flowserve pumps

8/21/2019 Flowserve Pumps

1/44

USER INSTRUCTIONS

CPX, CPXR, CPXN and CPXP

Single stage, end suction, centrifugal, chemical processpumps

PCN=71569117 02-10 (E) (Based on C937KH013, C937KH054,C961KH001 and C937KH067.) Original instructions.

Installation

OperationMaintenance

These instructions must be read prior to installing,operating, using and maintaining this equipment.


2/44

CPX, CPXR, CPXN and CPXP USER INSTRUCTIONS ENGLISH 71569117 02-10

Page 2 of 44 flowserve.com

CONTENTSPage

1 INTRODUCTION AND SAFETY............................ 4

1.1 General ........................................................... 41.2 CE marking and approvals.............................. 4

1.3 Disclaimer .......................................................4

1.4 Copyright ......................................................... 41.5 Duty conditions................................................ 4

1.6 Safety.............................................................. 51.7 Nameplate and safety labels........................... 81.8 Specific machine performance........................ 91.9 Noise level.......................................................9

2 TRANSPORT AND STORAGE............................ 102.1 Consignment receipt and unpacking............. 102.2 Handling ........................................................102.3 Lifting.............................................................102.4 Storage..........................................................102.5 Recycling and end of product life.................. 10

3 DESCRIPTION .................................................... 113.1 Configurations............................................... 11

3.2 Name nomenclature...................................... 11

3.3 Design of major parts .................................... 11

3.4 Performance and operating limits ................. 11

4 INSTALLATION.................................................... 12

4.1 Location.........................................................124.2 Part assemblies............................................. 124.3 Foundation .................................................... 124.4 Grouting ........................................................124.5 Initial alignment .............................................124.6 Piping ............................................................ 134.7 Final shaft alignment check ..........................15

4.8 Electrical connections ................................... 154.9 Protection systems........................................ 16

5 COMMISSIONING, START-UP, OPERATIONAND SHUTDOWN ........................................... 16

5.1 Pre-commissioning procedure ...................... 165.2 Pump lubricants ............................................ 17

5.3 Open impeller clearance............................... 18

5.4 Direction of rotation....................................... 18

5.5 Guarding .......................................................185.6 Priming and auxiliary supplies ...................... 185.7 Starting the pump..........................................195.8 Running the pump.........................................195.9 Stopping and shutdown................................. 205.10 Hydraulic, mechanical and electrical duty... 20

Page

6 MAINTENANCE ...................................................21

6.1 General ..........................................................216.2 Maintenance schedule...................................22

6.3 Spare parts.....................................................22

6.4 Recommended spares...................................236.5 Tools required ................................................23

6.6 Fastener torques............................................236.7 Setting impeller clearance .............................236.8 Disassembly ..................................................246.9 Examination of parts ......................................256.10 Assembly .....................................................266.11 Sealing arrangements..................................28

7 FAULTS; CAUSES AND REMEDIES...................31

8 PARTS LISTS AND DRAWINGS .........................338.1 CPX and CPXN .............................................338.2 CPXR.............................................................35

8.3 CPXP .............................................................368.4 CPX, CPXR, CPXN and CPXP

additional details..........................................38

8.5 Parts interchangeability .................................39

8.6 General arrangement drawing.......................40

9 CERTIFICATION..................................................41

10 OTHER RELEVANT DOCUMENTATIONAND MANUALS................................................41

10.1 Supplementary User Instruction manuals....41

10.2 Change notes ..............................................4110.3 Additional sources of information.................41


3/44



INDEXPage

Additional sources (10.3)......................................... 41Alignment of shafting (see 4.3, 4.5 and 4.7)Assembly (6.10)....................................................... 26ATEX marking (1.6.4.2) ............................................. 7

Bearing sizes and capacities (5.2.2)........................ 17CE marking and approvals (1.2)................................ 4Certification (9) ........................................................41Change notes (10.2)................................................ 41Clearances, impeller (6.7) ....................................... 23Commissioning and operation (5)............................ 16Compliance, ATEX (1.6.4.1)......................................7Configurations (3.1) ................................................. 11Copyright (1.4) ........................................................... 4Design of major parts (3.3) ......................................11Direction of rotation (5.4) ......................................... 18Disassembly (6.8).................................................... 24Disclaimer (1.3).......................................................... 4

Dismantling (6.8, Disassembly) ............................... 24Drawings (8) ............................................................ 33Duty conditions (1.5).................................................. 4Electrical connections (4.8) .....................................15End of product life (2.5) ........................................... 10Examination of parts (6.9) ....................................... 25Fastener torques (6.6) ............................................. 23Faults; causes and remedies (7) .............................31Foundation (4.3) ...................................................... 12General arrangement drawing (8.6) ........................ 40General assembly drawings (8) ............................... 33Grouting (4.4)........................................................... 12Guarding (5.5).......................................................... 18

Handling (2.2) .......................................................... 10Hydraulic, mechanical and electrical duty (5.10)..... 20Impeller clearance (see 5.3 and 6.7)Inspection (6.2.1 and 6.2.2)..................................... 22Installation (4) .......................................................... 12Lifting (2.3)............................................................... 10Location (4.1)........................................................... 12Lubrication (see 5.1.1, 5.2 and 6.2.3)Lubrication schedule (5.2.5) ....................................17Maintenance (6)....................................................... 21Maintenance schedule (6.2) ....................................22Name nomenclature (3.2)........................................ 11Nameplate (1.7.1)......................................................8Operating limits (3.4.1) ............................................ 11

Ordering spare parts (6.3.1) .................................... 22Part assemblies (4.2)............................................... 12Parts interchangeability (8.5)...................................39Parts lists (8)............................................................ 33Performance (3.4).................................................... 11Piping (4.6) .............................................................. 13Pre-commissioning (5.1).......................................... 16Priming and auxiliary supplies (5.6)......................... 18Protection systems (4.9)..........................................16

Page

Reassembly (6.10, Assembly) .................................26Receipt and unpacking (2.1) ....................................10Recommended fill quantities (see 5.2.2)..................17Recommended grease lubricants (5.2.3).................17

Recommended oil lubricants (5.2.1) ........................17Recommended spares (6.4).....................................23Recycling (2.5) .........................................................10Replacement parts (6.3 and 6.4).........................22/23Running the pump (5.8) ...........................................19Safety action (1.6.3) ...................................................5Safety labels (1.7.2) ...................................................8Safety markings (1.6.1) ..............................................5Safety, protection systems (see 1.6 and 4.9)Sealing arrangements (6.11)....................................28Sectional drawings (8)..............................................33Setting impeller clearance (6.7) ...............................23Sound pressure level (1.9, Noise level) .....................9

Sources, additional information (10.3) .....................41Spare parts (6.3) ......................................................22Specific machine performance (1.8) ..........................9Starting the pump (5.7).............................................19Stop/start frequency (5.8.5)......................................20Stopping and shutdown (5.9) ...................................20Storage, pump (2.4) .................................................10Storage, spare parts (6.3.2) .....................................23Supplementary manuals or information sources......41Supplementary User Instructions (10.1)...................41Thermal expansion (4.5.1) .......................................12Tools required (6.5) ..................................................23Torques for fasteners (6.6).......................................23

Trouble-shooting (see 7) ..........................................31Vibration (5.8.4)........................................................20


4/44



1 INTRODUCTION AND SAFETY

1.1 General

These instructions must always be keptclose to the product's operating location or

directly with the product.

Flowserve products are designed, developed andmanufactured with state-of-the-art technologies inmodern facilities. The unit is produced with greatcare and commitment to continuous quality control,utilising sophisticated quality techniques and safetyrequirements.

Flowserve is committed to continuous qualityimprovement and being at service for any furtherinformation about the product in its installation andoperation or about its support products, repair anddiagnostic services.

These instructions are intended to facilitatefamiliarization with the product and its permitted use.Operating the product in compliance with theseinstructions is important to help ensure reliability inservice and avoid risks. The instructions may nottake into account local regulations; ensure suchregulations are observed by all, including thoseinstalling the product. Always coordinate repairactivity with operations personnel, and follow all plantsafety requirements and applicable safety and healthlaws and regulations.

These instructions must be read prior toinstalling, operating, using and maintaining theequipment in any region worldwide. Theequipment must not be put into service until allthe conditions relating to safety, noted in theinstructions, have been met. Failure to follow andapply the present user instructions is consideredto be misuse. Personal injury, product damage,delay or failure caused by misuse are not coveredby the Flowserve warranty.

1.2 CE marking and approvalsIt is a legal requirement that machinery and equipment

put into service within certain regions of the world shallconform with the applicable CE Marking Directivescovering Machinery and, where applicable, Low VoltageEquipment, Electromagnetic Compatibility (EMC),Pressure Equipment Directive (PED) and Equipment forPotentially Explosive Atmospheres (ATEX).

Where applicable, the Directives and any additionalApprovals, cover important safety aspects relating tomachinery and equipment and the satisfactory provisionof technical documents and safety instructions. Whereapplicable this document incorporates informationrelevant to these Directives and Approvals.

To confirm the Approvals applying and if the product isCE marked, check the serial number plate markingsand the Certification. (See section 9, Certification.)

1.3 DisclaimerInformation in these User Instructions is believedto be reliable. In spite of all the efforts ofFlowserve Corporation to provide sound and allnecessary information the content of this manualmay appear insufficient and is not guaranteed byFlowserve as to its completeness or accuracy.

Flowserve manufactures products to exacting

International Quality Management System Standardsas certified and audited by external QualityAssurance organisations. Genuine parts andaccessories have been designed, tested andincorporated into the products to help ensure theircontinued product quality and performance in use.As Flowserve cannot test parts and accessoriessourced from other vendors the incorrectincorporation of such parts and accessories mayadversely affect the performance and safety featuresof the products. The failure to properly select, installor use authorised Flowserve parts and accessories isconsidered to be misuse. Damage or failure caused

by misuse is not covered by the Flowserve warranty.In addition, any modification of Flowserve products orremoval of original components may impair the safetyof these products in their use.

1.4 CopyrightAll rights reserved. No part of these instructions maybe reproduced, stored in a retrieval system ortransmitted in any form or by any means without priorpermission of Flowserve Pump Division.

1.5 Duty conditionsThis product has been selected to meet the

specifications of your purchaser order. Theacknowledgement of these conditions has been sentseparately to the Purchaser. A copy should be keptwith these instructions.

The product must not be operated beyondthe parameters specified for the application.If there is any doubt as to the suitability of theproduct for the application intended, contactFlowserve for advice, quoting the serial number.


5/44



If the conditions of service on your purchase order aregoing to be changed (for example liquid pumped,temperature or duty) it is requested that the user seeksthe written agreement of Flowserve before start up.

1.6 Safety

1.6.1 Summary of safety markingsThese User Instructions contain specific safetymarkings where non-observance of an instruction wouldcause hazards. The specific safety markings are:

This symbol indicates electrical safetyinstructions where non-compliance will involve a highrisk to personal safety or the loss of life.

This symbol indicates safety instructions wherenon-compliance would affect personal safety and couldresult in loss of life.

This symbol indicates hazardous and toxic fluidsafety instructions where non-compliance would affectpersonal safety and could result in loss of life.

This symbol indicates safety instructionswhere non-compliance will involve some risk to safeoperation and personal safety and would damage theequipment or property.

This symbol indicates explosive atmosphere zonemarking according to ATEX. It is used in safetyinstructions where non-compliance in the hazardousarea would cause the risk of an explosion.

This symbol is used in safety instructions toremind not to rub non-metallic surfaces with a drycloth; ensure the cloth is damp. It is used in safetyinstructions where non-compliance in the hazardousarea would cause the risk of an explosion.

This sign is not a safety symbol but indicatesan important instruction in the assembly process.

1.6.2 Personnel qualification and trainingAll personnel involved in the operation, installation,inspection and maintenance of the unit must bequalified to carry out the work involved. If the personnel

in question do not already possess the necessaryknowledge and skill, appropriate training and instructionmust be provided. If required the operator maycommission the manufacturer/supplier to provideapplicable training.

Always coordinate repair activity with operations andhealth and safety personnel, and follow all plantsafety requirements and applicable safety and healthlaws and regulations.

1.6.3 Safety actionThis is a summary of conditions and actions to helpprevent injury to personnel and damage to theenvironment and to equipment. For products usedin potentially explosive atmospheres section 1.6.4also applies.

NEVER DO MAINTENANCE WORKWHEN THE UNIT IS CONNECTED TO POWER

GUARDS MUST NOT BE REMOVED WHILETHE PUMP IS OPERATIONAL

DRAIN THE PUMP AND ISOLATE PIPEWORKBEFORE DISMANTLING THE PUMP

The appropriate safety precautions should be takenwhere the pumped liquids are hazardous.

FLUORO-ELASTOMERS (When fitted.)When a pump has experienced temperatures over250 C (482 F), partial decomposition of fluoro-elastomers (example: Viton) will occur. In thiscondition these are extremely dangerous and skincontact must be avoided.

HANDLING COMPONENTSMany precision parts have sharp corners and thewearing of appropriate safety gloves and equipmentis required when handling these components. To lift

heavy pieces above 25 kg (55 lb) use a craneappropriate for the mass and in accordance withcurrent local regulations.

THERMAL SHOCKRapid changes in the temperature of the liquid withinthe pump can cause thermal shock, which can resultin damage or breakage of components and should beavoided.

NEVER APPLY HEAT TO REMOVE IMPELLERTrapped lubricant or vapour could cause an explosion.

HOT (and cold) PARTSIf hot or freezing components or auxiliary heatingsupplies can present a danger to operators andpersons entering the immediate area action must betaken to avoid accidental contact. If completeprotection is not possible, the machine access mustbe limited to maintenance staff only, with clear visualwarnings and indicators to those entering theimmediate area. Note: bearing housings must not beinsulated and drive motors and bearings may be hot.


6/44



If the temperature is greater than 80 C (175 F) orbelow -5 C (23 F) in a restricted zone, or exceedslocal regulations, action as above shall be taken.

HAZARDOUS LIQUIDSWhen the pump is handling hazardous liquids caremust be taken to avoid exposure to the liquid by

appropriate siting of the pump, limiting personnelaccess and by operator training. If the liquid isflammable and or explosive, strict safety proceduresmust be applied.

Gland packing must not be used when pumpinghazardous liquids.

PREVENT EXCESSIVE EXTERNALPIPE LOADDo not use pump as a support for piping. Do not mountexpansion joints, unless allowed by Flowserve in writing,so that their force, due to internal pressure, acts on the

pump flange.

NEVER RUN THE PUMP DRY

ENSURE CORRECT LUBRICATION(See section 5, Commissioning, startup, operation andshutdown.)

ONLY CHECK DIRECTION OFMOTOR ROTATION WITH COUPLING ELEMENT/PINS REMOVEDStarting in reverse direction of rotation will damage thepump.

START THE PUMP WITH OUTLETVALVE PART OPENED(Unless otherwise instructed at a specific point in theUser Instructions.)This is recommended to minimize the risk ofoverloading and damaging the pump or motor at full orzero flow. Pumps may be started with the valve furtheropen only on installations where this situation cannotoccur. The pump outlet control valve may need to beadjusted to comply with the duty following the run-upprocess. (See section 5, Commissioning start-up,operation and shutdown.)

INLET VALVES TO BE FULLY OPENWHEN PUMP IS RUNNINGRunning the pump at zero flow or below therecommended minimum flow continuously will causedamage to the pump and mechanical seal.

DO NOT RUN THE PUMP ATABNORMALLY HIGH OR LOW FLOW RATESOperating at a flow rate higher than normal or at a flowrate with no back pressure on the pump may overloadthe motor and cause cavitation. Low flow rates maycause a reduction in pump/bearing life, overheating of

the pump, instability and cavitation/vibration.

1.6.4 Products used in potentially explosiveatmospheres

Measures are required to:

Avoid excess temperature

Prevent build up of explosive mixtures

Prevent the generation of sparks

Prevent leakages Maintain the pump to avoid hazard

The following instructions for pumps and pump units

when installed in potentially explosive atmospheresmust be followed to help ensure explosion protection.For ATEX, both electrical and non-electrical equipmentmust meet the requirements of European Directive94/9/EC. Always observe the regional legal Exrequirements eg Ex electrical items outside the EU maybe required certified to other than ATEX eg IECEx, UL.

1.6.4.1 Scope of compliance

Use equipment only in the zone for which it isappropriate. Always check that the driver, drivecoupling assembly, seal and pump equipment are

suitably rated and/or certified for the classification of thespecific atmosphere in which they are to be installed.

Where Flowserve has supplied only the bare shaftpump, the Ex rating applies only to the pump. Theparty responsible for assembling the ATEX pump setshall select the coupling, driver and any additionalequipment, with the necessary CE Certificate/Declaration of Conformity establishing it is suitable forthe area in which it is to be installed.

The output from a variable frequency drive (VFD) cancause additional heating effects in the motor and so,

for pumps sets with a VFD, the ATEX Certification forthe motor must state that it is covers the situationwhere electrical supply is from the VFD. Thisparticular requirement still applies even if the VFD isin a safe area.


7/44



1.6.4.2 MarkingAn example of ATEX equipment marking is shownbelow. The actual classification of the pump will beengraved on the nameplate.

II 2 GD c IIC 135 C (T4)

Equipment GroupI = MiningII = Non-mining

Category2 or M2 = high level protection3 = normal level of protection

Gas and/or dustG = GasD = Dust

c = Constructional safety(in accordance with EN13463-5)

Gas Group (Equipment Category 2 only)IIA Propane (typical)IIB Ethylene (typical)IIC Hydrogen (typical)

Maximum surface temperature (Temperature Class)(see section 1.6.4.3.)

1.6.4.3 Avoiding excessive surface temperatures

ENSURE THE EQUIPMENT TEMPERATURECLASS IS SUITABLE FOR THE HAZARD ZONE

Pumps have a temperature class as stated in the

ATEX Ex rating on the nameplate. These are basedon a maximum ambient of 40 C (104 F); refer toFlowserve for higher ambient temperatures.

The surface temperature on the pump is influencedby the temperature of the liquid handled. Themaximum permissible liquid temperature depends onthe ATEX temperature class and must not exceed thevalues in the table that follows.

emperature classto EN13463-1

Maximum surfacetemperature permitted

Temperature limit ofliquid handled

T6T5

T4T3T2T1

85 C (185 F)100 C (212 F)

135 C (275 F)200 C (392 F)300 C (572 F)450 C (842 F)

Consult FlowserveConsult Flowserve

115 C (239 F) *180 C (356 F) *275 C (527 F) *400 C (752 F) *

*The table only takes the ATEX temperature class into consideration. Pumpdesign or material, as well as component design or material, may furtherlimit the maximum working temperature of the liquid.

The temperature rise at the seals and bearings anddue to the minimum permitted flow rate is taken intoaccount in the temperatures stated.

The responsibility for compliance with thespecified maximum liquid temperature is with theplant operator.

Temperature classification Tx is used when the liquidtemperature varies and when the pump is required to beused in differently classified potentially explosiveatmospheres. In this case the user is responsible forensuring that the pump surface temperature does notexceed that permitted in its actual installed location.

Avoid mechanical, hydraulic or electrical overload byusing motor overload trips, temperature monitors or apower monitor and make routine vibration monitoringchecks.

In dirty or dusty environments, make regular checksand remove dirt from areas around close clearances,bearing housings and motors.

Where there is any risk of the pump being run against aclosed valve generating high liquid and casing externalsurface temperatures fit an external surfacetemperature protection device.

Pumps with threaded on impellers onlyDo not attempt to check the direction of rotation with thecoupling element/pins fitted due to the risk of severecontact between rotating and stationary components.

Pumps with key drive impellers onlyIf an explosive atmosphere exists during theinstallation, do not attempt to check the direction of

rotation by starting the pump unfilled. Even a shortrun time may give a high temperature resulting fromcontact between rotating and stationary components.

Additional requirements for CPXP pumps onlyWhere the system operation does not ensure control ofpriming, as defined in these User Instructions, and themaximum permitted surface temperature of the T Classcould be exceeded, fit an external surface temperatureprotection device.

1.6.4.4 Preventing the build up of explosivemixtures

ENSURE THE PUMP IS PROPERLY FILLEDAND VENTED AND DOES NOT RUN DRY

Ensure the pump and relevant suction and dischargepipeline system is totally filled with liquid at all timesduring the pump operation, so that an explosiveatmosphere is prevented.


8/44



In addition it is essential to make sure that sealchambers, auxiliary shaft seal systems and anyheating and cooling systems are properly filled.

If the operation of the system cannot avoid thiscondition, fit an appropriate dry run protection device(for example liquid detection or a power monitor).

To avoid potential hazards from fugitive emissions ofvapour or gas to atmosphere the surrounding areamust be well ventilated.

1.6.4.5 Preventing sparks

To prevent a potential hazard from mechanicalcontact, the coupling guard must be non-sparking.

To avoid the potential hazard from random inducedcurrent generating a spark, the baseplate must beproperly grounded.

Avoid electrostatic charge: do not rub non-metallicsurfaces with a dry cloth; ensure cloth is damp.

For ATEX the coupling must be selected to complywith 94/9/EC. Correct coupling alignment must bemaintained.

Additional requirement for metallic pumps onnon-metallic baseplatesWhen metallic components are fitted on a non-metallic baseplate they must be individually earthed.

1.6.4.6 Preventing leakage

The pump must only be used to handle liquidsfor which it has been approved to have the correctcorrosion resistance.

Avoid entrapment of liquid in the pump and associatedpiping due to closing of suction and discharge valves,which could cause dangerous excessive pressures tooccur if there is heat input to the liquid. This can occur ifthe pump is stationary or running.

Bursting of liquid containing parts due to freezingmust be avoided by draining or protecting the pump

and ancillary systems.

Where there is the potential hazard of a loss of a sealbarrier fluid or external flush, the fluid must be monitored.

If leakage of liquid to atmosphere can result in ahazard, install a liquid detection .

1.6.4.7 Maintenance to avoid the hazard

CORRECT MAINTENANCE IS REQUIRED TOAVOID POTENTIAL HAZARDS WHICH GIVE ARISK OF EXPLOSION

The responsibility for compliance with maintenanceinstructions is with the plant operator.

To avoid potential explosion hazards duringmaintenance, the tools, cleaning and paintingmaterials used must not give rise to sparking oradversely affect the ambient conditions. Where thereis a risk from such tools or materials, maintenancemust be conducted in a safe area.

It is recommended that a maintenance plan andschedule is adopted. (See section 6, Maintenance.)

1.7 Nameplate and safety labels

1.7.1 NameplateFor details of nameplate, see the Declaration ofConformity, or separate documentation included withthese User Instructions.

1.7.2 Safety labels

Oil lubricated units only:


9/44



1.8 Specific machine performanceFor performance parameters see section 1.5, Dutyconditions. Where performance data has been suppliedseparately to the purchaser these should be obtainedand retained with these User Instructions.

1.9 Noise levelAttention must be given to the exposure of personnelto the noise, and local legislation will define whenguidance to personnel on noise limitation is required,and when noise exposure reduction is mandatory.This is typically 80 to 85 dBA.

The usual approach is to control the exposure time to

the noise or to enclose the machine to reduce emittedsound. You may have already specified a limitingnoise level when the equipment was ordered,

however if no noise requirements were defined, thenattention is drawn to the following table to give an

indication of equipment noise level so that you cantake the appropriate action in your plant.

Pump noise level is dependent on a number ofoperational factors, flow rate, pipework design andacoustic characteristics of the building, and so the

values given are subject to a 3 dBA tolerance andcannot be guaranteed.

Similarly the motor noise assumed in the pump andmotor noise is that typically expected from standardand high efficiency motors when on load directly drivingthe pump. Note that a motor driven by an inverter mayshow an increased noise at some speeds.

If a pump unit only has been purchased for fitting withyour own driver then the pump only noise levels in thetable should be combined with the level for the driverobtained from the supplier. Consult Flowserve or anoise specialist if assistance is required in combiningthe values.

It is recommended that where exposure approachesthe prescribed limit, then site noise measurementsshould be made.

The values are in sound pressure level LpAat 1 m(3.3 ft) from the machine, for free field conditionsover a reflecting plane.

For estimating sound power level LWA(re 1 pW) thenadd 14 dBA to the sound pressure value.

Typical sound pressure level LpAat 1 m reference 20 Pa, dBA

3 550 r/min 2 900 r/min 1 750 r/min 1 450 r/minMotor sizeand speed

kW (hp) Pumponly

Pump andmotor

Pumponly

Pump andmotor

Pumponly

Pump andmotor

Pumponly

Pump andmotor


10/44



2 TRANSPORT AND STORAGE

2.1 Consignment receipt and unpackingImmediately after receipt of the equipment it must bechecked against the delivery/shipping documents forits completeness and that there has been no damage

in transportation. Any shortage and/or damage mustbe reported immediately to Flowserve Pump Divisionand must be received in writing within one month ofreceipt of the equipment. Later claims cannot beaccepted.

Check any crate, boxes or wrappings for anyaccessories or spare parts that may be packedseparately with the equipment or attached to sidewalls of the box or equipment.

Each product has a unique serial number. Checkthat this number corresponds with that advised andalways quote this number in correspondence as wellas when ordering spare parts or further accessories.

2.2 HandlingBoxes, crates, pallets or cartons may be unloadedusing fork lift vehicles or slings dependent on theirsize and construction.

2.3 Lifting

A crane must be used for all pump sets inexcess of 25 kg (55 lb). Fully trained personnel mustcarry out lifting, in accordance with local regulations.

The pump and cast iron baseplate set should be liftedas shown:

Where the baseplate is folded steel there are nospecific lifting points provided for this completemachine set (unless so identified). Any lifting pointsthat can be seen are provided only for dismantlingparts for servicing. Slings, ropes and other liftinggear should be positioned where they cannot slip andwhere a balanced lift is obtained.

Before lifting the driver alone, refer to themanufacturers instructions.

2.4 Storage

Store the pump in a clean, dry locationaway from vibration. Leave piping connection coversin place to keep dirt and other foreign material out ofpump casing. Turn pump at intervals to preventbrinelling of the bearings and the seal faces, if fitted,from sticking.

The pump may be stored as above for up to 6months. Consult Flowserve for preservative actionswhen a longer storage period is needed.

2.5 Recycling and end of product lifeAt the end of the service life of the product or itsparts, the relevant materials and parts should berecycled or disposed of using an environmentallyacceptable method and local requirements. If theproduct contains substances that are harmful to theenvironment, these should be removed and disposedof in accordance with current regulations. This alsoincludes the liquids and/or gases that may be used in

the "seal system" or other utilities.

Make sure that hazardous substances aredisposed of safely and that the correct personalprotective equipment is used. The safetyspecifications must be in accordance with the currentregulations at all times.


11/44



3 DESCRIPTION

3.1 ConfigurationsThe pump is a modular designed centrifugal pumpthat can be built to achieve almost all chemical liquidpumping requirements. (See 3.2 and 3.3 below.)

3.2 Name nomenclatureThe pump size will be engraved on the nameplatetypically as below:

80-50CPX200

Nominal suction size in mm

Nominal discharge size in mm

Configuration see 3.3.1 and 3.3.2 below

Nominal ISO 2858 maximum impeller diameter

The typical nomenclature above is the general guideto the CPX configuration description. Identify theactual pump size and serial number from the pumpnameplate. Check that this agrees with theapplicable certification provided.

3.3 Design of major parts

3.3.1 Pump casingThe pump casing is designed with a horizontalcentreline end inlet and a vertical centreline top outletwhich makes it self venting.

In addition, the CPXP pump casing is designed with aself priming action which works on the reflux principlefor suction lifts up to 7 m (23 ft).

For ease of maintenance, the pump is constructed sothat pipe connectors do not have to be disturbedwhen internal maintenance is required.

On the CPX, CPXR and CPXP the casing feet padsare underneath the casing. On the CPXN they are onthe shaft centreline.

3.3.2 ImpellerAn open impeller is fitted. (On the CPXR the impelleris recessed into the back of the casing.)

3.3.3 ShaftThe large diameter stiff shaft, mounted on bearings,has a keyed drive end.

3.3.4 Bearing housingThe bearing housing enables adjustment of impellerface clearance via the bearing carrier jacking screws.

3.3.5 Pump bearings and lubricationThe pump is fitted with ball and or roller type bearingswhich may be configured differently dependent onuse. The bearings may be oil or grease lubricated.

3.3.6 CoverThe cover has spigots between the pump casing andbearing housing for optimum concentricity.

A fully confined gasket forms the seal between thepump casing and the cover.

The covers designs provide improved performance ofmechanical seals.

The design enables one of a number of sealing

options to be fitted.

3.3.7 Shaft sealThe mechanical seal(s) attached to the drive shaftseals the pumped liquid from the environment. Glandpacking may be fitted as an option on the CPX, CPXRand CPXN.

3.3.8 DriverThe driver is normally an electric motor. Different driveconfigurations may be fitted such as internal combustionengines, turbines, hydraulic motors etc driving viacouplings, belts, gearboxes, drive shafts etc.

3.3.9 AccessoriesAccessories may be fitted when specified by thecustomer.

Fan cooling is available for high temperature operation.(This is a fan fitted within the coupling guard to blowcooling air over the bearing housing and shaft.)

3.4 Performance and operating limitsThis product has been selected to meet thespecifications of the purchase order. See section 1.5.

The following data is included as additionalinformation to help with your installation. It is typical,and factors such as temperature, materials, and sealtype may influence this data. If required, a definitivestatement for your particular application can beobtained from Flowserve.

3.4.1 Operating limitsNormal maximum ambient temp. +40 C (104 F).Maximum pump speed: refer to the nameplate.


12/44



4 INSTALLATION

Equipment operated in hazardous locationsmust comply with the relevant explosion protectionregulations. See section 1.6.4, Products used inpotentially explosive atmospheres.

4.1 LocationThe pump should be located to allow room for access,ventilation, maintenance and inspection with ampleheadroom for lifting and should be as close aspracticable to the supply of liquid to be pumped. Referto the general arrangement drawing for the pump set.

4.2 Part assembliesOn baseplated pump sets the coupling elements aresupplied loose. It is the responsibility of the installerto ensure that the pump set is finally lined up asdetailed in section 4.5.2, Alignment methods.

4.3 Foundation

There are many methods of installingpump units to their foundations. The correct methoddepends on the size of the pump unit, its location andnoise and vibration limitations. Non-compliance withthe provision of correct foundation and installationmay lead to failure of the pump and, as such, wouldbe outside the terms of the warranty.

Ensure the following are met:a) The baseplate should be mounted onto a firm

foundation, either an appropriate thickness ofquality concrete or sturdy steel framework. (Itshould NOT be distorted or pulled down onto thesurface of the foundation, but should besupported to maintain the original alignment.)

b) Install the baseplate onto packing pieces evenlyspaced and adjacent to foundation bolts.

c) Level with shims between baseplate and packingpieces.

d) The pump and driver have been aligned beforedispatch however the alignment of pump and motorhalf coupling must be checked. If this is incorrect, itindicates that the baseplate has become twistedand should be corrected by re-shimming.

e) If not supplied, guarding shall be fitted as necessaryto meet the requirements of ISO 12100 and EN953.

4.4 GroutingWhere applicable, grout in the foundation bolts.

After adding pipework connections and rechecking thecoupling alignment, the baseplate should then begrouted in accordance with good engineering practice.If in any doubt, please contact your nearest servicecentre for advice.

Grouting provides solid contact between the pump unitand foundation, prevents lateral movement of vibratingequipment and dampens resonant vibrations.

Foundation bolts should only be fully tightened whenthe grout has cured.

4.5 Initial alignment

4.5.1 Thermal expansion

The pump and motor will normallyhave to be aligned at ambient temperature with anallowance for thermal expansion at operatingtemperature. In pump installations involving highliquid temperatures, the unit should be run at theactual operating temperature, shut down and thealignment checked immediately.

4.5.2 Alignment methods

Pump and driver must be isolatedelectrically and the half couplings disconnected.

The alignment MUST be checked.

Although the pump will have been aligned at the factoryit is most likely that this alignment will have beendisturbed during transportation or handling. Ifnecessary, align the motor to the pump, not the pump tothe motor.

Alignment is achieved by adding or removing shimsunder the motor feet and also moving the motor

horizontally as required. In some cases where thealignment cannot be achieved it will be necessary tomove the pump before recommencing the aboveprocedure.

For couplings with narrow flanges use a dial indicatoras shown. The alignment values are maximums forcontinuous service.


13/44



Parallel

Angular

Permissible misalignment limits at working temperature:

Parallel alignment- 0.25 mm (0.010 in.) TIR maximum

Angular alignment- 0.3 mm (0.012 in.) TIR maximum for couplingsnot exceeding 100 mm (4 in.) flange diameter- 0.5 mm (0.020 in.) TIR maximum for couplingsover 100 mm (4 in.) diameter

When checking parallel alignment, the total indicatorread-out (TIR) shown is twice the value of the actual

shaft displacement.

Align in the vertical plane first, then horizontally bymoving motor. Maximum pump reliability is obtained bynear perfect alignment of 0.05 - 0.075 mm (0.002 -0.003 in.) parallel and 0.05 mm (0.002 in.) per 100 mm(4 in.) of coupling flange diameter as angularmisalignment.

4.5.3 Check for soft foot

This is a check to ensure that there is no unduestress on the driver holding down bolts; due to non-level baseplate or twisting. To check, remove allshims and clean surfaces and tighten down driver tothe baseplate. Set a dial indicator as shown in sketchand loosen off the holding down bolt while noting anydeflection reading on the dial test Indicator - amaximum of 0.05 mm (0.002 in.) is consideredacceptable but any more will have to be corrected byadding shims. For example, if the dial test indicatorshows the foot lifting 0.15 mm (0.006 in.) then this isthe thickness of shim to be placed under that foot.Tighten down and repeat the same procedure on allother feet until all are within tolerance.

Complete piping as below and see sections 4.7,Final shaft alignment checkup to and including section5, Commissioning, startup, operation and shutdown,before connecting driver and checking actual rotation.

4.6 Piping

Protective covers are fitted to the pipeconnections to prevent foreign bodies entering duringtransportation and installation. Ensure that thesecovers are removed from the pump before connectingany pipes.

4.6.1 Suction and discharge pipework

Never use pump as a support for piping.

Maximum forces and moments allowed on the pumpflanges vary with the pump size and type. To minimize

these forces and moments that may, if excessive, causemisalignment, hot bearings, worn couplings, vibrationand the possible failure of the pump casing, thefollowing points should be strictly followed:

Prevent excessive external pipe load

Never draw piping into place by applying force topump flange connections

Do not mount expansion joints so that their force,due to internal pressure, acts on the pump flange

Ensure piping and fittings are flushedbefore use.

Take into account the available NPSHwhich must be higher than the required NPSH of thepump.

Ensure piping for hazardous liquids is arrangedto allow pump flushing before removal of the pump.

4.6.1.1 CPX, CPXR and CPXN onlyIn order to minimize friction losses and hydraulicnoise in the pipework it is good practice to choosepipework that is one or two sizes larger than thepump suction and discharge. Typically mainpipework velocities should not exceed 2 m/s (6 ft/sec)

suction and 3 m/s (9 ft/sec) on the discharge.

4.6.1.2 CPXP self primer onlyThe delivery pipework must permit priming air toescape unhindered from the pump during the primingcycle, without back pressure and prevent excessiverun-back of liquid on shutdown to minimise syphoning.

Priming air may be vented in one of the following ways:


14/44



1) The discharge pipework regulating valve, if fitted,may be partly opened during the priming cycle tofreely vent the air.

2) An automatic air release valve may be fitted to thedischarge pipework, between the pump and anyvalves, providing that gases and vapours given offare environmentally safe and acceptable forrelease into the atmosphere.

3) An air bleed pipe may be run from the dischargepipework, between the pump and any valves, backto the suction tank or sump. This arrangement willrequire a manual or automatic control during normaloperation to prevent continuous re-circulation of thepumped liquid.

4.6.2 Suction piping

4.6.2.1 CPX, CPXR and CPXN suction pipinga) The inlet pipe should be one or two sizes larger

than the pump inlet bore and pipe bends should

be as large a radius as possible.b) On suction lift the piping should be inclined up

towards the pump inlet with eccentric reducersincorporated to prevent air locks.

c) On positive suction, the inlet piping must have aconstant fall towards the pump.

d) The pipe next to the pump should be the samediameter as the pump suction and have a minimumof two pipe diameters of straight section betweenthe elbow and the pump inlet flange. Where theNPSH margin is not large, it is recommended thatthe pipe straight is 5 to 10 pipe diameter. (Seesection 10.3, Reference 1.) Inlet strainers, when

used, should have a net 'free area' of at least threetimes the inlet pipe area.

e) Fitting isolation and non-return valves will alloweasier maintenance.

f) Never throttle pump on suction side and neverplace a valve directly on the pump inlet nozzle.

4.6.2.2 CPXP suction pipinga) The inlet pipe should be as short as possible,

airtight and the smallest volume as practical for thepump flow rate so as to be able to prime in quickly.Where inlet pipe volume is large an inlet ball-footvalve or flap valve will be required.

b) It is recommended that the pump inlet pipe is nolarger than the pump inlet bore or such that thesuction velocity is in the range of 3 to 5 m/sec(10 to 16 ft/sec). The piping should slope downtowards the pump casing suction flange.

c) Allow a minimum of two pipe diameters of straightsection between the elbow and inlet flange.

d) Fitting an isolation valve will allow easiermaintenance.

e) Never throttle pump on suction side and neverplace a valve directly on the pump inlet nozzle.

4.6.3 Discharge piping

4.6.3.1 CPX, CPXR and CPXN discharge pipinga) A non-return valve should be located in the

discharge pipework to protect the pump fromexcessive back pressure and hence reverserotation when the unit is stopped.

b) Fitting an isolation valve will allow easiermaintenance.

4.6.3.2 CPXP discharge pipinga) In order to minimize friction losses and hydraulic

noise in the pipework it is good practice to choosepipework that is one or two sizes larger than thepump discharge. Typically main pipework velocitiesshould not exceed 3 m/s (9 ft/sec) on the discharge.Pipework expanders should have a maximum angle

of divergence of 9 degrees.b) If a non-return valve is located in the discharge

pipework then a vent/bleed pipe should be fittedfrom the discharge pipe back to the sump orsource tank.

c) A regulating valve should be fitted in the dischargepipework unless pump flow is controlled by thedelivery system design.

4.6.4 Auxiliary piping

The connections that are to be pipedup will have been fitted with protective metal or

plastic plugs which will need to be removed.

4.6.4.1 CPX, CPXR and CPXN pumps fitted withpacked glandsWhen suction pressure is below ambient pressureand differential head is less than 10 m (32.8 ft), it maybe necessary to feed gland packing with liquid toprovide lubrication and prevent the ingress of air.

4.6.4.2 Pumps fitted with mechanical sealsThe conical design of the cover provides excellentliquid circulation around the seal and will not normallyrequire a separate flush for single internal seals.

Single seals requiring re-circulation will normally beprovided with the auxiliary piping from pump casingalready fitted.


15/44



Flowserve seal connections are designated as follows:Q - quenchF - flushD - drain outletBI - barrier fluid in (double seals)BO - barrier fluid out (double seals)H - heating jacketC - cooling jacket

Covers having an auxiliary quench connection,require connection to a suitable source of liquid flow,low pressure steam or static pressure from a headertank. Recommended pressure is 0.35 bar (5 psi) orless. Check General arrangement drawing.

Dual seals, both pressurised and unpressurised,require a barrier liquid between the seals, compatiblewith the pumped liquid.

With back-to-back double seals, the barrier liquid

should be at a minimum pressure of 1 bar (14.5 psi)above the maximum pressure on the pump side ofthe inner seal. (See chart.) The barrier liquidpressure must not exceed limitations of the seal onthe atmospheric side. For toxic service the barrierliquid supply and discharge must be handled safelyand in line with local legislation.

Notes:a) Total seal pressure is equal to pressure at seal plus suction

pressure.

b) For pumped liquid viscosities greater than 440 Centistokesmultiply the differential pressure by 1.25 for 125, 160 and 200size pumps and by 2.0 for larger sizes.

c) Differential pressure in bar equals head in metres multiplied byspecific gravity all divided by 10.19.

d) Ensure to check the seal minimum and maximum pressurelimits are not exceeded and the pressure is agreed withFlowserve.

Special seals may require modification to auxiliarypiping described above. Consult Flowserve if unsureof correct method or arrangement.

For pumping hot liquids, to avoid seal damage, it isrecommended that any external flush/cooling supplybe continued after stopping the pump.

4.6.4.3 Pumps fitted with heating/cooling jacketsConnect the heating/cooling pipes from the sitesupply. The top connection should be used as theoutlet to ensure complete filling/venting of theannulus with heating/cooling liquids; steam is usuallyin at the top, out at the bottom.

4.6.5 Final checksCheck the tightness of all bolts in the suction anddischarge pipework. Check also the tightness of allfoundation bolts.

4.7 Final shaft alignment checkAfter connecting piping to the pump, rotate the shaftseveral times by hand to ensure there is no bindingand all parts are free. Recheck the couplingalignment, as previously described, to ensure no pipestrain. If pipe strain exists, correct piping.

4.8 Electrical connections

Electrical connections must be madeby a qualified Electrician in accordance with relevantlocal national and international regulations.

It is important to be aware of the EUROPEANDIRECTIVE on potentially explosive areas wherecompliance with IEC60079-14 is an additionalrequirement for making electrical connections.

It is important to be aware of the EUROPEANDIRECTIVE on electromagnetic compatibility whenwiring up and installing equipment on site. Attentionmust be paid to ensure that the techniques used duringwiring/installation do not increase electromagneticemissions or decrease the electromagnetic immunity ofthe equipment, wiring or any connected devices. If inany doubt contact Flowserve for advice.

The motor must be wired up inaccordance with the motor manufacturer'sinstructions (normally supplied within the terminalbox) including any temperature, earth leakage,current and other protective devices as appropriate.The identification nameplate should be checked toensure the power supply is appropriate.


16/44



A device to provide emergency stopping mustbe fitted.

If not supplied pre-wired to the pump unit, thecontroller/starter electrical details will also be suppliedwithin the controller/starter.

For electrical details on pump sets with controllerssee the separate wiring diagram.

See section 5.4, Direction of rotationbefore connecting the motor to the electrical supply.

4.9 Protection systems

The following protection systems arerecommended particularly if the pump is installed in apotentially explosive area or is handling a hazardousliquid. If in any doubt consult Flowserve.

If there is any possibility of the system allowing thepump to run against a closed valve or belowminimum continuous safe flow a protection deviceshould be installed to ensure the temperature of theliquid does not rise to an unsafe level.

If there are any circumstances in which the systemcan allow the pump to run dry, or start up empty, apower monitor should be fitted to stop the pump orprevent it from being started. This is particularlyrelevant if the pump is handling a flammable liquid.

If leakage of product from the pump or its associatedsealing system can cause a hazard it isrecommended that an appropriate leakage detectionsystem is installed.

To prevent excessive surface temperatures atbearings it is recommended that temperature orvibration monitoring is carried out.

5 COMMISSIONING, START-UP,OPERATION AND SHUTDOWN

These operations must be carried

out by fully qualified personnel.

5.1 Pre-commissioning procedure

5.1.1 LubricationDetermine the mode of lubrication of the pump set,eg grease, oil etc.

For oil lubricated pumps, fill thebearing housing with correct grade of oil to thecorrect level, ie sight glass [3856] orconstant leveloiler bottle [3855].

When fitted with a constant level oiler, the bearinghousing should be filled by unscrewing or hinging backthe transparent bottle and filling it with oil. Where anadjustable body Denco oiler is fitted this should be set to

the height shown in the following diagram:

The oil filled bottle should then be refitted so as toreturn it to the upright position. Filling should berepeated until oil remains visible within the bottle.

Approximate oil volumes are shown in section 5.2.2,Bearing sizes and capacities.

Grease lubricated pumps and electric motors aresupplied pre-greased.

Where the ambient temperature is very low speciallubricants are required. Where oil lubrication is

utilized and the ambient is less than -5 C (23 F)ensure the oils pour point is at least 15 C (27 F)below the ambient temperature or use oil class SAE5W-50 or API-SJ and ensure the upper operatingrange of the oil is then not exceeded.

Other drivers and gearboxes, if appropriate, shouldbe lubricated in accordance with their manuals.


17/44



5.2 Pump lubricants

5.2.1 Recommended oil lubricants

Oil Splash / force feed / purge oil mist lubrication

Viscosity cSt@ 40 C

32 46 68

Oil temperature range *

-5 to 65 C

(23 to 149 F)

-5 to 78 C

(23 to 172 F)

-5 to 80 C

(23 to 176 F)

Centrifugalpump

lub

rication

Designation to ISO 3448and DIN51524 part 2

ISO VG 3232 HLP

ISO VG 4646 HLP

ISO VG 6868 HLP

BP Castrol Energol HLP-HM 32 Energol HLP-HM 46 Energol HLP-HM 68

ESSO NUTO HP 32 NUTO HP 46 NUTO HP 68

ELF/Total

ELFOLNA DS 32Azolla ZS 32



LSC (for oil mist) LSO 32 (Synthetic oil) LSO 46 (Synthetic oil) LSO 68 (Synthetic oil)

ExxonMobil Mobil DTE 24 Mobil DTE 25 Mobil DTE 26

Q8 Q8 Haydn 32 Q8 Haydn 46 Q8 Haydn 68

Shell Shell Tellus 32 Shell Tellus 46 Shell Tellus 68

Chevron Texaco Rando HD 32 Rando HD 46 Rando HD 68

Wintershall (BASF Group) Wiolan HS32 Wiolan HS46 Wiolan HS68

Oilcompaniesand

lubricants

Fuchs Renolin CL 32 Renolin CL 46 Renolin CL 68

* Note that it normally takes 2 hours for bearing temperature to stabilize and the final temperature will depend on the ambient, r/min, pumpagetemperature and pump size. Also some oils have a greater viscosity index than the minimum acceptable of 95 (eg Mobil DTE13M) which mayextend the minimum temperature capability of the oil. Always check the grade capability where the ambient is less than -5 C (23 F). Use LSC for oil mist. Oil parameters provide flash point >166 C (331 F), density >0.87 @ 15 C (59 F), pour point of -10 C (14 F) or lower.

5.2.2 Bearing sizes and capacitiesGrease lubricated

medium duty bearingsGrease lubricated

heavy duty bearingsGrease lubricated bearing

capacities g (oz.)Framesize

Pump end Drive end Pump end Drive end* Pump end Drive end

1234

6207 Z C36309 Z C36311 Z C36313 Z C3

3306 Z C33309 Z C33311 Z C33313 Z C3

6207 Z C36309 Z C36311 Z C36313 Z C3

7306 pair back-to-back7309 pair back-to-back7311 pair back-to-back7313 pair back-to-back

6 (0.2.)13 (0.5)18 (0.6)20 (0.7)

14 (0.5)25 (0.9)35 (1.2)46 (1.6)

* Nilos ring fitted into bearing locknut [3712.2]

Oil lubricated

medium duty bearings

Oil lubricated

heavy duty bearings

Oil lubricated optional

heavy duty bearingsFramesize

Pump end Drive end Pump end Drive end Pump end Drive end

Frame oil capacity

(approx.)litre (fl.oz)

1234

6207 C36309 C36311 C36313 C3

3306 C33309 C33311 C33313 C3

6207 C36309 C36311 C36313 C3


NUP 207 C3NUP 309 C3NUP 311 C3NUP 313 C3


0.7 (23)1.8 (61)1.4 (47)2.8 (95)

Note: the bearing sizes do not constitute a purchasing specification.

5.2.3 Recommended grease lubricantsGrease NLGI 2 * NLGI 3

Temp. range-20 to +100 C(-4 to +212 F)

-20 to +100 C(-4 to +212 F)

Designationacc. to DIN

KP2K-25 KP3K-20

BP Energrease LS-EP2 Energrease LS-EP3

Elf Multis EP2 Multis EP3Fuchs RENOLIT EP2 RENOLIT EP3

ESSO Beacon EP2 Beacon EP3

Mobil Mobilux EP2 Mobilux EP3 **

Q8 Rembrandt EP2 Rembrandt EP3

Shell Alvania EP2 Alvania EP2

Texaco Multifak EP2 Multifak EP3

SKF LGEP 2

* NLGI 2 is an alternative grease and is not to be mixed with othergrades.

** Standard pre-packed grease for fitted antifriction bearings.

5.2.4 Recommended fill quantitiesRefer to section 5.2.2, Bearing sizes and capacities.

5.2.5 Lubrication schedule

5.2.5.1 Oil lubricated bearingsNormal oil change intervals are 4 000 operating hours

or not more than 6 months. For pumps on hot serviceor in severely damp or corrosive atmosphere, the oilwill require changing more frequently. Lubricant andbearing temperature analysis can be useful inoptimizing lubricant change intervals.

The lubricating oil should be a high quality mineral oilhaving foam inhibitors. Synthetic oils may also beused if checks show that the rubber oil seals will not beadversely affected.


18/44



The bearing temperature may be allowed to rise to50 C (90 F) above ambient, but should not exceed82 C (180 F) (API 610 limit). A continuously risingtemperature, or an abrupt rise, indicates a fault.

Pumps which handle high temperature liquids mayrequire their bearings to be cooled to prevent bearingtemperatures exceeding their limits.

5.2.5.2 Grease lubricated bearingsWhen grease nipples are fitted, one charge betweengrease changes is advisable for most operatingconditions; ie 2 000 hours interval. Normal intervalsbetween grease changes are 4 000 hours or notmore than 6 months.

The characteristics of the installation and severity ofservice will determine the frequency of lubrication.Lubricant and bearing temperature analysis can beuseful in optimizing lubricant change intervals.

The bearing temperature may be allowed to rise to55 C (99 F) above ambient, but should not exceed95 C (204 F). For most operating conditions, aquality grease having a lithium soap base and NLGIconsistency of No 2 or No 3 is recommended. Thedrop point should exceed 175 C (350 F).

Never mix greases containing differentbases, thickeners or additives.

5.3 Open impeller clearanceThe impeller clearance is set in the factory. This may

require adjustment because of piping attachment orincrease in temperatures. For setting instructions seesection 6.7, Setting impeller clearance.

5.4 Direction of rotation

Serious damage can result if the pumpis started or run in the wrong direction of rotation.

The pump is shipped with the coupling elementremoved. Ensure the direction of rotation of the motor iscorrect before fitting the coupling element. Direction ofrotation must correspond to the direction arrow.

If maintenance work has been carriedout to the site's electricity supply, the direction ofrotation should be re-checked as above in case thesupply phasing has been altered.

5.5 Guarding

Guarding is supplied fitted to the pump set.

In member countries of the EU and EFTA, it is a legalrequirement that fasteners for guards must remaincaptive in the guard to comply with the MachineryDirective 2006/42/EC. When releasing such guards,the fasteners must be unscrewed in an appropriateway to ensure that the fasteners remain captive.

Whenever guarding is removed or disturbed ensurethat all the protective guards are securely refittedprior to start-up.

5.6 Priming and auxiliary supplies

5.6.1 CPX, CPXR and CPXN filling and priming

Ensure inlet pipe and pump casing iscompletely full of liquid before starting continuousduty operation.

Priming may be carried out with an ejector, vacuum

pump interceptor or other equipment, or by floodingfrom the inlet source.

When in service, pumps using inlet pipes with footvalves may be primed by passing liquid back from theoutlet pipe through the pump.

5.6.2 CPXP filling and self priming

Fill the pump with liquid to be pumped,or compatible liquid, via the filling plug [6569.4],before starting continuous duty operation.

Pump housingfilling hole.

When the initial fillreaches the suctionpipe, excess liquid willflow out of the casing.

Pump size Initial fill litre (US gal.)

40-40CPXP125 2.5 (0.65)80-80CPXP125 6.0 (1.50)

40-40CPXP160 3.0 (0.80)

80-80CPXP160 6.5 (1.75)

40-40CPXP200 5.0 (1.35)

65-65CPXP200 8.5 (2.25)

80-80CPXP250 12.0 (3.20)

100-100CPXP250 36.0 (9.50)

100-100CPXP315 14.8 (3.95)

150-150CPXP315 18.0 (4.80)


19/44



The pump has self-priming action for which a separateair pump is not normally required.

5.6.3 Auxiliary supplies

Ensure all electrical, hydraulic,pneumatic, sealant and lubrication systems (as

applicable) are connected and operational.

5.7 Starting the pump

5.7.1 Starting the CPX, CPXR and CPXN

a) Ensure flushing and/or cooling/heating liquid supplies are turned ON, beforestarting pump.

b) CLOSE the outlet valve.c) OPEN all inlet valves.d) Prime the pump.e) Start motor and check the outlet pressure.

f) If the pressure is satisfactory, SLOWLY open theoutlet valve.

g) Do not run the pump against aclosed valve for more than 30 seconds.

h) If the pump has to fill the system it may take ashort time before the outlet is pressurised.

i) If NO pressure, or LOW pressure, STOP thepump. Refer to section 7, Faults; causes andremediesfor fault diagnosis.

5.7.2 Starting the CPXP pump

a) Ensure flushing and/or cooling/heating liquid supplies are turned ON, beforestarting pump.

b) CLOSE the outlet valve.c) OPEN all inlet valves.

d) Prime the pump. (See section5.6.2.) The pump casing MUST initially be filledwith compatible liquid before starting the unit.

e) Damage will occur if the pump is run dry or forprolonged periods with no incoming liquid.

f) Subsequent filling should not be necessary unlessthe pump has been emptied or drained of fluid.

g) Start the motor and, if no specific provision has

been made in the delivery pipework for evacuatingthe primed air, open the delivery valve byapproximately 10% to allow priming air to escape.

h) When the pump has primed, check outletpressure.

i) If the pressure is satisfactory, SLOWLY open theoutlet valve.

j) It is recommended that the priming time is noted.Priming times in excess of 5 minutes will indicatea pump or system fault. Any noticeableincreases in priming time on subsequent startswill also indicate a fault. Irregular use could leadto the risk of 'evaporation' of the priming fluid.

k) Do not run the pump with the outletvalve closed for a period longer than 30 seconds.

l) If the pump has to fill the system it may take ashort time before the outlet is pressurized.

m) If NO pressure, or LOW pressure, STOP thepump. Refer to section 7, Faults; causes andremediesfor fault diagnosis.

5.8 Running the pump

5.8.1 Pumps fitted with packed glandIf the pump has a packed gland there must be someleakage from the gland. Gland nuts should initially be

finger-tight only. Leakage should take place soonafter the stuffing box is pressurised.

The gland must be adjusted evenly to givevisible leakage and concentric alignment of the glandring to avoid excess temperature. If no leakage takesplace the packing will begin to overheat. Ifoverheating takes place the pump should be stoppedand allowed to cool before being re-started. Whenthe pump is re-started, check to ensure leakage istaking place at the packed gland.

If hot liquids are being pumped it may be necessary to

slacken the gland nuts to achieve leakage.

The pump should be run for 30 minutes with steadyleakage and the gland nuts tightened by 10 degrees at atime until leakage is reduced to an acceptable level,normally 30 to 120 drops per minute. Bedding in of thepacking may take another 30 minutes.

Care must be taken when adjusting the glandon an operating pump. Safety gloves are essential.

Loose clothing must not be worn to avoid beingcaught up by the pump shaft. Shaft guards must bereplaced after the gland adjustment is complete.

Never run gland packing dry, even fora short time.

5.8.2 Pumps fitted with mechanical sealMechanical seals require no adjustment. Any slightinitial leakage will stop when the seal is run in.


20/44



Before pumping dirty liquids it is advisable, if possible, torun the pump in using clean liquid to safeguard the sealface.

External flush or quench should bestarted before the pump is run and allowed to flow for aperiod after the pump has stopped.

Never run a mechanical seal dry,even for a short time.

5.8.3 Bearings

If the pumps are working in a potentiallyexplosive atmosphere temperature or vibrationmonitoring at the bearings is recommended.

If bearing temperatures are to be monitored it isessential that a benchmark temperature is recordedat the commissioning stage and after the bearing

temperature has stabilized. Record the bearing temperature (t) and the

ambient temperature (ta)

Estimate the likely maximum ambienttemperature (tb)

Set the alarm at (t+tb-ta+5) C (t+tb-ta+10) Fand the trip at 100 C (212 F) for oil lubricationand 105 C (220 F) for grease lubrication

It is important, particularly with grease lubrication, tokeep a check on bearing temperatures. After start upthe temperature rise should be gradual, reaching amaximum after approximately 1.5 to 2 hours.

This temperature should then remain constant ormarginally reduce with time. Refer to section 5.2.5for further information.

5.8.4 Normal vibration levels, alarm and tripFor guidance, pumps generally fall under a classificationfor rigid support machines within the Internationalrotating machinery standards and the recommendedmaximum levels below are based on those standards.

Alarm and trip values for installedpumps should be based on the actual measurements(N) taken on the pump in the fully commissioned asnew condition. Measuring vibration at regularintervals will then show any deterioration in pump orsystem operating conditions.

Horizontal pumpsVibration velocity

unfiltered r.m.s. Motor 15 kWmm/sec (in./sec)

Motor > 15 kWmm/sec (in./sec)

Normal N 3.0 (0.12) 4.5 (0.18)

Alarm Nx 1.25 3.8 (0.15) 5.6 (0.22)

Shutdown trip Nx 2.0 6.0 (0.24) 9.0 (0.35)

Where a grease lubricated unit is utilized in a verticalshaft configuration with a duck-foot bend onto thepump suction, the following apply:

Vibration velocity unfiltered r.m.s

Vertical configurationsmm/sec (in./sec)

Normal N 7.1 (0.28)

Alarm Nx 1.25 9.0 (0.35)

Shutdown trip Nx 2.0 14.2 (0.56)

5.8.5 Stop/start frequencyPump sets are normally suitable for the number ofequally spaced stop/starts per hour shown in thetable below. Check capability of the driver andcontrol/starting system before commissioning.

Motor rating kW (hp)Maximum stop/starts

per hour

Up to 15 (20) 15

Between 15 (20) and 90 (120) 10

Above 90 (120) 6

Where duty and standby pumps are installed it isrecommended that they are run alternately every week.

5.9 Stopping and shutdown

a) Close the outlet valve, but ensurethat the pump runs in this condition for no morethan a few seconds.

b) Stop the pump.c) Switch off flushing and/or cooling/heating liquid

supplies at a time appropriate to the process.

d) For prolonged shut-downs andespecially when ambient temperatures are likely

to drop below freezing point, the pump and anycooling and flushing arrangements must bedrained or otherwise protected.

5.10 Hydraulic, mechanical and electricaldutyThis product has been supplied to meet the performancespecifications of your purchase order, however it isunderstood that during the life of the product these maychange. The following notes may help the user decidehow to evaluate the implications of any change. If indoubt contact your nearest Flowserve office.

5.10.1 Specific gravity (SG)Pump capacity and total head in metres (feet) do notchange with SG, however pressure displayed on apressure gauge is directly proportional to SG. Powerabsorbed is also directly proportional to SG. It istherefore important to check that any change in SGwill not overload the pump driver or over-pressurizethe pump.


21/44



5.10.2 ViscosityFor a given flow rate the total head reduces withincreased viscosity and increases with reducedviscosity. Also for a given flow rate the powerabsorbed increases with increased viscosity, andreduces with reduced viscosity. It is important thatchecks are made with your nearest Flowserve office ifchanges in viscosity are planned.

5.10.3 Pump speedChanging pump speed effects flow, total head, powerabsorbed, NPSHR, noise and vibration. Flow varies indirect proportion to pump speed, head varies as speedratio squared and power varies as speed ratio cubed.The new duty, however, will also be dependent on thesystem curve. If increasing the speed, it is importanttherefore to ensure the maximum pump workingpressure is not exceeded, the driver is not overloaded,NPSHA > NPSHR, and that noise and vibration arewithin local requirements and regulations.

5.10.4 Net positive suction head (NPSHA)NPSH available (NPSHA) is a measure of the headavailable in the pumped liquid, above its vapourpressure, at the pump suction branch.

NPSH required (NPSHR) is a measure of the headrequired in the pumped liquid, above its vapourpressure, to prevent the pump from cavitation. It isimportant that NPSHA > NPSHR. The margin betweenNPSHA > NPSHRshould be as large as possible.

If any change in NPSHAis proposed, ensure these

margins are not significantly eroded. Refer to thepump performance curve to determine exactrequirements particularly if flow has changed.

If in doubt please consult your nearest Flowserveoffice for advice and details of the minimum allowablemargin for your application.

5.10.5 Pumped flowFlow must not fall outside the minimum andmaximum continuous safe flow shown on the pumpperformance curve and or data sheet.

6 MAINTENANCE

6.1 General

It is the plant operator's responsibility to ensurethat all maintenance, inspection and assembly workis carried out by authorized and qualified personnelwho have adequately familiarized themselves withthe subject matter by studying this manual in detail.(See also section 1.6.)

Any work on the machine must be performed when itis at a standstill. It is imperative that the procedurefor shutting down the machine is followed, asdescribed in section 5.9.

Guard fasteners must remain captive duringdismantling of guards, as described in section 5.5.

On completion of work all guards and safety devicesmust be re-installed and made operative again.

Before restarting the machine, the relevantinstructions listed in section 5, Commissioning, startup, operation and shut downmust be observed.

Oil and grease leaks may make the groundslippery. Machine maintenance must alwaysbegin and finish by cleaning the ground and theexterior of the machine.

If platforms, stairs and guard rails are required formaintenance, they must be placed for easy access toareas where maintenance and inspection are to becarried out. The positioning of these accessoriesmust not limit access or hinder the lifting of the part tobe serviced.

When air or compressed inert gas is used in themaintenance process, the operator and anyone in thevicinity must be careful and have the appropriateprotection.

Do not spray air or compressed inert gas on skin.

Do not direct an air or gas jet towards other people.

Never use air or compressed inert gas to cleanclothes.

Before working on the pump, take measures toprevent an uncontrolled start. Put a warning boardon the starting device with the words:"Machine under repair: do not start".

With electric drive equipment, lock the main switchopen and withdraw any fuses. Put a warning boardon the fuse box or main switch with the words:

"Machine under repair: do not connect".

Never clean equipment with inflammable solvents orcarbon tetrachloride. Protect yourself against toxicfumes when using cleaning agents.


22/44



6.2 Maintenance schedule

It is recommended that a maintenance plan andschedule is adopted, in line with these UserInstructions, to include the following:a) Any auxiliary systems installed must be monitored,

if necessary, to ensure they function correctly.b) Gland packings must be adjusted correctly to

give visible leakage and concentric alignment ofthe gland follower to prevent excessivetemperature of the packing or follower.

c) Check for any leaks from gaskets and seals.The correct functioning of the shaft seal must bechecked regularly.

d) Check bearing lubricant level, and if the hoursrun show a lubricant change is required.

e) Check that the duty condition is in the safeoperating range for the pump.

f) Check vibration, noise level and surface temperatureat the bearings to confirm satisfactory operation.

g) Check dirt and dust is removed from areas aroundclose clearances, bearing housings and motors.

h) Check coupling alignment and re-align if necessary.

Our specialist service personnel can help withpreventative maintenance records and providecondition monitoring for temperature and vibration toidentify the onset of potential problems.

If any problems are found the following sequence ofactions should take place:a) Refer to section 7, Faults; causes and remedies,

for fault diagnosis.

b) Ensure equipment complies with therecommendations in this manual.

c) Contact Flowserve if the problem persists.

6.2.1 Routine inspection (daily/weekly)

The following checks should be madeand the appropriate action taken to remedy anydeviations:a) Check operating behaviour. Ensure noise,

vibration and bearing temperatures are normal.b) Check that there are no abnormal fluid or

lubricant leaks (static and dynamic seals) and

that any sealant systems (if fitted) are full andoperating normally.c) Check that shaft seal leaks are within acceptable

limits.d) Check the level and condition of oil lubricant. On

grease lubricated pumps, check running hourssince last recharge of grease or complete greasechange.

e) Check any auxiliary supplies eg heating/cooling(if fitted) are functioning correctly.

Refer to the manuals of any associatedequipment for routine checks needed.

6.2.2 Periodic inspection (six monthly)

a) Check foundation bolts for

security of attachment and corrosion.b) Check pump running records for hourly usage to

determine if bearing lubricant requires changing.c) The coupling should be checked for correct

alignment and worn driving elements.

Refer to the manuals of any associatedequipment for periodic checks needed.

6.2.3 Re-lubricationFor general guidelines refer to section 5.2.5,Lubrication schedule.

Lubricant and bearing temperature analysis can beuseful in optimizing lubricant change intervals.

6.2.4 Mechanical sealsWhen leakage becomes unacceptable the seal [4200]will need replacement.

6.2.5 Gland packingThe stuffing box split gland [4120] can be completelyremoved for re-packing or to enable the addition of extrarings of packing. The stuffing box is normally suppliedwith a lantern ring [4134] to enable a clean orpressurised flush to the centre of the packing. If not

required, this can be replaced by an extra 2 rings ofpacking.

6.3 Spare parts

6.3.1 Ordering of sparesFlowserve keeps records of all pumps that have beensupplied. When ordering spares the followinginformation should be quoted.

1) Pump serial number.2) Pump size.3) Part name taken from section 8.4) Part number taken from section 8.5) Number of parts required.

The pump size and serial number are shown on thepump nameplate.

To ensure continued satisfactory operation,replacement parts to the original design specificationshould be obtained from Flowserve. Any change tothe original design specification (modification or use


23/44



of a non-standard part) will invalidate the pumpssafety certification.

6.3.2 Storage of sparesSpares should be stored in a clean dry area awayfrom vibration. Inspection and re-treatment ofmetallic surfaces (if necessary) with preservative isrecommended at 6 monthly intervals.

6.4 Recommended sparesFor two years operation (as per VDMA 24296).

Number of pumps(including stand-by)

Part no. Designation

2 3 4 5 6/7 8/9 10(+)

2200 Impeller 1 2 3 30%

2100 Shaft 1 2 3 30%

3712.1 Bearing locknut 1 2 3 4 50%

2400 Sleeve (if fitted) 2 3 4 50%

3011 Radial ball bearing 1 2 3 4 50%

3013 Thrust bearing 1 2 3 4 50%4590.1 * Gasket 4 6 8 9 12 150%

4610.1 O-ring 4 6 8 9 12 150%

4610.2 O-ring 4 6 8 9 10 100%

2540.2 Flinger 1 2 3 30%

4130 Gland packing 2 3 4 40%

4134 Lantern ring 1 2 3 30%

4200 Mechanical seals 1 2 3 30%

- Power end - - - - - 1 2

* Note: for CPXR replace with the following part:

4590.1 Gasket 8 12 16 18 24 300%

Additional spares for keyed impeller option

2912.1 /2912.2

Impeller nut 1 2 3 30%

4610.4O-ring(if sleeve fitted)

2 3 4 50%

4610.5 O-ring 4 6 8 9 12 150%

6700.2 Key 1 2 3 30%

6.5 Tools requiredA typical range of tools that will be required tomaintain these pumps is listed below.

Readily available in standard tool kits, and dependenton pump size:

Open ended spanners (wrenches) to suit up toM 24 screws/nuts

Socket spanners (wrenches), up to M 24 screws

Allen keys, up to 10 mm (A/F)

Range of screwdrivers

Soft mallet

More specialized equipment:

Bearing pullers

Bearing induction heater

Dial test indicator

C-spanner (wrench) - for removing shaft nut.(If difficulties in sourcing are encountered, consult

Flowserve.) Coupling grip/shaft spanner

6.6 Fastener torquesFastener Screw size Torque Nm (lbf ft)

All except whereotherwise stated

M8M10M12M16M20

16 (12)25 (18)35 (26)80 (59)130 (96)

Impeller nut

M12M16M22M24

16 (12)41 (31)106 (79)

135 (100)

Non-metallic gaskets incur creeprelaxation - before commissioning the pump checkand retighten fasteners to tightening torques stated.

6.7 Setting impeller clearance

This procedure may be required after the pump hasbeen dismantled or a different clearance is required.

Before carrying out this procedure ensure that themechanical seal(s) [4200] fitted can tolerate a changein their axial setting, otherwise it will be necessary todismantle the unit and reset the seal axial position

after adjusting the impeller clearance.

Clearance mm (in.)

TempC(F)

Impellersup to

210 mm

Impellers211 mm to260 mm

Impellersover 260 mm

(except *)

(*)150CPX400

(*)200CPX400

(*)150CPX500

50 (122)100 (212)150 (302)200 (392)250 (482)

0.3 (0.012)0.4 (0.016)0.5 (0.020)0.6 (0.024)0.7 (0.028)

0.4 (0.016)0.5 (0.020)0.6 (0.024)0.7 (0.028)0.8 (0.032)

0.5 (0.020)0.6 (0.024)0.7 (0.028)0.8 (0.032)0.9 (0.036)

1.0 (0.040)1.0 (0.040)1.1 (0.044)1.2 (0.048)1.3 (0.052)


24/44



a) Disconnect the coupling if it has limited axialflexibility

b) Record the gap between the bearing carrier[3240] and bearing housing [3200] using feelergauges.

c) Loosen the bearing carrier screws [6570.2] andback off the bearing carrier 2 mm (0.08 in.) usingthe jacking screws [6570.3].

For CPX, CPXN and CPXP

d) Tighten the bearing carrier screws [6570.2] evenly,drawing the bearing carrier towards the bearinghousing, until the impeller [2200] contacts the pumpcasing. [1100] Turn the shaft [2100], during thisprocedure, until a detectable rub is obtained. Thisis the zero clearance position.

e) Set a dial indicator to zero on the shaft end ormeasure the bearing carrier to bearing housinggap and record the measurement.

f) Slacken the bearing carrier screws [6570.2].g) Tighten jacking screws [6570.3] evenly (about one

flat at a time) until the dial indicator or feeler gaugeshows the correct impeller clearance from the zeroclearance position. This clearance should bebetween 0.3 and 2 mm (0.008 and 0.080 in.)depending on the nature of the pumped fluid. (Seetable above.)

h) Evenly tighten the bearing carrier screws [6570.2]keeping the dial indicator or feeler gaugesreading the correct setting. Then tighten the hexnuts [6580.1] to lock the jacking screws inposition.

For CPXR only

The impeller does not have a fine frontclearance setting and adjustment of the impelleris not normally required.

d) Tighten the jacking screws [6570.3] evenly, pushingthe bearing carrier away from the bearing housing,until the impeller [2200] contacts the cover. [1220]Turn the shaft [2100], during this procedure, until adetectable rub is obtained. This is the zeroclearance position.

e) Set a dial indicator to zero on the shaft end ormeasure the bearing carrier to bearing housinggap and record the measurement.

f) Slacken the jacking screws [6570.3].g) Tighten bearing carrier screws [6570.2] evenly

(about one flat at a time) until the dial indicator orfeeler gauge shows the correct impeller clearancefrom the zero clearance position. This clearanceshould be 1.5 - 2 mm (0.06 - 0.08 in.) (See drawing.)

h) Tighten the jacking screws [6570.3] until theycontact the bearing carrier, keeping the dialindicator or feeler gauges reading the correctsetting. Then tighten the hex nuts [6580.1] tolock the jacking screws in position.

For all pump types

i) Compare the original and final gaps between thebearing carrier and bearing housing to check ifthe movement of the shaft has exceeded the sealcapability (over/under compression of seal).Re-position the seal to correct this.

j) Check that the shaft [2100] can turn freely withoutbinding.

k) If a cartridge seal [4200] is fitted it should bereset at this point.

l) Ensure the coupling distance between shaft ends(DBSE) is correct. Reset/re-align if necessary.

6.8 Disassembly

Refer to Safetysection before dismantling thepump.

Before dismantling the pump foroverhaul, ensure genuine Flowserve replacementparts are available.

Refer to sectional drawings for part numbers andidentification. See section 8, Parts lists and drawings.

6.8.1 Bearing housingTo remove, proceed as follows:a) Disconnect all auxiliary pipes and tubes where

applicable.b) Remove coupling guard and disconnect coupling.c) If oil lubricated frame, drain oil by removing drain

plug [6569.3].d) R

flowserve pumps

Documents