Related Manuals for Flowserve FLEX 6300
Summary of Contents for Flowserve FLEX 6300
- Page 1 Flowserve FLEX™ Installation Operation Isobaric Energy Recovery Device Maintenance 21TEM14546 EN Original Instructions These instructions must be read prior to installing, operating, and maintaining this equipment.
- Page 2 FLEX User Instruction – 21TEM14546 EN Copyright All rights reserved. No part of these instructions may be reproduced, stored in a retrieval system, or transmitted in any form or by any means without prior permission of Flowserve Corporation. Document Version...
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Page 3: Table Of Contents
FLEX User Instruction – 21TEM14546 EN CONTENTS General Information ........................4 Scope of manual ............................4 Disclaimer ..............................4 Certification instruction ..........................5 Units ................................5 Safety Information ........................... 6 Intended use ..............................6 Safety symbols and description ........................6 General hazard sources ..........................7 Responsibility of the operating company ....................8 Qualified personnel and targeted group ....................8 Industrial health and safety measures .......................9 Protective equipment ..........................9... - Page 4 FLEX User Instruction – 21TEM14546 EN Torque requirements ..........................29 Disassembly ..............................29 Reassembly ..............................30 Post-maintenance inspection ........................31 Spare parts ..............................31 Troubleshooting Guide ......................... 33 Decommissioning and Recommissioning .................. 34 Decommissioning ............................34 Recommissioning ............................34 10 Returns and Disposal ........................35 10.1 Returns ................................
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Page 5: General Information
Flowserve parts and accessories is considered to be misuse. Damage or failure caused by misuse is not covered by Flowserve’s warranty. In addition, any modification of Flowserve products or removal of original components may impair the safety of these products in use. -
Page 6: Certification Instruction
Certification instruction It is a legal requirement that machinery and equipment put into service within certain regions of the world shall conform to the Marking Directives applicable to Flowserve products (i.e., Machinery Directive, Low Voltage Directive, Electromagnetic Compatibility (EMC) Directive, Pressure Equipment Directive (PED), Equipment for Potentially Explosive Atmospheres (ATEX), etc.). -
Page 7: Safety Information
The product/system must not be operated beyond the parameters specified for the application. If there is any doubt as to the suitability of the product/system for the application intended, contact Flowserve for advice, quoting the serial number. • Installing, operating, or maintaining the product/system in any way that is not covered in this User Instruction could cause death, serious personal injury, or damage to the equipment. -
Page 8: General Hazard Sources
2.3.1 Mechanical Hazards Lifting limits and guidelines Note: The load values mentioned in this section are Flowserve recommendations only. All lifting must be done in compliance with site safety protocol, local regulations, and related industry standards. -
Page 9: Responsibility Of The Operating Company
FLEX User Instruction – 21TEM14546 EN • Repetitive lifting of any kind should be evaluated as part of a documented end-user safety program. 2.3.2 Additional hazards DRAIN AND ISOLATE PIPEWORK BEFORE DISMANTLING Residual high-pressure can remain in the FLEX units depending on how the system is shut down. Ensure the FLEX units have been isolated from the system and relieved of all pressure before dismantling any connections on the device. -
Page 10: Industrial Health And Safety Measures
FLEX User Instruction – 21TEM14546 EN Industrial health and safety measures Follow industry safety standards including the use of appropriate equipment in required areas. Protective equipment Necessary protective equipment including personal protective equipment shall adhere to facility standards. Page 9 of 43... -
Page 11: Product Description
General product description Figure 1: Isometric view of the Flowserve FLEX™ The Flowserve FLEX™ is an isobaric energy recovery device designed for reverse osmosis seawater desalination applications. It takes the energy of a high-pressure fluid waste stream and transfers the pressure energy to a low-pressure fluid supply stream. The simple design does not require any external power, has only one moving part, and uses corrosion-proof materials for high reliability and long life. -
Page 12: Flex Design
FLEX User Instruction – 21TEM14546 EN FLEX design The following sections describe the functions of the primary components in the FLEX. For further clarity, refer to Figure 1 and Figure 12 (page 30) for isometric and exploded views of the device. 3.2.1 Vessel The vessel acts as the primary pressure containment boundary for the device and contains passageways (called ports or nozzles) that direct flow between external pipe connections and... -
Page 13: Function In An Ro System
FLEX User Instruction – 21TEM14546 EN Function in an RO system The Flowserve FLEX™ is an isobaric energy recovery device designed for reverse osmosis (RO) seawater desalination applications. It takes the energy of a high-pressure fluid waste stream and transfers the pressure energy to a low-pressure fluid supply stream. The simple design does not require any external power, has only one moving part, and uses corrosion-proof materials for high reliability and long life. -
Page 14: Header Design
FLEX User Instruction – 21TEM14546 EN Filtration of the process fluid must occur upstream of the FLEX device to avoid damaging the unit and the precision clearances inside of it. Filters should have a maximum particle size of 20 μm (0.8 mils) or smaller. - Page 15 FLEX User Instruction – 21TEM14546 EN An analysis of the total system resistance from header inlet to header outlet provides some important guidelines on how to design headers to achieve an even flow distribution between FLEX units operating in parallel with each other: 1.
- Page 16 High-pressure headers and piping are typically made of duplex or super duplex stainless steel because of its corrosion resistance and strength. For the low-pressure headers and piping, Flowserve recommends the use of Polyethylene (PE) or Polypropylene (PP) rather than Polyvinylchloride (PVC) wherever possible.
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Page 17: Connections
FLEX User Instruction – 21TEM14546 EN Connections 3.6.1 Piping connections Each FLEX unit has four pipe end connections with grooved ends for split couplings: • FLEX 6300 3-inch NPS pipe Grooved pipe end (to Victaulic OGS specifications) • FLEX 8600... -
Page 18: Packaging, Lifting And Storage
Any shortage or damage must be reported immediately to Flowserve and must be received in writing within one month of receipt of the goods. Later claims cannot be accepted. -
Page 19: Packaging
(such as 1 of 3, 2 of 3, etc.) and contain a copy of the packing list. 4.3.2 Typical Flowserve packaging FLEX units shipped from a Flowserve facility will typically be packaged in the following manner: (see the pictures in Figure 6 through Figure 10 for examples) •... - Page 20 FLEX User Instruction – 21TEM14546 EN Figure 6: Multiple containers on a pallet Figure 7: Single FLEX container Figure 8: Top of protective padding Figure 9: Top protective padding removed Figure 10: FLEX unit with nozzle covers Page 19 of 43...
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Page 21: Lifting
Use a choker hitch sling pulled tight around the nozzles to lift an assembled FLEX unit. USE LIFTING ASSISTANCE FOR HEAVY OBJECTS AND AWKWARD LIFTS Flowserve recommends a crane be used for all devices in excess of 23 kg (50 lb). Fully trained personnel must carry out lifting in accordance with local regulations. -
Page 22: Installation
FLEX User Instruction – 21TEM14546 EN Installation Inspection and preparation 5.1.1 Location The FLEX should be located to allow room for access, maintenance, and inspection with ample headroom for lifting. 5.1.2 Protection of openings USE PROTECTIVE COVERS ON FLEX PORTS WHEN NOT IN SERVICE When the FLEX is shipped, all openings are covered. -
Page 23: Mounting And Installation
FLEX User Instruction – 21TEM14546 EN Prior to installing a FLEX, a check can be performed to verify that the rotor is able to spin freely inside the device. There are two ways to perform this verification: 1. Rock the FLEX back and forth while looking into one of the low-pressure ports to see that the rotor spins freely from the rest of the device. - Page 24 FLEX User Instruction – 21TEM14546 EN 6. A mounting strap can be used around the vessel body or vessel flange to secure the device from vibration and pressure loads. DO NOT OVERTIGHTEN VESSEL CLAMPS Overtightening clamps around the vessel body can cause distortion of the FLEX and affect performance of the unit.
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Page 25: Operation
FLEX User Instruction – 21TEM14546 EN Operation Commissioning Prior to starting the FLEX system, it is essential that the following checks be made. 1. FLEX unit properly secured to the mounting bracket 2. All fasteners tightened to the correct torque 3. -
Page 26: Normal Operation
FLEX User Instruction – 21TEM14546 EN Normal operation The FLEX is a completely passive device with no controls, speed, or position settings of its own. The device is controlled by the amount of flow and pressure put into it by other pumps and valves in the system. -
Page 27: Shut Down
FLEX User Instruction – 21TEM14546 EN A sight glass in the vessel allows observation and measurement of rotor speed with an optical tachometer. Measured speed can be compared to the rated speed on the data sheet at the conditions of operation. A speed significantly higher or lower than expected may indicate a malfunction of the FLEX, an imbalance of high-pressure and low-pressure flow, or an imbalance of flow between units when multiple units are installed in parallel. - Page 28 FLEX User Instruction – 21TEM14546 EN 1. Flush the system and FLEX units (both high-pressure and low-pressure sides) with fresh water to remove salt and prevent mineral buildup. 2. Preventative measures should be taken to inhibit biological growth. HIGH-PRESSURE REMAINS AFTER SHUTDOWN Even when the pumps are shut down, high-pressure can remain in the system due to osmotic pressure at the membranes.
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Page 29: Maintenance
FLEX User Instruction – 21TEM14546 EN Maintenance The FLEX does not require scheduled or preventative maintenance. As long as the device is properly operated and flushed before extended shutdowns, the device is designed to operate maintenance free for many years. Maintenance procedure Any work on the FLEX must be performed when it is at a standstill and de-energized state. -
Page 30: Tools, Equipment, And Fixtures
4. Remove the remaining vessel from the cartridge. Use caution to avoid damaging ceramic cartridge components with the metal vessels. 5. Remove and discard the balance pocket O-rings and end cover O-rings. Disassembly of the cartridge without training from Flowserve personnel is not recommended. Table 5: Parts list ITEM... -
Page 31: Reassembly
FLEX User Instruction – 21TEM14546 EN BOLT, FLANGE WASHER, FLANGE VESSEL, SEAWATER CARTRIDGE VESSEL, BRINE SIGHT-GLASS O-RING, FLANGE O-RING, BALANCE POCKET O-RING, END COVER O-RING, END COVER O-RING, BALANCE POCKET WASHER, FLANGE NUT, FLANGE Figure 12: Exploded view Reassembly 1. Check that cartridge rotor spins freely before assembling unit. (See section 5.1.5) 2. -
Page 32: Post-Maintenance Inspection
3. Ensure covers are placed over the vessel ports to prevent ingress of contaminants. Spare parts When ordering spare parts, the following information should be provided to Flowserve: a) Product serial number b) Product size c) Part name – taken from the parts list/sectional drawing d) Part number –... - Page 33 FLEX User Instruction – 21TEM14546 EN To ensure continued satisfactory operation, replacement parts to the original design specification should be obtained from Flowserve. Any change to the original design specification (modification or use of non-standard part) will invalidate the product safety certification.
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Page 34: Troubleshooting Guide
This guide is meant to cover the most common problems that might occur. If situations outside this scope are encountered, and experienced operators and maintenance personnel are unable to remedy the situation, please consult with Flowserve’s field service department. Table 6: Troubleshooting recommendations... -
Page 35: Decommissioning And Recommissioning
FLEX User Instruction – 21TEM14546 EN Decommissioning and Recommissioning Decommissioning See the instructions in section 6.4 for proper shut down procedures. Recommissioning See sections 5 and 6.1 for proper installation and commissioning procedures. Page 34 of 43... -
Page 36: Returns And Disposal
Flowserve. Returned products shall be emptied, cleaned, and preserved before returning the equipment to Flowserve. Flowserve will open the returned equipment only if the contamination declaration is present. See section 4.3 for guidelines on appropriate FLEX packaging. -
Page 37: Technical Data
Approximate weights are shown in Table 7. For exact dimensions and weights of the product ordered, refer to the general arrangement drawing included upon receiving the product. Table 7: Equipment dimensions and weights DESCRIPTION UNITS FLEX 6300 FLEX 8600 Dry weight kg (lb) 29 (63) -
Page 38: Noise Level
FLEX User Instruction – 21TEM14546 EN 11.4 Noise level Attention must be given to the exposure of personnel to noise. Local legislation will define when guidance to personnel on noise limitation is required, and when noise exposure reduction is mandatory. This is typically 80 to 85 dBA. The usual approach is to control the exposure time to high noise levels, use hearing protection, or to enclose the machine to reduce emitted sound. -
Page 39: Annex A: Declaration Of Conformity
FLEX User Instruction – 21TEM14546 EN Annex A: Declaration of Conformity If the product/system is being sold into a country which requires a Declaration of Conformity (DoC), an example of each DoC for the subject product/system must be included in this Annex. Below is an example of Declaration of Conformity for the product/system. -
Page 40: Annex B: Supplementary User Instructions
FLEX User Instruction – 21TEM14546 EN Annex B: Supplementary User Instructions Supplementary instructions such as instrumentation, controller, coupling, mounting component, etc. are provided as separate documents in their original format. If further copies of these are required, they should be obtained from the supplier for retention with these User Instructions. Page 39 of 43... - Page 41 FLEX User Instruction – 21TEM14546 EN NOTES: Page 40 of 43...
- Page 42 FLEX User Instruction – 21TEM14546 EN NOTES: Page 41 of 43...
- Page 43 FLEX User Instruction – 21TEM14546 EN Page 42 of 43...
- Page 44 Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended function safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve product might be used in numerous application under a wide variety of industrial service conditions.
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