Flowserve Pump Division - Consolidated Pumps CPXP Pump Division I.O.M. Installation, Operation and Maintenance IDP Pumps Type CPXP SELF PRIMING, FRAME MOUNTED CHEMICAL PROCESS PUMP

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  • Flowserve Pump Division

    I.O.M. Installation, Operation and Maintenance

    IDP PumpsType CPXP

    SELF PRIMING, FRAME MOUNTEDCHEMICAL PROCESS PUMP

    Instruction Manual C961KH001 - 03/02

  • INSTRUCTION MANUAL CPXP ENGLISH C961KH001 - 03/02

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    INTRODUCTION

    Flowserve

    Flowserve's products and brands are the leading names in their fields: the CPX range ofprocess pumps specifically focus on demanding chemical process applications. The pumpsare manufactured at modern facilities, utilising state of art equipment and sophisticated qualitycontrol techniques. Flowserve is proud of earning preferred supplier status to many of world'sleading processing companies. Engineered, manufactured, sold and serviced to ISO 9001quality certification, Flowserve pumps are truly world class products.

    With more than 120 years of experience in servicing the needs of world-wide processindustries, Flowserve has become the unchallenged leader in hydraulic design engineering,materials expertise and application know-how. Committed to continuous quality improvement,Flowserve controls the complete product life cycle - from application engineering, design,melting and casting, to cellular manufacturing, to assembly and testing, to the supply ofaftermarket products, repair and diagnostic services.

    Flowserve is on hand to provide technical support and special services specific to the needs ofits customers.

    CopyrightAll rights reserved. No part of this manual may be reproduced, stored in a retrieval system ortransmitted in any form or by any means without prior permission of Flowserve Pump Division.

    CE Mark SystemIt is a legal requirement that machinery and equipment put into service within the EuropeanUnion shall conform with the applicable European Union Directives covering Machinery, LowVoltage Equipment and EMC.

    Where applicable the European Union Directives cover important Safety aspects relating tomachinery and equipment and the satisfactory provision of technical documents and safetyinstructions. This document incorporates information relevant to these Directives. TheManual should be read prior to installing, operating, using and maintaining the equipment.The equipment must not be put into service until all the conditions relating to safety noted inthe Manual have been met.

    DisclaimerFlowserve manufactures products to exacting International Quality Management SystemStandards (ISO 9001) as certified and audited by Lloyd's Register Quality Assurance Limited.Genuine parts and accessories have been designed, tested and incorporated into theproducts to ensure their continued product quality and performance in use. As Flowservecannot test parts and accessories sourced from other vendors the incorrect incorporation ofsuch parts and accessories may adversely affect the performance and safety features of theproducts. The failure to properly select, install or use authorised Flowserve parts andaccessories is considered to be misuse. Damage or failure caused by misuse is not coveredby Flowserve's warranty. In addition, any modification of Flowserve products or removal oforiginal components may impair the safety of these products in their use.

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    1 NAMEPLATE & WARNING LABELS

    1.1 Nameplate

    For details of nameplate, see the Declaration of conformity

    1.2 Warning labels

    Oil lubricated units only

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    2 SAFETY

    2.1 Duty conditions

    2.1.1 This pump has been selected to meet the dutyand service conditions advised on your order. Theacknowledgement of these conditions has been sentseparately to the Purchaser. A copy should be keptwith this manual.

    2.1.2 If there is any doubt as to the suitability of thepump for the application intended, contact Flowservefor advice, quoting the pump serial number.

    2.2 Safety actionAlways co-ordinate repair activity with operationspersonnel, and follow all plant safety requirements andapplicable safety and health laws/regulations.

    THIS IS A SUMMARY OF CONDITIONS ANDACTIONS TO PREVENT INJURY TO PERSONNELAND DAMAGE TO EQUIPMENT.

    This sign indicates safety instructionswhere non-compliance would affect personal safety.

    This symbol indicates electrical safetyinstructions where non-compliance would affectpersonal safety.

    This symbol indicates safety instructions wherenon-compliance would affect the safe operation orprotection of the pump or pump unit.

    2.2.1 PREVENT EXCESSIVE EXTERNALPIPE LOADDo not use pump as a support for piping. Do notmount expansion joints so that their force, due tointernal pressure, acts on the pump flange.

    2.2.2 ONLY CHECK DIRECTION OF MOTORROTATION WITH COUPLING ELEMENT/PINSREMOVEDStarting in reverse direction of rotation will damage thepump.

    2.2.3 START THE PUMP WITH OUTLETVALVE CLOSEDThis is recommended to avoid the risk of overloadingand damaging the pump motor at full flow. Pumpsmay be started with the valve open only oninstallations where this situation cannot occur.

    2.2.4 ENSURE CORRECT LUBRICATION(See: "Making ready for operation - Lubrication".)

    2.2.5 NEVER RUN THE PUMP DRY2.2.6 INLET VALVES TO BE FULLY OPENWHEN PUMP IS RUNNINGRunning the pump at zero flow or below therecommended minimum flow continuously will causethe shaft, packing or mechanical seal to run hot and failwithin a short time.

    2.2.7 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 ofthe pump, instability and cavitation/vibration.

    2.2.8 NEVER DO MAINTENANCE WORKWHILST THE UNIT IS CONNECTED TO POWER

    2.2.9 NEVER APPLY HEAT TOREMOVE IMPELLERTrapped lubricant or vapour could cause an explosion.

    2.2.10 HANDLING COMPONENTSMany precision parts have sharp corners and the wearingof appropriate safety gloves and equipment is requiredwhen handling these components. To lift heavy piecesabove 30kg (66lbs) use a crane corresponding to themass and in accordance with current local regulations.

    2.2.11 DRAIN PUMP AND ISOLATEPIPEWORK BEFORE DISMANTLING THE PUMPThe appropriate safety precautions should be takenwhere the pumped liquids are hazardous.

    2.2.12 FLUORO-ELASTOMERS(When fitted to high temperature units).

    When a pump has experienced temperatures over250C(482F), partial decomposition of fluoro-elastomers (eg viton) will occur. In this condition theseare extremely dangerous and skin contact must beavoided.

    2.2.13 THERMAL SHOCKRapid changes in the temperature of the liquid withinthe pump can cause thermal shock, which can result indamage or breakage of components. Thermal shockshould be avoided, particularly so where the materialof the pump is not resistant to such loading.

    2.2.14 HOT (and cold) PARTSIf hot or freezing components or auxiliary heatingsupplies can present a danger to operators, they mustbe shielded to avoid accidental contact. If completeprotection is not possible, machine access must belimited to maintenance staff only. Note: drive motorsand bearings may be hot.

    IF THE TEMPERATURE IS GREATER THAN 80C(175F) OR BELOW 5C (20F), A VISUALWARNING INDICATOR SUCH AS A WARNINGPLATE MUST BE PLACED CLEARLY ON THEEQUIPMENT.

    2.2.15 HAZARDOUS LIQUIDSWhen the pump is handling hazardous liquids caremust be taken to avoid liquid contact using theappropriate health and safety procedures. Pumplocation and personnel access/training should considerand address these site dangers.

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    2.3 Potentially explosive atmospheresAlways check that the driver, drive coupling assemblyand pump equipment are suitably rated and/or certifiedfor the classification of the specific atmosphere inwhich they are to be installed. See section 16,Certification.

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    3. CONTENTSPAGE

    INTRODUCTION 2

    1 NAMEPLATE & WARNING LABELS 3

    2 SAFETYDuty conditions 4Safety action 4Potentially explosive atmospheres 5

    3 CONTENTS 6

    4 PUMP TECHNICAL DATAPerformance 7Noise level 7Pressure limits 7Flange loads 7Pump lubricants 8Recommended screw torques 8

    5 PRODUCT DESCRIPTIONGeneral 9Pump casing 9Impeller 9Shaft 9Bearing housing 9Pump bearings and lubrication 9Seal housing 9Shaft seal 9Driver 9Accessories 9

    6 STORAGE 9

    7 INSTALLATIONUnpacking and inspection 9Handling 9Location 10Foundation 10Grouting 10Alignment of couplings 10Electrical connections 11Pipework connections 11Final piping check 12Auxiliary piping 12

    8 MAKING READY FOR OPERATIONLubrication 12Direction of rotation 13Guarding 13Open impeller clearance 13Primary and auxiliary supplies 13Filling and self priming 13

    9 STARTING AND RUNNING THE PUMPStarting 13Running pumps fitted with packed glands 14Running pumps fitted with mechanical seals 14Stop/start frequency 14

    PAGE

    10 STOPPING AND SHUTDOWN 14

    11 PREVENTATIVE MAINTENANCE &SERVICINGMaintenance schedule 14Routine inspection (daily/weekly) 14Periodic inspection (6 monthly) 14Lubrication data 14Gland packing 15Mechanical seals 15Setting impeller front clearance 15

    12 DISMANTLING AND ASSEMBLYDismantling 15Examination of parts 16Assembly 17

    13 SEALING ARRANGEMENTSSingle seal types 19Cartridge seal types 20Tandem seal types 20Double seal types 20External seal types 20Packed gland seal types 20

    14 SPARE PARTSOrdering of spares 21Storage of spares 21Recommended spares 21

    15 GENERAL ARRA