Flowserve Mark 3 User Instructions
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Flowserve Mark 3 User Instructions

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Pump Division
Mark 3 High Silicon Iron Pumps
USER INSTRUCTIONS:
INSTALLATION, OPERATION, MAINTENANCE
PCN=71569249 09-04 (E)
These instructions must be read prior to installing,
operating, using and maintaining this equipment.

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  • Page 1 ® Pump Division Mark 3 High Silicon Iron Pumps USER INSTRUCTIONS: INSTALLATION, OPERATION, MAINTENANCE PCN=71569249 09-04 (E) These instructions must be read prior to installing, operating, using and maintaining this equipment.

  • Page 2: Table Of Contents

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® 6.8 Examination of parts ........32 CONTENTS 6.9 Assembly of pump and seal......35 Page 7 FAULTS; CAUSES AND REMEDIES ....41 1 INTRODUCTION AND SAFETY ......3 1.1 General ............3 BLANK8 PARTS LIST AND DRAWINGS ....

  • Page 3: Introduction And Safety

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® To confirm the Approvals applying and if the product is 1 INTRODUCTION AND SAFETY CE marked, check the serial number plate markings and the Certification. (See section 9, Certification.) 1.1 General...

  • Page 4: Safety

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® 1.6 Safety NEVER DO MAINTENANCE WORK WHEN THE UNIT IS CONNECTED TO POWER 1.6.1 Summary of safety markings (Lock out.) These User Instructions contain specific safety markings where non-observance of an instruction would DRAIN THE PUMP AND ISOLATE PIPEWORK cause hazards.
  • Page 5 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® immediate area. Note: bearing housings must not be THE PUMP SHAFT MUST TURN insulated and drive motors and bearings may be hot. CLOCKWISE WHEN VIEWED FROM THE MOTOR If the temperature is greater than 68 °C (175 °F) or It is absolutely essential that the rotation of the motor below 5 °C (20 °F) in a restricted zone, or exceeds...
  • Page 6 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® 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...

  • Page 7: Name Plate And Safety Labels

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® To avoid potential hazards from fugitive emissions of 1.6.4.7 Maintenance of the centrifugal pump to vapor or gas to atmosphere, the surrounding area avoid a hazard must be well ventilated.

  • Page 8: Noise Level

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® The values are based on the noisiest non-geared 1.8 Noise level electric motors that are likely to be encountered. When pump noise level exceeds 85 dB(A) attention They represent sound pressure levels at 1 m (3.3 ft) must be given to prevailing Health and Safety from the directly driven pump, for "free field over a...

  • Page 9: Transport And Storage

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® 2 TRANSPORT AND STORAGE 2.3.1.4 Bare pump Sling through the pump adapter and around the outboard end of the bearing housing with separate slings. Choker 2.1 Consignment receipt and unpacking...

  • Page 10: Recycling And End Of Product Life

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® The pump may be stored as above for up to 6 2.5 Recycling and end of product life months. Consult Flowserve for preservative actions At the end of the service life of the product or its when a longer storage period is needed.

  • Page 11: Nomenclature

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® 3.2 Nomenclature 3.3.2 Split Gland Yoke The pump size will be engraved on the nameplate The seal chamber is cast integral to the casing typically as below: volute. The gland yoke is clamped around the seal 2 K 3 X 1.5 H - 10 /9.5 OP...

  • Page 12: Location

    None Zirconium B752, Gr. 702C ® Duriron, Durichlor 51 and Superchlor are registered trademarks of Flowserve Corporation. ® Ferralium is a registered trademark of Langley Alloys. ® Hastelloy is a registered trademark of Haynes International, Inc. ® Inconel and Monel are registered trademarks of International Nickel Co. Inc.

  • Page 13: Part Assemblies

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® 4.2 Part assemblies installed, given reasonable care in handling, without damage. It must also be rigid enough The supply of motors and baseplates are optional. when properly installed to resist operating loads.
  • Page 14 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® Assemble the stilt bolt up through hole in the cups [7] under each stilt location, and lower the bottom plate and hold in place. baseplate down to the floor.

  • Page 15: Grouting

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® vertical alignment, and by moving the pump for and discharge flanges. DO NOT stress the horizontal alignment. baseplate. e) If the fasteners are centered, then the baseplate e) Do not bolt the suction or discharge flanges of the may be twisted.

  • Page 16: Initial Alignment

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® Grout the baseplate. A non-shrinking grout Mark 3A and ANSI 3A design should be used. Make sure that the grout fills the If an adjustment is necessary, add or remove area under the baseplate.
  • Page 17 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® equal to the fastener diameter but that do not bottom 4.6.4 Allowable nozzle loads out in the tapped holes before the joint is tight. High Silicon Iron cannot support piping loads.
  • Page 18 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® 4.6.6 Auxiliary piping Figure 4-11 Tap 5 4.6.6.1 Mechanical seal When the pump is intended to be equipped with a mechanical seal, it is Flowserve standard practice to install the mechanical seal in the pump prior to shipment.

  • Page 19: Electrical Connections

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® 4.8 Final shaft alignment check 4.8.1 Horizontal pumps a) Level baseplate if appropriate. b) Mount and level pump if appropriate. Level the pump by putting a level on the discharge flange.

  • Page 20: Protection Systems

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® • g) Operate the pump for at least an hour or until it Seal support system operational • reaches final operating temperature. Shut the Bearing lubrication • pump down and recheck alignment while the pump Bearing housing cooling system operational •...
  • Page 21 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® Note that on ANSI 3A™ power ends there is no temperatures. The normal oil change interval is based constant level oiler. As stated above, proper oil level on temperature and is shown in figure 5-6.
  • Page 22 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® Figure 5-5: Maximum external housing Figure 5-8: Regreasable configuration temperatures Lubrication Temperature Oil bath 82 °C (180 °F) Oil mist 82 °C (180 °F) Grease 94 °C (200 °F) The maximum temperature that the bearing can be exposed to is 105 °C (220 °F).

  • Page 23: Impeller Clearance

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® 5.3 Impeller clearance The impeller clearance was set at the factory based on the application temperature at the time the pump was purchased (see figure 5-10). For an open impeller the clearance is set to the front cover (suction side).

  • Page 24: Priming And Auxiliary Supplies

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® following instructions enable the user to properly fit in the shell flange until it comes all the way this guard to the pump and motor. through and locks the top and bottom together.

  • Page 25: Stopping And Shutdown

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® life, shaft deflection and bearing housing vibration limits documented in the latest version of ASME B73.1M. 5.8.5 Operation in sub-freezing conditions Pumps may be operated at lower flows, but it must be...

  • Page 26: Maintenance

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® Ensuring that NPSH is larger than Oil and grease leaks may make the ground NPSH by the suggested margin will greatly enhance slippery. Machine maintenance must always pump performance and reliability. It will also reduce...

  • Page 27: Spare Parts

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® d) Check bearing lubricant level, and the remaining and the cost of the spare part. Section 8 identifies all of hours before a lubricant change is required. the components that make up each pump addressed in e) Check that the duty condition is in the safe this manual.

  • Page 28: Fastener Torques

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® impeller. It also contains “nose cones” which protect shaft threads and O-rings during maintenance. This tool kit can be ordered from your local Flowserve sales engineer or from a Flowserve distributor or representative.
  • Page 29 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® The impeller could have sharp edges, See section 5.3 for impeller clearance settings. which could cause an injury. It is very important to wear heavy gloves. Example: If a pump was to be placed in a service with an operating temperature of 150 °C (302 °F) the...

  • Page 30: Disassembly

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® Unscrew the impeller and remove from the shaft. Discard the impeller gasket [4590]. 6.7 Disassembly 6.7.1 Pump removal Do not apply heat to the a) Before performing any maintenance, disconnect the impeller.
  • Page 31 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® w) Because the O-rings [4610.2] will cause some resistance in removing the bearing carrier assembly from the housing, hold the bearing carrier flange firmly and with slight rotation, pull it out of the bearing housing.

  • Page 32: Examination Of Parts

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® This is accomplished by removing the cap screws 6.7.3 Split Gland Yoke Disassembly [6570.5], which thread into the bearing housing. It should not be necessary to remove the split gland Mark 3 design yoke [4121].
  • Page 33 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® A micrometer should be used to check these outside Figure 6-17 diameter (OD) dimensions on the shaft. Group 2 50.000/49.987 Bearing (1.9685/1.9680) Figure 6-16 bearing/ 50.013/50.003 Suggested Suggested Shaft...
  • Page 34 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® both the IB and OB bearing surfaces are consistently within the minimum/maximum values shown in figure 6-18. An inside caliper should be used to check these ID dimensions in the bearing housing.

  • Page 35: Assembly Of Pump And Seal

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® concentricity should be less than 0.13 mm (0.005 in.). The diagram below shows how to measure this concentricity. Alignment Many companies today are using laser alignment Concentricity which is a more sophisticated and accurate technique.
  • Page 36 1. These bearings are open on both sides. They are lubricated by oil bath or oil mist. 2. These bearings are pre-greased by Flowserve. Replacement bearings will generally not be pre-greased, so grease must be applied by the user. They have a single shield, which is located on the side next to the grease buffer, or reservoir. The bearings draw grease from the reservoir as it is needed.
  • Page 37 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® bearing mounting techniques are used, steps An alternate method of installing bearings is to heat must be taken to ensure the outboard bearing is the bearings to 93 °C (200 °F) by means of an oven firmly positioned against the shaft shoulder.
  • Page 38 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® style, the cavity between these two lips should be housing [3200]. The bearing carrier [3240] should filled with grease. When installing this part, the large be lubricated with oil on the O-rings and threads...
  • Page 39 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® Configuration A: Tap 5 (top) – As shown in Section 8. d) Tighten set screws on the seal to lock the rotating • Casing seal chamber [1100] with one chamber unit to the shaft.
  • Page 40 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® h) Attach the gland/seat to the casing [1100] using c) Install the packing rings [4130] and seal cage studs [6570.6] and nuts [6580.2]. halves [4134] into the stuffing box as shown in Install the impeller [2200] as instructed in section figures 4-11 and 4-12.

  • Page 41: Faults; Causes And Remedies

    ® 7 FAULTS; CAUSES AND REMEDIES The following is a guide to troubleshooting problems with Flowserve Mark 3 pumps. Common problems are analyzed and solutions offered. Obviously, it is impossible to cover every possible scenario. If a problem exists that is not covered by one of the examples, then refer to one of the books listed in section 10 Additional sources of information or contact a Flowserve sales engineer or distributor/representative for assistance.
  • Page 42 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® Pump not reaching design flow rate ⇓ ⇓ Pump not reaching design head (TDH) ⇓ ⇓ No discharge or flow with pump running ⇓ ⇓ Pump operates for short period, then loses prime ⇓...

  • Page 43: Blank8 Parts List And Drawings

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® BLANK Page 43 of 48...

  • Page 44: Parts List And Drawings

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® 8 PARTS LIST AND DRAWINGS 8.1 Mark 3 High Silicon Iron Pump, Group 2 Page 44 of 48...
  • Page 45 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® Item No. Part Description Item No. Part Description 1100 Casing 4310.1 Oil Seal – Inboard 1223 Suction Cover 4310.2 Oil Seal – Outboard 1240 Clamping Ring 4590.1 Gasket – Cover 1245.1...

  • Page 46: General Arrangement Drawing

    USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® 8.2 General arrangement drawing American National Standard for Centrifugal Pumps The typical general arrangement drawing and any for Nomenclature, Definitions, Design and Application specific drawings required by the contract will be sent (ANSI/HI 1.1-1.3)
  • Page 47 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® BLANK Page 47 of 48...
  • Page 48 USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04 ® FLOWSERVE REGIONAL SALES OFFICES: USA and Canada Latin America and Caribbean Flowserve Corporation (Pump Division) Flowserve Corporation (Pump Division) 5215 North O’Connor Blvd. Suite 2300 6840 Wynnwood Lane Irving, Texas 75039, USA...

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