Flowserve IJ Installation Operation & Maintenance
  1. Manuals
  2. Brands
  3. Flowserve Manuals
  4. Water Pump
  5. IJ
  6. Installation operation & maintenance
Flowserve IJ Installation Operation & Maintenance

Flowserve IJ Installation Operation & Maintenance

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
VINTAGE PARTS MARKETING
PRODUCT LINE:
HERITAGE COMPANY:
CONFIGURATION:
TYPICAL APPLICATION:
VINTAGE:
PRODUCT LIFESPAN:
SUBJECT:
Note: The IJ was specifically geared for the API refinery
market. The BFI was the boilerfeed version of the IJ.
Pacific did not publish price book curves for these
pumps. The IJDS is the double suction version. The IJ
was officially made passive in 1994 as part of the IDP
integration, but is still sold today in some applications,
or as a duplicate. The stiff shaft successor of the IJ is
the WIK, mainly sold in decoker applications.
NOTE: This information is intended for the use of Flowserve Employees.
The information provided is based on standard catalogue / price book
information. Details for specific units or serial numbers may be different as
a result of non-standard construction, and parts, repairs and upgrades
provided by Flowserve or third parties.
IJ - IJDS
Pacific Pumps
Barrel pump - diffuser
Refinery, Pipeline
1958 - 1994
rd
API 610, 3
– 8
Installation and Operations
Manual (IOM)
th

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the IJ and is the answer not in the manual?

Questions and answers

Related Manuals for Flowserve IJ

Summary of Contents for Flowserve IJ

  • Page 1 1994 as part of the IDP integration, but is still sold today in some applications, or as a duplicate. The stiff shaft successor of the IJ is the WIK, mainly sold in decoker applications. NOTE: This information is intended for the use of Flowserve Employees.
  • Page 2 IJ PUMP INSTALLATION OPERATION & MAINTENANCE...
  • Page 4 The sales contract between the parties contains the sole warranty for this equipment. During initial start-up of the equipment, it is recommended that the services of an Flowserve service representative be obtained to assure trouble-free operation. In some cases, the presence of a Flowserve service representative may be a contractual requirement for continuation of warranty.
  • Page 5 IJ PUMP OPERATION AND MAINTENANCE MANUAL BO2660-01...

  • Page 6: Table Of Contents

    IJ PUMP OPERATION AND MAINTENANCE MANUAL TABLE OF CONTENTS PREFACE ............................. xi OPERATING SPECIFICATIONS......................xiii TORQUE PROCEDURE ........................xvii 1. DESCRIPTION ..........................1-1 1.1 PHYSICAL DESCRIPTION.....................1-1 1.1.1 GENERAL FEATURES ....................1-1 1.1.1.1 Intermediate Cover-Diffuser ..................1-1 1.1.1.2 Suction Spacer and Discharge Diffuser-Spacer............1-1 1.1.1.3 Wearing Rings and Bushings ..................1-1 1.1.1.4 Impellers........................1-2...
  • Page 7 IJ PUMP OPERATION AND MAINTENANCE MANUAL TABLE OF CONTENTS (CONTINUED) 2.2 STORAGE ..........................2-5 2.2.1 PUMP PRESERVATIVE STANDARDS ................. 2-6 2.2.1.1 Precautions At Job Site ....................2-6 2.2.1.2 Short-Term Indoor Storage ..................2-6 2.2.1.3 Short-Term Outdoor Storage ..................2-6 2.2.1.4 Long-Term Indoor Storage ..................2-7 2.2.1.5 Long-Term Outdoor Storage..................
  • Page 8 IJ PUMP OPERATION AND MAINTENANCE MANUAL TABLE OF CONTENTS (CONTINUED) 3.5.2 SEAL PIPING ........................3-29 3.5.2.1 Carbon Steel Piping....................3-29 3.5.2.2 Stainless Steel Piping ....................3-29 4. OPERATION, MAINTENANCE, AND INSPECTION ............4-1 4.1 STARTUP ..........................4-1 4.1.1 READYING AND SERVICING DRIVER ...............4-1 4.1.2 READYING AND SERVICING PUMP AND AUXILIARY SYSTEMS......4-1 4.1.2.1 Initial Steps in Preparing Brand-New or Factory-Overhauled Pump and Auxiliary...
  • Page 9 IJ PUMP OPERATION AND MAINTENANCE MANUAL TABLE OF CONTENTS (CONTINUED) 6.1.8 LIFTING..........................6-2 6.1.9 INSTALLATION SCHEDULES ..................6-2 6.2 LUBE OIL SYSTEM COMPONENT MAINTENANCE............6-4 6.2.1 REPLACEMENT LUBE OIL SYSTEM COMPONENT..........6-4 6.2.2 REPAIRING AND ADJUSTING LUBE OIL SYSTEM COMPONENT ......6-4 6.2.3 BASEPLATE MOUNTED RESERVOIR.................
  • Page 10 IJ PUMP OPERATION AND MAINTENANCE MANUAL TABLE OF CONTENTS (CONTINUED) 6.5.2.6 Internal Assembly......................6-19 6.5.2.6.1 Visual Inspection ....................6-19 6.5.2.6.2 Checking Running Clearances................6-20 6.5.2.6.3 Checking Shaft Straightness................6-21 6.5.2.6.4 Checking Fit Of Impellers And Balancing Drum With Shaft ......6-21 6.5.2.6.5 Checking Concentricity Of Rotating Assembly ..........6-22 6.5.2.6.6 Renewing Impeller Wearing Surfaces ..............6-23...
  • Page 11 IJ PUMP OPERATION AND MAINTENANCE MANUAL BO2660-01...

  • Page 12: Preface

    IJ PUMP OPERATION AND MAINTENANCE MANUAL PREFACE This Flowserve manual is a guide for the operation and maintenance of this pump. For the convenience of experienced pump users, standard pump terminology is used in this manual. This manual is for the journeyman millwright. Information on the use of tools, techniques, and machining processes related to the trade are excluded.
  • Page 13 IJ PUMP OPERATION AND MAINTENANCE MANUAL BO2660-01...

  • Page 14: Operating Specifications

    IJ PUMP OPERATION AND MAINTENANCE MANUAL OPERATING SPECIFICATIONS PUMP SERIAL NUMBER BXXXXX-01 Pump design clearances are listed below. Use these clearances for restoration when clearances have increased approximately 50% as evidenced by a decrease in performance or excessive vibration. English...
  • Page 15 IJ PUMP OPERATION AND MAINTENANCE MANUAL OPERATING SPECIFICATIONS PUMP SERIAL NUMBER BXXXXX-01 (CONTINUED) English Metric Part-to-Part fits Inch, F mm, C Suction spacer, intermediate cover, discharge cover interference fit Head-to-case gap shall be parallel all around within .002 Head-to-case nut torque procedure See procedure in this section.
  • Page 16 IJ PUMP OPERATION AND MAINTENANCE MANUAL OPERATING SPECIFICATIONS PUMP SERIAL NUMBER BXXXXX-01 (CONTINUED) Table 1 Clearances for Journal Bearings and Oil Baffles English Units (inches) Shaft Diameter Sleeve Bearing Oil Baffle Over Including Min. Max. Min. Max. 0.00 1.00 .0025 .0040...
  • Page 17 IJ PUMP OPERATION AND MAINTENANCE MANUAL BO2660-01...

  • Page 18: Torque Procedure

    IJ PUMP OPERATION AND MAINTENANCE MANUAL TORQUE PROCEDURE SINGLE ROW HEAD-TO-CASE BOLTING METAL-TO-METAL GASKETED JOINTS 1. Clean and inspect each stud or bolt, nut, washer, and the facing on the flanges against which the nuts will rotate. Look for severe galling, pitting, etc. If any of the above mentioned items are damaged beyond repair, replace that item.
  • Page 19 IJ PUMP OPERATION AND MAINTENANCE MANUAL 100% FINAL TORQUE VALUE BY STUD/BOLT DIAMETER Stud diameter (in) Torque value Stud diameter (in) Torque value (ft-lb) (ft-lb) 36.9 1-3/4 1968 9/16 53.7 1-7/8 2430 73.3 2960 2-1/4 4250 2-1/2 5860 2-3/4 7830...

  • Page 20: Description

    Flowserve Company. For an illustrative description of the physical features of your pump, see Flowserve Product Engineering drawings in the back of this manual; these drawings define your as built/as shipped pump. Although this section includes some...

  • Page 21: Impellers

    For a description of seal piping, see PIPING drawings in the back of this manual. 1.1.1.9 Baseplates The pump is factory mounted on a baseplate and its driver (if furnished by Flowserve) is mounted on a baseplate or soleplate (see OUTLINE drawings in the back of this manual).

  • Page 22: Operating Principles

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 1.2 OPERATING PRINCIPLES The following discussions are focused on the principles that underlie the operation of your pump. Where figures are not included with the text, see the PUMP ASSEMBLY drawing and schematics in the back of this manual, which also provide pictorial support of the text.

  • Page 23: Minimum Flow

    IJ PUMP OPERATION AND MAINTENANCE MANUAL on the outboard shaft seal as well as the pressure reducing sleeve. It also serves to transfer leakage past the drum to the suction system. 1.2.4 MINIMUM FLOW Another phenomenon of the multi-stage pump is for the temperature of the liquid to rise progressively as it is pushed through the pump.

  • Page 24: Pressure Switch

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 1.2.9.2 Pressure Switch The lube oil system is factory-equipped with a pressure switch that is set to cut out the auxiliary lube oil pump when the main lube oil pump comes up to pressure and to cut in and start the auxiliary pump for lubrication during coastdown and in case the main pump fails in service.

  • Page 26: Receiving, Storage, And Preinstallation

    2.1 RECEIVING Flowserve ships the pump mounted on its cradle and soleplates, which is secured to a skid formed of heavy timbers, and when greater protection is necessary provides a shipping enclosure as well. If Flowserve provides the driver and the auxiliary equipment, they are shipped separately, but prepared and handled in the same manner as the pump.

  • Page 27: Baseplate-Mounted Pump And Driver

    IJ PUMP OPERATION AND MAINTENANCE MANUAL CAUTION Parts can be damaged by using the end of the pump shaft as lifting points. Avoid lifting the pump by nozzles or drip pockets, they are not stressed for the load. NOTE Whenever practicable, rig or fabricate an apparatus of...

  • Page 28: Soleplate-Mounted Barrel Pump

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 2.1.3.2 Soleplate-Mounted Barrel Pump There are two sets of four cardinal points that can be used to lift the combined weight of barrel pump, cradle and soleplates. Their positions are physically defined by holes in each corner of the cradle and by holes in each pump foot.

  • Page 29: Multistage Rotor

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 1. Remove sides and end of box. 2. Remove fastenings that hold assembly to box, then remove plastic cover. 3. Place nylon strap or soft cable around diffuser-cover, near center of assembly. The weight of the suction spacer normally causes the inboard half of assembly to be heavier than outboard half.

  • Page 30: Storage

    10 degrees of the perpendicular to the horizon. 2.2 STORAGE This section provides storage data for pumps and manufactured by Flowserve. Storage data for drivers and other auxiliary equipment may be found in the Appendix of this manual.

  • Page 31: Pump Preservative Standards

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 2.2.1 PUMP PRESERVATIVE STANDARDS For domestic shipments the following standards, consistent with those recommended by the American Petroleum Institute for pumps, are applied: 1. All inner surfaces and internal parts of the pump casings and bearing housings are fully coated with a petroleum-based rust preventative, except as follows: a.

  • Page 32: Long-Term Indoor Storage

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 2.2.1.4 Long-Term Indoor Storage Factory preservative measures will protect the pump for long-term (greater than 6 months) storage with the following precautions taken at the site: 1. At the beginning of the storage period: a.

  • Page 33: Rotor Preservative Standards

    2.2.3 DEPRESERVING NOTE It is recommended that an Flowserve service representative be employed to inspect any equipment stored for more than 12 months. 1. Clean petroleum-based preservative from all parts of pump by using a petroleum-based solvent such as kerosene or naphtha.

  • Page 34: Preinstallation

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 2.3 PREINSTALLATION Poor location and use of inadequate standards for the preparation of the foundation adversely affect pump life. A good foundation is particularly important since it can be a primary factor in preventing vibration, a major cause of wear and failure of the pump.
  • Page 35 IJ PUMP OPERATION AND MAINTENANCE MANUAL Figure 2-1 Foundation Bolt BO2660-01 2-10...

  • Page 36: Installation And Coupling

    3.1.1 CONNECTING TO FLANGED NOZZLES The face of pipe flanges must be parallel and flush with the suction and discharge nozzles on the pump case. Piping must not be pulled into position with flange bolts. Additionally, Flowserve recommends the following: 1.
  • Page 37 IJ PUMP OPERATION AND MAINTENANCE MANUAL Figure 3-1 Vapor Pockets Figure 3-2 Suction Piping Temporary Screen BO2660-01...

  • Page 38: Welding To Nozzles

    When suction and discharge piping is welded to nozzles on the pump case special precautions are necessary to prevent foreign object damage to parts within the case. Temporary screens cannot be installed in the suction or inlet piping of all welded joints. Hence, as an alternative, Flowserve recommends: 1.

  • Page 39: One Baseplate For Entire Train Of Units

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 4. precision machinist level or equivalent tool; 5. optical alignment equipment such as an alignment laser or jig transit that is capable of measuring to 0.001 in (0.02 mm); 6. dial indicator; 7. indicator bracket.
  • Page 40 IJ PUMP OPERATION AND MAINTENANCE MANUAL 3. Set baseplate with pump on shims and/or leveling screws, bending anchor bolts as necessary to align them with holes in baseplate. NOTE Pump feet and their holddown bolts are inaccessible with lagging in place.
  • Page 41 IJ PUMP OPERATION AND MAINTENANCE MANUAL Figure 3-4 Leveling Pump End Crosswise Figure 3-5 Leveling Driver End Crosswise BO2660-01...
  • Page 42 IJ PUMP OPERATION AND MAINTENANCE MANUAL Figure 3-6 Leveling Driver End Lengthwise Figure 3-7 Leveling Pump End Lengthwise 3). Tighten foundation anchor bolts, and pump feet holddown bolts. As you tighten bolts, position level as illustrated in the four leveling figures and check leveling in both crosswise and lengthwise directions.

  • Page 43: Baseplates (Or Soleplates) In Train

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 4). After baseplate is anchored and leveled with specified space between it and foundation, it must be grouted in a manner as described under GROUTING. 3.2.3 BASEPLATES (OR SOLEPLATES) IN TRAIN. Where driver, pump, and any other unit that couples in train with the pump will be mounted on...
  • Page 44 IJ PUMP OPERATION AND MAINTENANCE MANUAL ALIGNMENT SCHEDULE 1. First, verify that turbine is correctly aligned with plant benchmark and fixed in its permanent position. 2. Next, set up common centerline by aligning centerline of high-speed pump soleplates with centerline of turbine shaft.
  • Page 45 IJ PUMP OPERATION AND MAINTENANCE MANUAL ALIGNMENT SCHEDULE 1. First, set up common centerline by aligning centerline of high-speed pump baseplate with plant bench mark. 2. Then, align centerline motor baseplate with common centerline. 3. Next, align centerline of low-speed...
  • Page 46 IJ PUMP OPERATION AND MAINTENANCE MANUAL 6. Using optical alignment equipment (see TOOLS AND EQUIPMENT above), align centerline of every baseplate (or pair of soleplates) within 0.015 inch (0.38 mm) of a common centerline (see BASEPLATE AND SOLEPLATES IN TRAIN and MULTIPLE BASEPLATES IN TRAIN figures).
  • Page 47 IJ PUMP OPERATION AND MAINTENANCE MANUAL Figure 3-10 Shaft Rough Alignment Schedules DIAL INDICATOR BRACKET PIPE BRACKET SPAN Figure 3-11 Determining Bar Sag BO2660-01 3-12...
  • Page 48 IJ PUMP OPERATION AND MAINTENANCE MANUAL NOTE All indicator readings must be taken on the periphery or rim of the coupling hub or shaft, and recorded as viewed from the fixed unit (see ALIGNMENT ORIENTATION figure). MOVABLE UNIT FIXED UNIT Figure 3-12 Alignment Orientation Attach bracket to the movable unit coupling hub or shaft.
  • Page 49 IJ PUMP OPERATION AND MAINTENANCE MANUAL Figure 3-13 Dial Indicator Setup For Alignment m. Remove bracket from movable unit coupling hub and attach to fixed unit coupling hub. n. Repeat steps g through l with readings taken on movable unit.

  • Page 50: Baseplate For Pump Or Single Unit

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 3.2.4 BASEPLATE FOR PUMP OR SINGLE UNIT To level a baseplate that is used only for the pump or a single unit, select the applicable method below: 1. Verify that baseplate is aligned to a common centerline with other baseplates (or soleplates) in train as instructed by steps 1 through 6 under BASEPLATES (OR SOLEPLATES) IN TRAIN above.

  • Page 51: Installing Nozzle Extensions And Grouting

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 6. Insure that steps 8 through 10 under BASEPLATES (OR SOLEPLATES) IN TRAIN above are complete before grouting. 3.3 INSTALLING NOZZLE EXTENSIONS AND GROUTING 3.3.1 GROUTING WITH CEMENT AND SAND A suitable grout mixture consists of one part Portland cement and one part coarse, clean sand by weight.

  • Page 52: Grouting With Epoxy

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 6. Pour grout through grout holes in baseplate (soleplates too, where holes have been provided) and working from sides, push grout between foundation and baseplate (or soleplates). 7. Work and rod grout until entire space between top of foundation and top of grout holes is full and absolutely free of air pockets.

  • Page 53: Installing Nozzle Extensions

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 5. Before epoxy grout is set but after it is apt to flow, remove cloth from around foundation bolts, exposing threads. 6. Allow epoxy grout to set for period specified by epoxy manufacturer, then: a.

  • Page 54: Tools And Equipment

    3.4.3 REASONS FOR FIELD ALIGNMENT OF PUMP AND DRIVER Although in some cases Flowserve does ship the driver mounted on the baseplate with the pump, the driver shaft is not precisely aligned with the pump shaft; thus, such shipments, as well as those where pump and driver are packed separately, must be field-aligned before operating the pump.

  • Page 55: Alignment Preconditions

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 3. Minor distortion in the baseplate may occur when it is bolted to its own foundation, which in turn may produce some misalignment between pump and driver if they are aligned and coupled before the baseplate is leveled and anchored on its foundation.
  • Page 56 IJ PUMP OPERATION AND MAINTENANCE MANUAL NOTE If your pump is driven by an electric motor with ball bearings, or by any other driver, then skip to step 5 of this procedure. 1. See that instructions have been complied with under above headings: a.

  • Page 57: Tapping Driver Mount Pads

    IJ PUMP OPERATION AND MAINTENANCE MANUAL NOTE After setting endspace the motor shaft should not be moved prior to scribing location of holddown bolts. 5. With motor shaft as positioned in step 4, or with driver shaft set as instructed in manufacturer’s instructions, set driver so that distance between ends of driver and pump...

  • Page 58: Cold Alignment

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 5. Reverse position of dial indicator and bracket and repeat step 4. 6. Remove dial indicator and bracket. 7. Scribe location of holddown bolts on mounting pads, then remove driver from pad. 8. Drill and tap holddown bolt holes.
  • Page 59 10. Set the bar sag amount(s) determined in steps 4 through 8 above into the indicator(s) as a plus amount (example: an indicated -0.003 would be set in as a +0.003) while in the upright (12 o'clock) position. NOTE Use of a shaft alignment graph, such as Flowserve Shaft Alignment Calculator (see...
  • Page 60 IJ PUMP OPERATION AND MAINTENANCE MANUAL a. release driver holddown bolts, if installed; b. using lifting equipment, lift driver and shim under feet for height correction; Figure 3-18 Alignment Measurement Points NOTE Horizontal movements should be controlled by jacking bolts, if installed.

  • Page 61: Hot Alignment

    IJ PUMP OPERATION AND MAINTENANCE MANUAL NOTE Unless hub is strapped down, it will vibrate when the driver is started in step 24. 24. Briefly operate driver in accordance with manufacturer's instructions (see APPENDIX) and observe rotation of shaft: its rotation must correspond to the direction in which the pump is designed to turn.

  • Page 62: Flushing Lube Oil System, Cleaning And Preserving Seal Piping

    1. storage, 2. installation, or 3. fabrication. Flowserve recommends the use of either flushing procedure that is given below; however, if your pump is equipped with an auxiliary lube oil pump, its use is preferred. NOTE Regardless of which procedure is used to flush the lube oil system, it will be necessary to employ a lube oil filter in the piping, downstream of the lube oil pump.

  • Page 63: Flushing Lube Oil System Without Using Auxiliary Lube Oil Pump

    IJ PUMP OPERATION AND MAINTENANCE MANUAL shut down auxiliary lube oil pump; then clean and reinstall filter. Restart auxiliary lube oil pump and continue flush. NOTE To prevent an accumulation of moisture from condensation when heated lube oil is used, allow lube oil to cool gradually during last hour or two of the cycle.

  • Page 64: Seal Piping

    3.5.2.1 Carbon Steel Piping Following rework or fabrication of carbon steel piping, to protect the seal from rust, scale, welding shot, grit and other foreign material, Flowserve recommends: 1. sandblasting inside and outside of piping to remove varnish and welding slag, 2.

  • Page 66: Operation, Maintenance, And Inspection

    OPERATING SPECIFICATIONS section of this manual, APPENDIX section of this manual, Flowserve Engineering drawings in back of this manual, or in your plant data file. 4.1 STARTUP Before being put on line (i.e., started), the pump, the driver, the gear if applicable (see OUTLINE drawing in the back of this manual), and the auxiliary systems require an external inspection for operational readiness.

  • Page 67: Initial Steps In Preparing For Operation Of Old Pump That Has Been Off-Line For Extended Period

    IJ PUMP OPERATION AND MAINTENANCE MANUAL housings, switches, auxiliary or spare lube oil pump motor, main and auxiliary or spare lube oil pumps, and valves for damage, installation, cleanliness, and security. 5. Ensure: a. that seal units are installed, and;...

  • Page 68: Checking And Replenishing Lube Oil Reservoir

    IJ PUMP OPERATION AND MAINTENANCE MANUAL NOTE To identify an individual valve that is normally closed during lube oil system operation, see the LUBE OIL SCHEMATIC in the back of this manual. Any valve that is not shown in the schematic as normally closed is normally open.
  • Page 69 IJ PUMP OPERATION AND MAINTENANCE MANUAL 1. Ensure: a. hand-operated valves are positioned as required in step 6 of SERVICING EMPTY LUBE OIL SYSTEM; b. lube oil reservoir is at level required in CHECKING AND REPLENISHING LUBE OIL RESERVOIR; c. inspections required above did not reveal any discrepancies which could not be corrected.

  • Page 70: Starting Pump

    IJ PUMP OPERATION AND MAINTENANCE MANUAL NOTE The recommended warm-up rate is given in OPERATING SPECIFICATIONS. 5. Start circulation in warm-up circuit and monitor flow, temperature, and pressure (see your plant's data file and OUTLINE drawing in the back of this manual).
  • Page 71 IJ PUMP OPERATION AND MAINTENANCE MANUAL 2. Start driver (see manufacturer's instructions in APPENDIX for starting driver). NOTE A sudden drop in discharge pressure usually means a failure in the system supplying liquid to the pump and vaporization of liquid inside the pump. Once the pump is shut down and rotation stops, it may be restarted after the vapor is cleared by opening the vent line.

  • Page 72: Operation

    IJ PUMP OPERATION AND MAINTENANCE MANUAL a. Pressure gauge (PI) in lube oil console should read pressure specified in LUBE OIL SCHEMATIC drawing in the back of this manual, b. Lube oil cooler inlet and outlet temperatures (if applicable) should read temperatures specified in OPERATING SPECIFICATIONS.
  • Page 73 IJ PUMP OPERATION AND MAINTENANCE MANUAL 7. Check lube oil inlet temperature indicator of pump bearings and driver and outlet temperature indicator of heat exchanger; readings should be approximately same. NOTE Because heat that is generated by a bearing is constant, a change in ambient temperature may require additional cooling of the bearings.

  • Page 74: Adjusting Packing Leakage Rate

    IJ PUMP OPERATION AND MAINTENANCE MANUAL manufacturer's data in APPENDIX). If differential pressure of lube oil is above that specified by lube oil console manufacturer, manually route lube oil through clean filter in accordance with its manufacturer's instructions in APPENDIX. Otherwise lube oil passage through filter is nominal.

  • Page 75: Stopping

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 3. throttling the discharge and reducing the speed. NOTE To take pump off line and put it in hot standby, see FROM ON-LINE OPERATION TO HOT STANDBY in STOPPING. 4.3 STOPPING There are usually two circumstances for stopping the pump: cold shutdown and hot standby.

  • Page 76: From On-Line Operation To Hot Standby

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 6. If a prolonged shutdown and temperature below 32°F (0°C) is anticipated, open all valves in drain lines and verify that cooling water systems, seal flush system, and case are drained. (To identify drains besides those on lube oil console, see OUTLINE and piping drawings in the back of this manual, and your plant’s data file.)

  • Page 77: Maintenance And Inspection Tips

    When a gasket is used the gasket thickness and material are critical; both shall identical to the original. 4.4.3 LUBE OIL CHANGE RECOMMENDATIONS Flowserve recommends that the lube oil in the pump be inspected periodically and changed whenever: 1. the lube oil color darkens, indicating contamination from dirt and foreign substances;...
  • Page 78 Thus to preclude such imminent damage to a Flowserve multistage pump when using an acid or caustic wash to clean a system that includes the pump, remove the internal assembly from the case and close off the seal cavities with blank plates, which can be supplied by the factory.

  • Page 80: Troubleshooting

    Should questions arise, contact your nearest Flowserve Sales Office (see PART ORDERING AND SERVICING INFORMATION).
  • Page 81 IJ PUMP OPERATION AND MAINTENANCE MANUAL Troubles Causes Failure to develop rated discharge Air or vapor in liquid pressure Pump not up to rated speed Wrong rotation Wearing rings worn Impeller damaged Internal leakage resulting from defective sealing surfaces Available NPSH not sufficient...

  • Page 82: Second Listing

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 5.1.2 SECOND LISTING In the following listing, the causes of vibration and their corrections are given in the order in which they are apt to occur: Cause of Vibration Correction Insufficient liquid at inlet impeller caused by...

  • Page 84: Replacement And Repair

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 6. REPLACEMENT AND REPAIR Replacement and repair instructions cover the disassembly, cleaning, inspection, repair (or replacement), and assembly of the major assemblies that make up the pump. Repair instructions for principal auxiliary equipment are prepared by their manufacturers (see APPENDIX or your plant's data file).

  • Page 85: Lifting

    For assurance that the rotor will be in its running position after installation of the internal assembly, the lower half of a bearing housing, a bearing, or a seal, Flowserve recommends the installation (or assembly) of major parts according to the schedules shown in figures below, particularly whenever seals or bearings are being installed.
  • Page 86 IJ PUMP OPERATION AND MAINTENANCE MANUAL Figure 6-2 Task Schedule For Installation of Major Part/Assembly BO2660-01...

  • Page 87: Lube Oil System Component Maintenance

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 6.2 LUBE OIL SYSTEM COMPONENT MAINTENANCE 6.2.1 REPLACEMENT LUBE OIL SYSTEM COMPONENT Isolation valves permit replacement of lube oil system components without draining the piping. Hence to replace a control valve, pressure switch, temperature switch, pressure indicator, heat exchanger, lube oil filter, or lube oil pump: 1.

  • Page 88: Tools And Equipment

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 4. fill reservoir with correct lube oil (see OPERATING SPECIFICATIONS). 6.3 TOOLS AND EQUIPMENT Normal hand tools are required for all maintenance on this equipment. Additional equipment required for specific areas of maintenance are described below.
  • Page 89 IJ PUMP OPERATION AND MAINTENANCE MANUAL Figure 6-3 Roll and Heel Bars 7. a vertical assembly apparatus which consists of: a. a base assembly, which consists of a base with a tube that is bushed with a soft metal bushing to hold the coupling end of the shaft and adjustable legs to support the suction spacer and stacked covers, b.

  • Page 90: Pump Disassembly

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 6.4 PUMP DISASSEMBLY 6.4.1 COUPLING REMOVAL CAUTION The procedures outlined in this subsection do not apply to keyless hydraulic fit couplings. For installation or removal of such couplings, refer to the applicable drawings in the back of this manual or the APPENDIX.

  • Page 91: Bearing Disassembly

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 6. Remove spider and lube-oil-pump-to-end-plate gasket. If necessary to remove a half-coupling, remove setscrew, slide half-coupling from shaft, and remove its key. 6.4.3 BEARING DISASSEMBLY 1. Remove any optional equipment, wiring, or piping obstructing removal of either bearing housing.

  • Page 92: Mechanical Seal

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 8. Disassemble thrust bearing (54) as follows: a. Remove thrust bearing shoes from top half of base rings. Then remove top half of base rings with leveling plates attached. b. Rotate bottom half of base rings to top. Remove shoes and lift off bottom halves of base rings with leveling plates attached.

  • Page 93: Removing Seal Housing

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 6.4.4.2 Removing Seal Housing To remove either inboard or outboard seal housing (if installed) follow the task outline below: 1. Comply with instructions under REMOVING SEAL UNIT above. 2. Disconnect all piping (if installed) from seal housing (105 or 106).

  • Page 94: Removing Head Without Using Carriage

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 8. Evenly tighten puller screws, pulling head (85) away from case (37) and bringing it to rest securely on carriage dowels. NOTE On some pumps, the discharge diffuser is welded to the discharge spacer as a single assembly. If this is the case, the discharge diffuser will not be removed with the head, but will be removed with the internal assembly.

  • Page 95: Internal Assembly

    Should you have difficulty in removing the assembly, contact your nearest Flowserve Sales Office for assistance (see PART ORDERING AND SERVICING INFORMATION). 3. To remove internal assembly from case, using hydraulic ram and pusher adapter, proceed as follows: a.

  • Page 96: Disassembling Internal Assembly

    IJ PUMP OPERATION AND MAINTENANCE MANUAL c. Place soft cable in eyebolt and pull cable straight back against coupling end of shaft and toward free end of the pump, while positioning assembly with lifting equipment until assembly begins to slide onto the track.

  • Page 97: Stage Number System And Balanced Parts

    IJ PUMP OPERATION AND MAINTENANCE MANUAL CAUTION Application of excessive heat can cause part distortion and damage. Application of insufficient heat can cause scouring of the parts when attempting removal. Ensure that the part is heated to the temperature specified in OPERATING SPECIFICATIONS before removal.

  • Page 98: Vertical Disassembly

    IJ PUMP OPERATION AND MAINTENANCE MANUAL number 1, and the numbering continues consecutively to the discharge stage. Therefore, in order to maintain dynamic balance of the rotor, it is very important to ensure that each impeller, split ring, and key are matched by stage number during disassembly and assembly.

  • Page 99: Horizontal Disassembly

    IJ PUMP OPERATION AND MAINTENANCE MANUAL b. Remove the intermediate cover (33) or destaging spacer (292) (if installed) using the procedure outlined in INTERFERENCE FIT PART REMOVAL above. 9. Remove the suction impeller (28) as follows: a. Set up soft-faced V-blocks near base assembly. The blocks should be positioned to support the shaft at points about 25% of total shaft length from the ends of the shaft.

  • Page 100: Part Cleaning, Inspection, And Repair

    IJ PUMP OPERATION AND MAINTENANCE MANUAL CAUTION During horizontal disassembly you may slightly lift the shaft to take the weight of the rotor off of an impeller bushing or wearing ring, making it easier to slide the impeller off of its key.

  • Page 101: Cleaning

    IJ PUMP OPERATION AND MAINTENANCE MANUAL should you require additional information about a condition or repair which is not covered here, contact your nearest Flowserve Service Department (see PART ORDERING AND SERVICING INFORMATION) . 6.5.1 CLEANING WARNING Petroleum solvents, alcohol, acetone and other such chemicals are injurious to health and may ignite from a spark;...

  • Page 102: Inspection And Repair

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 6.5.2.4.2 Inspection and Repair Inspect, clean, and replace seal parts in accordance with the seal manufacturer’s installation and assembly drawing in the APPENDIX. Before installing the seal unit, visually inspect: 1. shaft for cleanliness, nicks, excessive wear, burrs, and galling;...
  • Page 103 IJ PUMP OPERATION AND MAINTENANCE MANUAL extensive examination is required, the inspection item is cross referenced to a detailed procedure. Inspect: 1. Shaft for scratches, nicks, burrs, and distortion; absolutely smooth surfaces and a straight shaft are required (see CHECKING SHAFT STRAIGHTNESS below).
  • Page 104 IJ PUMP OPERATION AND MAINTENANCE MANUAL SPECIFICATIONS and trueness according to instructions under RENEWING IMPELLER WEARING SURFACES REPLACING IMPELLER WEARING RINGS REPLACING STATIONARY WEARING RINGS below. 6.5.2.6.3 Checking Shaft Straightness CAUTION Application of heat to straighten shaft will cause more distortion.

  • Page 105: Checking Running Clearances

    IJ PUMP OPERATION AND MAINTENANCE MANUAL a. Using micrometers to measure diameter of bore at each end of pressure reducing sleeve and the corresponding diameter of shaft, then, b. Comparing diameter of bore of pressure reducing sleeve with the corresponding diameter of shaft;...

  • Page 106: Renewing Impeller Wearing Surfaces

    4. New undersized stationary wearing rings and bushings must be installed to maintain the proper running clearance (see CHECKING RUNNING CLEARANCES above). For details about obtaining undersized parts from Flowserve, see PART ORDERING AND SERVICING INFORMATION. 5. A record should be kept of the decrease in skirt and hub diameters and the undersize of wearing rings and bushings.

  • Page 107: Replacing Bushings

    IJ PUMP OPERATION AND MAINTENANCE MANUAL CAUTION Striking or cutting into parent metal of stationary part will make replacement necessary. 1. Machine off, or using rotary file grind off, welds that retain keys to metal of parent part or drill out setscrews, whichever is applicable.
  • Page 108 IJ PUMP OPERATION AND MAINTENANCE MANUAL WEARING SURFACE above), the standard size bushing should be used for replacement. A bushing, whether standard or undersize, is manufactured to be pressed into the parent part. The following procedure will guide you in replacing a bushing.

  • Page 109: Replacing Impeller Wearing Rings

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 6.5.2.6.9 Replacing Impeller Wearing Rings Unless the impeller skirt wearing surface has been ground down, the standard size wearing ring should be used for replacement. To replace an impeller wearing ring proceed as follows:...

  • Page 110: Pump Assembly

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 9. See that there is no damage to the wearing surface. 6.6 PUMP ASSEMBLY 6.6.1 INTERNAL ASSEMBLY 6.6.1.1 Assembling Internal Assembly To assemble the internal assembly, proceed as follows: 6.6.1.1.1 Interference Fit Part Installation To install an interference fit part, proceed with the following general procedure: 1.

  • Page 111: Vertical Assembly

    IJ PUMP OPERATION AND MAINTENANCE MANUAL WARNING Use lifting gear when moving any part that weighs more than 50 lbs. (22 kg) to prevent personnel injury and part damage due to dropping. Always ensure that hot parts are handled with soft cables or hands protected by heat-resistant gloves to prevent personnel injury.
  • Page 112 IJ PUMP OPERATION AND MAINTENANCE MANUAL c. With nylon lifting strap under shaft at coupling side of suction impeller (28) and soft cable in shaft hoisting fitting, use two hoists to lift the shaft into a vertical position. Remove the nylon lifting strap.

  • Page 113: Installing Internal Assembly

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 10. Securely clamp assembly in vertical assembly apparatus. 11. With one hoist attached to each end of the vertical assembly apparatus with soft cables, tip the internal assembly into a horizontal position and position it so that the intermediate covers (33) rest on wooden blocks.
  • Page 114 IJ PUMP OPERATION AND MAINTENANCE MANUAL Figure 6-5 Rotor Lateral Movement CAUTION If a hydraulic ram and adapter cannot be used, you may install an eyebolt in the coupling end of the shaft and pull the internal assembly into the case with a cable. However, use of the eyebolt and cable may cause damage to the internal assembly, and should be avoided.

  • Page 115: Head

    Proceed with the assembly of the head as follows: NOTE For guidance in tack welding replacement parts, contact your nearest Flowserve Sales Office (see PART ORDERING AND SERVICING INFORMATION). 1. Cool pressure reducing bushing (65) in dry ice to shrink it enough to slide it into head. Secure bushing with method employed originally by the factory (see step 2 under PUMP DISASSEMBLY: HEAD above).

  • Page 116: Installing Head Without Using Carriage

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 1. Adjust carriage puller screws to allow head (85) to be pushed fully on carriage dowels. Using hoist, lift head and push it onto dowels, bottoming it against carriage frame. If desired, leave hoist connected to head.

  • Page 117: Rotor Axial Alignment

    IJ PUMP OPERATION AND MAINTENANCE MANUAL b. Loosen bearing housing bolting. c. Use jacking bolts on bearing housings to center rotor in seal bore. d. Tighten bearing housing bolting. e. Reindicate shaft to ensure it is still centered in seal bores.

  • Page 118: Mechanical Seal

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 5. Disassemble inner parts of thrust bearing. a. Remove thrust bearing shoes from top half of base ring, then lift off top half of base ring. b. Rotate bottom half of base ring to expose remaining inner thrust bearing shoes, remove shoes, and lift off bottom half of base ring.

  • Page 119: Installing Seal Unit

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 1. Install new seal housing gasket (111) on housing (105 or 106). 2. Verify that case mating surface for gasket (111) is clean, smooth, and even. 3. Attach lifting equipment to housing (105 or 106) and position housing in head (85) or inboard end of case (37), whichever is applicable.
  • Page 120 17. Firmly push shaft in one direction until it stops solidly and set dial indicator to zero. NOTE If in doubt about how to machine the end cover, contact your nearest Flowserve Sales Office (See PART ORDERING AND SERVICING INFORMATION). 18. Push shaft in opposite direction until it stops solidly. Read dial indicator. Shaft movement should be within the thrust bearing axial clearance specified under OPERATING SPECIFICATIONS.

  • Page 121: Main Lube Oil Pump Installation

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 6.6.6 MAIN LUBE OIL PUMP INSTALLATION These instructions provide for installation of a lubricating oil (lube oil) pump that is flange-mounted to the outboard bearing housing end cover for direct and axial coupling of its shaft with the pump shaft.

  • Page 122: Coupling Installation

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 4. Insure that conduit for vibration probe wires, key phasor, or pipe plug is installed in largest diameter hole in top of bearing housing end cover (61). 5. Connect piping to lube oil pump.

  • Page 123: Final Assembly Tasks

    IJ PUMP OPERATION AND MAINTENANCE MANUAL Some straight half-couplings are secured in position with shaft nuts as well as keys. 3. installing key on driver or pump shaft and sliding cold sleeve and O-ring followed by heated hub (or heated solid half-coupling, if so equipped) onto shaft until half-coupling is positioned as shown by the OUTLINE drawing in the back of this manual;...

  • Page 124: Parts Ordering And Servicing Information

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 7. PARTS ORDERING AND SERVICING INFORMATION Flowserve sales offices and other facilities are located throughout the world. Contact the sales office nearest you for sales and service or for assistance with parts and repairs. Your computerized parts list follows the addresses listed below.

  • Page 125: Service Centers (North America)

    IJ PUMP OPERATION AND MAINTENANCE MANUAL 7.2 SERVICE CENTERS (NORTH AMERICA) Baton Rouge Service Center Rancho Dominguez Service Center 3904 Windsong Dr. 1909 East Cashdan Baton Rouge LA, 70817 Dominguez Hills, CA 90220 Phone: (225) 293-5780 Phone: (310) 608-4500 Fax:...

  • Page 126: International Offices

    PART ORDERING AND SERVICING INFORMATION Vancouver Service Center Woodbridge Service Center 10400 NE 13 . Avenue 120 Vinyl Court Vancouver, WA 98686 Woodbridge, Ontario, L4L 4A3 Phone: (360) 573-5211 Phone: (905) 856-1140 Fax: (360) 574-7656 Fax: (905) 856-2010 7.3 INTERNATIONAL OFFICES Austria Italy (Caserta) Industriestrasse B/6...
  • Page 127 IJ PUMP OPERATION AND MAINTENANCE MANUAL Rossmore Business Park, Ellesmerfe Port South Wirral L65 3EN, United Kingdom Phone: 44 151 3560555 Fax: 44 151 3556222 United Kingdom (Grangemouth) BP Oils Gragemouth Ref, P.O. Box 30, Bo’ness Road Grangemouth, Stirlingshire, Scotland FK3 9XQ...
  • Page 128 Phone: 9714 370995 Fax: 7 502 220 3036 Fax: 9714 377250 Saudi Arabia United Kingdom Flowserve Flowserve (UK) Ltd. c/o E.A. Juffali & Brothers Queensway Team Valley Trading Estate P.O. Box 86 Gateshead Tyne & Wear NE11 0QB Riyadh 11411, Saudi Arabia Phone: 091 4875051 Phone: 1 402 2222 Ext.

Table of Contents