Flowserve Durco Mark 3 Installation, Operation & Maintenance Manual
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Flowserve Durco Mark 3 Installation, Operation & Maintenance Manual

Standard two piece bearing frame foot mounted, centreline mounted and unitized self-priming chemical process pumps
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USER INSTRUCTIONS
Installation
Durco® Mark 3™ ISO frame mounted
Operation
Standard two piece bearing frame foot mounted, centreline
Maintenance
mounted and unitized self-priming chemical process pumps
PCN= 85392719 06-12 (E). Original instructions.
These instructions must be read prior to installing,
operating, using and maintaining this equipment.

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Summary of Contents for Flowserve Durco Mark 3

  • Page 1 USER INSTRUCTIONS Installation Durco® Mark 3™ ISO frame mounted Operation Standard two piece bearing frame foot mounted, centreline Maintenance mounted and unitized self-priming chemical process pumps PCN= 85392719 06-12 (E). Original instructions. These instructions must be read prior to installing, operating, using and maintaining this equipment.

  • Page 2: Table Of Contents

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 CONTENTS Page Page 1 INTRODUCTION AND SAFETY ......4 6 MAINTENANCE ..........26 1.1 General ............4 6.1 General ............26 1.2 CE marking and approvals ......4 6.2 Maintenance schedule ........26 1.3 Disclaimer ............
  • Page 3 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 INDEX Page Page Additional sources (10.3) ......... 48 Protection systems (4.9) ..........20 Alignment of shafting (see 4.3, 4.5 and 4.8) Reassembly (6.10, Assembly) .........32 Assembly (6.10) ............32 Receipt and unpacking (2.1) ........11 ATEX marking (1.6.4.2) ..........

  • Page 4: Introduction And Safety

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 machinery and equipment and the satisfactory provision INTRODUCTION AND SAFETY of technical documents and safety instructions. Where applicable this document incorporates information 1.1 General relevant to these Directives and Approvals. These instructions must always be kept...

  • Page 5: Safety

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 If the conditions of service on your purchase order are Always coordinate repair activity with operations and going to be changed (for example liquid pumped, health and safety personnel, and follow all plant...

  • Page 6: Durco Mark 3 Iso Frame Mounted English 85392719

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 If the temperature is greater than 80 ºC (175 ºF) or DO NOT RUN THE PUMP AT below -5 ºC (23 ºF) in a restricted zone, or exceeds ABNORMALLY HIGH OR LOW FLOW RATES local regulations, action as above shall be taken.
  • Page 7 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 1.6.4.2 Marking Maximum permitted liquid temperature for pumps An example of ATEX equipment marking is shown with self-priming casing below. The actual classification of the pump will be Maximum surface Temperature limit of Temperature engraved on the nameplate.
  • Page 8 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 1.6.4.6 Additional requirements for self-priming 1.6.4.10 Preventing leakage pumps only Where the system operation does not ensure control of The pump must only be used to handle liquids priming, as defined in these User Instructions, and the...

  • Page 9: Nameplate And Safety Labels

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 and when noise exposure reduction is mandatory. 1.7 Nameplate and safety labels This is typically 80 to 85 dBA. 1.7.1 Nameplate The usual approach is to control the exposure time to...
  • Page 10 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 Typical sound pressure level L at 1 m reference 20 µPa, dBA Motor size 3 550 r/min 2 900 r/min 1 750 r/min 1 450 r/min and speed Pump Pump Pump...

  • Page 11: Transport And Storage

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 TRANSPORT AND STORAGE 2.3.2 Pump and folded steel or polycrete baseplate set Where the baseplate is folded steel or polycrete there 2.1 Consignment receipt and unpacking are no specific lifting points provided for the complete machine set.

  • Page 12: Storage

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 • 2.4 Storage A = Extended flow hydraulic (B = standard hydraulic) • Store the pump in a clean, dry location RV = Impeller design (RV = Reverse vane, OP = away from vibration.

  • Page 13: Performance And Operating Limits

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 A fully confined gasket forms the seal between the INSTALLATION pump casing and the cover. Equipment operated in hazardous locations The cover designs provide improved performance of must comply with the relevant explosion protection mechanical seals.

  • Page 14: Grouting

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 indicates that the baseplate has become twisted For couplings with narrow flanges use a dial indicator and should be corrected by re-shimming. as shown. The alignment values are maximums for e) If not supplied, guarding shall be fitted as necessary continuous service.

  • Page 15: Piping

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 Tighten down and repeat the same procedure on all Priming air may be vented in one of the following ways: other feet until all are within tolerance. 1) The discharge pipework regulating valve, if fitted, may be partly opened during the priming cycle to freely vent the air.
  • Page 16 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 e) Fitting an isolation valve will allow easier A spool piece should be installed in maintenance. suction line so that the suction strainer may be Never throttle pump on suction side and never installed and removed with a pressure gauge place a valve directly on the pump inlet nozzle.
  • Page 17 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 4.6.4 Allowable nozzle loads All individual values which are greater than the The pump complies with ISO 5199 shaft deflection following values must be referred to Flowserve for limits for the following flange loads. The values are approval.
  • Page 18 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 Forces in N (lbf) Moments in Nm (lbf•ft) Suction Discharge Suction Discharge Size Ɖ Ɖ Ɖ Ɖ M Ɖ Ɖ Ɖ Ɖ F Ɖ Ɖ Ɖ Ɖ M Ɖ Ɖ Ɖ Ɖ F...
  • Page 19 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 4.6.5 Final checks reliable seals. Consult Flowserve or the seal Check the tightness of all bolts in the suction and manufacturer for guidance if required. discharge pipework. Check also the tightness of all foundation bolts.

  • Page 20: Electrical Connections

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 4.7 Electrical connections 4.9 Protection systems Electrical connections must be made by The following protection systems are a qualified Electrician in accordance with relevant recommended particularly if the pump is installed in a local national and international regulations.

  • Page 21: Commissioning, Start-Up, Operation

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 The oil filled bottle should then be refitted so as to COMMISSIONING, START-UP, return it to the upright position. OPERATION AND SHUTDOWN Filling should be repeated until oil remains visible These operations must be carried within the bottle.

  • Page 22: Pump Lubricants

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 5.2 Pump lubricants 5.2.1 Recommended oil lubricants Splash / force feed / purge oil mist/ pure oil mist lubrication Viscosity cSt @ 40 ºC -5 to 65 ºC -5 to 78 ºC -5 to 80 ºC...

  • Page 23: Impeller Clearance

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 5.2.3.1 Food grade grease, when applicable: 5.6 Priming and auxiliary supplies NSF H1 Klubersynth UH1 64-62 is the food grade grease option and it is NLGI grade 2. 5.6.1 Filling and priming, non self primer casing 5.2.4...

  • Page 24: Running The Pump

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 5.7 Starting the pump m) If NO pressure, or LOW pressure, STOP the pump. Refer to section 7, Faults; causes and remedies for fault diagnosis. 5.7.1 Starting the non self primer casing pump 5.8 Running the pump...

  • Page 25: Stopping And Shutdown

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 5.8.3 Bearings 5.8.5 Stop/start frequency Pump sets are normally suitable for the number of equally spaced stop/starts per hour shown in the If the pumps are working in a potentially explosive atmosphere temperature or vibration table below.

  • Page 26: Maintenance

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 5.10.3 Pump speed Before restarting the machine, the relevant Changing pump speed effects flow, total head, power instructions listed in section 5, Commissioning, start absorbed, NPSH , noise and vibration. Flow varies in up, operation and shut down must be observed.

  • Page 27: Maintenance Schedule

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 6.2 Maintenance schedule e) Check any auxiliary supplies eg heating/cooling (if fitted) are functioning correctly. It is recommended that a maintenance plan Refer to the manuals of any associated and schedule is adopted, in line with these User equipment for routine checks needed.

  • Page 28: Spare Parts

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 For food grade grease the grease change and 6.4 Recommended spares relubrication intervals are half those of the conventional For two years operation (as per VDMA 24296). greases. Number of pumps...

  • Page 29: Fastener Torques

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 6.6 Fastener torques b) Rotating the bearing carrier [3240] the width of one of the indicator patterns cast into the bearing Fastener Screw size Torque Nm (lbf•ft) carrier moves the impeller [2200] axially 0.1 mm 16 (12) (0.004 in.).

  • Page 30: Disassembly

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 c) Rotating the bearing carrier [3240] the width of one of the indicator patterns cast into the bearing carrier moves the impeller [2200] axially 0.1 mm (0.004 in.). Example: for an impeller setting of 1.5 mm (0.059 in.) simply move the bearing carrier clockwise fifteen indicator patterns for the required clearance.

  • Page 31: Examination Of Parts

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 Remove pump casing gasket [4590.1] and discard. g) Remove shaft sleeve (if fitted). A replacement gasket will be required for assembly. h) On non-cartridge seals the stationary seat Clean gasket mating surfaces.

  • Page 32: Assembly

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 6.9.3 Gaskets, O-rings and V-ring when fitted below: After dismantling, discard and replace. 6.9.4 Bearings It is recommended that bearings are not re-used after any removal from the shaft. Grease 6.9.5...
  • Page 33 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 o) Install the shaft assembly into the bearing housing 0.5 to 2 mm (0.02 to 0.08 in.) [3200] until the gap is approximately 5 mm (0.2 in.). 6.10.2 Seal cover and seal assembly a) Extreme cleanliness is required.

  • Page 34: Sealing Arrangements

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 6.11.1 Single seal types 6.10.4.2 Impeller assembly with key drive impeller 6.11.1.1 Single stepped balanced seal a) Fit a new impeller sealing gasket [4590.4] against shaft shoulder. b) Fit impeller key [6700.2].
  • Page 35 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 6.11.1.4 Single seal with external lip seal 6.11.2 Cartridge seal types 6.11.2.1 Cartridge seal in Seal Sentry conical cover Q - Rp ¼ in. quench D - Rp ¼ in. drain F - Rp ¼...
  • Page 36 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 6.11.4 Double seal types 6.11.5.1 External seal 6.11.4.1 Double back-to-back seal with Flowserve eccentric pumping annulus circulation D - drain 6.11.6 Packed gland seal types 6.11.6.1 Packed gland with fibre packing 4130 BI - Rp ¼...

  • Page 37: Faults; Causes And Remedies

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 FAULTS; CAUSES AND REMEDIES FAULT SYMPTOM P u m p o v e r h e a t s a n d s e i z e s ⇓ ⇓ ⇓ ⇓...
  • Page 38 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 FAULT SYMPTOM P u m p o v e r h e a t s a n d s e i z e s ⇓ ⇓ ⇓ ⇓ B e a r i n g s h a v e s h o r t l i f e ⇓...

  • Page 39: Parts Lists And Drawings

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 PARTS LISTS AND DRAWINGS 8.1 Mark 3 ISO 8.1.1 Open impeller (OP) sectional drawing Drawing taken from B731/2082 8.1.2 Open impeller (OP) parts list 4330 Labyrinth ring Item Description 4590.1 Gasket 4590.2...
  • Page 40 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 8.1.3 Reverse vane (RV) impeller sectional drawing Drawing taken from B731/2081 8.1.4 Reverse vane (RV) impeller parts list Item Description 4330 Labyrinth ring 4590.1 Gasket 1100 Casing 4590.2 Gasket * 1220 Cover 4610.1...

  • Page 41: Center Line Mounted, Recessed Impeller And Self Primer Configurations

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 8.2 Center line mounted, recessed impeller and self primer configurations 8.2.1 Center line mounted sectional drawing Drawing taken from C128/002 8.2.2 Center line mounted casing parts list 4330 Labyrinth ring Item...
  • Page 42 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 8.2.3 Recessed impeller pump sectional drawing Drawing taken from B731/2083 8.2.4 Recessed impeller pump parts list 4305 Shaft seal ring 4330 Labyrinth ring Item Description 4590.1 Gasket 1100 Casing 4590.2 Gasket *...
  • Page 43 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 8.2.5 Self priming casing pump sectional drawing Drawing taken from C665/076 8.2.6 Self priming casing pump parts list 4330 Labyrinth ring Item Description 4590.1 Gasket 1100 Casing 4590.2 Gasket * 1220 Cover 4610.1...

  • Page 44: Additional Details

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 8.3 Additional details 8.3.2 Open impeller (OP) key drive impeller option 8.3.1 Bearing housing sealing details 2100 2400 4610.4 6700.2 2200 4610.5 SLEEVED SHAFT SHOWN ABOVE CENTRE-LINE. 2912.1 (includes heli-coil 6589)

  • Page 45: Parts Interchangeability

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 8.4 Parts interchangeability 8.4.1 Durco Mark3 ISO A hydraulic parts interchangeability Drawing taken from E576/159, issue date 12/04/12 Note: Pump sizes marked with a * in the table above are only available with open impeller Page 45 of 52 flowserve.com...
  • Page 46 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 8.4.2 Durco Mark3 ISO B hydraulic parts interchangeability Drawing taken from E576/159, issue date 12/04/12 Note: Pump sizes marked with a * in the table above are only available with open impeller Page 46 of 52 flowserve.com...
  • Page 47 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 8.4.3 Self-priming and recessed impeller pumps parts interchangeability Drawing taken from E576/159, issue date 12/04/12 Page 47 of 52 flowserve.com...

  • Page 48: General Arrangement Drawing

    DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 8.5 General arrangement drawing 10.3 Additional sources of information The typical general arrangement drawing and any specific drawings required by the contract will be sent Reference 1: to the Purchaser separately unless the contract...
  • Page 49 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 Notes: Page 49 of 52 flowserve.com...
  • Page 50 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 Notes: Page 50 of 52 flowserve.com...
  • Page 51 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 Notes: Page 51 of 52 flowserve.com...
  • Page 52 DURCO MARK 3 ISO FRAME MOUNTED ENGLISH 85392719 06-12 FLOWSERVE REGIONAL SALES OFFICES: Your Flowserve factory contact: USA and Canada Flowserve Corporation 5215 North O’Connor Blvd., Suite 2300 Irving, Texas 75039-5421, USA Telephone +1 972 443 6500 Fax +1 972 443 6800...

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