 General description of pump ..................................7
4.2 Installation
Protection of openings and threads .......................8
Rigid baseplates overview...................................8
Installation and Alignment
Factory Alignment
Procedure........................................................8
Recommended Procedure for
Baseplate Installation and
Final Field Alignment .......................................9
New Grouted Baseplates ..........................9
Existing Grouted Baseplates...................10
Stilt Mounted Baseplates........................10
Zirconium Components........................................11
Piping connection Suction/discharge ................11
Mechanical Seal ...................................................12
Packing ................................................................13
Piping connection Seal/packing
support system .............................................13
Piping connection Bearing housing
cooling system ..............................................13
Piping connection Support leg cooling
for centerline mounting option ......................13
Piping connection Heating/cooling fluid
for jacketed cover/casing ...............................14
Piping connection Oil mist lubrication
system...........................................................14
Coupling...............................................................15
Coupling guard maintenance.........................15
C-flange motor adapter
Special considerations..............................15
4.3 Operation
Rotation check .....................................................16
Pre start-up checks ..............................................16
(See Maintenance Section for details)
Impeller setting .............................................16
Shaft seal ......................................................16
Seal/packing support system ........................16
Bearing lubrication ........................................16
Bearing housing cooling system ...................16
Pump Division
Grease
Regreaseable bearings .............................33
Shielded bearings .....................................33
Sealed bearings ........................................33
Oil mist ........................................................33
Reinstallation .......................................................33
4.6 Spare parts ........................................................34
How to order spare parts .....................................34
Appendix A.
Appendix B.
Appendix C.
Appendix D.
Appendix E.
Appendix F.
Appendix G.
Appendix H.
Appendix I.
Appendix J.
Appendix K.
Pump Division
Section 1.0
THE COMPANY
Among Flowserve Corporations brands, Durco has long been
recognized as the leading name in chemical process pumps.
Durco pumps are manufactured at Flowserves modern
facilities, utilizing state-of-the-art equipment and sophisticated
quality control techniques. Flowserve provides technical
support and special services specific to the needs of its
customers. Flowserve is proud of earning preferred supplier
status with many of the world's leading processing companies.
Engineered and manufactured, sold and serviced to ISO 9001
quality certification, Durco process pumps are truly world class
products. And with more than 120 years of experience in
serving the needs of the worldwide process industries,
Flowserve has become the unchallenged leader in hydraulic
design engineering, materials expertise, and application knowhow. Committed to continuous quality improvement, Flowserve
controls the complete product life cycle from melting and
casting, to cellular manufacturing to assembly and testing, to
supply of aftermarket products, repair and diagnostic services.
The advanced design and precision manufacture of the rugged,
heavy-duty Mark III chemical service pump significantly
enhance bearing and seal life, thereby extending mean time
between planned maintenance (MTBPM). Its exclusive features
provide significant performance benefits for chemical pump
users. Most notable among these are:
1. The exclusive reverse vane impeller offers important
performance-enhancing, maintenance-reducing advantages.
2. The exclusive external micrometer shaft adjustment provides
dead accurate setting of impeller clearance in seconds.
3. The ANSI 3A power end, SealSentry family of seal
chambers, Ultralign pump/motor shaft alignment system
and the BaseLine family of baseplates are building blocks
for improved MTBPM.
A Flowserve Sales Engineer, Representative or Distributor will
be happy to review the advanced product features that make the
Mark III the leader in chemical pumping technology.
Pump Division
Section 2.0
DANGER
DANGER Immediate hazards which WILL result in severe
personal injury or death.
WARNING
WARNING Hazards or unsafe practices which COULD result in
severe personal injury or death.
CAUTION
CAUTION Hazards or unsafe practices which COULD result in
minor personal injury or product or property damage.
NOTE: ALWAYS COORDINATE REPAIR ACTIVITY WITH OPERATIONS PERSONNEL, AND FOLLOW ALL PLANT SAFETY
REQUIREMENTS AND APPLICABLE SAFETY AND HEALTH LAWS/REGULATIONS.
Pump Division
Section 2.0
CD4M
DS
300
100
DC2
DC3
200
TEMPERATURES C
250
300
D4
D4L
1500
DINC
D20
1250
DNI
150
1000
DS
DCI LOW TEMPERATURE
LIMIT
100
50
CR29
CD4M
UPPER LIMIT
DCI
UPPER LIMIT
100
300
300
500
700
Ductile Iron
High Chrome Iron
High Chrome Iron
High Chrome Iron
Carbon Steel
Durco CF8
Durco CF3
Durco CF8M
Durco CF3M
Durcomet 100
Durimet 20
Durcomet 5
Durco CY40
Durco M35
Nickel
Chlorimet 2
Chlorimet 3
Duriron
Durichlor 51
Superchlor
Durco DC8
Titanium
Titanium-Pd
Zirconium
DCI
CR28
CR29
CR35
DS
D2
D2L
D4
D4L
CD4M
D20
DV
DIN
DM
DNI
DC2
DC3
D
D51
SD51
DC8
Ti
Ti-Pd
Zr
None
None
None
None
None
CF8
CF3
CF8M
CF3M
CD4MCu
CN7M
None
CY40
M351
CZ100
N7M
CW6M
None
None
None
None
None
None
None
300
DS
DINC
DC2
DC3
2250
2000
D2 D4
D2L D4L
D20
CD4M
UPPER LIMIT
200
1500
1250
GROUP I & II
CLASS 300 MARK III PUMPS
BASED ON ANSI B16.5
GROUP III
CLASS 300 MARK III PUMPS
LIMITED TO CLASS 150 RATINGS
150
CLASS 300
FLANGES
-100
100
1000
TI
TIP
ZR
750
500
300
400
500
600
700
TEMPERATURES F
ASTM Specifications
None
None
None
None
Carbon Steel
304
304L
316
316L
Ferralium
Alloy 20
None
Inconel 600
Monel 400
Nickel 200
Hastelloy B
Hastelloy C
None
None
None
None
Titanium
Titanium-Pd
Zirconium
A395
A532 class III
None
None
A216 Gr. WCB
A744, Gr. CF8
A744, Gr. CF3
A744, Gr. CF8M
A744, Gr. CF3M
A744, Gr. CD4MCu
A744, Gr. CN7M
None
A744, Gr. CY40
A744, Gr. M351
A744, Gr. CZ100
A494, Gr. N7M
A494, Gr. CW6M
A518
A518
A518
None
B367, Gr. C3
B367, Gr. C8A
B752, Gr. 702C
Duriron, Durichlor 51 and Superchlor are registered trademarks of Flowserve Corporation Ferralium is a registered trademark of Langley Alloys
Hastelloy is a registered trademark of Haynes International, Inc. Inconel and Monel are registered trademarks of International Nickel Co. Inc.
350
1750
TEMPERATURES F
250
D4
500
600
200
250
100
400
150
DS
LOW
TEMPERATURE
LIMIT
DNI
100
CD4M
250
CLASS 150
FLANGES
-100
750
50
DM
1750
D2
D2L
350
2000
DM
200
-50
350
TI
TIP
ZR
DCI
250
150
50
TEMPERATURES C
-50
Pump Division
Section 3.0
3.3 STORAGE
3.2 NAMEPLATE
An example of the nameplate used on the Mark III pump is
shown below. This nameplate, which is always mounted on the
Mark III bearing housing, is shown in Figure 3.
FIGURE 3
How To Identify Durco Mark III Process Pump
Pump Division
Serial No.
Equipment No.
Purchase Order
Model
Size
2K6X4M-13A/124RV
MDP
Material
Date, DD/MMM/YY
Flowserves pump size code is used to indicate the size of the pump.
For example, consider the following:
2K6X4M13A/124RV
2 indicates a medium size pump
frame - in this example, a Group 2
1=Group 1 (small frame)
2=Group 2 (medium frame)
3=Group 3 (large frame)
K = Mark 3 style power end
J = Mark 3 style PE arranged for
Mark 2 wet end
No letter and no preceding number
indicates a Mark 2 power end
Nominal suction port size
Nominal discharge port size
Modifier for specialty pumps
blank or no letter = Standard pump
M = Sealmatic
L = Non-metallic wet end
R = Recessed impeller
H = High silicon iron
US = Unitized self-priming S = Old style self-priming
V = Vertical in-line
T = Teflon lined wet end
LF = Lo-Flo
E = Durcon wet end
Nominal maximum impeller diameter
13 = 13 inch
Pump design variation
A = This pump has been redesigned from an earlier
version. The impeller and casing are no longer
interchangeable with the earlier version.
H = This pump is designed for a higher flow capacity than
another pump with the same basic designation.
Examples: 4X3-10 and 4X3-10H; 6X4-10 and 6X4-10H;
10X8-16 and 10X8-16H. In each case the pump with
the H is designed for a higher flow capacity.
HH = This pump is designed for a higher head than another
pump with the same basic designation.
Example: 4X3-13 and 4X3-13HH
Actual impeller size
124 = 124/8 or 121/2 in diameter; 83 = 83/8 in; 106 = 106/8 or 103/4 in
Impeller style
RV = Reverse vane impeller; OP = Open impeller
Pump Division
Section 3.4
LIFTING
Solid wood skids are utilized. Holes are drilled in the skid to
accommodate the anchor bolt holes in the baseplate, or the
casing and bearing housing feet holes on assemblies less
baseplate. Tackwrap sheeting is then placed on top of the skid
and the pump assembly is placed on top of the Tackwrap. Metal
bolts with washers and rubber bushings are inserted through
the skid, the Tackwrap, and the assembly from the bottom of
the skid and are then secured with hex nuts. When the nuts are
snugged down to the top of the baseplate or casing and
bearing housing feet, the rubber bushing is expanded, sealing
the hole from the atmosphere. Desiccant bags are placed on
the Tackwrap. The Tackwrap is drawn up around the assembly
and hermetically (heat) sealed across the top. The assembly is
completely sealed from the atmosphere and the desiccant will
absorb any entrapped moisture. A solid wood box is then used
to cover the assembly to provide protection from the elements
and handling. This packaging will provide protection up to
twelve months without damage to mechanical seals, bearings,
lip seals, etc. due to humidity, salt laden air, dust, etc.
After unpacking, protection will be the responsibility of the user.
Addition of oil to the bearing housing will remove the inhibitor.
If units are to be idle for extended periods after addition of
lubricants, inhibitor oils and greases should be used.
Every three months, the shaft should be rotated
approximately 10 revolutions.
CAUTION
Do not use eye bolts or cast-in lifting lugs to lift pump, motor,
and baseplate assemblies.
Before lifting the equipment refer to the pump data sheet for the
complete assembly weight.
Pump Components:
Casing (#100): Use a choker hitch pulled tight around the
discharge nozzle.
Rear cover (#106): Insert an eye hook in the drilled and
tapped hole at the top of the cover. Use either a sling or
hook through the eye bolt.
Bearing housing (#119): Group I. Insert a sling between the
upper and lower support ribs between the housing barrel
and the casing attachment flange. Use a choker hitch
when slinging. Caution, make sure there are no sharp
edges on the bottom side of the ribs which could cut
the sling.
Group 2 and 3. Insert either a sling or hook through the
lifting lug located on the top of the housing.
Power end: Same as bearing housing.
Bare Pump: Sling around the pump discharge nozzle, and
around the outboard end of the bearing housing with
separate slings. Choker hitches must be used at both
attachment points and pulled tight. Make sure the
completion of the choker hitch on the discharge nozzle is
toward the coupling end of the pump shaft as shown in
Figure 4. The sling lengths should be adjusted to balance
the load before attaching the lifting hook.
Pump, motor and baseplate assembly: If the baseplate has
lifting holes cut in the sides at the end, (Type A Group 3,
Type D, and Type E bases) insert lifting S hooks at the
four corners and use slings or chains to connect to the
lifting eye as shown in Figure 5. Do not use slings
through the lifting holes.
For other baseplates sling around the pump discharge
nozzle, and around the outboard end of the motor frame
using choker hitches pulled tight (Figure 6). The sling
should be positioned so the weight is not carried through
the motor fan housing. Make sure the completion of the
choker hitch on the discharge nozzle is toward the
coupling end of the pump shaft as shown in Figure 6.
Pump Division
Section 3.4
FIGURE 4
FIGURE 5
FIGURE 6
Pump Division
Section 4.0
Pump Division
Section 4.2
4.2 INSTALLATION
PROTECTION OF OPENINGS AND THREADS
When the pump is shipped all threads and all openings are
covered. This protection/covering should not be removed until
installation. If, for any reason, the pump is removed from
service, this protection should be reinstalled.
FIGURE 8
Pump Division
Section 4.2
FIGURE 9
Shims
(For Vertical
Alignment)
Baseplate
Plastic Tubing
Around Bolt
Grout
Dam
Wedge
Packing
Sleeve
Locking Tab
Welded to Bolt
Anchor
Bolt
Washer
Concrete
Foundation
Pump Division
Section 4.2
5.
6.
7.
8.
motor hold down bolts and motor foot holes to move the
motor into final alignment. If the pump and motor were
properly reinstalled to the baseplate or if they were not
removed from the baseplate and there has been no transit
damage, and also if the above steps where done properly,
the pump and driver should be within 0.015 in (0.38 mm)
FIM (Full Indicator Movement) parallel, and 0.0025 in/in
(0.0025 mm/mm) FIM angular. If this is not the case first
check to see if the driver mounting fasteners are centered
in the driver feet holes. If not, recenter the fasteners and
perform a preliminary alignment to the above tolerances by
shimming under the motor for vertical alignment, and by
moving the pump for horizontal alignment.
Grout the baseplate. A non-shrinking grout should be
used. Make sure that the grout fills the area under the
baseplate. After the grout has cured, check for voids and
repair them. Jackscrews, shims and wedges should be
removed from under the baseplate at this time. If they were
to be left in place, they could rust, swell, and cause
distortion in the baseplate.
Run piping to the suction and discharge of the pump. There
should be no piping loads transmitted to the pump after
connection is made. Recheck the alignment to verify that
there are no significant loads.
Perform final alignment. Check for soft-foot under the
driver. An indicator placed on the coupling, reading in the
vertical direction, should not indicate more than 0.002 in
(0.05 mm) movement when any driver fastener is
loosened. Align the driver first in the vertical direction by
shimming underneath its feet. When satisfactory alignment
is obtained the number of shims in the pack should be
minimized. It is recommended that no more than five
shims be used under any foot. Final horizontal alignment is
made by moving the driver. Maximum pump reliability is
obtained by having near perfect alignment. Flowserve
recommends no more than 0.002 in (0.05mm) parallel, and
0.0005 in/in (0.0005 mm/mm) angular misalignment.
Operate the pump for at least an hour, or until it reaches
final operating temperature. Shut the pump down and
recheck alignment while the pump is hot. Piping thermal
expansion may change the alignment. Realign pump as
necessary.
3.
4.
5.
6.
Pump Division
Section 4.2
WARNING
Zirconium 702 and high chrome iron have relatively low impact
strengths. These materials could crack if subjected to excessive
temperature changes, pressure changes or impacts.
FIGURE 11
Mark III Pump Installation Using Expansion Joints
Fixed axial supports must
be designed to resist the
collapsing forces of the
expansion joint selected
and to permit adjustment
to pump flanges without
loading or creating
forces on flanges.
Expansion joint
WARNING
Piping Forces: Take care during installation and operation to
minimize pipe forces and/or moments on the pump casing.
Forces and moments must be kept within the limits given in
Appendix I.
Many bellows type joints have an effective area larger than the
pipe area. The force resulting from application of system
pressure over the effective area when combined with other live
and dead loads must not exceed the values given in Appendix I.
If the combined forces and moments are greater than the
values from Appendix I, a piping system as shown in Figure 11
must be used.
Suction Piping
To avoid NPSH and suction problems, suction pipe sizes must
be at least as large as the pump suction connection. Never use
pipe or fittings on the suction that are smaller in diameter than
the pump suction size.
Figure 12 illustrates the ideal piping configuration with a
minimum of 10 pipe diameters between the source and the
pump suction. In most cases, horizontal reducers should be
eccentric and mounted with the flat side up as shown in Figure
13 with a maximum of one pipe size reduction. Never mount
eccentric reducers with the flat side down. Horizontally
mounted concentric reducers should not be used if there is
any possibility of entrained air in the process fluid. Vertically
mounted concentric reducers are acceptable. In applications
where the fluid is completely deaerated and free of any vapor or
suspended solids, concentric reducers are preferable to
eccentric reducers.
FIGURE 12
Good Piping Practice
DIAMETERS
FIGURE 13
Good Piping Practice
SUCTION
11
Pump Division
Section 4.2
FIGURE 14
Suction pressure limits
MAXIMUM ALLOWABLE SUCTION PRESSURE kPa
Mark III
REVERSE VANE IMPELLER
MAXIMUM ALLOWABLE
SUCTION PRESURE
1750 RPM
SPECIFIC GRAVITY
Suction pressure limits for Mark III pumps with reverse vane
impellers are given in Figure 14. The curves show maximum
allowable suction pressure at various specific gravities. Note
that Class 300 flanges may be necessary. Note also that for
front vane open impellers the suction pressure is limited only
by the pressure/ temperature curves shown in Figure 1.
SPECIFIC GRAVITY
WARNING
Discharge Piping
Install a valve in the discharge line. This valve is required for
regulating flow and/or to isolate the pump for inspection and
maintenance.
WARNING
When fluid velocity in the pipe is high, for example, 10 f/s
(3 m/s) or higher, a rapidly closing discharge valve can cause a
damaging pressure surge. A dampening arrangement should be
provided in the piping.
MECHANICAL SEAL
When the pump is intended to be equipped with a mechanical
seal, it is Flowserves standard practice to install the mechanical
seal in the pump prior to shipment. Specific order requirements
may specify that the seal be shipped separately, or none be
supplied. It is the pump installers responsibility to determine if
a seal was installed. If a seal was supplied but not installed, the
seal and installation instructions will be shipped with the pump.
WARNING
Failure to ensure that a seal is installed may result in serious
leakage of the pumped fluid.
Seal and seal support system must be installed and operational
as specified by the seal manufacturer.
12
Pump Division
Section 4.2
PACKING
FIGURE 16
WARNING
Failure to ensure that packing is installed may result in serious
leakage of the pumped fluid.
PIPING CONNECTION
SEAL/PACKING SUPPORT SYSTEM
Tap V
Lip Seal
Seal Cage
Packing
PIPING CONNECTION
BEARING HOUSING COOLING SYSTEM
Make connections as shown below. Liquid at less than 90F
(32C) should be supplied at a regulated flow rate of at least
1 gpm (0.06 l/s).
WARNING
If the pump has a seal support system, it is mandatory that this
system be fully installed and operational before the pump is
started.
If packing is used:
Packing Lubrication Water, when compatible with the pumpage, should be introduced into Tap V (Figure 15) at pressure 10
to 15 lbf/in2 (69 to 103 kPa) above the stuffing box pressure.
The gland should be adjusted to give a flow rate of 20 to 30
drops per minute for clean fluid. For abrasive applications, the
regulated flow rate should be 1-2 gpm (0.06-0.13 l/s).
FIGURE 15
Tap V
Outlet
Inlet
Inlet
Pump Division
Section 4.2
Suction Inlet
Valve
Drain
Plug
Suggested Plumbing to
Obtain Drain When
Using Liquid
Notes:
1. When circulating steam, use top hole for inlet. Both
bottom holes must be plumbed together for outlet, to
ensure draining both sides of jacket.
2. When circulating liquid, use both bottom holes as inlets.
Use top hole as outlet.
PIPING CONNECTION
OIL MIST LUBRICATION SYSTEM
The piping connections for an oil mist lubrication system are
shown below.
OIL MIST READY HOUSING WET SUMP
Locate Vent Fitting
Above Horizontal CL At
Assy
1/2 NPT
1/4 NPT
Opp Side
1/2 NPT
1 NPT
1/4 NPT
Opp Side
14
Pump Division
Section 4.2
COUPLING
CAUTION
A direction arrow is cast on the front of the Casing (See
Figure 17) and on the Bearing Housing. Make sure the motor
rotates in the same direction before coupling the motor to the
Pump. It is absolutely essential that the rotation of the motor
be checked before connecting the shaft coupling. Incorrect
rotation of the pump, for even a short time, can dislodge the
impeller which may cause serious damage to the pump. All
Durco pumps turn clockwise as viewed from the motor end or,
conversely, counterclockwise when viewed from the suction
end as shown in Figure 17.
WARNING
Power must never be applied to the driver when the coupling
guard is not installed.
The Durco coupling guard is of the clam shell design and is
shown in Figure 19. It is hinged at the top. It can be removed by
loosening one of the foot bolts and sliding the support leg out
from under the cap screw (note that the foot is slotted). The leg
can then be rotated upward and half of the guard can be disengaged (unhinged) from the other. Note that only one side of
the guard needs to be removed. To reassemble simply reverse
the above procedure.
FIGURE 17
Refer to Appendix J for trimming and assembly instructions for
the ClearGuard coupling guard.
Flowserve coupling guards are safety devices intended to
protect workers from inherent dangers of the rotating pump
shaft, motor shaft and coupling. It is intended to prevent entry
of hands, fingers or other body parts into a point of hazard by
reaching through, over, under or around the guard. No standard
coupling guard provides complete protection from a disintegrating coupling. Flowserve cannot guarantee their guards will
completely contain an exploding coupling.
The Durco coupling guard shown in Figure 19 conforms to the
U.S.A. standard ASME B15.1, Safety Standard for Mechanical
Power Transmission Apparatus. Flowserve manufacturing
facilities worldwide conform to local coupling guard
regulations.
FIGURE 19
Typical
Non-Spacer
Coupling
15
Typical Spacer
Coupling
Pump Division
Section 4.3
4.3 OPERATION
ROTATION CHECK
CAUTION
It is absolutely essential that the rotation of the motor be
checked before connecting the shaft coupling. Incorrect
rotation of the pump, for even a short time, can dislodge and
damage the impeller, casing, shaft and shaft seal. All Durco
pumps turn clockwise as viewed from the motor end. A
direction arrow is cast on the front of the casing as shown in
Figure 17. Make sure the motor rotates in the same direction.
16
Pump Division
Section 4.4
FIGURE 20
CAUTION
Ensuring that NPSHA is larger than NPSHR by the suggested
margin will greatly enhance pump performance and reliability.
It will also reduce the likelihood of cavitation, which can
severely damage the pump.
MINIMUM FLOW
Minimum continuous stable flow is the lowest flow at which the
pump can operate and still conform to the bearing life, shaft
deflection and bearing housing vibration limits of ANSI/ASME
B73.1M-1991. Pumps may be operated at lower flows, but it
must be recognized that the pump may not conform to one or
more of these limits. For example, vibration may exceed the
limit set by the ASME standard. The size of the pump, the
energy absorbed, and the liquid pumped are some of the
considerations in determining the minimum flow.
Typically, limitations of 10% of the capacity at the best
efficiency point (BEP) should be specified as the minimum flow.
However, Flowserve has determined that several pumps must
be limited to higher minimum flows to provide optimum
service. The following are the recommended minimum flows
for these specific pumps:
17
Pump Size
1K3X2-6
2K3X2-8
2K4X3-8
2K3X2-10
2K4X3-10
2K6X4-10
2K3X2-13
2K4X3-13
2K6X4-13
ALL GROUP 3 PUMPS*
ALL OTHER SIZES
60 Hz
Minimum
flow
RPM (% of BEP)
50 Hz
Minimum
flow
RPM (% of BEP)
3500
3500
3500
3500
3500
3500
3500
3500
1750
1750
ANY
2900
2900
2900
2900
2900
2900
2900
2900
1450
1450
ANY
25%
25%
25%
33%
33%
50%
50%
50%
50%
50%
10%
21%
21%
21%
28%
28%
42%
42%
42%
42%
42%
10%
*In some cases, the 3K6X4-16 can be used at lower than 50% of BEP, by making a
modification. Contact Flowserve Engineering if this pump is to be used at a lower flow.
WARNING
Do not operate the pump at below Minimum Thermal Flow, as
this could cause an excessive temperature rise. Contact a
Flowserve Sales Engineer for determination of Minimum
Thermal flow.
DANGER
Never operate pump with both the suction and discharge valves
closed. This could cause an explosion.
2. A standard centrifugal pump will not move liquid unless the
pump is primed. A pump is said to be primed when the
casing and the suction piping are completely filled with
liquid. Open discharge valve a slight amount. This will allow
any entrapped air to escape and will normally allow the
Pump Division
Section 4.4
DANGER
SHUTDOWN CONSIDERATIONS
When the pump is being shutdown, the procedure should be
the reverse of the start-up procedure. First, slowly close the
discharge valve, shutdown the driver, then close the suction
valve. Remember, closing the suction valve while the pump is
running is a safety hazard and could seriously damage the
pump and other equipment.
TROUBLESHOOTING
The following is a guide to troubleshooting problems with Durco pumps. Common problems are analyzed and solutions are offered.
Obviously, it is impossible to cover every possible scenario. If a problem exists that is not covered by one of the examples, then refer
to one of the books listed in the Sources of Additional Information section or contact a local Flowserve Sales Engineer or
Distributor/Representative for assistance.
PROBLEM
POSSIBLE CAUSE
RECOMMENDED REMEDY
Problem #1
Pump not reaching design
flow rate
1.1
Insufficient NPSH. (Noise may
not be present.)
1.2
System head greater than
anticipated.
18
Pump Division
Section 4.4
PROBLEM
POSSIBLE CAUSE
RECOMMENDED REMEDY
1.3
Entrained air. Air leak from
atmosphere on suction side.
1.4
Entrained gas from process.
1.5
Speed too low.
1.6
Direction of rotation wrong.
1.7
Impeller too small.
1.8
Impeller clearance too large.
1.9
Plugged impeller, suction line or casing
which may be due to a product or large
solids.
1.10
Wet end parts (casing cover, impeller)
worn, corroded or missing.
Problem #2.0
Pump not reaching design
head (TDH).
2.1
Refer to possible causes under
Problem #1.0.
Problem #3.0
No discharge or flow with
3.1
Not properly primed.
3.2
Direction of rotation wrong.
3.3
Entrained air. Air leak from
atmosphere on suction side.
3.4
Plugged impeller, suction line or
casing which may be due to a
fibrous product or large solids.
3.5
Damaged pump shaft, impeller.
4.1
Insufficient NPSH.
4.2
Entrained air. Air leak from
atmosphere on suction side.
Problem #4.0
Pump operates for short
period, then loses prime.
19
Pump Division
Section 4.4
PROBLEM
POSSIBLE CAUSE
RECOMMENDED REMEDY
Problem #5.0
Excessive noise from
wet end.
5.1
Cavitation - insufficient NPSH available.
5.2
Abnormal fluid rotation due to
complex suction piping.
5.3
Impeller rubbing.
Problem #6.0
Excessive noise from
power end.
6.1
Bearing contamination appearing
on the raceways as scoring, pitting,
scratching, or rusting caused by
adverse environment and
entrance of abrasive contaminants
from atmosphere.
6.2
Brinelling of bearing identified by
indentation on the ball races, usually
caused by incorrectly applied forces in
assembling the bearing or by shock
loading such as hitting the bearing or
drive shaft with a hammer.
6.3
False brinelling of bearing identified
again by either axial or circumferential
indentations usually caused by
vibration of the balls between the races
in a stationary bearing.
6.4
Thrust overload on bearing identified by
flaking ball path on one side of the outer
race or in the case of maximum capacity
bearings, may appear as a spalling of the
races in the vicinity of the loading slot.
(Please note: maximum capacity bearings
are not recommended in Mark III
pumps.) These thrust failures are caused
by improper mounting of the bearing or
excessive thrust loads.
6.5
Misalignment identified by fracture of
ball retainer or a wide ball path on the
inner race and a narrower cocked ball
path on the outer race. Misalignment is
caused by poor mounting practices or
defective drive shaft. For example,
bearing not square with the centerline or
possibly a bent shaft due to improper
handling.
20
Pump Division
Section 4.4
PROBLEM
POSSIBLE CAUSE
RECOMMENDED REMEDY
6.6
Bearing damaged by electric
arcing identified as electroetching of both inner and outer
ring as a pitting or cratering.
Electrical arcing is caused by a
static electrical charge eminating from belt drives, electrical
leakage or short circuiting.
6.7
Bearing damage due to improper
lubrication, identified by one or
more of the following:
1. Abnormal bearing temperature
rise.
2. A stiff cracked grease
appearance.
3. A brown or bluish discoloration
of the bearing races.
21
Pump Division
Section 4.5
4.5 MAINTENANCE
DISASSEMBLY
PREVENTIVE MAINTENANCE
DANGER
Lock out power to driver to prevent personal injury.
2. Close the discharge and suction valves, and drain all liquid
from the pump.
3. Close all valves on auxiliary equipment and piping, then
disconnect all auxiliary piping.
4. Decontaminate the pump as necessary.
DANGER
If Durco pumps contain dangerous chemicals, it is important to
follow plant safety guidelines to avoid personal injury or death.
5. Remove the coupling guard. (See page 15 on Coupling
Guards.)
6. Remove the spacer from the coupling.
7. Remove casing fasteners (#115A).
8. Remove the fasteners holding the bearing housing foot to
the baseplate.
9. Move the power end, rear cover, and seal chamber
assembly away from the casing. Discard the casing/ cover
gasket (#107).
CAUTION
The power end and rear cover assembly is heavy. It is
important to follow plant safety guidelines when lifting it.
10. Transport the assembly to the maintenance shop.
11. Remove the coupling hub from the pump shaft (#105).
12. Using the shaft key (#130), mount the impeller wrench
from the Durco Tool Kit (Figure 21) to the end of the
shaft. With the wrench handle pointing to the left when
viewed from the impeller end, grasp the impeller (#103)
firmly with both hands (wear heavy gloves), by turning the
impeller in the clockwise direction move the wrench handle
to the 11:00 oclock position and then spin the impeller
quickly in a counterclockwise direction so that the wrench
makes a sudden impact with a hard surface on the bench.
After several sharp raps, the impeller should be free.
22
Pump Division
Section 4.5
FIGURE 23
DANGER
Do not apply heat to the impeller. If liquid is entrapped in the
hub, an explosion could occur.
Refer to Appendix F for instructions on removing the seal,
sleeve, and rear cover plate if pump is equipped with a
SealSentry FMI seal chamber. This is the Durco seal
chamber that does not have a separate gland. The gland is
integral to the seal chamber.
13. Remove the seal or packing gland nuts (#111A).
14. Remove the two cap screws (#140) which attach the rear
cover plate to the adapter. Carefully remove the rear cover
plate (#106).
FIGURE 22
23
20. If the power end is oil lubricated, remove the drain plug
(#134) and drain the oil from the bearing housing (#119).
21. If the pump has lip seals, a deflector (#114) will be
present. Remove it.
22. Loosen the three set screws (#201A) on the bearing carrier
(#201). The bearing carrier must be completely unscrewed
from the bearing housing. Note: Do not pry against the
shaft.
Mark IIIA design
The face of the bearing carrier has three square lugs that
protrude from the surface. The bearing carrier is turned by
using an open end wrench on one of the square lugs as
shown in Figure 25.
Pump Division
Section 4.5
FIGURE 25
FIGURE 26
CAUTION
Applying pressure to the outer race could permanently damage
the bearings.
FIGURE 25A
27. The Mark IIIA design has an optional oil slinger (#122)
located between the bearings. If present, inspect it for
damage or looseness. Remove if it needs to be replaced.
28. On Group 2 and 3 pumps, the bearing housing (#119)
must be separated from the bearing housing adapter
(#108).
Mark IIIA design
This is accomplished by removing the capscrews (#139)
which thread into the bearing housing.
Old style Mark III design
This is accomplished by removing the hexnuts (#139A)
and the capscrews (#139). The adapter O-ring (#131)
should be discarded.
29. If lip seals (#118) and (#129) (Figure 27) are used, they
should be removed from the bearing housing and adapter
and discarded.
24
Pump Division
Section 4.5
FIGURE 27
FIGURE 30
CLEANING/INSPECTION
All parts should now be thoroughly cleaned and inspected. New
bearings, O-rings, gaskets, and lip seals should be used. Any
parts that show wear or corrosion should be replaced with new
genuine Flowserve parts.
WARNING
It is important that only non-flammable, non-contaminated
cleaning fluids are used. These fluids must comply with plant
safety and environmental guidelines.
25
Pump Division
Section 4.5
ASSEMBLY
Note: Refer to Figure 31 for all bolt torque information.
It is very important that all pipe threads be sealed properly.
PTFE tape provides a very reliable seal over a wide range of
fluids, but it has a serious shortcoming if not used properly. If,
during application to the threads, the tape is wrapped over the
end of the male thread, strings of the tape will be formed off
when threaded into the female fitting. This string can then tear
away and lodge in the piping system. If this occurs in the seal
flush system, small orifices can become blocked effectively
shutting off flow. For this reason, Flowserve does not
recommend the use of PTFE tape as a thread sealant.
FIGURE 31
Recommended Bolt Torques (US Customary Units)
Item
Description
Group 1
Non-lubricated
Group 2
Non-lubricated
Group 3
Non-lubricated
201E
201E
139
111
111
115
N/A
3/16 in - 2 ft lbf
N/A
3/8 in - 10 ft lbf
3/8 in - 40 ft lbf
1/2 in - 25 ft lbf
5/16 in - 6 ft lbf
5/16 in - 6 ft lbf
5/8 in - 53 ft lbf
1/2 in - 25 ft lbf
1/2 in - 97 ft lbf
3/4 in - 75 ft lbf
140
201A
136
195
3/8 in - 11 ft lbf
3/8 in - 11 ft lbf
1/2 in - 27 ft lbf
N/A
N/A
3/16 in - 2 ft lbf
1/2 in - 27 ft lbf
3/8 in - 10 ft lbf
3/8 in - 40 ft lbf
1/2 in - 25 ft lbf
5/8 in - 45 ft lbf
3/8 in - 11 ft lbf
1/2 in - 27 ft lbf
3/4 in - 94 ft lbf
3/8 in - 10 ft lbf
1/2 in - 27 ft lbf
1/2 in - 27 ft lbf
1 in - 228 ft lbf
1/2 in - 25 ft lbf
Note: For lubricated or PTFE-coated threads, use 75% of the values given.
Recommended Bolt Torques (Metric)
Item
Description
Group 1
Non-lubricated
Group 2
Non-lubricated
Group 3
Non-lubricated
201E
201E
139
111
111
115
N/A
3/16 in - 3 N m
N/A
3/8 in - 13 N m
3/8 in - 54 N m
1/2 in - 34 N m
5/16 in - 8 N m
5/16 in - 8 N m
5/8 in - 72 N m
1/2 in - 34 N m
1/2 in - 130 N m
3/4 in - 102 N m
140
201A
136
195
3/8 in - 15 N m
3/8 in - 15 N m
1/2 in - 37 N m
N/A
N/A
3/16 in - 3 N m
1/2 in - 37 N m
3/8 in - 13 N m
3/8 in - 54 N m
1/2 in - 34 N m
5/8 in - 61 N m
3/8 in - 15 N m
1/2 in - 37 N m
3/4 in - 130 N m
3/8 in - 13 N m
1/2 in - 37 N m
1/2 in - 37 N m
1 in - 300 N m
1/2 in - 34 N m
Note: For lubricated or PTFE-coated threads, use 75% of the values given.
26
Pump Division
Section 4.5
Outboard
Bearing
Slinger
Inboard
Bearing
Bearing installation
Mounting of bearings on shafts must be done in a clean
environment. Bearing and power end life can be drastically
reduced if even very small foreign particles work their way into
the bearings.
FIGURE 32A
The chart shown in Figure 33 gives the SKF part numbers for
bearings in Durco Mark III pumps. Note that the term inboard
Outboard
Bearing
Shield
Inboard
Bearing
FIGURE 33
Durco Mark III Bearings
Group
1
Type of Bearings
Oil bath/mist Open1
Regreasable Single Shielded2
Greased for life Double Shielded3
Sealed for life Double Sealed4
Inboard
Single Row,
Deep Groove5
6207-C3
6207-ZC3
6207-2ZC3
6207-2RSIC3
6310-C3
6310-ZC3
6310-2ZC3
6310-2RSIC3
5310-AHC3
5310-AZC3
5310-A2ZC3
5310-A2RSC3
7310-BECBY
NA6
NA7
NA7
6314-C3
6314-ZC3
6314-2ZC3
6314-2RSIC3
5314-AC3
5314-AZC3
5314-A2ZC3
5314-A2RSC3
7314-BECBY
NA6
NA7
NA7
1
2
27
Optional Outboard
Duplex Angular
Contact5
7306-BECBY
NA6
NA7
NA7
These bearings are open on both sides. They are lubricated by oil bath or oil mist.
These bearings are pre-greased by Flowserve. Replacement bearings will generally not be pre-greased, so grease must be applied by the user. They
have a single shield, which is located on the side next to the grease buffer, or reservoir. The bearings draw grease from the reservoir as it is needed.
The shield protects the bearing from getting too much grease, which would generate heat. The grease reservoir is initially filled with grease by
Flowserve. Lubrication fittings are provided, to allow the customer to periodically replenish the grease, as recommended by the bearing and/or
grease manufacturer.
These bearings are shielded on both sides. They come pre-greased by the bearing manufacturer. The user does not need to regrease these bearings.
The shields do not actually contact the bearing race, so no heat is generated.
These bearings are sealed on both sides. They come pre-greased by the bearing manufacturer. The user does not need to regrease these bearings.
The seals physically contact and rub against the bearing race, which generates heat. These bearings are not recommended at speeds above 1750
RPM.
The codes shown are SKF codes. Inboard and outboard bearings have the C3, greater than Normal clearance. These clearances are recommended
by SKF to maximize bearing life.
Regreasable Single Shielded bearings are not available in the duplex configuration; however, open oil bath-type bearings can be used for the
regreasable configuration. These bearings must be pre-greased during assembly. Lubrication fittings are provided, to allow the user to periodically
replenish the grease, as recommended by the bearing and/or grease manufacturer.
Not available.
Pump Division
Section 4.5
BEARING INSTALLATION
FOR POWER END ASSEMBLY (CONTD)
Both bearings have a slight interference fit which requires
that they be pressed on the shaft with an arbor or hydraulic
press. A chart giving bearing fits is shown in Figure 35. Even
force should be applied to the inner race only. Never press
on the outer race, as the force will damage the balls and
races. An alternate method of installing bearings is to heat
the bearings to 200F (93C) in an oven or induction heater.
Then place them quickly in position on the shaft.
CAUTION
Never heat the bearings above 230F (110C). To do so will
likely cause the bearing fits to permanently change, leading to
early failure.
FIGURE 34
Bearing Position Old Style Mark III Design
MARK III
MARK III
STANDARD SHAFT
DUPLEX BRG SHAFT
GROUP
A
GROUP
A
1
211/16 in (68 mm)
1
23/8 in (61 mm)
2
515/32 in (139 mm)
2
53/32 in (129 mm)
3
*
3
*
*Inboard bearing located against shoulder
FIGURE 35
Bearing Fits (inches)*
OB brg/shaft Bearing
Shaft
Fit
IB brg/shaft Bearing
Shaft
Fit
OB brg/hsg Bearing
Housing
Fit
IB brg/hsg Bearing
Housing
Fit
Group 1
1.1811/1.1807
1.1816/1.1812
0.0009T/0.0001T
1.3780/1.3775
1.3785/1.3781
0.0010T/0.0001T
2.8346/2.8341
2.8346/2.8353
0.0012L/0.0000L
2.8346/2.8341
2.8346/2.8353
0.0012L/0.0000L
Group 2
1.9685/1.9680
1.9690/1.9686
0.0010T/0.0001T
1.9685/1.9680
1.9690/1.9686
0.0010T/0.0001T
4.3307/4.3301
4.3310/4.3316
0.0015L/0.0003L
4.3307/4.3301
4.3310/4.3316
0.0015L/0.0003L
Group 3
2.7559/2.7553
2.7565/2.7560
0.0012T/0.0001T
2.7559/2.7553
2.7565/2.7560
0.0012T/0.0001T
5.9055/5.9047
5.9056/5.9067
0.0020L/0.0001L
5.9055/5.9047
5.9058/5.9065
0.0018L/0.0003L
Outboard
Bearing
Inboard
Bearing
CAUTION
It must be understood that fixtures and equipment used to press
the bearing must be designed so no load is ever transmitted
through the bearing balls. This would damage the bearing.
The locknut (#124) and lockwasher (#125) should be
installed. The locknut should be torqued to the value shown
in Figure 37. At this point the lockwasher tang must be bent
into the locknut.
FIGURE 37
Pump
Press Force
lbf (N)
Locknut Torque
ftlbf (Nm)
Group 1
Group 2
Group 3
1300 (5,780)
2500 (11,100)
4500 (20,000)
Pump Division
Section 4.5
5. Duplex angular contact bearings must be mounted back-toback with the wider thrust sides of the outer races in
contact with each other as shown in Figure 38. Only
bearings designed for universal mounting should be used.
SKFs designation is BECB. NTNs designation is G.
Note: A special shaft is required when using duplex angular
contact bearings.
FIGURE 38
OUTER
RACE
THRUST SIDES
Lip seals
If lip seals were used (see Figure 28), install new lip seals in the
bearing carrier (#201) and the housing (#119) (Group 1) or the
adapter (#108) (Group 2 and 3). The lip seals (#118 and #129)
are double lip style, the cavity between the lips should be 1/2 to
2/3 filled with grease.
Labyrinth seals
Refer to Appendix G.
Magnetic seals
Follow the installation instructions provided by the
manufacturer.
WARNING
Never compress the snap ring unless it is positioned around
the shaft and between the bearings. In this configuration, it is
contained therefore if it should slip off the compression tool it
is unlikely to cause serious injury.
29
Pump Division
Section 4.5
FIGURE 39
Gland installation
Install the gland (#190) and stationary seal components
following the seal manufacturers instructions. Slide the gland
and stationary seal components onto the shaft until it lightly
touches the bearing housing or adapter. Install the gland gasket
(#190G) into the gland. See Figure 41.
FIGURE 41
Seal installation
Install the rotating unit onto the shaft (or sleeve) using a seal
guide following the seal manufacturers instructions (Figure 43).
30
Pump Division
Section 4.5
FIGURE 42
FIGURE 45
Reverse Vane
Impeller
FIGURE 43
Packing/gland installation
Install the packing rings (#113) and seal cage halves (#112)
into the stuffing box as shown in Figure 16. Always stagger the
end gaps 90 to ensure a better seal. To speed installation of
each ring, have an assistant turn the pump shaft in one
direction. This movement of the shaft will tend to draw the rings
into the stuffing box. A split gland (#110) is an assembly of two
matched gland halves that are bolted together. Unbolt the gland
halves and install the gland halves around the shaft. Bolt the
halves together to form a gland assembly. Now, install the
gland assembly (#110) using studs (#111) and nuts (#111A).
Lightly snug up the gland. Final adjustments must be made
after the pump has begun operation.
31
Pump Division
Section 4.5
BEARING LUBRICATION
Oil bath
The standard bearing housing bearings are oil bath lubricated
and are not lubricated by Flowserve. Before operating the
pump, fill the bearing housing to the center of the oil sight glass
with the proper type oil. (See Figure 46 for approximate amount
of oil required do not overfill.)
above, proper oil level is the center of the bulls eye sight
glass (#200) (Figure 29).
In many pumping applications lubricating oil becomes
contaminated before it loses its lubricating qualities or breaks
down. For this reason it is recommended that the first oil
change take place after approximately 160 hours of operation,
at which time, the used oil should be examined carefully for
contaminants. During the initial operating period monitor the
bearing housing operating temperature. Record the external
bearing housing temperature. See Figure 49 for maximum
acceptable temperatures. The normal oil change interval is
based on temperature and is shown in Figure 50.
FIGURE 46
Amount of Oil Required
Pump Size
Group 1
Group 2
Group 3
MK IIIA Amount
8.5 oz (251 ml)
32 oz (946 ml)
48 oz (1419 ml)
FIGURE 47
Recommended Lubricants
Mineral Oil
Synthetic
On the Mark IIIA design, an optional oil slinger is available. The
oil slinger is not necessary; however, if used, it provides an
advantage by allowing a larger tolerance in acceptable oil level.
Without an oil slinger, the oil level in the bearing housing must
be maintained at 1/8 in (3 mm) from the center of the sight
glass. The sight glass has a 1/4 in (6 mm) hole in the center of
its reflector. The bearing housing oil level must be within the
circumference of the center hole to ensure adequate lubrication
of the bearings.
MK III Amount
5 oz (148 ml)
19 oz (560 ml)
48 oz (1419 ml)
Grease
FIGURE 48
Oil Viscosity Grades
Maximum Oil
Temperature
Up to 160F (71C)
160-175F (71-80C)
175-200F (80-94C)
ISO
Viscosity Grade
46
68
100
Minimum
Viscosity Index
95
95
95
FIGURE 49
Maximum External Housing Temperatures
Lubrication
Oil bath
Oil mist
Grease
Temperature
180F* (82C)
180F* (82C)
200F* (94C)
32
Pump Division
Section 4.5
FIGURE 50
Relubrication Intervals*
Lubricant
Grease
Mineral Oil
Synthetic Oil**
Under 160F
(71C)
6 mo
6 mo
18 mo
160-175F
(71-80C)
3 mo
3 mo
18 mo
175-200F
(80-94C)
1.5 mo
1.5 mo
18 mo
Grease
Single shielded regreasable bearings
When the grease lubrication option is specified, single shielded
bearings, grease fittings and vent pipe plugs are installed
inboard and outboard. The bearings are packed with Esso
Unirex N3 grease prior to assembly. For relubrication, a grease
with the same type base (non-soap polyuride) and oil (mineral)
should be used. To regrease, remove the pipe plug from both
the inboard and outboard bearing location. See Figure 51.
WARNING
To regrease bearings under coupling guard, stop pump, lock
the motor, remove coupling guard, then regrease the bearings.
Apply grease through the fittings until it comes out of the vent
holes, then reinstall the pipe plugs.
Bearings configured as shown in Figure 32A will draw grease
across the shield as needed.
FIGURE 51
Regreaseable Configuration
1/8 NPT
Tap Drill Thru
(2) Places
33
CAUTION
Do not fill the housing with oil when greased bearings are used.
The oil will leach the grease out of the bearings and the life of
the bearings may be drastically reduced.
Double shielded or double sealed bearings
These bearings are packed with grease by the bearing manufacturer and should not be relubricated. Maintenance intervals
for these bearings are greatly affected by their operating
temperature and pump speed. However, the shielded bearing
typically operates cooler, thus extending its life. Refer to Figure
50 for recommended maintenance intervals.
Oil mist
When optional oil mist lubricated bearings are specified, the
bearing housing is furnished with a plugged 1/2 in NPT top inlet
for connection to the users oil mist supply system, a vent
fitting in the bearing carrier, and a plugged 1/4 in NPT bottom
drain. See Oil Mist Lubrication System on Page 14.
Do not allow oil level to remain above the center of the bearing
housing sight glass window with purge mist (wet sump)
systems.
The optional oil slinger must not be used with an oil mist
system.
REINSTALLATION
The pump is now ready to be returned to service. It should be
reinstalled as described in the installation section.
Pump Division
Section 4.6
34
Pump Division
Section 4.6
FIGURE 52 - Group 1
35
ITEM
DESCRIPTION
100
CASING
103
IMPELLER
104
IMPELLER GASKET
105
SHAFT
106
107
108
109
109A
SHIM
110
GLAND - PACKING
111
STUD - GLAND
111A
HEXNUT - GLAND
112
113
PACKING
OPT.
114
DEFLECTOR INBOARD
OPT.
115
STUD - CASING
115A
HEXNUT - CASING
118
119
BEARING HOUSING
120
BEARING INBOARD
121
BEARING OUTBOARD
122
OIL SLINGER
124
LOCKNUT - BEARING
125
LOCKWASHER - BEARING
129
130
KEY - SHAFT/COUPLING
131
O-RING - ADAPTER
133
134
135
136
CAPSCREW - FOOT
139
140
CAPSCREW - COVER/ADAPTER
153
MECHANICAL SEAL
177
HOOK SLEEVE
190
190G
GLAND GASKET
200
201
BEARING CARRIER
201A
201B
201C
N/A
OPT.
OPT.
OPT.
N/A
N/A
OPT.
201D
OPT.
201E
SOC-CAPSCREW CLAMP
OPT.
Pump Division
Section 4.6
FIGURE 53 - Group 2
ITEM
DESCRIPTION
100
CASING
103
IMPELLER
104
IMPELLER GASKET
105
SHAFT
106
107
108
109
109A
SHIM
110
GLAND - PACKING
111
STUD - GLAND
111A
HEXNUT - GLAND
112
113
PACKING
OPT.
114
DEFLECTOR INBOARD
OPT.
115
STUD - CASING
115A
HEXNUT - CASING
118
119
BEARING HOUSING
120
BEARING INBOARD
121
BEARING OUTBOARD
122
OIL SLINGER
124
LOCKNUT - BEARING
125
LOCKWASHER - BEARING
129
130
KEY - SHAFT/COUPLING
131
O-RING - ADAPTER
133
134
135
136
CAPSCREW - FOOT
139
140
CAPSCREW - COVER/ADAPTER
153
MECHANICAL SEAL
177
HOOK SLEEVE
190
190G
GLAND GASKET
200
201
BEARING CARRIER
201A
201B
201C
OPT.
OPT.
OPT.
OPT.
201D
OPT.
201E
SOC-CAPSCREW CLAMP
OPT.
36
Pump Division
Section 4.6
FIGURE 54 - Group 3
37
ITEM
DESCRIPTION
100
CASING
103
IMPELLER
104
IMPELLER GASKET
105
SHAFT
106
107
108
109
109A
SHIM
110
GLAND - PACKING
111
STUD - GLAND
111A
HEXNUT - GLAND
112
113
PACKING
OPT.
114
DEFLECTOR INBOARD
OPT.
115
STUD - CASING
115A
HEXNUT - CASING
118
119
BEARING HOUSING
120
BEARING INBOARD
121
BEARING OUTBOARD
122
OIL SLINGER
124
LOCKNUT - BEARING
125
LOCKWASHER - BEARING
129
130
KEY - SHAFT/COUPLING
131
O-RING - ADAPTER
133
134
135
136
CAPSCREW - FOOT
139
140
CAPSCREW - COVER/ADAPTER
153
MECHANICAL SEAL
177
HOOK SLEEVE
190
190G
GLAND GASKET
200
201
BEARING CARRIER
201A
201B
201C
201D
201E
SOC-CAPSCREW CLAMP
OPT.
OPT.
OPT.
OPT.
Pump Division
Section 5.0
standard family of shafts. The repeller slips over the end of the
standard shaft with a hook coming against the end of the shaft.
The hook is squeezed and held in place by the impeller.
The Sealmatic can be supplied on any Group 2 or Group 3
Mark III pump.
38
Pump Division
Section 5.2
5.2 OVERVIEW
FIGURE 56 Group 2
REPELLER FUNCTION
This pump differs from the conventional Mark III in that it has a
repeller (#181). The repeller is a hydro-dynamic sealing device.
When the pump is operating, it pumps the fluid out of the seal
chamber.
DESIGN DIFFERENCE
The rear cover/repeller cover design is different for Group 2 and
Group 3 pumps. Figure 56 shows the Group 2 design and
Figure 57 shows the Group 3 design. Note: Only the reverse
vane impeller can be used in the Sealmatic pump. The front
vane open style impeller should not be used.
SEAL OPTIONS
When the pump is not operating, a static seal is required. Three
designs are available. The choice of design depends on the
application.
FIGURE 55
Item
100
103
104
106
107
110
111
111A
112
113
115
115A
140
180
181
181A
182
183
190
195
297
298
299
330
39
Part Name
Casing
Impeller
Impeller Gasket
Rear Cover
Rear Cover Gasket
Gland
Stud
Hex Nut
Seal Cage
Packing
Casing Studs
Casing Studs Nuts
Capscrews - Adapter to Cover
Cover Repeller
Repeller
Repeller O-ring
Gasket - Repeller Cover
Repeller O-ring
Gland
Capscrews - Repeller Cover to Cover
Seat
Lip Seal
Lip Seal O-ring
Mechanical Seal
FIGURE 57 Group 3
Pump Division
Section 5.2
Checkmatic Option B
FIGURE 58
FIGURE 61
FIGURE 59
Shaft
40
Pump Division
Section 5.3
5.3 OPERATION
GENERAL INFORMATION
The Durco Mark III Sealmatic pump was designed and sized to
specific operating requirements. The Flowserve sales person
has carefully selected the correct Sealmatic pump for the
customers system. Under no circumstance should a Sealmatic
pump be operated under any conditions other than those for
which it was intended without the recommendation of a
Flowserve sales representative.
START-UP
When starting a Sealmatic pump for the first time make certain
that the suction valve is completely open, the discharge valve is
throttled and that there is liquid in the pump. Determine that
there will be a positive head at the suction when start-up is
made. Check the technical data and nameplate to make certain
that the repeller is capable of handling the suction head.
41
Pump Division
Section 5.4
5.4 MAINTENANCE
DISASSEMBLY OF GROUP 2 PUMPS
1. Remove the impeller (#103).
2. Remove the gland nuts (#111A).
3. Remove the capscrews (#195) that hold the rear cover (106)
to the repeller cover (#180). Remove the cover.
4. The repeller (#181) is now exposed and should be free to
slip from the shaft. If not, take two flat tools such as heavy
screwdrivers and insert between the repeller and repeller
cover at two points 180 apart and exert firm pressure
against the repeller. This should break it free from the shaft.
5. Remove the repeller cover (#180).
6. Remove shaft seal components and gland.
42
Pump Division
Section 5.5
100
90
80
70
60
50
40
30
20
10
0
30
20
10
0
2
4
6
8
STATIC SUCTION PRESSURE IN FEET
10
12
FIGURE 63A
Temperature Rise in Repeller Chamber
vs. Static Suction Head
9
18
22.4
40
30
20
10
10 GPM (2 m3/h)
20 GPM (4 m3/h)
16.8
11.2
5.6
0
20
10
0
20
40
STATIC SUCTION PRESSURE IN FEET
60
FIGURE 63
Air Ingress into Product at Standard Atmosphere
vs. Static Suction Head
There are two basic repeller configurations, one to accommodate only positive suction heads of fairly large magnitude
and another dual head repeller that will accommodate suction
heads that may be negative as well as positive; while the pump
is in operation, however, the magnitude of its positive head
capability is reduced. It should be understood that under no
circumstances can the pump be started and primed unless the
suction piping is flooded with liquid. This requirement would
preclude the use of a SEALMATIC pump as a normally
employed self-priming pump. Performance capabilities of the
available repellers are given in the Flowserve bulletin Sealmatic
Repeller Selection Curves.
Pump Division
Section 5.6
ITEM
DESCRIPTION
100
CASING
103
IMPELLER
104
IMPELLER GASKET
105
SHAFT
106
107
108
109
109A
SHIM
110
GLAND - PACKING
111
STUD - GLAND
111A
HEXNUT - GLAND
112
113
PACKING
OPT.
114
DEFLECTOR INBOARD
OPT.
115
STUD - CASING
115A
HEXNUT - CASING
118
OPT.
119
BEARING HOUSING
120
BEARING INBOARD
121
BEARING OUTBOARD
122
OIL SLINGER
124
LOCKNUT - BEARING
125
LOCKWASHER - BEARING
129
130
KEY - SHAFT/COUPLING
131
O-RING - ADAPTER
133
134
135
136
CAPSCREW - FOOT
139
140
CAPSCREW - COVER/ADAPTER
153
MECHANICAL SEAL
177
HOOK SLEEVE
180
COVER - REPELLER
OPT.
OPT.
OPT.
181
REPELLER
190
190G
GLAND GASKET
200
201
BEARING CARRIER
201A
201B
201C
201D
201E
SOC-CAPSCREW CLAMP*
330
MECHANICAL SEAL
*OPTIONAL GROUP 2
44
Pump Division
Section 6.0
45
Pump Division
Section 6.2
FIGURE 64
FIGURE 65
PRIMING CHAMBER FILL
TAP II
TAP III
TAP I
FIGURE 66
46
Pump Division
Section 6.2
.6
4.8
16
293
12
220
146
73
6
8
10
12
14
MINIMUM SUBMERGENCE (S), ft
FIGURE 67
FIGURE 68
16
47
Pump Division
Section 6.3
FIGURE 69
ITEM
DESCRIPTION
100
CASING
103
IMPELLER
104
IMPELLER GASKET
105
SHAFT
106
107
108
109
109A
SHIM
110
GLAND - PACKING
111
STUD - GLAND
111A
HEXNUT - GLAND
112
113
PACKING
OPT.
114
DEFLECTOR INBOARD
OPT.
115
STUD - CASING
115A
HEXNUT - CASING
118
OPT.
119
BEARING HOUSING
120
BEARING INBOARD
121
BEARING OUTBOARD
122
OIL SLINGER
124
LOCKNUT - BEARING
125
LOCKWASHER - BEARING
129
130
KEY - SHAFT/COUPLING
131
O-RING - ADAPTER*
133
134
135
136
CAPSCREW - FOOT
139
140
CAPSCREW - COVER/ADAPTER
153
MECHANICAL SEAL
177
HOOK SLEEVE
190
OPT.
OPT.
OPT.
190G
GLAND GASKET
200
201
BEARING CARRIER
201A
201B
201C
201D
OPT.
201E
SOC-CAPSCREW CLAMP
OPT.
*GROUP 2 ONLY
48
Pump Division
Section 7.0
49
to the swirling flow so that the fluid flows smoothly out of the
pump. Top, center-line discharge is not desirable as the extra
bends in the discharge nozzle necessary to locate the flange in
the center would disrupt the flow and increase the possibility of
wearing out the casing.
Except for the impeller and casing, all other parts are identical
to the standard Mark III pump.
Pump Division
Section 7.2
The impeller is set off of the rear cover plate, just like the
reverse vane impeller on the Mark III standard pump. Refer
to Appendix D for instructions on setting the impeller.
The parts diagram is the same as the Mark III standard pump
with the exception of the casing and impeller. The pump shown
below is a Group 2. Refer to Figure 52 to see a Group 1 pump,
or to see the duplex angular contact bearing option.
FIGURE 70
ITEM
DESCRIPTION
100
CASING
103
IMPELLER
104
IMPELLER GASKET
105
SHAFT
106
107
108
109
109A
SHIM
110
GLAND - PACKING
111
STUD - GLAND
111A
HEXNUT - GLAND
112
113
PACKING
OPT.
114
DEFLECTOR INBOARD
OPT.
115
STUD - CASING
115A
HEXNUT - CASING
118
OPT.
119
BEARING HOUSING
120
BEARING INBOARD
121
BEARING OUTBOARD
122
OIL SLINGER
124
LOCKNUT - BEARING
125
LOCKWASHER - BEARING
129
130
KEY - SHAFT/COUPLING
131
O-RING - ADAPTER*
133
134
135
136
CAPSCREW - FOOT
139
140
CAPSCREW - COVER/ADAPTER
153
MECHANICAL SEAL
177
HOOK SLEEVE
190
OPT.
OPT.
OPT.
190G
GLAND GASKET
200
201
BEARING CARRIER
201A
201B
201C
201D
OPT.
201E
SOC-CAPSCREW CLAMP
OPT.
*GROUP 2 ONLY
50
Pump Division
Section 8.0
The Durco Mark III Lo-Flo Pump has a special design casing
and impeller which allows it to work very reliably at low flows.
The pump has an impeller with radial vanes that twist around
the hub, and a circular, concentric casing. This design ensures
that, at low flows, no significant hydraulic radial forces are
transmitted to the shaft. Minimum flow on this pump is
Minimum Thermal Flow. This is defined as the minimum flow
that will not cause an excessive temperature rise.
The impeller for his pump is set off the casing, just like the
standard front vane open style impeller. Refer to Appendix E for
instructions on how to install, remove, and set this impeller.
WARNING
Do not operate the Lo-Flo pump below Minimum Thermal Flow,
as this could cause an excessive temperature rise. Contact a
Flowserve Sales Engineer for determination of Minimum
Thermal flow.
Only the impeller and casing are special, all other parts are
standard Mark III parts. Note: The adapter on the 13 in pump is
the standard adapter but with 16 holes drilled in it for
attachment to the casing.
51
Pump Division
Section 8.3
DESCRIPTION
100
CASING
103
IMPELLER
104
IMPELLER GASKET
105
SHAFT
106
107
108
109
109A
SHIM
110
GLAND - PACKING
111
STUD - GLAND
111A
HEXNUT - GLAND
112
113
PACKING
OPT.
114
DEFLECTOR INBOARD
OPT.
115
STUD - CASING
115A
HEXNUT - CASING
118
OPT.
119
BEARING HOUSING
120
BEARING INBOARD
121
BEARING OUTBOARD
122
OIL SLINGER
124
LOCKNUT - BEARING
125
LOCKWASHER - BEARING
129
130
KEY - SHAFT/COUPLING
131
O-RING - ADAPTER*
133
134
135
136
CAPSCREW - FOOT
139
140
CAPSCREW - COVER/ADAPTER
153
MECHANICAL SEAL
177
HOOK SLEEVE
190
OPT.
OPT.
OPT.
190G
GLAND GASKET
200
201
BEARING CARRIER
201A
201B
201C
201D
OPT.
201E
SOC-CAPSCREW CLAMP
OPT.
* GROUP 2 ONLY
52
Pump Division
Appendix A
APPENDIX A
desired, it can be accomplished by use of our C-Plus
optional alignment feature, described in Section 3. If
desired, alignment may be checked with indicators as
shown:
1.2
PUMP INSTALLATION
2.1
2.2
2.3
2.4
FIGURE A-1
Coupling Hub
Motor Shaft
Item
1
Reqd.
1
Matl.
SR
SR
SR
5A
5B
6
7
1
1
1
1
SR
SR
SR
SR
53
Pump Shaft
Description
Miniature Indicator,
Lug Back Starrett *80-144J
3/8 dia x 2-1/2 post with
1/4-20 x 5/8 thd. &
3/8-16x3/4 thd.
1/4 x 1/4 Starrett
*657S Sleeve
3/8 x 1/4 Starrett
*196L Sleeve
1/4-20 Hex nut
3/8-16 Hex nut
1/4 dia x 5 rod
Indicator attachment,
Starrett *657Y
CAUTION
2.5
Coupling Hub
2.6
Pump Division
Appendix A
WARNING
Failure to secure capscrews properly could cause coupling
component(s) to become dislodged during operation resulting
in personal injury.
2.7
FIGURE A-2
Motor
Adjuster
Jam Nut
Spacer
Ring
3.1.1 With the C-Plus alignment feature and the indicator kit in
place, alignment is changed by moving the motor radially
using the four adjustment screws. Adjusting screws are
located to push on four of the motor mounting studs as
shown in Figure A-2.
3.2 The motor mounting screws must be snug but not tight
when attempting to adjust motor location. Depending on
the size of motor it may be necessary to check the
alignment with the motor fasteners tight. Corrections
may be made until 0.002 in (0.05 mm) FIM (or the
desired) alignment is achieved. The adjusters, adjuster
jam nuts and the motor fasteners should all be tightened.
3.3 The indicator kit should be removed, the coupling and
coupling guard installed as described in paragraphs 2.6
and 2.7.
Nut
Motor
Mounting
Stud
Motor
Adapter
4.1
54
Pump Division
Appendix A
Optional
Front Vane
Open
Impeller
Standard
Reverse
Vane
Impeller
ITEM
100
103
104
105
106
107
110
111
111A
DESCRIPTION
CASING
IMPELLER
GASKET, IMPELLER
SHAFT
COVER PLATE
GASKET, COVER
GLAND
STUD, GLAND
HEXNUT, GLAND
ITEM
120
121
124
125
129
130
133
134
135
DESCRIPTION
BEARING I.B.
BEARING O.B.
LOCKNUT, BEARING
LOCKWASHER, BEARING
OIL SEAL O.B.
KEY SHAFT/CPLG
OILER, TRICO
PLUG, DRAIN
PLUG, VENT
112
113
140
153
114
115
DEFLECTOR IL.B.
STUD, CASING
115A
118
119
HEXNUT, CASING
OIL SEAL I.B.
HOUSING, BEARING
55
ITEM
201B
201C
400
401
401A
402
402A
403
405
DESCRIPTION
O-RING
RING, SNAP
ADAPTER, C-FACE
FOOT, ADJUSTABLE
SET SCREW
GUARD, COUPLING
SCREW, HEX HEAD
SCREW, HEX HEAD
MOTOR
CAPSCREW, CVR-HSG
SEAL, STUFF BOX
405A
405B
STUD, MOTOR
HEXNUT, MOTOR
177
190
SLEEVE, HOOK
FLANGE, FOLLOWER
406
408
RING SPACER
ADJUSTER SCREW
200
201
201A
SIGHT GLASS
CARRIER, BEARING
SET SCREW
411
Pump Division
Appendix A
Optional
Front Vane
Open
Impeller
Standard
Reverse
Vane
Impeller
ITEM
100
103
104
105
106
107
108
110
DESCRIPTION
CASING
IMPELLER
GASKET, IMPELLER
SHAFT
COVER PLATE
GASKET, COVER
ADAPTER, BRG-HSG
GLAND
ITEM
120
121
124
125
129
130
131
133
DESCRIPTION
BEARING I.B.
BEARING O.B.
LOCKNUT, BEARING
LOCKWASHER, BEARING
OIL SEAL O.B.
KEY SHAFT/CPLG
O-RING, ADAPTER
OILER, TRICO
ITEM
201
201A
201B
201C
400
401
401A
402
DESCRIPTION
CARRIER, BEARING
SET SCREW
O-RING
RING, SNAP
ADAPTER, C-FACE
FOOT, ADJUSTABLE
SET SCREW
GUARD, COUPLING
111
111A
112
STUD, GLAND
HEXNUT, GLAND
SEAL CAGE HALVE
134
135
139
PLUG, DRAIN
PLUG, VENT
CAPSCREW, ADAPTER
402A
403
405
113
114
115
PACKING
DEFLECTOR IL.B.
STUD, CASING
139A
140
153
405A
405B
406
STUD, MOTOR
HEXNUT, MOTOR
RING SPACER
115A
HEXNUT, CASING
177
SLEEVE
408
ADJUSTER SCREW
118
119
190
200
FLANGE, FOLLOWER
SIGHT GLASS
411
56
Pump Division
Appendix A
MARK III 2K PROCESS PUMP C FACE ADAPTER (284TC & Larger Motors)
CROSS SECTIONAL PARTS LIST
Optional
Front Vane
Open
Impeller
Standard
Reverse
Vane
Impeller
ITEM
100
103
104
105
106
107
108
110
111
DESCRIPTION
CASING
IMPELLER
GASKET, IMPELLER
SHAFT
COVER PLATE
GASKET, COVER
ADAPTER, BRG-HSG
GLAND
STUD, GLAND
ITEM
120
121
124
125
129
130
131
133
134
DESCRIPTION
BEARING I.B.
BEARING O.B.
LOCKNUT, BEARING
LOCKWASHER, BEARING
OIL SEAL O.B.
KEY SHAFT/CPLG
O-RING, ADAPTER
OILER, TRICO
PLUG, DRAIN
111A
112
HEXNUT, GLAND
SEAL CAGE HALVE
135
139
PLUG, VENT
CAPSCREW, ADAPTER
113
114
PACKING
DEFLECTOR IL.B.
139A
140
115
115A
118
STUD, CASING
HEXNUT, CASING
OIL SEAL I.B.
119
HOUSING, BEARING
57
ITEM
201
201A
201B
201C
400
401
401A
402
402A
DESCRIPTION
CARRIER, BEARING
SET SCREW
O-RING
RING, SNAP
ADAPTER, C-FACE
FOOT, ADJUSTABLE
SET SCREW
GUARD, COUPLING
SCREW, HEX HEAD
403
405
405A
405B
STUD, MOTOR
HEXNUT, MOTOR
153
177
190
SEAL - MECHANICAL
SLEEVE
FLANGE, FOLLOWER
406
408
411
RING SPACER
ADJUSTER SCREW
ADJUSTER JAM NUT
200
SIGHT GLASS
Pump Division
Appendix B
APPENDIX B
ASSEMBLY OF STILT AND SPRING
MOUNTED BASEPLATES
Flowserve offers stilt and spring mounted baseplates. (See
Figure B-1 for stilt mounted option.) General instructions for
assembling these baseplates are given below. For dimensional
information, please refer to the appropriate Flowserve
Sales Print.
FIGURE B-1
FIGURE B-2
STILT BOLT
NUTS
LOCK WASHER
FLOOR CUP
Pump Division
Appendix B
FIGURE B-3
STILT BOLT
BOTTOM SPRING
(31/4 in (83 mm) OD X 4 in (102 mm) FL/CUPS)
TOP SPRING
(2 in (51 mm) OD X 4 in (102 mm) FL/CUPS)
NUTS
FLAT WASHER
LOCK WASHER
FLOOR CUP
59
Pump Division
Appendix C
APPENDIX C
CRITICAL MEASUREMENTS AND
TOLERANCES FOR MAXIMIZING MTBPM
PARAMETERS THAT SHOULD BE CHECKED BY USERS
Flowserve recommends that the user check the following
measurements and tolerances whenever pump maintenance is
performed. Each of these measurements is described in more
detail on the following pages.
Topic
Shaft
Diameter tolerance,
under bearings
ASME
B73.1M
Std.
in (mm)
Suggested
By Major
Seal
Vendors
in (mm)
N.S.
Suggested
And/Or
Provided
By Flowserve
in (mm)
0.0002 (0.005)
Impeller
Balance
Bearing Housing
Diameter (ID) tolerance
at bearings
Power End Assembly
Shaft Runout
Shaft Sleeve Runout
Radial Deflection - Static
Shaft Endplay
Seal Chamber
Face Squareness to Shaft
Register Concentricity
Complete Pump
Shaft movement caused
by pipe strain
Alignment
Vibration at bearing
housing
See Note 1
N.S.
0.0005 (0.013)
0.002 (0.05)
0.002 (0.05)
0.001 (0.03)
0.002 (0.05)
0.001 (0.03)
0.002 (0.05)
N.S.
N.S.
0.003 (0.076)
0.002 (0.05)
0.002 (0.05)
0.002 (0.05)
0.003 (0.08)
0.001 (0.03)
0.003 (0.08)
0.005 (0.13)
0.005 (0.13)
0.005 (0.13)
N.S.
N.S.
0.25 in/s
(6.3 mm/s)
0.002 (0.05)
0.002 (0.05)
See Note 2
See Note 3
Topic
Shaft - Maximum roughness
at seal chamber
Bearing Housing - Bore
Concentricity
Complete Pump - Dynamic
Shaft Deflection*
ASME
B73.1M
Std.
32in
(0.80 m)
0.005 in
(0.13 mm)
Suggested
By Major
Seal
Vendors
0.002 in
(0.05 mm)
Suggested
And/Or
Provided
By Flowserve
16in
(0.40 m)
0.001 in
(0.025 mm)
0.002 in
(0.05 mm)
*The ASME standard recommends 0.005 in (0.13 mm) max deflection at the impeller,
while Flowserve provides 0.002 in (0.05 mm) max deflection at the mechanical seal.
The two recommendations are essentially equivalent.
OVERVIEW
When Flowserve introduced the ANSI 3 Power End, a new
concept called The Signature Program was announced. The
objective of this program is to provide our customers with a
complete pumping system with at least three years MTBPM.
Obtaining this objective requires a major commitment from
Flowserve, the seal manufacturer and other suppliers, and
the customer.
First of all, the reliability of a process pump largely depends
upon the correct selection of equipment, including the pump,
seal, and accessories. However, proper handling, installation,
maintenance, and operation are equally important. To maximize
reliability certain parameters must be measured and maintained
within certain specified tolerances.
The primary purpose of this appendix is to provide a summary
of these various physical parameters and the associated
tolerances which Flowserve feels are vital to maximizing pump
MTBPM. (A secondary benefit of controlling these parameters
can be a reduction of seal emissions.) When appropriate, the
appendix also shows pictorially how to take the various
measurements.
SHAFT
Before installing the shaft into the power end it is important to
check the following parameters.
60
Pump Division
Appendix C
Group 1
1.1811/1.1807
Group 2
1.9685/1.9680
Group 3
2.7559/2.7553
1.1816/1.1812
0.0009T/0.0001T
1.9690/1.9686
0.0010T/0.0001T
2.7565/2.7560
0.0012T/0.0001T
1.3780/1.3775
1.3785/1.3781
1.9685/1.9680
1.9690/1.9686
2.7559/2.7553
2.7565/2.7560
0.0010T/0.0001T
0.0010T/0.0001T
0.0012T/0.0001T
IB bearing/
shaft
in
Bearing
Shaft
Metric
OB bearing/
shaft mm
Bearing
Group 1
30.000/29.990
Group 2
50.000/49.987
Group 3
70.000/69.985
Shaft
Fit
Bearing
Shaft
Fit
30.013/30.003
0.023T/0.003T
35.000/34.989
35.014/35.004
0.025T/0.004T
50.013/50.003
0.026T/0.003T
50.000/49.987
50.013/50.003
0.026T/0.003T
70.015/70.002
0.030T/0.002T
70.000/69.985
70.015/70.002
0.030T/0.002T
IB bearing/
shaft mm
Fit
US Customery Units
OB bearing/ Bearing
housing - Housing
in
Fit
IB bearing/ Bearing
housing - Housing
in
Fit
Group 1
2.8346/2.8341
Group 2
4.3307/4.3301
Group 3
5.9055/5.9047
2.8346/2.8353
0.0012L/0.0000L
4.3310/4.3316
0.0015L/0.0003L
5.9056/5.9067
0.0020L/0.0001L
2.8346/2.8341
2.8346/2.8353
4.3307/4.3301
4.3310/4.3316
5.9055/5.9047
5.9058/5.9065
0.0012L/0.0000L
0.0015L/0.0003L
0.0018L/0.0003L
Metric
OB bearing/ Bearing
housing - Housing
mm
Fit
Group 1
71.999/71.986
Group 2
110.000/109.985
Group 3
150.000/149.979
71.999/72.017
0.031L/0.000L
110.007/110.022
0.037L/0.007L
150.002/150.030
0.051L/0.002L
IB bearing/ Bearing
housing - Housing
mm
Fit
71.999/71.986
71.999/72.017
0.031L/0.000L
110.000/109.985
110.007/110.022
0.037L/0.007L
150.000/149.979
150.007/150.025
0.046L/0.007L
Impeller Balancing
Shaft runout can shorten the life of the bearings and the
mechanical seal. The following diagram shows how to measure
shaft/shaft sleeve runout. Note that both ends need to be
checked. The runout should be 0.001 in (0.025 mm) FIM or less.
FIGURE C-1
BEARING HOUSING
Diameter (ID) tolerance at bearings
An inside caliper should be used to check the dimension of the
ID of the housing and bearing carrier. The diameter must be
within the following min/max values given in order to provide
the proper bearing tightness.
61
Pump Division
Appendix C
Register Concentricity
An eccentric seal chamber bore or gland register can interfere
with the piloting and centering of the seal components and alter
the hydraulic loading of the seal faces, resulting in reduction of
seal life and performance. The seal chamber register concentricity should be less than 0.005 in (0.13 mm). The diagram
below shows how to measure this concentricity.
FIGURE C-5
Shaft Endplay
The maximum amount of axial shaft movement, or endplay, on
a Durco pump should be 0.001 in (0.03 mm) and is measured
as shown below. Observe indicator movement while tapping the
shaft from each end in turn with a soft mallet. Shaft endplay can
cause several problems. It can cause fretting or wear at the
point of contact between the shaft and the secondary sealing
element. It can also cause seal overloading or underloading and
possibly chipping of the seal faces. It can also cause the faces
to separate if significant axial vibration occurs.
FIGURE C-3
COMPLETE PUMP
Shaft Movement Caused by Pipe Strain
Pipe strain is any force put on the pump casing by the piping.
Pipe strain should be measured as shown below. Install the
indicators as shown before attaching the piping to the pump.
The suction and discharge flanges should now be bolted to the
piping separately while continuously observing the indicators.
Indicator movement should not exceed 0.002 in (0.05 mm).
FIGURE C-6
Pump Shaft
SEAL CHAMBER
Face Squareness to Shaft
Also referred to as Seal Chamber Face Run-Out. This runout
occurs when the seal chamber face is not perpendicular to the
shaft axis. This will cause the gland to cock, which causes the
stationary seat to be cocked, which causes the seal to wobble.
This runout should be less than 0.003 in (0.08 mm) and should
be measured as shown below:
FIGURE C-4
Alignment
Misalignment of the pump and motor shafts can cause the
following problems:
Failure of the mechanical seal
Failure of the motor and/or pump bearings
Failure of the coupling
Excessive vibration/noise
The schematics below show the technique for a typical rim and
face alignment using a dial indicator. It is important that this
alignment be done after the flanges are loaded, and at typical
operating temperatures. If proper alignment cannot be
maintained a C-flange motor adapter and/or stilt/spring
mounting should be considered.
62
Pump Division
Appendix C
FIGURE C-7
Parallel
Angular
Many companies today are using laser alignment which is a
more sophisticated and accurate technique. With this method a
laser and sensor measure misalignment. This is fed to a
computer with a graphic display which shows the required
adjustment for each of the motor feet.
Vibration Analysis
Vibration Analysis is a type of condition monitoring where a
pumps vibration signature is monitored on a regular, periodic
basis. The primary goal of vibration analysis is extension on
MTBPM. By using this tool Flowserve can often determine not
only the existence of a problem before it becomes serious, but
also the root cause and possible the solution.
Modern vibration analysis equipment not only detects if a
vibration problem exists, but can also suggest the cause of the
problem. On a centrifugal pump, these causes can include the
following: unbalance, misalignment, defective bearings,
resonance, hydraulic forces, cavitation, and recirculation. Once
identified, the problem can be corrected, leading to increased
MTBPM for the pump.
Flowserve does not make vibration analysis equipment, however Flowserve strongly urges customers to work with an
equipment supplier or consultant to establish an on-going
vibration analysis program.
The ASME standard for vibration at the bearing housing is
0.25 inches/second (6.35 mm/sec) peak velocity or 0.0025
inches (0.064 mm) peak-to-peak displacement. Flowserve
recommends the following peak velocities:
Group 1
Group 2
Group 3
0.1 in/s
0.15 in/s
0.25 in/s
(2.5 mm/s)
(3.8 mm/s)
(6.4 mm/s)
63
Pump Division
Appendix D
APPENDIX D
INSTALLATION/CLEARANCE SETTING FOR
REVERSE VANE IMPELLER
FIGURE D-3
WARNING
The impeller could have sharp edges which could cause an
injury. It is very important to wear heavy gloves.
Tighten the impeller with the impeller wrench from the Durco
tool kit. To do this, grasp the impeller in both hands and, with
the impeller wrench handle to the left (viewed from the impeller
end of the shaft) (Figure D-1), spin the impeller forcefully in a
clockwise direction to impact the impeller wrench handle on
the work surface to the right (Figure D-2).
FIGURE D-1
Indicator
Pattern
Rotation Equipment To
0.004 in (0.1 mm) Axial
Movement
CAUTION
Do not attempt to tighten the impeller on the shaft by hitting
the impeller with a hammer or any other object or by inserting
a pry bar between the impeller vanes. Serious damage to the
impeller may result from such actions.
FIGURE D-2
CAUTION
It is recommended that two people install a Group 3 impeller.
The weight of a Group 3 impeller greatly increases the chance
of thread damage and subsequent lock-up concerns.
64
Pump Division
Appendix D
(93)
(93 to 121)
(122 to 149)
(150 to 176)
(177 to 204)
(205 to 232)
(232)
Notes
1. For 3 x 1.5-13 and 3x2-13 at 3500 rpm add 0.003 in
(0.08 mm).
2. Rotation of bearing carrier from center of one lug to center
of next results in axial shaft movement of 0.004 in
(0.1 mm).
3. Reverse vane impeller set to cover, open impeller to casing.
FIGURE D-5
65
Pump Division
Appendix E
APPENDIX E
INSTALLATION/CLEARANCE SETTING FOR
FRONT VANE OPEN STYLE IMPELLER
Install the impeller (#103) by screwing it onto the shaft (use
heavy gloves) until it firmly seats against the shaft shoulder.
WARNING
The impeller could have sharp edges which could cause an
injury. It is very important to wear heavy gloves.
WARNING
Care should be taken in the handling of high chrome iron
impellers.
Tighten the impeller with the impeller wrench from the Durco
tool kit. To do this, grasp the impeller in both hands and, with
the impeller wrench handle to the left (viewed from the impeller
end of the shaft) (Figure E-1), spin the impeller forcefully in a
clockwise direction to impact the impeller wrench handle on the
work surface to the right (Figure E-2).
FIGURE E-1
CAUTION
Do not attempt to tighten the impeller on the shaft by hitting the
impeller with a hammer or any other object or by inserting a
pry bar between the impeller vanes. Serious damage to the
impeller may result from such actions.
Like all front vane open style impellers, the Durco open impeller
clearance must be set off the casing. The casing must be
present to accurately set the impeller clearance. (Realizing that
this can be very difficult, Flowserve strongly promotes the use
of reverse vane impellers, which do not require the presence of
the casing to be properly set.)
Attach the power end/rear cover plate assembly to the casing.
Now set the impeller clearance by loosening the set screws
(#201A) and rotating the bearing carrier (#201) to obtain the
proper clearance. Turn the bearing carrier clockwise until the
impeller comes into light rubbing contact with the casing.
Rotating the shaft at the same time will accurately determine
this zero setting. Now, rotate the bearing carrier counterclockwise to get the proper clearance. Refer to Figure E-4 for
the proper impeller clearance. Rotating the bearing carrier the
width of one of the indicator patterns cast into the bearing
carrier moves the impeller axially 0.004 in (0.1 mm). (See
Figure E-3.)
FIGURE E-3
FIGURE E-2
Indicator
Pattern
Rotation Equipment To
0.004 in (0.1 mm) Axial
Movement
Pump Division
Appendix E
FIGURE E-4
Impeller Clearance Settings
Temperature F (C)
<200
200 to 250
251 to 300
301 to 350
351 to 400
401 to 450
>450
(93)
(93 to 121)
(122 to 149)
(150 to 176)
(177 to 204)
(205 to 232)
(232)
Notes
1. For 3 x 1.5-13 and 3x2-13 at 3500 rpm add 0.003 in
(0.08 mm).
2. Rotation of bearing carrier from center of one lug to center
of next results in axial shaft movement of 0.004 in
(0.1 mm).
3. Reverse vane impeller set to cover, open impeller to casing.
FIGURE E-5
CAUTION
It is recommended that two people install a Group 3 impeller.
The weight of a Group 3 impeller greatly increases the chance
of thread damage and subsequent lock-up concerns.
67
Pump Division
Appendix F
APPENDIX F
REMOVAL/INSTALLATION OF SEALS WITH
SEALSENTRY FMI SEAL CHAMBER
FIGURE F-1
REMOVAL
After removing the impeller, slide the hook sleeve off the shaft.
Remove the rotating unit from the sleeve. Remove cover.
Remove the stationary seat from the seal chamber counter
bore.
INSTALLATION
1.
2.
3.
4.
5.
6.
7.
8.
68
Pump Division
Appendix G
APPENDIX G
DURCO MARK III MAINTENANCE
INSTRUCTIONS BEARING HOUSING OIL
SEALS (LABYRINTH TYPE) INPRO/SEAL
VBXX BEARING ISOLATORS
3.
INTRODUCTION
Flowserve Corporation provides pumps fitted with a variety of
labyrinth oil seals. While these instructions are written specifically for the Inpro/Seal VBXX labyrinth, they also apply to seals
of other manufacturers. Specific installation instructions
included with the seal, regardless of manufacturer, should be
observed.
The Inpro VBXX Bearing Isolator is a labyrinth type seal which
isolates the bearings from the environment (uncontaminated),
and retains the oil in the bearing housing. The bearing isolator
consists of a rotor and a stator. The rotor revolves with the
shaft, driven by a close fitted drive ring that rotates with the
shaft. the stator is a stationary component that fits into the
housing bore with a press fit (nominal 0.002 in (0.05 mm)
interference) and with an O ring gasket seal. The two pieces
are assembled as a single unit, and are axially locked together
by an O ring. There is no mechanical contact between the
rotor and stator when the isolator is running.
Stator
Stator
4.
5.
Rotor
Rotor
Vapor Block
Ring
Vapor
Block
Ring
Drive
Ring
Drive Ring
6.
Lube
LubeReturn
Return
Pump Division
Appendix G
70
Pump Division
Appendix H
APPENDIX H
SEALMATIC PUMP: INSTALLATION OF
REPELLER COVER, REPELLER, COVER,
IMPELLER.
GROUP 2 PUMPS:
GROUP 3 PUMPS:
1. Install the repeller cover (#180) over the shaft and push it
all the way back until it touches the bearing housing.
2. Install the repeller cover/cover gasket (#182).
3. Install a new repeller O-ring (#181A) to the repeller groove.
Lubricate the O-ring with liquid soap.
4. Install the slip-on repeller (#181) onto the shaft.
5. Install the cover (#106) to the adapter. Attach to the
adapter using capscrews (#140).
6. Attach the repeller cover to the cover using the capscrews
(#195).
7. Loosen the set screws (#201A) in the bearing carrier.
8. The repeller may now be set to the repeller cover. Hold the
repeller firmly against the end of the shaft by temporarily
installing a seal guide. Rotate the bearing carrier
counterclockwise until the repeller contacts the repeller
cover. Now rotate the bearing carrier clockwise to obtain a
0.015 to 0.020 in (0.38-0.51 mm) clearance. (Refer to
Appendix D for information on how bearing carrier rotation
affects axial shaft movement.)
9. Finally, snug the set screws (#201A) against the housing to
lock the setting.
10. Install the impeller gasket (#104) into the impeller and
install the impeller firmly to the shaft, after removing the
seal guide. (Refer to Appendix D for information on how to
tighten impeller to shaft.) The correct repeller setting
should correctly set the impeller. This can be checked with
a feeler gage, check the closest impeller vane clearance.
This gap should be 0.015 to 0.020 in (0.38-0.51 mm). If
the impeller gap is outside of the correct setting, it may be
readjusted to get the best gap at the repeller and impeller.
71
Pump Division
Appendix I
APPENDIX I
ALLOWABLE NOZZLE LOADS DURCO PUMPS (ASME B73.1M)
FIGURE I-1: Axis System
The loads listed in Figure I-2 are the combined values resolved
to the center of the pump, except for the Fr + Mr/3 limits, which
apply to the separate suction and discharge flanges. Some
piping analysis programs calculate forces and moments on
each flange, and do not translate them to a common point at
the center of the pump. The formulas in Figure I-3 and Dimensions in Figure I-4 can be used to translate the forces and
moments on each flange to the common center point.
Fx
1.5 x 1
120
295
235
590
295
295
325
220
1.5 x 1.5
120
295
235
590
295
295
325
325
2x1
145
365
285
730
365
365
435
220
Mz
Flange
Suction
Frs+Mrs/3
Loading
Discharge
Frd+Mrd/3
2 x 1.5
165
405
325
815
405
405
435
325
2x2
175
435
350
875
435
435
435
435
3 x 1.5
220
545
435
1090
545
545
650
325
3x2
235
590
470
1170
590
590
650
435
3x3
260
650
520
1300
650
650
650
650
4x3
325
815
650
1625
815
815
865
650
6x4
470
1170
940
2345
1170
1170
1300
865
8x6
610
1520
1215
3030
1520
1520
1730
1300
10 x 8
670
1670
1335
3350
1670
1670
1870
1730
72
Pump Division
Appendix I
Fx
1.5 x 1
534
1046
802
401
Mz
401
Flange
Suction
Frs+Mrs*1.09
Loading
Discharge
Frd+Mrd*1.09
1446
979
1446
1.5 x 1.5
534
1313
1046
802
401
401
1446
2x1
645
1624
1268
993
496
496
1936
979
2 x 1.5
734
1802
1446
1108
551
551
1936
1446
1936
2x2
779
1936
1558
1190
592
592
1936
3 x 1.5
979
2425
1936
1482
741
741
2893
1446
3x2
1046
2626
2092
1591
802
802
2893
1936
3x3
1157
2893
2314
1768
884
884
2893
2893
4x3
1446
3627
2893
2210
1108
1108
3849
2893
6x4
2093
5207
4183
3189
1591
1591
5785
3849
8x6
2715
6764
5407
4121
2067
2067
7699
5785
10 x 8
2982
7432
5941
4556
2271
2271
8322
7699
Fx = Fxs + Fxd
Same
Fy = Fys + Fyd
Same
Fz = Fzs + Fzd
Same
Same
Same
Same
Same
Same
Same
Same
Where:
Forces are expressed lbf or N and moments are expressed in
lbfft or Nm.
Forces and Moments are positive in the directions shown on
Figure I-1.
Fx = Calculated total force in the x direction at the center of the
pump.
Fxs = Force in the x direction applied to the suction nozzle.
Fxd = Force in the x direction applied to the discharge nozzle.
Mx = Calculated total moment about the x-axis at the center of
the pump.
Mxs = Moment about the x-axis applied to the suction nozzle.
Frs = Resultant force applied to the suction.
Mrs = Resultant moment applied to the suction.
73
Same
Pump Division
Appendix I
Metric (meters)
Pump Size
H
L
M
H
1K1.5 x 1-6
6.5
4
0
0.165
1K3 x 1.5-6
6.5
4
0
0.165
1K3 x 2-6
6.5
4
0
0.165
1K1.5 x 1LF-4
6.5
4
0
0.165
1K1.5 x 1LF-8
6.5
4
0
0.165
11K1.5 x 1-8
6.5
4
0
0.165
1K3 x 1.5-8
7.5
4
0
0.191
2K3 x 2-8
9.5
4
0
0.241
2J4 x 3-8
11
4
0
0.279
2K2 x 1-10A
8.5
4
0
0.216
2J2 x 1LF-10
8.5
4
0
0.216
2K3 x 1.5-10A
8.5
4
0
0.216
2K3 x 2-10A
9.5
4
0
0.241
2K4 x 3-10
11
4
0
0.279
2K4 x 3-10H
12.5
4
0
0.318
2K6 x 4-10
13.5
4
0
0.343
2K6 x 4-10H
13.5
4
0
0.343
2K3 x 1.5-13
10.5
4
0
0.267
2K3 x 1.5LF-13
10.5
4
0
0.267
2K3 x 2-13
11.5
4
0
0.292
2K4 x 3-13
12.5
4
0
0.318
2K4 x 3-13HH
12.5
4
0
0.318
2K6 x 4-13A
13.5
4
0
0.343
3K8 x 6-14A
16
6
0
0.406
3K10 x 8-14
18
6
0
0.457
3K6 x 4-16
16
6
0
0.406
3K8 x 6-16A
18
6
0
0.457
3K10 x 8-16
19
6
0
0.483
3K10 x 8-16H
19
6
0
0.483
3K10 x 8-17
20
6
0
0.508
1J1x5 x 1US-6
7.25
4
2.5
0.184
1K1.5 x 1.5US-8
7.875
5
4
0.200
2K2 x 1.5US-10
10
5.25
4
0.254
2K3 x 2US-10
10.5
5.25
4
0.267
2K4 x 3US-10H
12.5
5.75
5
0.318
2K3 x 2US-13
12
5.25
4
0.305
2K4 x 3US-13
13.5
5.75
5
0.343
2K6 x 4US-13A
15
6
5
0.381
1J2 x 2R-6
6.5
3.25
2.75
0.165
2K2 x 2R-10
8.5
3.5
5.25
0.216
2K3 x 3R-10
9
4.25
5.125
0.229
2K4 x 3R-13
10.5
4.125
6.625
0.267
2K6 x 4R-13
11.5
4.75
6.625
0.292
Sealmatic versions have the same dimensions and allowable loads as the above standard pumps.
L
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.152
0.152
0.152
0.152
0.152
0.152
0.152
0.102
0.127
0.133
0.133
0.146
0.133
0.146
0.152
0.083
0.089
0.108
0.105
0.121
M
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0.064
0.102
0.102
0.102
0.127
0.102
0.127
0.127
0.070
0.133
0.130
0.168
0.168
FIGURE I-5
M
H
M
Unitized Self-Priming
Recessed Impeller
L
Standard, Lo-Flo, Sealmatic
74
Pump Division
Appendix J
APPENDIX J
CLEARGUARD TRIMMING AND
ASSEMBLY INSTRUCTIONS
Trimming Instructions
1. Measure minimum distance from the center of mounting
hole in the baseplate to the motor at diameter as shown
above.
2. Locate a reference center of the slot in the coupling guard
flange. Transfer measurement from Step 1 to the guard
using this reference center.
3. Trim the motor end of guard according to the above
measurement. Trimming is best done with a band saw, but
most other types of manual or power saws give acceptable
results. Care must be taken to ensure that there is no gap
larger than 0.24 in (6 mm) between the motor and the
coupling guard.
4. Note: If motor diameter is smaller than guard diameter, trim
guard so that it extends over the end of the motor as far as
possible.
5. Deburr the trimmed end with a file or a sharp knife. Care
must be taken to eliminate all sharp edges.
75
Assembly Instructions
6. Place the bottom and top halves of the ClearGuard around
the coupling.
7. Install the support legs by inserting and then rotating the top
flange of the leg through the slot in the shell flange until it
comes all the way through and locks the top and bottom
together.
8. Attach the support legs to the baseplate using the fasteners
and washers provided.
9. Install fasteners in the holes provided to secure the guard
flanges together.
Pump Division
Appendix K
APPENDIX K
ADDITIONAL SOURCES OF INFORMATION
The following are excellent sources for additional information
on Durco Mark III pumps, and centrifugal pumps in general.
Pump Engineering Manual, R.E. Syska, J.R. Birk, Flowserve
Corporation, Dayton, Ohio, 1980.
Specification for Horizontal End Suction Centrifugal Pumps for
Chemical Process, ASME B73.1M The American Society of
Mechanical Engineers, New York, NY, 1991.
American National Standard for Centrifugal Pumps for
Nomenclature, Definitions, Application and Operation, Hydraulic
Institute, 9 Sylvan Way, Parsippany, New Jersey 07054-3802.
Durco Pump Parts Catalog
Durco Mark III Sales Bulletin
Durco Mark III Technical Bulletin
RESP73H Application of ASME B73.1M-1991, Specification for
Horizontal End Suction Centrifugal Pumps for Chemical
Process, Process Industries Practices, Construction Industry
Institute, The University of Texas at Austin, 3208 Red River
Street, Suite 300, Austin, Texas 78705.
Pump Handbook, 2nd edition, Igor J. Karassik et al, McGrawHill, Inc., New York, NY, 1986.
Centrifugal Pump Sourcebook, John W. Dufour and William E.
Nelson, McGraw-Hill, Inc., New York, NY, 1993.
Pumping Manual, 9th edition, T.C. Dickenson, Elsevier
Advanced Technology, Kidlington, United Kingdom, 1995.
76
Hydraulic Engineering
Mechanical Design
Materials Expertise
Smart Technology
Manufacturing Technology
Pump Division
Your local Flowserve representative:
Latin America
Flowserve de Venezuela S.A.
Pump Division
Torre Ejecutiva No. 75-51
Ave. 4 Bella Vista entre calles 75 y 76
1 er Piso Ofic. 1B, Maracaibo
Edo. Zulia 4002-010. Venezuela
Telephone: 58 61 932 767
Telefax: 58 61 933 114
Asia Pacific
Flowserve Pte. Ltd.
Pump Division
12 Tuas Avenue 20
Singapore 638824
Republic of Singapore
Telephone: 65 862 3332
Telefax: 65 868 4603