Professional Documents
Culture Documents
CONTENTS
Page Page
1 INTRODUCTION AND SAFETY............................ 4 6 MAINTENANCE ...................................................19
1.1 General ........................................................... 4 6.1 General ..........................................................19
1.2 CE marking and approvals.............................. 4 6.2 Maintenance schedule...................................19
1.3 Disclaimer ....................................................... 4 6.3 Spare parts.....................................................20
1.4 Copyright......................................................... 4 6.4 Recommended spares and consumable items
1.5 Duty conditions................................................ 4 .......................................................................21
1.6 Safety .............................................................. 5 6.5 Disassembly ..................................................21
1.7 Nameplate and safety labels........................... 8 6.6 Examination of parts ......................................22
1.8 Specific machine performance........................ 8 6.7 Assembly .......................................................22
1.9 Noise level....................................................... 9 7 FAULTS; CAUSES AND REMEDIES...................24
2 TRANSPORT AND STORAGE............................ 10 8 PARTS LISTS AND DRAWINGS .........................26
2.1 Consignment receipt and unpacking............. 10 8.1 Sectional drawing ...........................................26
2.2 Handling ........................................................ 10 8.2 Sectional drawing parts list .............................29
2.3 Lifting ............................................................ 10 8.3 General arrangement drawing........................29
2.4 Storage.......................................................... 10
2.5 Recycling and end of product life.................. 10 9 CERTIFICATION ..................................................30
3 PUMP DESCRIPTION......................................... 11 10 OTHER RELEVANT DOCUMENTATION AND
3.1 Design of major parts .................................... 11 MANUALS .....................................................30
3.2 Performance and operating limits ................. 11 10.1 Supplementary User Instructions .................30
10.2 Change notes ...............................................30
4 INSTALLATION.................................................... 11 10.3 Additional sources of information..................30
4.1 Location......................................................... 11
4.2 Foundation .................................................... 11
4.3 Grouting ........................................................ 12
4.4 Initial alignment ............................................. 12
4.5 Piping ............................................................ 13
4.6 Final shaft alignment check .......................... 14
4.7 Electrical connections ................................... 14
4.8 Protection systems........................................ 14
5 COMMISSIONING, START-UP, OPERATION AND
SHUTDOWN................................................. 15
5.1 Pre-commissioning procedure ...................... 15
5.2 Pump lubricants ............................................ 15
5.3 Direction of rotation ....................................... 16
5.4 Guarding ........................................................ 16
5.5 Priming and auxiliary supplies ...................... 16
5.6 Starting the pump .......................................... 17
5.7 Running the pump......................................... 17
5.8 Stopping and shutdown................................. 18
5.9 Hydraulic, mechanical and electrical duty..... 18
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INDEX
Page Page
Additional sources (10.3) ......................................... 30 Replacement parts (see 6.3 and 6.4).......................20
Alignment of shafting (see 4.2, 4.4 and 4.6) Running the pump (5.7) ...........................................17
Assembly (6.7)......................................................... 22 Safety action (1.6.3) ...................................................5
ATEX marking (1.6.4.2) ............................................. 7 Safety labels (1.7.2) ...................................................8
CE marking and approvals (1.2)................................ 4 Safety markings (1.6.1) ..............................................5
Certification (9) ........................................................ 30 Safety, protection systems (see 1.6 and 4.8)
Change notes (10.2) ................................................ 30 Sectional drawings (8.1)...........................................26
Commissioning and operation (5)............................ 15 Sound level (see 1.9, Noise level)..............................9
Compliance, ATEX (1.6.4.1)...................................... 6 Sources, additional information (10.3) .....................30
Copyright (1.4) ........................................................... 4 Spare parts (6.3) ......................................................20
Direction of rotation (5.3) ......................................... 16 Specific machine performance (1.8) ..........................8
Disassembly (6.5) .................................................... 21 Starting the pump (5.6).............................................17
Disclaimer (1.3).......................................................... 4 Stop/start frequency (5.7.6)......................................18
Dismantling (see 6.5, Disassembly) ........................ 21 Stopping and shutdown (5.8) ...................................18
Drawings (8) ............................................................ 26 Storage, pump (2.4) .................................................10
Duty conditions (1.5).................................................. 4 Storage, spare parts (6.3.2) .....................................21
Electrical connections (4.7) ..................................... 14 Supplementary manuals or information sources (10)
End of product life (2.5) ........................................... 10 ............................................................................30
Examination of parts (6.6) ....................................... 22 Thermal expansion (4.4.1) .......................................12
Faults; causes and remedies (7) ............................. 24 Trouble-shooting (see 7) ..........................................24
Foundation (4.2) ...................................................... 11 Vibration (5.7.5)........................................................18
General arrangement drawing (8.3) ........................ 29
Grouting (4.3)........................................................... 12
Guarding (5.4).......................................................... 16
Handling (2.2) .......................................................... 10
Hydraulic, mechanical and electrical duty (5.9) ....... 18
Inspection (6.2.1 and 6.2.2) ..................................... 20
Installation (4) .......................................................... 11
Internal coating (6.2.5)............................................. 20
Lifting (2.3) ............................................................... 10
Location (4.1)........................................................... 11
Lubrication (see 5.1.1 and 5.2)
Lubrication schedule (5.2.3) .................................... 16
Maintenance (6)....................................................... 19
Maintenance schedule (6.2) .................................... 19
Nameplate (1.7.1) ...................................................... 8
Operating limits (3.2) ............................................... 11
Ordering spare parts (6.3.1) .................................... 20
Parts lists (8.2)......................................................... 29
Performance (3.2).................................................... 11
Piping (4.5) .............................................................. 13
Pre-commissioning (5.1).......................................... 15
Protection systems (4.8) .......................................... 14
Reassembly (see 6.7, Assembly) ............................ 22
Receipt and unpacking (2.1).................................... 10
Recommended grease lubricants (5.2.2) ................ 16
Recommended oil lubricants (5.2.1)........................ 15
Recommended spares (6.4) .................................... 21
Recycling (2.5)......................................................... 10
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1 INTRODUCTION AND SAFETY To confirm the Approvals applying and if the product is
CE marked, check the serial number plate markings
1.1 General and the Certification. (See section 9, Certification.)
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1.9 Noise level and high efficiency motors when on load directly
Attention must be given to the exposure of personnel driving the pump. Note that a motor driven by an
to the noise, and local legislation will define when inverter may show an increased noise at some
guidance to personnel on noise limitation is required, speeds.
and when noise exposure reduction is mandatory.
This is typically 80 to 85 dBA. If a pump unit only has been purchased for fitting with
your own driver then the “pump only” noise levels in the
The usual approach is to control the exposure time to table should be combined with the level for the driver
the noise or to enclose the machine to reduce emitted obtained from the supplier. Consult Flowserve or a
sound. You may have already specified a limiting noise specialist if assistance is required in combining
noise level when the equipment was ordered, the values.
however if no noise requirements were defined, then
It is recommended that where exposure approaches
attention is drawn to the following table to give an
the prescribed limit, then site noise measurements
indication of equipment noise level so that you can
should be made.
take the appropriate action in your plant.
The values are in sound pressure level LpA at 1 m
Pump noise level is dependent on a number of (3.3 ft) from the machine, for “free field conditions
operational factors, flow rate, pipework design and over a reflecting plane”.
acoustic characteristics of the building, and so the
values given are subject to a 3 dBA tolerance and For estimating sound power level LWA (re 1pW) then
cannot be guaranteed. add 17 dBA to the sound pressure value.
Similarly the motor noise assumed in the “pump and
motor” noise is that typically expected from standard
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Each product has a unique serial number. Check A crane must be used for all pump sets in
that this number corresponds with that advised and excess of 25kg (55 Ib). Fully trained personnel must
always quote this number in correspondence as well carry out lifting, in accordance with local regulations.
as when ordering spare parts or further accessories.
The driver weight is recorded on its nameplate or
2.2 Handling mass plate.
Boxes, crates, pallets or cartons may be unloaded
using fork-lift vehicles or slings dependent on their 2.4 Storage
size and construction.
Store the pump in a clean, dry location
2.3 Lifting away from vibration. Leave piping connection covers
in place to keep dirt and other foreign material out of
2.3.1 Slinging of motor pumps units pump casing. Turn pump at intervals to prevent
brinelling of the bearings and the seal faces, if fitted,
Use handling means in accordance with motor from sticking.
pump unit mass mentioned on the CE plate. For the
masses of the pumps bare end of shaft see table § The pump may be stored as above for up to 6
2.2.2 and nameplate. months. Consult Flowserve for preservative actions
when a longer storage period is needed.
To avoid distortion, the pump unit
should be lifted as shown. 2.5 Recycling and end of product life
At the end of the service life of the product or its
parts, the relevant materials and parts should be
recycled or disposed of using an environmentally
acceptable method and local regulations. If the
product contains substances that are harmful to the
environment, these should be removed and disposed
of in accordance with current regulations. This also
includes the liquids and or gases that may be used in
the "seal system" or other utilities.
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b) Install the baseplate onto packing pieces evenly 4.4.1 Thermal expansion
spaced and adjacent to foundation bolts.
The pump and motor will normally
have to be aligned at ambient temperature and
should be corrected to allow for thermal expansion at
operating temperature. In pump installations
involving high liquid temperatures, the unit should be
run at the actual operating temperature, shut down
and the alignment checked immediately.
Foundation bolts should only be fully tightened when Permissible misalignment limits at working
the grout has cured. temperature:
• Parallel alignment within 0.2mm TIR
4.4 Initial alignment • Angular alignment within 0.1mm
Before connecting the couplings verify Pumps with thick flanged non-spacer couplings can
the motor rotation direction. be aligned by using a straight-edge across the
outside diameters of the coupling hubs and
measuring the gap between the machined faces
using feeler gauges, measuring wedge or callipers.
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When the electric motor has sleeve bearings it is d) Allow a minimum of two pipe diameters of
necessary to ensure that the motor is aligned to run straight section between the elbow and inlet
on its magnetic centreline. flange.
Refer to the motor manual for details. e) Inlet strainers, when used, should have a net `free
area' of at least three times the inlet pipe area.
f) Do not install elbows at an angle other than
A button (screwed into one of the shaft ends) is perpendicular to the shaft axis. Elbows parallel
normally fitted between the motor and pump shaft to the shaft axis will cause uneven flow.
ends to fix the axial position. g) Except in unusual circumstances strainers are
not recommended in inlet piping. If considerable
4.5 Piping foreign matter is expected a screen installed at
the entrance to the wet well is preferable.
h) Fitting an isolator and non-return valves can
The user must verify that the equipment is allow easier maintenance.
isolated from any external sources of vibration. i) Never throttle pump on suction side and never
place a valve directly on the pump inlet nozzle.
Protective covers are fitted to the pipe
connections to prevent foreign bodies entering during 4.5.3 Discharge piping
transportation and installation. Ensure that these A non-return valve should be located in the discharge
covers are removed from the pump before connecting pipe work to protect the pump from excessive back
any pipes. pressure and hence reverse rotation when the unit is
stopped.
4.5.1 Suction and discharge pipe work
4.5.4 Auxiliary piping
Never use the pump as a support for
piping. 4.5.4.1 Pumps fitted with packed gland
When suction pressure is below ambient pressure it
Maximum forces and moments allowed on the pump is necessary to feed the gland packing with liquid to
flanges vary with the pump size and type. To minimize provide lubrication and prevent the ingress of air.
these forces and moments that may, if excessive, cause
misalignment, hot bearings, worn couplings, vibration When pumping 'dirty' liquids a clean liquid supply to
and the possible failure of the pump casing, the the gland is recommended.
following points should be strictly followed:
• Prevent excessive external pipe load 4.5.4.2 Pumps fitted with mechanical seals
• Never draw piping into place by applying force to Single seals requiring re-circulation will normally be
pump flange connections provided with the auxiliary piping from pump casing
• Do not mount expansion joints so that their force, already fitted.
due to internal pressure, acts on the pump flange.
Seal housings/covers having an auxiliary quench
connection require connection to a suitable source of
Ensure piping and fittings are flushed liquid flow, low pressure steam or static pressure
before use. from a header tank. Recommended pressure is 0.35
bar (5psi) or less. Check General arrangement
Ensure piping for hazardous liquids is arranged drawing.
to allow pump flushing before removal of the pump.
Special seals may require modification to auxiliary
4.5.2 Suction piping piping described above. Consult separate User
a) The inlet pipe should be one or two sizes larger Instructions and or Flowserve if unsure of correct
than the pump inlet bore and pipe bends should method or arrangement.
be as large a radius as possible.
b) On suction lift the piping should be inclined up For pumping hot liquids, to avoid seal damage, it is
towards the pump inlet with eccentric reducers recommended that any external flush/cooling supply
incorporated to prevent air locks. be continued after stopping the pump.
c) On positive suction, the inlet piping must have a
constant fall towards the pump.
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5 COMMISSIONING, START-UP,
OPERATION AND SHUTDOWN
Viscosity cSt at 40 ºC 32 46 68
Oil temp. range * ºC -5 to 65 -5 to 78 -5 to 80
(ºF) (-23 to 149) (-23 to 172) (-23 to 176)
Designation according HL/HLP 32 HL/HLP 46 HL/HLP 68
to DIN51502 ISO VG
BP BP Energol HL32 BP Energol HL46 BP Energol HL68
BP Energol HLP32 BP Energol HLP46 BP Energol HLP68
DEA Anstron HL32 Anstron HL46 Anstron HL68
Anstron HLP32 Anstron HLP46 Anstron HLP68
OLNA 32
Oil companies and lubricants
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5.2.2 Recommended grease lubricants The characteristics of the installation and severity of
Grease
Grease nipples service will determine the frequency of lubrication.
NLGI 2 * NLGI 3 ** Lubricant and bearing temperature analysis can be
Temp. range ºC -20 to +100 -20 to +100 useful in optimizing lubricant change intervals.
(ºF) (-4 to +212) (-4 to +212)
Designation The bearing temperature may be allowed to rise to
K2K-20 K2K 30
according to DIN 55 ºC (131 ºF) above ambient but should not exceed
BP Energrease LS2 Energrease LS3 95 °C (204 °F). For most operating conditions a quality
DEA Glissando 20 Glissando 30 grease having a lithium soap base and NLGI
Elf Elfmulti 2 Elfmulti 3
consistency of No 2 or No 3 is recommended. The
drop point should exceed 175 ºC (350 ºF).
Esso Beacon 2 Beacon 3
Mobil Mobilux 2 Mobilux 3 Never mix greases containing different
Q8 Rembrandt 2 Rembrandt 3 bases, thickeners or additives.
Shell Alvania Fett G2 Alvania R3
Alvania Fett R2 5.3 Direction of rotation
Texaco Multilak 20 Multilak 30
Multilak EP2 Multilak EP3 Starting or operating pumps with the
Wintershall
Wiolub LFK 2 –
wrong direction of rotation can be harmful to the
(BASF Group) pumps. Ensure that the pump rotation is the same as
SKF LGMT 2 LGMT 3 the arrow on the pump casing.
Silkolene G55/T G56/T It is preferable to check the direction of rotation
* NLGI 2 is an alternative grease and is not to be mixed with other before installing the coupling. If not, the pump must
grades be filled in with the liquid before start-up.
** Factory packed bearings for the temperature range with grease
nipples
If maintenance work has been carried
out to the site's electricity supply, the direction of
5.2.3 Lubrication schedule rotation should be re-checked as above in case the
supply phasing has been altered.
5.2.4.1 Oil lubricated bearings
Normal oil change intervals are 4 000 operating hours 5.4 Guarding
or at least every 6 months. For pumps on hot service
or in severely damp or corrosive atmosphere, the oil Guarding is supplied fitted to the pump set.
will require changing more frequently. Lubricant and
If this has been removed or disturbed ensure
bearing temperature analysis can be useful in
that all the protective guards around the pump
optimizing lubricant change intervals.
coupling and exposed parts of the shaft are securely
fixed.
The lubricating oil should be a high quality oil having
oxidisation and foam inhibitors, or synthetic oil.
5.5 Priming and auxiliary supplies
The bearing temperature may be allowed to rise to
50 ºC (122 ºF).above ambient, but should not exceed Where there is any risk of the pump being run
82 ºC (180 ºF). A continuously rising temperature, or against a closed valve generating high liquid and
an abrupt rise, indicate a fault. casing external surface temperatures it is
recommended that users fit an external surface
5.2.4.2 Grease lubricated bearings temperature protection device.
When grease nipples are fitted, one charge between
grease changes is advisable for most operating Ensure all electrical, hydraulic,
conditions, ie 2 000 hours interval. pneumatic, sealant and lubrication systems (as
applicable) are connected and operational.
Normal intervals between grease changes are 4 000
hours or at least every 6 months. Ensure the inlet pipe and pump casing
are completely full of liquid before starting continuous
duty operation.
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These operations must be carried out by personnel The pump should be run for 30 minutes with steady
with approved qualifications. leakage and the gland nuts tightened by 10 degrees
liquid before starting continuous duty operation. at a time until leakage is reduced to an acceptable
level, normally a minimum of 120 drops per minute is
5.6 Starting the pump required. Bedding in of the packing may take another
30 minutes.
a) Ensure flushing and/or cooling/
heating liquid supplies are turned ON before Care must be taken when adjusting the gland
starting the pump. on an operating pump. Safety gloves are essential.
b) CLOSE the outlet valve. Loose clothing must not be worn to avoid being
c) OPEN all inlet valves. caught up by the pump shaft. Shaft guards must be
d) Prime the pump. replaced after the gland adjustment is complete.
e) Ensure all vent connections are closed Never run gland packing dry, even for
before starting. a short time.
f) Start motor and check outlet pressure.
g) If the pressure is satisfactory, slowly OPEN outlet 5.7.3 Pumps fitted with mechanical seal
control valve. Mechanical seals require no adjustment. Any slight
initial leakage will stop when the seal is run in.
h) Do not run the pump with the
outlet valve closed for a period longer than 30 Before pumping dirty liquids it is advisable, if
seconds. possible, to run in the pump mechanical seal using
i) If NO pressure, or LOW pressure, STOP the clean liquid to safeguard the seal face.
pump. Refer to section 7, Faults; causes and
remedies, for fault diagnosis. External flush or quench should be
started before the pump is run and allowed to flow for
5.7 Running the pump a period after the pump has stopped.
5.7.1 Venting the pump Never run a mechanical seal dry, even
for a short time.
Vent the pump to enable all trapped air to
escape taking due care with hot or hazardous liquids. 5.7.4 Bearings
Under normal operating conditions, after the pump
If the pumps are working in a potentially
has been fully primed and vented, it should be
explosive atmosphere, temperature or vibration
unnecessary to re-vent the pump.
monitoring at the bearings is recommended.
If bearing temperatures are to be monitored it is
5.7.2 Pumps fitted with packed gland
essential that a benchmark temperature is recorded
If the pump has a packed gland there must be some
at the commissioning stage and after the bearing
leakage from the gland. Gland nuts should initially be
temperature has stabilized.
finger-tight only. Leakage should take place soon
after the stuffing box is pressurized. • Record the bearing temperature (t) and the
ambient temperature (ta)
If no leakage takes place the packing will begin to • Estimate the likely maximum ambient
overheat. If overheating takes place the pump should temperature (tb)
be stopped and allowed to cool before being re- • Set the alarm at (t+tb-ta+5) °C [(t+tb-ta+10) °F]
started. When the pump is re-started, check to and the trip at 100 °C (212 °F) for oil lubrication
ensure leakage is taking place at the packed gland. and 105 °C (220 °F) for grease lubrication
It is important, particularly with grease lubrication, to
If hot liquids are being pumped it may be necessary keep a check on bearing temperatures. After start up
to slacken the gland nuts to achieve leakage. the temperature rise should be gradual, reaching a
maximum after approximately 1.5 to 2 hours. This
temperature rise should then remain constant or
marginally reduce with time. (Refer to section 6.2.3.1
for further information.)
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5.7.5 Normal vibration levels, alarm and trip 5.9 Hydraulic, mechanical and electrical
For guidance, pumps generally fall under a classification duty
for rigid support machines within the International This product has been supplied to meet the
rotating machinery standards and the recommended performance specifications of your purchase order,
maximum levels below are based on those standards. however it is understood that during the life of the
product these may change. The following notes may
Alarm and trip values for installed
help the user decide how to evaluate the implications
pumps should be based on the actual measurements
of any change. If in doubt contact your nearest
(N) taken on site on the bearing housings of the
Flowserve office.
pump in the fully commissioned as new condition.
The example (N) value is given for the preferred
5.9.1 Specific gravity (SG)
operating flow region (typically this may extend to 70
Pump capacity and total head in meters (feet) do not
to 120% of the pump best efficiency point); outside
change with SG, however pressure displayed on a
the preferred flow region the actual vibration
pressure gauge is directly proportional to SG. Power
experienced may be multiplied by up to two.
absorbed is also directly proportional to SG. It is
therefore important to check that any change in SG
These standard values can vary with the rotational will not overload the pump driver or over-pressurize
speed and the power absorbed by the pump. For any the pump.
special case, contact your nearest Flowserve office.
5.9.2 Viscosity
Measuring vibration at regular intervals will show any For a given flow rate the total head reduces with
deterioration in pump or system operating conditions. increased viscosity and increases with reduced
Horizontal Vertical pumps viscosity. Also for a given flow rate the power
Vibration velocity –
unfiltered
pumps mm/s mm/s (in./s) absorbed increases with increased viscosity, and
(in./s) r.m.s. r.m.s. reduces with reduced viscosity. It is important that
Normal N ≤ 5.6 (0.22) ≤ 7.1 (0.28) checks are made with your nearest Flowserve office if
Alarm N x 1.25 ≤ 7.1 (0.28) ≤ 9.0 (0.35) changes in viscosity are planned.
Shutdown trip N x 2.0 ≤ 11.2 (0.44) ≤ 14.2 (0.56)
5.9.3 Pump speed
5.7.6 Stop/start frequency Changing pump speed effects flow, total head, power
Pump sets are normally suitable for the number of absorbed, NPSHR, noise and vibration. Flow varies in
equally spaced stop/starts per hour shown in the direct proportion to pump speed, head varies as speed
table below. Check actual capability of the driver and ratio squared and power varies as speed ratio cubed.
control/starting system before commissioning. The new duty, however, will also be dependent on the
Motor rating kW (hp) Maximum stop/starts per hour system curve. If increasing the speed, it is important
Up to 15 (20) 15 therefore to ensure the maximum pump working
Between 15 (20) and 90 (120) 10 pressure is not exceeded, the driver is not overloaded,
90 (120) to 150 (200) 6 NPSHA > NPSHR, and that noise and vibration are
Above 150 (200) Refer within local requirements and regulations.
Where duty and standby pumps are installed it is
recommended that they are run alternately every week. 5.9.4 Net positive suction head (NPSHA)
NPSH available (NPSHA) is the head available at the
5.8 Stopping and shutdown impeller inlet, above the vapour pressure of the
pumped liquid.
a) Close the outlet valve, but ensure
that the pump runs in this condition for no more NPSH required (NPSHR) is the minimum head required
than a few seconds. at the impeller inlet, above the vapour pressure of the
b) Stop the pump. pumped liquid, to avoid excessive cavitation and
c) Switch off flushing and/or cooling/heating liquid extreme performance degradation.
supplies at a time appropriate to the process.
It is important that NPSHA > NPSHR. The margin
d) For prolonged shut-downs and between NPSHA > NPSHR should be as large as
especially when ambient temperatures are likely possible.
to drop below freezing point, the pump and any
cooling and flushing arrangements must be
drained or otherwise protected.
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If any change in NPSHA is proposed, ensure these When air or compressed inert gas is used in the
margins are not significantly eroded. Refer to the maintenance process, the operator and anyone in the
pump performance curve to determine exact vicinity must be careful and have the appropriate
requirements particularly if flow has changed. If in protection.
doubt please consult your nearest Flowserve office
for advice and details of the minimum allowable Do not spray air or compressed inert gas on skin.
margin for your application.
Do not direct an air or gas jet towards other people.
5.9.5 Pumped flow
Flow must not fall outside the minimum and Never use air or compressed inert gas to clean clothes.
maximum continuous safe flow shown on the pump
performance curve and or data sheet. Before working on the pump, take measures to
prevent an uncontrolled start. Put a warning board
6 MAINTENANCE on the starting device with the words:
"Machine under repair: do not start".
6.1 General
With electric drive equipment, lock the main switch
open and withdraw any fuses. Put a warning board
If a belt drive is used, the assembly and tension
on the fuse box or main switch with the words:
of the belts must be verified during regular
"Machine under repair: do not connect".
maintenance procedure.
Never clean equipment with inflammable solvents or
In dirty or dusty environments, regular checks carbon tetrachloride. Protect yourself against toxic
must be made and dirt removed from areas around fumes when using cleaning agents.
close clearances, bearing housings and motors.
6.2 Maintenance schedule
It is the plant operator's responsibility to ensure
that all maintenance, inspection and assembly work
It is recommended that a maintenance plan and
is carried out by authorized and qualified personnel
who have adequately familiarized themselves with schedule is adopted, in line with these User
the subject matter by studying this manual in detail. Instructions. It should include the following:
(See also section 1.6.2.) a) The pump must be completely vented and
drained and rendered inert before any
Any work on the machine must be performed when it disassembly operation.
is at a standstill. It is imperative that the procedure b) Any auxiliary systems installed must be
for shutting down the machine is followed, as monitored, if necessary, to ensure they function
described in section 5.8. correctly.
c) During cleaning of the pump ensure the
On completion of work all guards and safety devices compatibility between the cleaning products and
the gaskets.
must be re-installed and made operative again.
d) Verify the condition of the gaskets.
Before restarting the machine, the relevant e) Gland packings must be adjusted correctly to
instructions listed in section 5, Commissioning, start give visible leakage and concentric alignment of
up, operation and shut down must be observed. the gland follower to prevent excessive
temperature of the packing or follower.
Mechanical seals should present no leakage.
Oil and grease leaks may make the ground
slippery. Machine maintenance must always f) Check for any leaks from gaskets and seals. The
begin and finish by cleaning the ground and the correct functioning of the shaft seal must be
exterior of the machine. checked regularly.
g) Check bearing lubricant level, and if the hours
If platforms, stairs and guard rails are required for run show a lubricant change is required.
h) Check that the duty condition is in the safe
maintenance, they must be placed for easy access to
areas where maintenance and inspection are to be operating range for the pump.
carried out. The positioning of these accessories i) Check vibration, noise level and surface
must not limit access or hinder the lifting of the part to temperature at the bearings to confirm
be serviced. satisfactory operation.
j) Check the tightness of the connections.
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⇓ P u m p l o s e s p r i m e a ft e r s t a r t i n g
A. System troubles
Pump not primed.
Check complete filling. Vent and/or prime.
Pump or suction pipe not completely filled with
liquid.
Suction lift too high or level too low.
Check NPSHA>NPSHR, proper submergence,
Insufficient margin between suction pressure and losses at strainers and fittings.
vapor pressure.
Excessive amount of air or gas in liquid. Check and purge pipes and system.
Air or vapor pocket in suction line. Check suction line design for vapor pockets.
Air leaks into suction line. Check suction pipe is airtight.
Air leaks into pump through mechanical seal, Check and replace faulty parts.
sleeve joints, casing joint or pipe plugs. CONSULT FLOWSERVE.
Foot valve too small. Investigate replacing the foot valve.
Foot valve partially clogged. Clean foot valve.
Inlet of suction pipe insufficiently submerged. Check out system design.
Speed too low. CONSULT FLOWSERVE.
Speed too high. CONSULT FLOWSERVE.
Operation at very low capacity. Measure value and check minimum permitted.
Remedy or CONSULT FLOWSERVE.
B. Mechanical troubles
Misalignment due to pipe strain. Check the flange connections and eliminate strains
using elastic couplings or a method permitted.
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FAULT SYMPTOM
Pump overhea ts and s eizes
⇓ Bearings have short life
⇓ Pump vibrates or is noisy
⇓ P u m p l o s e s p r i m e a ft e r s t a r t i n g
Mechanical seal improperly installed. Check alignment of faces or damaged parts and
assembly method used.
Shaft running off centre because of worn bearings Check misalignment and correct if necessary. If
or misalignment. alignment satisfactory check bearings for excessive
wear.
Impeller out of balance resulting in vibration.
Abrasive solids in liquid pumped. Check and CONSULT FLOWSERVE.
Internal misalignment of parts preventing seal ring
and seat from mating properly.
Mechanical seal was run dry. Check mechanical seal condition and source of dry
running and repair.
Internal misalignment due to improper repairs Check method of assembly, possible damage or
causing impeller to rub. state of cleanliness during assembly.
Remedy or CONSULT FLOWSERVE, if necessary.
Excessive thrust caused by a mechanical failure Check wear condition of impeller, its clearances and
inside the pump. liquid passages.
Excessive grease in ball bearings. Check method of regreasing.
Lack of lubrication for bearings. Check hours run since last change of lubricant, the
schedule and its basis.
Improper installation of bearings (damage during Check method of assembly, possible damage or
assembly, incorrect assembly, wrong type of state of cleanliness during assembly and type of
bearing etc). bearing used. Remedy or CONSULT
FLOWSERVE, if necessary.
Damaged bearings due to contamination. Check contamination source and replace damaged
bearings.
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9 CERTIFICATION
Certificates determined from the Contract
requirements are provided with these instructions
where applicable. Examples are certificates for CE
marking, ATEX marking etc. If required, copies of
other certificates sent separately to the Purchaser
should be obtained from the Purchaser for retention
with these User Instructions.
Reference 2:
th
Pumping Manual, 9 edition, T.C. Dickenson,
Elsevier Advanced Technology, United Kingdom, 1995.
Reference 3:
nd
Pump Handbook, 2 edition, Igor J. Karassik et al,
McGraw-Hill Inc., New York, 1993.
Reference 4:
ANSI/HI 1.1-1.5, Centrifugal Pumps - Nomenclature,
Definitions, Application and Operation.
Reference 5:
ANSI B31.3 - Process Piping.
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Nota :
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FLOWSERVE REGIONAL
Your Flowserve factory contacts: SALES OFFICES: