Mark Darco

®
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.
USER INSTRUCTIONS MARK 3 High Silicon Iron ENGLISH 71569249 09-04
®
CONTENTS 6.8 Examination of parts ..................................... 32

Page 6.9 Assembly of pump and seal.......................... 35
1 INTRODUCTION AND SAFETY ........................... 3 7 FAULTS; CAUSES AND REMEDIES ................. 41
1.1 General ........................................................... 3 BLANK8 PARTS LIST AND DRAWINGS ............... 43
1.2 CE marking and approvals.............................. 3
1.3 Disclaimer ....................................................... 3 8 PARTS LIST AND DRAWINGS ........................... 44
1.4 Copyright......................................................... 3 8.1 Mark 3 High Silicon Iron Pump, Group 2...... 44
1.5 Duty conditions ............................................... 3 8.2 General arrangement drawing...................... 46
1.6 Safety .............................................................. 4 9 CERTIFICATION................................................. 46
1.7 Name plate and safety labels ......................... 7
1.8 Noise level ...................................................... 8 10 OTHER RELEVANT DOCUMENTATION AND
MANUALS.......................................................... 46
2 TRANSPORT AND STORAGE ............................. 9 10.1 Supplementary User Instructions ............... 46
2.1 Consignment receipt and unpacking .............. 9 10.2 Change notes ............................................. 46
2.2 Handling.......................................................... 9 10.3 Additional sources of information ............... 46
2.3 Lifting............................................................... 9
2.4 Storage............................................................ 9
2.5 Recycling and end of product life.................. 10
3 DESCRIPTION .................................................... 10
3.1 Configurations............................................... 10
3.2 Nomenclature................................................ 11
3.3 Design of major parts.................................... 11
3.4 Performance and operation limits ................. 11
4.1 Location ........................................................ 12
4.2 Part assemblies ............................................ 13
4.3 Foundation .................................................... 13
4.4 Grouting ........................................................ 15
4.5 Initial alignment ............................................. 16
4.6 Piping ............................................................ 16
4.7 Electrical connections ................................... 19
4.8 Final shaft alignment check .......................... 19
4.9 Protection systems........................................ 20
5 COMMISSIONING, STARTUP, OPERATION AND
SHUTDOWN ...................................................... 20
5.1 Pre-commissioning procedure ...................... 20
5.2 Pump lubricants ............................................ 20
5.3 Impeller clearance......................................... 23
5.4 Direction of rotation....................................... 23
5.5 Guarding ....................................................... 23
5.6 Priming and auxiliary supplies ...................... 24
5.7 Starting the pump.......................................... 24
5.8 Running or operation .................................... 24
5.9 Stopping and shutdown................................. 25
5.10 Hydraulic, mechanical and electrical duty... 25
6 MAINTENANCE .................................................. 26
6.1 Maintenance schedule .................................. 26
6.2 Spare parts.................................................... 27
6.3 Recommended spares and consumable items
....................................................................... 27
6.4 Tools required ............................................... 27
6.5 Fastener torques........................................... 28
6.6 Setting impeller clearance and impeller
replacement................................................... 28
6.7 Disassembly.................................................. 30
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1 INTRODUCTION AND SAFETY To confirm the Approvals applying and if the product is
CE marked, check the serial number plate markings
1.1 General and the Certification. (See section 9, Certification.)
These instructions must always be kept 1.3 Disclaimer

close to the product's operating location or
directly with the product. Information in these User Instructions is believed
to be reliable. In spite of all the efforts of
Flowserve products are designed, developed and Flowserve Pump Division to provide sound and all
manufactured with state-of-the-art technologies in necessary information the content of this manual
modern facilities. The unit is produced with great may appear insufficient and is not guaranteed by
care and commitment to continuous quality control, Flowserve as to its completeness or accuracy.
utilizing sophisticated quality techniques, and safety
requirements. Flowserve manufactures products to exacting
International Quality Management System Standards
Flowserve is committed to continuous quality as certified and audited by external Quality
improvement and being at your service for any further Assurance organizations. Genuine parts and
information about the product in its installation and accessories have been designed, tested and
operation or about its support products, repair and incorporated into the products to help ensure their
diagnostic services. continued product quality and performance in use.
As Flowserve cannot test parts and accessories
These instructions are intended to facilitate sourced from other vendors the incorrect
familiarization with the product and its permitted use. incorporation of such parts and accessories may
Operating the product in compliance with these adversely affect the performance and safety features
instructions is important to help ensure reliability in of the products. The failure to properly select, install
service and avoid risks. The instructions may not or use authorized Flowserve parts and accessories is
take into account local regulations; ensure such considered to be misuse. Damage or failure caused
regulations are observed by all, including those by misuse is not covered by the Flowserve warranty.
installing the product. Always coordinate repair In addition, any modification of Flowserve products or
activity with operations personnel, and follow all plant removal of original components may impair the safety
safety requirements and applicable safety and health of these products in their use.
laws/regulations.
1.4 Copyright
These instructions must be read prior to All rights reserved. No part of these instructions may
installing, operating, using and maintaining the be reproduced, stored in a retrieval system or
equipment in any region worldwide. The transmitted in any form or by any means without prior
equipment must not be put into service until all permission of Flowserve Pump Division.
the conditions relating to safety noted in the
instructions, have been met. 1.5 Duty conditions
This product has been selected to meet the
1.2 CE marking and approvals specifications of your purchaser order. The
It is a legal requirement that machinery and equipment acknowledgement of these conditions has been sent
put into service within certain regions of the world shall separately to the Purchaser. A copy should be kept
conform with the applicable CE Marking Directives with these instructions.
covering Machinery and, where applicable, Low Voltage
Equipment, Electromagnetic Compatibility (EMC), The product must not be operated beyond
Pressure Equipment Directive (PED) and Equipment for the parameters specified for the application. If
Potentially Explosive Atmospheres (ATEX). there is any doubt as to the suitability of the
product for the application intended, contact
Where applicable, the Directives and any additional Flowserve for advice, quoting the serial number.
Approvals, cover important safety aspects relating to
machinery and equipment and the satisfactory provision If the conditions of service on your purchase order are
of technical documents and safety instructions. Where going to be changed (for example liquid pumped,
applicable this document incorporates information temperature or duty) it is requested that the user seeks
relevant to these Directives and Approvals. the written agreement of Flowserve before start up.
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1.6 Safety
NEVER DO MAINTENANCE WORK
1.6.1 Summary of safety markings WHEN THE UNIT IS CONNECTED TO POWER
These User Instructions contain specific safety (Lock out.)
markings where non-observance of an instruction would
cause hazards. The specific safety markings are: DRAIN THE PUMP AND ISOLATE PIPEWORK
BEFORE DISMANTLING THE PUMP
This symbol indicates electrical safety The appropriate safety precautions should be taken
instructions where non-compliance will involve a high where the pumped liquids are hazardous.
risk to personal safety or the loss of life.
FLUOROELASTOMERS (When fitted.)
This symbol indicates safety instructions where When a pump has experienced temperatures over
non-compliance would affect personal safety and 250 ºC (482 ºF), partial decomposition of
could result in loss of life. fluoroelastomers (example: Viton) will occur. In this
condition these are extremely dangerous and skin
This symbol indicates “hazardous and toxic fluid” contact must be avoided.
safety instructions where non-compliance would affect
personal safety and could result in loss of life. HANDLING COMPONENTS
Many precision parts have sharp corners and the
This symbol indicates safety wearing of appropriate safety gloves and equipment
instructions where non-compliance will involve some is required when handling these components. To lift
risk to safe operation and personal safety and would heavy pieces above 25 kg (55 lb) use a crane
damage the equipment or property. appropriate for the mass and in accordance with
current local regulations.
This symbol indicates explosive atmosphere
zone marking according to ATEX. It is used in safety NEVER OPERATE THE PUMP WITHOUT THE
instructions where non-compliance in the hazardous COUPLING GUARD AND ALL OTHER SAFETY
area would cause the risk of an explosion. DEVICES CORRECTLY INSTALLED
This sign is not a safety symbol but indicates GUARDS MUST NOT BE REMOVED WHILE
an important instruction in the assembly process. THE PUMP IS OPERATIONAL
1.6.2 Personnel qualification and training THERMAL SHOCK

All personnel involved in the operation, installation, Rapid changes in the temperature of the liquid within
inspection and maintenance of the unit must be the pump can cause thermal shock, which can result
qualified to carry out the work involved. If the in damage or breakage of components and should be
personnel in question do not already possess the avoided. High Silicon Iron should be heated and
necessary knowledge and skill, appropriate training cooled slowly. Changes in temperature should not
and instruction must be provided. If required the exceed 55˚C (100˚F) per hour.
operator may commission the manufacturer/supplier
to provide applicable training. MECHANICAL SHOCK
High Silicon Iron is subject to breakage from
Always coordinate repair activity with operations and mechanical shock. Care should be taken when
health and safety personnel, and follow all plant handling and operating the pump.
safety requirements and applicable safety and health
laws and regulations. NEVER APPLY HEAT TO REMOVE IMPELLER
Trapped lubricant or vapor could cause an explosion.
1.6.3 Safety action
HOT (and cold) PARTS
This is a summary of conditions and actions to If hot or freezing components or auxiliary heating
help prevent injury to personnel and damage to equipment can present a danger to operators and
the environment and to equipment. For products persons entering the immediate area, action must be
used in potentially explosive atmospheres taken to avoid accidental contact (such as shielding). If
section 1.6.4 also applies. complete protection is not possible, the machine access
must be limited to maintenance staff only with clear
visual warnings and indicators to those entering the
Page 4 of 48
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immediate area. Note: bearing housings must not be

insulated and drive motors and bearings may be hot. THE PUMP SHAFT MUST TURN
CLOCKWISE WHEN VIEWED FROM THE MOTOR
If the temperature is greater than 68 °C (175 °F) or END
below 5 °C (20 °F) in a restricted zone, or exceeds It is absolutely essential that the rotation of the motor
local regulations, action as above shall be taken. be checked before installation of the coupling spacer
and starting the pump. Incorrect rotation of the pump
HAZARDOUS LIQUIDS for even a short period can unscrew the impeller,
When the pump is handling hazardous liquids care which can cause significant damage.
must be taken to avoid exposure to the liquid by
appropriate pump placement, limiting personnel 1.6.4 Products used in potentially explosive
access and by operator training. If the liquid is atmospheres
flammable and/or explosive, strict safety procedures
must be applied. Measures are required to:
• Avoid excess temperature
Gland packing must not be used when pumping • Prevent build up of explosive mixtures
hazardous liquids. • Prevent the generation of sparks
• Prevent leakages
• Maintain the pump to avoid hazard
PREVENT EXCESSIVE EXTERNAL
PIPE LOAD
Do not use pump as a support for piping. Do not The following instructions for pumps and pump units
mount expansion joints, unless allowed by Flowserve when installed in potentially explosive atmospheres
in writing, so that their force, due to internal pressure, must be followed to help ensure explosion protection.
acts on the pump flange. Both electrical and non-electrical equipment must meet
the requirements of European Directive 94/9/EC.
ENSURE CORRECT LUBRICATION
(See section 5, Commissioning, startup, operation 1.6.4.1 Scope of compliance
and shutdown.)
Use equipment only in the zone for which it is
NEVER EXCEED THE MAXIMUM appropriate. Always check that the driver, drive
DESIGN PRESSURE (MDP) AT THE coupling assembly, seal and pump equipment are
TEMPERATURE SHOWN ON THE PUMP suitably rated and/or certified for the classification of
NAMEPLATE the specific atmosphere in which they are to be
See section 3 for pressure versus temperature installed.
ratings based on the material of construction.
Where Flowserve has supplied only the bare shaft
NEVER OPERATE THE PUMP WITH pump, the Ex rating applies only to the pump. The
THE DISCHARGE VALVE CLOSED party responsible for assembling the pump set shall
(Unless otherwise instructed at a specific point in the select the coupling, driver, seal and any additional
User Instructions.) equipment, with the necessary CE Certificate/
(See section 5, Commissioning start-up, operation Declaration of Conformity establishing it is suitable
and shutdown.) for the area in which it is to be installed.
NEVER RUN THE PUMP DRY OR The output from a variable frequency drive (VFD) can
WITHOUT PROPER PRIME (Casing flooded) cause additional heating affects in the motor. On
pump installations controlled by a VFD, the ATEX
NEVER OPERATE THE PUMP WITH Certification for the motor must state that it covers the
THE SUCTION VALVE CLOSED situation where electrical supply is from the VFD.
It should be fully opened when the pump is running. This particular requirement still applies even if the
VFD is in a safe area.
NEVER OPERATE THE PUMP AT
ZERO FLOW OR FOR EXTENDED PERIODS
BELOW THE MINIMUM CONTINUOUS FLOW
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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 Temperature
Maximum Temperature limit of liquid
engraved on the nameplate. class to surface handled (* depending on
temperature material and construction
EN 13463-1
permitted variant - check which is lower)
II 2 GD c IIC 135ºC (T4) T6 85 °C (185 °F) Consult Flowserve
T5 100 °C (212 °F) Consult Flowserve
T4 135 °C (275 °F) 110 °C (230 °F) *
Equipment Group
T3 200 °C (392 °F) 175 °C (347 °F) *
I = Mining T2 300 °C (572 °F) 270 °C (518 °F) *
II = Non-mining T1 450 °C (842 °F) 350 °C (662 °F) *
Category
The responsibility for compliance with the specified
2 or M2 = High level protection
maximum liquid temperature is with the plant
3 = normal level of protection
operator.
Gas and/or dust
G = Gas Temperature classification “Tx” is used when the
D= Dust liquid temperature varies and the pump could be
installed in different hazardous atmospheres. In this
c = Constructional safety case the user is responsible for ensuring that the
(in accordance with prEn13463-5) pump surface temperature does not exceed that
Gas Group (Equipment Category 2 only) permitted in the particular hazardous atmosphere.
IIA – Propane (Typical)
IIB – Ethylene (Typical) Do not attempt to check the direction of rotation with the
IIC – Hydrogen (Typical) coupling element/pins fitted due to the risk of severe
contact between rotating and stationary components.
Maximum surface temperature (Temperature Class)
(see section 1.6.4.3) Where there is any risk of the pump being run against a
closed valve generating high liquid and casing external
1.6.4.3 Avoiding excessive surface temperatures surface temperature, it is recommended that users fit an
external surface temperature protection device.
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE Avoid mechanical, hydraulic or electrical overload by
using motor overload trips, temperature monitor or a
Pump liquid temperature power monitor and perform routine vibration monitoring.
Pumps have a temperature class as stated in the ATEX
Ex rating on the nameplate. These are based on a In dirty or dusty environments, regular checks must
maximum ambient temperature of 40 ºC (104 ºF); refer be made and dirt removed from areas around close
to Flowserve for higher ambient temperatures. clearances, bearing housings and motors.
The surface temperature on the pump is influenced by 1.6.4.4 Preventing the build up of explosive
the temperature of the liquid handled. The maximum mixtures
permissible liquid temperature depends on the
temperature class and must not exceed the values in the ENSURE PUMP IS PROPERLY FILLED AND
table applicable below. The temperature rise at the seals VENTED AND DOES NOT RUN DRY
and bearings and due to the minimum permitted flow rate
is taken into account in the temperatures stated. Ensure that the pump and relevant suction and discharge
piping is totally filled with liquid at all times during the
Maximum permitted liquid temperature for pumps pumps operation so that an explosive atmosphere is
Maximum Temperature limit of liquid prevented. In addition, it is essential to make sure that
Temperature surface handled (* depending on
class to temperature material and construction
seal chambers, auxiliary shaft seal systems and any
EN 13463-1 permitted variant – check which is lower) heating and cooling systems are properly filled.
T6 85 °C (185 °F) Consult Flowserve
T5 100 °C (212 °F) Consult Flowserve If the operation of the system can not avoid this
T4 135 °C (275 °F) 115 °C (239 °F) * condition it is recommended that you fit an
T3 200 °C (392 °F) 180 °C (356 °F) *
T2 300 °C (572 °F) 275 °C (527 °F) * appropriate dry run protection device (for example
T1 450 °C (842 °F) 400 °C (752 °F) * liquid detection or a power monitor).
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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.
CORRECT MAINTENANCE IS REQUIRED TO
1.6.4.5 Preventing sparks AVOID POTENTIAL HAZARDS WHICH GIVE A
RISK OF EXPLOSION
To prevent a potential hazard from mechanical
contact, the coupling guard must be non-sparking The responsibility for compliance with maintenance
and anti-static for Category 2. instructions is with the plant operator.
To avoid the potential hazard from random induced To avoid potential explosion hazards during maintenance,
current generating a spark, the baseplate must be the tools, cleaning and painting materials used must not
properly grounded. give rise to sparking or adversely affect the ambient
conditions. Where there is a risk from such tools or
Avoid electrostatic charge. Do not rub non-metallic materials, maintenance must be conducted in a safe area.
surfaces with a dry cloth; ensure the cloth is damp.
It is recommended that a maintenance plan and
The coupling must be selected to comply with schedule is adopted. (See section 6, Maintenance.)
94/9/EC and correct alignment must be maintained.
1.7 Name plate and safety labels
Additional requirements for pumps on non-
metallic baseplates 1.7.1 Nameplate
When metallic components are fitted on a non- For details of nameplate, see the Declaration of
metallic baseplate they must be individually earthed. Conformity and section 3.
1.6.4.6 Preventing leakage 1.7.2 Safety labels
Pumps with mechanical seal. The pump must

only be used to handle liquids for which it has been
approved to have the correct corrosion resistance.
Avoid entrapment of liquid in the pump and associated

piping due to closing of suction and discharge valves,
which could cause dangerous excessive pressures to
occur if there is heat input to the liquid. This can occur if
the pump is stationary or running.
Bursting of liquid containing parts due to freezing

must be avoided by draining or protecting the pump
and auxiliary systems.
Where there is the potential hazard of a loss of a seal

barrier fluid or external flush, the fluid must be monitored. Oil lubricated units only:
If leakage of liquid to atmosphere can result in a
hazard, the installation of a liquid detection device is
recommended.
DurcoShieldTM (Splash/Shaft Guard) only:
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1.8 Noise level The values are based on the noisiest non-geared
When pump noise level exceeds 85 dB(A) attention electric motors that are likely to be encountered.
must be given to prevailing Health and Safety They represent sound pressure levels at 1 m (3.3 ft)
Legislation, to limit the exposure of plant operating from the directly driven pump, for "free field over a
personnel to the noise. The usual approach is to reflecting plane". For estimating LwA sound power
control exposure time to the noise or to enclose the level (re 1 pW) add 14dBA to the sound pressure
machine to reduce emitted sound. You may have value.
already specified a limiting noise level when the
equipment was ordered, however if no noise If a pump unit only has been purchased, for fitting
requirements were defined then machines above a with your own driver, then the "pump only" noise
certain power level will exceed 85 dB(A). In such levels from the table should be combined with the
situations consideration must be given to the fitting of level for the driver obtained from the supplier.
an acoustic enclosure to meet local regulations.
If the motor is driven by an inverter it may show an
Pump noise level is dependent on a number of factors - increase in noise level at some speeds. Consult a
the type of motor fitted, the operating capacity, pipework Noise Specialist for the combined calculation.
design and acoustic characteristics of the building.
For units driven by equipment other than
Typical sound pressure levels measured in dB, and electric motors or units contained within enclosures,
A-weighted are shown in the table below. The figures see the accompanying information sheets and
are indicative only, they are subject to a +3 dB manuals.
tolerance, and cannot be guaranteed.
Typical sound pressure level, dBA, LpA at 1 m reference 20 µPa

Motor size 3550 r/min 2900 r/min 1750 r/min 1450 r/min
and speed Pump and Pump Pump and Pump Pump and Pump Pump and Pump
motor only motor only motor only motor only
kW (hp) dBA dBA dBA dBA dBA dBA dBA dBA
<0.55 (<0.75) 71 66 64 62 64 62 63 62
0.75 (1) 74 66 67 62 67 62 63 62
1.1 (1.5) 74 68 67 64 67 64 65 64
1.5 (2) 77 70 70 66 70 66 66 66
2.2 (3) 78 72 71 68 71 68 68 68
3 (4) 81 74 74 70 74 70 70 70
4 (5) 82 75 75 71 75 71 71 71
5.5 (7.5) 90 77 83 73 76 73 72 71
7.5 (10) 90 78 83 74 77 74 73 72
11 (15) 91 80 84 76 78 76 74 73
15 (20) 92 83 85 79 80 79 76 75
18.5 (25) 92 83 85 79 80 79 76 75
22 (30) 92 83 85 79 81 79 77 75
30 (40) 100 85 93 81 84 80 80 76
37 (50) 100 86 93 82 84 80 80 76
45 (60) 100 87 93 83 84 80 80 76
55 (75) 100 88 95 84 86 81 82 77
75 (100) 100 90 95 86 88 81 83 78
90 (120) 100 90 95 86 90 81 85 78
110 (150) 100 91 95 87 91 83 86 79
150 (200) 101 92 96 88 91 83 86 79
200 (270) (1) (1) (1) (1) (1) 83 (1) 80
300 (400) - - - - (1) 84 (1) 81
(1) Motors in this range are generally job specific and noise levels should be calculated based on actual equipment installed.
For 960 r/min reduce 1450 r/min values by 5 dBA.
Page 8 of 48
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2 TRANSPORT AND STORAGE 2.3.1.4 Bare pump

Sling through the pump adapter and around the outboard
2.1 Consignment receipt and unpacking end of the bearing housing with separate slings. Choker
Immediately after receipt of the equipment it must be hitches must be used at both attachment points and
checked against the delivery/shipping documents for pulled tight. The sling lengths should be adjusted to
its completeness and that there has been no damage balance the load before attaching the lifting hook.
in transportation. Any shortage and/or damage must
be reported immediately to Flowserve Pump Division Figure 2-1
and must be received in writing within one month of
receipt of the equipment. Later claims cannot be
accepted.
Check any crate, boxes or wrappings for any

accessories or spare parts that may be packed
separately with the equipment or attached to side
walls of the box or equipment.
Each product has a unique serial number. Check

that this number corresponds with that advised and
always quote this number in correspondence as well
as when ordering spare parts or further accessories.
2.2 Handling
Boxes, crates, pallets or cartons may be unloaded
using fork lift vehicles or slings dependent on their
size and construction.
2.3 Lifting
Pumps and motors often have integral
lifting lugs or eye bolts. These are intended for use in
only lifting the individual piece of equipment.
Do not use eye bolts or cast-in lifting 2.3.2 Lifting pump, motor and baseplate assembly
lugs to lift pump, motor and baseplate assemblies.
If the baseplate has lifting holes cut in the sides at the
To avoid distortion, the pump unit end (Type D and Type E bases) insert lifting S hooks at
should be lifted as shown. the four corners and use slings or chains to connect to
the lifting eye. (Figure 2-1.) Do not use slings through
Care must be taken to lift components the lifting holes.
or assemblies above the center of gravity to prevent
the unit from flipping. This is especially true with For other baseplates, sling through the pump adapter,
In-Line pumps. and around the outboard end of the motor frame using
choker hitches pulled tight (Figure 2-1.). The sling
2.3.1 Lifting pump components should be positioned so the weight is not carried
through the motor fan housing.
2.3.1.1 Casing [1100]
Use a choker hitch pulled tight around the discharge
2.4 Storage
nozzle.
Store the pump in a clean, dry location
away from vibration. Leave flange covers in place to
2.3.1.2 Bearing housing [3200]
keep dirt and other foreign material out of pump
Insert either a sling or hook through the lifting lug
casing. Turn the pump shaft at regular intervals to
located on the top of the housing.
prevent brinelling of the bearings and the seal faces,
if fitted, from sticking.
2.3.1.3 Power end
Same as bearing housing.
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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. parts, the relevant materials and parts should be
recycled or disposed of using an environmentally
2.4.1 Short term storage and packaging acceptable method and in accordance with local
Normal packaging is designed to protect the pump regulations. If the product contains substances that
and parts during shipment and for dry, indoor storage are harmful to the environment, these should be
for up to six months or less. The following is an removed and disposed of in accordance with current
overview of our normal packaging: local regulations. This also includes the liquids
• All loose unmounted items are packaged in a and/or gases that may be used in the "seal system"
water proof plastic bag and placed under the or other utilities.
coupling guard
• Inner surfaces of the bearing housing, shaft (area Make sure that hazardous substances are
through bearing housing) and bearings are coated disposed of safely and that the correct personal
with Cortec VCI-329 rust inhibitor, or equal. protective equipment is used. The safety
specifications must be in accordance with the current
Bearing housings are not filled with oil local regulations at all times.
prior to shipment
• Regreasable bearings are packed with grease 3 DESCRIPTION
(EXXON POLYREX EM for horizontal pumps)
3.1 Configurations
• The internal surfaces of ferrous casings, covers, The Durco Mark 3 chemical process pumps are,
flange faces, and the impeller surface are single stage, centrifugal pumps. The High Silicon
sprayed with Cortec VCI-389, or equal Iron pump conforms dimensionally to ASME B73.1M.
• Exposed shafts are taped with Polywrap The pump does not have cast on flanges and does
• Flange covers are secured to both the suction not offer back pull out.
and discharge flanges
• In some cases with assemblies ordered with Figure 3-1: Nameplate mounted to housing
external piping, components may be
disassembled for shipment
• The pump must be stored in a covered, dry
location Serial No.
Equipment No.
Purchase Order
2.4.2 Long term storage and packaging Model
Long term storage is defined as more than six Size 2K3X1.5 H-10/9.5 OP
months, but less than 12 months. The procedure MDP
Material
Flowserve follows for long term storage of pumps is Date DD/MMM/YY
given below. These procedures are in addition to the
short term procedure.
• Each assembly is hermetically (heat) sealed from
the atmosphere by means of tack wrap sheeting
and rubber bushings (mounting holes)
• Desiccant bags are placed inside the tack
wrapped packaging
• A solid wood box is used to cover the assembly
This packaging will provide protection for up to twelve

months from humidity, salt laden air, dust etc.
After unpacking, protection will be the responsibility of

the user. Addition of oil to the bearing housing will
remove the inhibitor. If units are to be idle for extended
periods after addition of lubricants, inhibitor oils and
greases should be used. Every three months, the pump
shaft should be rotated approximately 10 revolutions.
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3.2 Nomenclature
The pump size will be engraved on the nameplate 3.3.2 Split Gland Yoke
typically as below: The seal chamber is cast integral to the casing
volute. The gland yoke is clamped around the seal
2 K 3 X 1.5 H - 10 /9.5 OP chamber neck. The gland yoke allows for seal
• Frame size chamber taps and provides the bolting ring for the
“2" indicates a medium size pump frame (in this gland.
example, a Group 2)
1 = Group 1 (small frame) 3.3.3 Impeller
2 = Group 2 (medium frame) The impeller is open type design.
3 = Group 3 (large frame)
• Power end 3.3.4 Suction Cover
K = Mark 3 style power end The front cover plate encapsulates the impeller and
Mark 3A – Standard contains the suction connection.
ANSI 3A – Optional (3 year guarantee)
• “3” = nominal suction port size (in.) 3.3.5 Shaft/sleeve
• “1.5” = Nominal discharge port size (in.) Solid and sleeved shafts are available, supported on
bearings, threaded impeller end and keyed drive end.
• Modifier for “specialty pumps”
H = High Silicon Iron
3.3.6 Pump bearings and lubrication
Blank or no letter = standard pump
Ball bearings are fitted as standard and may be either
M = Sealmatic
oil or grease lubricated.
R = recessed impeller
US = unitized self-priming
3.3.7 Bearing housing
V = vertical In-Line
Large oil bath reservoir.
LF = Lo-Flo
• Nominal maximum impeller diameter. “10” = 10 in.
3.3.8 Shaft seal
• Pump design variation The mechanical seal(s), attached to the pump shaft,
A = This pump has been redesigned from an earlier seals the pumped liquid from the environment. Gland
version. The impeller and casing are no longer packing may be fitted as an option.
interchangeable with the earlier version.
H = This pump is designed for a higher flow capacity 3.3.9 Driver
than another pump with the same basic The driver is normally an electric motor. Different drive
designation. (Examples: 4X3-10 and 4X3-10H; configurations may be fitted such as internal combustion
6X4-10 and 6X4-10H; 10X8-16 and 10X8-16H. engines, turbines, hydraulic motors etc driving via
HH = This pump is designed for a higher head than couplings, belts, gearboxes, drive shafts etc.
another pump with the same basic designation.
(Example: 4X3-13 and 4X3-13HH.) 3.3.10 Accessories
• Actual impeller size Accessories may be fitted when specified by the
“9.5” = 9 ½ in. diameter; 8.13 = 8 ⅛ in; customer.
10.75 = 10 ¾ in
(Previous annotation: 124 = 12 4/8 or 12 ½ in.
diameter; 83 = 8 ⅜ in.)
3.4 Performance and operation limits
This product has been selected to meet the
• Impeller style
specification of your purchase order. See section 1.5.
RV = reverse vane impeller; OP = Open impeller
The following data is included as additional information
3.3 Design of major parts to help with your installation. It is typical, and factors
such as liquid being pumped, temperature, material of
3.3.1 Pump casing construction, and seal type may influence this data. If
The seal chamber is cast integral to the casing volute required, a definitive statement for your application can
and only the discharge connection is integral to the be obtained from Flowserve.
casing. The casing must be installed prior to the
impeller. 3.4.1 Alloy cross reference chart
Figure 3-2 is the Alloy cross-reference chart for all
Mark 3 pumps. E3042 is the material code for High
Silicon Iron Pump wet ends.
Page 11 of 48
®
Figure 3-2: Alloy cross-reference chart

Flowserve Designation Durco Legacy ACI Equivalent Wrought ASTM Material
Material Code Codes Designation Designation Specifications Group No.
E3020 Ductile iron DCI None None A395, Gr. 60-40-18 1.0
E3033 High chrome iron CR28 None None A532 class 3 Cr
E4027 High chrome iron CR29 None None None Cr
E4028 High chrome iron CR35 None None None Cr
C3009 Carbon steel DS None Carbon steel A216 Gr. WCB 1.1
C3062 Durco CF8 D2 CF8 304 A744, Gr. CF8 2.1
C3069 Durco CF3 D2L CF3 304L A744, Gr. CF3 2.1
C3063 Durco CF8M D4 CF8M 316 A744, Gr. CF8M 2.2
C3067 Durco CF3M D4L CF3M 316L A744, Gr. CF3M 2.2
C3107 Durcomet 100 CD4M CD4MCuN Ferralium® A995, Gr. CD4MCuN 2.8
C4028 Durimet 20 D20 CN7M Alloy 20 A744, Gr. CN7M 3.17
C4029 Durcomet 5 DV None None None 2.2
K3005 Durco CY40 DINC CY40 Inconel® 600 A494, Gr. CY40 3.5
K3007 Durco M35 DMM M351 Monel® 400 A494, Gr. M35-1 3.4
K3008 Nickel DNI CZ100 Nickel 200 A494, Gr. CZ100 3.2
K4007 Chlorimet 2 DC2 N7M Hastelloy® B A494, Gr. N7M 3.7
K4008 Chlorimet 3 DC3 CW6M Hastelloy® C A494, Gr. CW6M 3.8
E3041 Duriron® D None None A518, Gr. 1 No load
E3042 Durichlor 51® D51 None None A518, Gr. 2 No load
E4035 Superchlor® SD51 None None A518, Gr. 2 No load
D4036 Durco DC8 DC8 None None None -
H3004 Titanium Ti None Titanium B367, Gr. C3 Ti
H3005 Titanium-Pd TiP None Titanium-Pd B367, Gr. C8A Ti
H3007 Zirconium Zr None Zirconium B752, Gr. 702C Ti
® 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.
3.4.2 Pressure-temperature ratings 4 INSTALLATION

The maximum allowable discharge pressure is
6.9 bar (100 psi) from -29 to 176˚C (-20 to 350˚F). High Silicon Iron components
3.4.3 Suction pressure limits If any of the components of the pump

Suction pressure is limited only by the pressure have been made of High Silicon Iron, the following
temperature ratings of the pump. Specific gravity is precautionary measures should be followed:
limited to 2.0. • Use hand wrenches rather than impact wrenches
• This equipment should not be subjected to
3.4.4 Minimum continuous flow sudden changes in temperature or pressure
The minimum continuous flow (MCF) is based on a • Avoid striking this equipment with any sharp blows
percentage of the best efficiency point (BEP). Figure
3-3 identifies the MCF. High Silicon Iron components
Figure 3-3: Minimum continuous flow Avoid any repair or fabrication welds
MCF % of BEP on High Silicon Iron components.
Pump size 1750/1450 1180/960
r/min r/min 4.1 Location
2K4x3H-13 20% 10% The pump should be located to allow room for
All other sizes 10% 10%
access, ventilation, maintenance, and inspection with
ample headroom for lifting and should be as close as
practicable to the supply of liquid to be pumped.
Refer to the general arrangement drawing for the

pump set.
Page 12 of 48
®
4.2 Part assemblies installed, given reasonable care in handling,

The supply of motors and baseplates are optional. without damage. It must also be rigid enough
As a result, it is the responsibility of the installer to when properly installed to resist operating loads.
ensure that the motor is assembled to the pump and 2. The baseplate must provide a reasonably flat
aligned as detailed in section 4.5 and 4.8. mounting surface for the pump and driver.
Uneven surfaces will result in a soft-foot condition
4.3 Foundation that may make alignment difficult or impossible.
Experience indicates that a baseplate with a top
4.3.1 Protection of openings and threads surface flatness of 1.25 mm/m (0.015 in./ft)
When the pump is shipped, all threads and all across the diagonal corners of the baseplate
openings are covered. This protection/covering provides such a mounting surface. Therefore,
should not be removed until installation. If, for any this is the tolerance to which we supply our
reason, the pump is removed from service, this standard baseplate. Some users may desire an
protection should be reinstalled. even flatter surface, which can facilitate
installation and alignment. Flowserve will supply
4.3.2 Rigid baseplates - overview flatter baseplates upon request at extra cost. For
The function of a baseplate is to provide a rigid example, mounting surface flatness of 0.17
foundation under a pump and its driver that maintains mm/m (0.002 in./ft) is offered on the Flowserve
alignment between the two. Baseplates may be Type E “Ten Point” baseplate shown in figure 4-1.
generally classified into two types: 3. The baseplate must be designed to allow the
user to final field align the pump and driver to
• Foundation-mounted, grouted design. (Figure 4-1.)
within their own particular standards and to
• Stilt mounted, or free standing. (Figure 4-2.)
compensate for any pump or driver movement
that occurred during handling. Normal industry
Figure 4-1
practice is to achieve final alignment by moving
the motor to match the pump. Flowserve practice
is to confirm in our shop that the pump assembly
can be accurately aligned. Before shipment, the
factory verifies that there is enough horizontal
movement capability at the motor to obtain a
“perfect” final alignment when the installer puts
the baseplate assembly into its original, top
leveled, unstressed condition.
Figure 4-2 4.3.3 Stilt and spring mounted baseplates

Flowserve offers stilt and spring mounted baseplates.
(See figure 4-2 for stilt mounted option.) The low
vibration levels of Mark 3 pumps allow the use of
these baseplates - provided they are of a rigid design.
The baseplate is set on a flat surface with no tie down
bolts or other means of anchoring it to the floor.
General instructions for assembling these baseplates

are given below. For dimensional information, please
refer to the appropriate Flowserve “Sales print.”
Baseplates intended for grouted installation are
designed to use the grout as a stiffening member. 4.3.3.1 Stilt mounted baseplate assembly
Stilt mounted baseplates, on the other hand, are instructions
designed to provide their own rigidity. Therefore the Refer to figure 4-3.
designs of the two baseplates are usually different. a) Raise or block up baseplate/pump above the
floor to allow for the assembly of the stilts.
Regardless of the type of baseplate used, it must b) Predetermine or measure the approximate
provide certain functions that ensure a reliable desired height for the baseplate above the floor.
installation. Three of these requirements are: c) Set the bottom nuts [2] above the stilt bolt head
1. The baseplate must provide sufficient rigidity to [1] to the desired height.
assure the assembly can be transported and d) Assemble lock washer [3] down over the stilt bolt.
Page 13 of 48
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e) 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.
f) Assemble the lock washer [3] and nut [2] on the i) Level and make final height adjustments to the
stilt bolt. Tighten the nut down on the lock suction and discharge pipe by first loosening the
washer. top nuts, and turning the bottom nuts to raise or
g) After all four stilts have been assembled, lower the baseplate.
position the baseplate in place, over the floor j) To make the stilt bolts more stable, tighten down
cups [4] under each stilt location, and lower the on the top nuts, compressing the top spring
baseplate to the floor. approximately 25 mm (1 in.), and lock the nuts in
h) Level and make final height adjustments to the place.
suction and discharge pipe by first loosening the k) It should be noted that the connecting pipelines
top nuts and turning the bottom nuts to raise or must be individually supported, and that the
lower the baseplate. spring mounted baseplate is not intended to
i) Tighten the top and bottom nuts at the lock support total static pipe loads.
washer [3] first then tighten the other nuts.
j) It should be noted that the connecting pipelines Figure 4-4
must be individually supported, and that the stilt
mounted baseplate is not intended to support
total static pipe load.
Figure 4-3
4.3.3.3 Stilt/spring mounted baseplates - motor

alignment
The procedure for motor alignment on stilt or spring
4.3.3.2 Stilt/spring mounted baseplate assembly mounted baseplates is similar to grouted baseplates.
instructions The difference is primarily in the way the baseplate is
Refer to figure 4-4. leveled.
a) Raise or block up baseplate/pump above the a) Level the baseplate by using the stilt adjusters.
floor to allow for the assembly of the stilts. (Shims are not needed as with grouted
b) Set the bottom nuts [4] above the stilt bolt head baseplates.)
[1]. This allows for 51 mm (2 in.) upward b) After the base is level, it is locked in place by
movement for the final height adjustment of the locking the stilt adjusters.
suction/discharge flange. c) Next the initial pump alignment must be checked.
c) Assemble the lock washer [6] flat washer [5] and The vertical height adjustment provided by the
bottom spring/cup assembly [2] down over the stilts allows the possibility of slightly twisting the
stilt bolt [1]. baseplate. If there has been no transit damage
d) Assemble the stilt bolt/bottom spring up through or twisting of the baseplate during stilt height
hole in the bottom plate and hold in place. adjustment, the pump and driver should be within
e) Assemble top spring/cup assembly [3] down 0.38 mm (0.015 in.) parallel, and 0.0025 mm/mm
over stilt bolt. (0.0025 in./in.) angular alignment. If this is not
f) Assemble flat washer [5], lock washer [6] and the case, check to see if the driver mounting
nuts [4] on the stilt bolt. fasteners are centered in the driver feet holes.
g) Tighten down top nuts, compressing the top d) If the fasteners are not centered there was likely
spring approximately 25 mm (1 in.). shipping damage. Re-center the fasteners and
h) After all four stilts have been assembled, perform a preliminary alignment to the above
position the baseplate in place, over the floor tolerances by shimming under the motor for
Page 14 of 48
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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. Slightly adjust (one turn of the pump to the piping until the baseplate foundation
adjusting nut) the stilts at the driver end of the is completely installed. If equipped, use leveling
baseplate and check for alignment to the above jackscrews to level the baseplate. If jackscrews
tolerances. Repeat as necessary while are not provided, shims and wedges should be
maintaining a level condition as measured from used. (See Figure 4-5.) Check for levelness in
the pump discharge flange. both the longitudinal and lateral directions.
f) Lock the stilt adjusters. Shims should be placed at all base anchor bolt
locations, and in the middle edge of the base if
The remaining steps are as listed for new grouted the base is more than 1.5 m (5 ft.) long. Do not
baseplates. rely on the bottom of the baseplate to be flat.
Standard baseplate bottoms are not machined,
4.4 Grouting and it is not likely that the field mounting surface
a) The pump foundation should be located as close is flat.
to the source of the fluid to be pumped as f) After leveling the baseplate, tighten the anchor
practical. bolts. If shims were used, make sure that the
b) There should be adequate space for workers to baseplate was shimmed near each anchor bolt
install, operate, and maintain the pump. The before tightening. Failure to do this may result in
foundation should be sufficient to absorb any a twist of the baseplate, which could make it
vibration and should provide a rigid support for impossible to obtain final alignment.
the pump and motor. g) Check the level of the baseplate to make sure
c) Recommended mass of a concrete foundation that tightening the anchor bolts did not disturb the
should be three times that of the pump, motor level of the baseplate. If the anchor bolts did
and base. Refer to figure 4-5. change the level, adjust the jackscrews or shims
as needed to level the baseplate.
Foundation bolts are imbedded in the h) Continue adjusting the jackscrews or shims and
concrete inside a sleeve to allow some tightening the anchor bolts until the baseplate is
movement of the bolt. level.
i) Check initial alignment. If the pump and motor
Figure 4-5 were removed from the baseplate proceed with
step j) first, then the pump and motor should be
reinstalled onto the baseplate using Flowserve’s
factory preliminary alignment procedure as
described in section 4.5, and then continue with
the following. As described above, pumps are
given a preliminary alignment at the factory. This
preliminary alignment is done in a way that ensures
that, if the installer duplicates the factory conditions,
there will be sufficient clearance between the motor
hold down bolts and motor foot holes to move the
motor into final alignment. If the pump and motor
were properly reinstalled to the baseplate or if they
were not removed from the baseplate and there has
d) Level the pump baseplate assembly. If the been no transit damage, and also if the above steps
baseplate has machined coplanar mounting where done properly, the pump and driver should
surfaces, these machined surfaces are to be be within 0.38 mm (0.015 in.) FIM (Full Indicator
referenced when leveling the baseplate. This Movement) parallel, and 0.0025 mm/mm (0.0025
may require that the pump and motor be removed in./in.) FIM angular. If this is not the case, first
from the baseplate in order to reference the check to see if the driver mounting fasteners are
machined faces. If the baseplate is without centered in the driver feet holes. If not, re-center
machined coplanar mounting surfaces, the pump the fasteners and perform a preliminary alignment
and motor are to be left on the baseplate. The to the above tolerances by shimming under the
proper surfaces to reference when leveling the motor for vertical alignment, and by moving the
pump baseplate assembly are the pump suction pump for horizontal alignment.
Page 15 of 48
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j) 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. After the grout has shims [109A] between the foot piece and the
cured, check for voids and repair them. bearing housing.
Jackscrews, shims and wedges should be Mark 3 design (old)
removed from under the baseplate at this time. If If an adjustment is necessary, the adjuster nut
they were to be left in place, they could rust, [6570.4B] is used to move the footpiece up or
swell, and cause distortion in the baseplate. down.
k) Run piping to the suction and discharge of the
pump. There should be no piping loads Figure 4-6
transmitted to the pump after connection is made.
Recheck the alignment to verify that there are no
significant loads.
4.5 Initial alignment

4.5.1 Horizontal initial alignment procedure
The purpose of factory alignment is to ensure that the
user will have full utilization of the clearance in the
motor holes for final job-site alignment. To achieve g) The spacer coupling gap is verified.
this, the factory alignment procedure specifies that h) The parallel and angular vertical alignment is
the pump be aligned in the horizontal plane to the made by shimming under the motor.
motor, with the motor foot bolts centered in the motor i) The motor feet holes are again centered on the
holes. This procedure ensures that there is sufficient motor mounting studs using the centering nut. At
clearance in the motor holes for the customer to field this point the centering nut is removed and
align the motor to the pump, to zero tolerance. This replaced with a standard nut. This gives
philosophy requires that the customer be able to maximum potential mobility for the motor to be
place the base in the same condition as the factory. horizontally moved during final, field alignment.
Thus the factory alignment will be done with the base All four motor feet are tightened down.
sitting in an unrestrained condition on a flat and level j) The pump and motor shafts are then aligned
surface. This standard also emphasizes the need to horizontally, both parallel and angular, by moving
ensure the shaft spacing is adequate to accept the the pump to the fixed motor. The pump feet are
specified coupling spacer. tightened down.
k) Both horizontal and vertical alignment is again
The factory alignment procedure is summarized final checked as is the coupling spacer gap.
below:
a) The baseplate is placed on a flat and level See section 4.8, Final shaft alignment.
workbench in a free and unstressed position.
b) The baseplate is leveled as necessary. Leveling 4.6 Piping
is accomplished by placing shims under the rails
of the base at the appropriate anchor bolt hole Protective covers are fitted to both the
locations. Levelness is checked in both the suction and discharge flanges of the casing and must
longitudinal and lateral directions. be removed prior to connecting the pump to any pipes.
c) The motor and appropriate motor mounting
hardware is placed on the baseplate and the 4.6.1 Suction and discharge piping
motor is checked for any planar soft-foot All piping must be independently supported, accurately
condition. If any is present it is eliminated by aligned and preferably connected to the pump by a
shimming. short length of flexible piping. The pump should not
d) The motor feet holes are centered on the motor have to support the weight of the pipe or compensate
mounting fasteners. This is done by using a for misalignment. It should be possible to install suction
centering nut as shown in figure 4-6. and discharge bolts through mating flanges without
e) The motor is fastened in place by tightening the pulling or prying either of the flanges. All piping must be
nuts on two diagonal motor mounting studs. tight. Pumps may air-bind if air is allowed to leak into
f) The pump is put onto the baseplate and leveled. the piping. If the pump flange(s) have tapped holes,
The foot piece under the bearing housing is select flange fasteners with thread engagement at least
adjustable. It is used to level the pump, if necessary.
Page 16 of 48
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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.
Therefore it is essential that both suction and discharge
4.6.2 Suction piping lines be supported independently of the pump and that
To avoid NPSH and suction problems, suction piping a flexible coupling or expansion joint be installed at
must be at least as large as the pump suction some point in the suction and discharge lines. Do not
connection. Never use pipe or fittings on the suction mount expansion joints so that their force, due to
that are smaller in diameter than the pump suction size. internal pressure, acts on the pump flange. Bellows tie
Figure 4-9 illustrates the ideal piping configuration with a rods may be required. Figures 4-9 and 4-10 show
minimum of 10 pipe diameters between the source and typical arrangements.
the pump suction. In most cases, horizontal reducers
should be eccentric and mounted with the flat side up as Figure 4-9
shown in figure 4-10 with a maximum of one pipe size
Fixed axial supports
reduction. Never mount eccentric reducers with the flat must be designed to
side down. Horizontally mounted concentric reducers resist the collapsing
should not be used if there is any possibility of entrained forces of the expansion Short spools for
air in the process fluid. Vertically mounted concentric joint selected and to axial support
permit adjustment to
reducers are acceptable. In applications where the fluid pump flanges without
is completely de-aerated and free of any vapor or loading or creating Expansion
suspended solids, concentric reducers are preferable to forces on flanges joint
eccentric reducers.
Figure 4-7 Figure 4-8
Figure 4-10
PTFE flexible
Avoid the use of throttling valves and strainers in the coupling or
expansion joint, such
suction line. Start up strainers must be removed shortly as Resistoflex Fixed Support to
before start up. When the pump is installed below the Coupling R6904, prevent vertical
source of supply, a valve should be installed in the Resistoflex movement of
suction line to isolate the pump and permit pump Expansion Joint discharge piping
R6905 or equivalent
inspection and maintenance. However, never place a
valve directly on the suction nozzle of the pump.
Refer to the Durco Pump Engineering Manual and

the Centrifugal Pump IOM Section of the Hydraulic
Institute Standards for additional recommendations
on suction piping. (See section 10.)
Refer to section 3.4 for performance and operating 4.6.5 Pump and shaft alignment check
limits. After connecting the piping, rotate the pump drive
shaft clockwise (viewed from motor end) by hand
4.6.3 Discharge piping several complete revolutions to be sure there is no
Install a valve in the discharge line. This valve is binding and that all parts are free. Recheck shaft
required for regulating flow and/or to isolate the pump alignment (see section 4.5). If piping caused unit to
for inspection and maintenance. be out of alignment, correct piping to relieve strain on
the pump.
When fluid velocity in the pipe is high,
for example, 3 m/s (10 ft/sec) or higher, a rapidly
closing discharge valve can cause a damaging
pressure surge. A dampening arrangement should
be provided in the piping.
Page 17 of 48
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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. Specific order requirements may specify
that the seal be shipped separately, or none be Grease lubrication, when compatible with the liquid being
supplied. It is the pump installer’s responsibility to pumped, may be used. Again, introduced into tap 5.
determine if a seal was installed. If a seal was
supplied but not installed, the seal and installation In non-abrasive applications the liquid being pumped
instructions will be shipped with the pump. may be sufficient to lubricate the packing without
need for external lines. Tap 5 should be plugged.
Failure to ensure that a seal is installed
may result in serious leakage of the pumped fluid. 4.6.6.3b Abrasive packing arrangement
The installation procedures are the same as the
Seal and seal support system must be installed and standard packing with some exceptions. A special lip
operational as specified by the seal manufacturer. seal is installed first, followed by two seal cage
assemblies, then two of the packing rings provided
The stuffing box/seal chamber/gland may have ports (figure 4-12). A flush line from a clean external
that have been temporarily plugged at the factory to source should be connected via tap 5, in the top of
keep out foreign matter. It is the installer’s the stuffing box.
responsibility to determine if these plugs should be
removed and external piping connected. Refer to the Figure 4-12
seal drawings and or the local Flowserve Tap 5
representative for the proper connections.
4.6.6.2 Packing
When the pump is intended to be equipped with shaft
packing, it is not Flowserve standard practice to
install the packing in the stuffing box prior to
shipment. The packing is shipped with the pump. It Lip Seal
is the pump installer’s responsibility to install the Seal Cage
packing in the stuffing box. Packing
4.6.6.4 Piping connection - bearing housing
Failure to ensure that the packing is cooling system
installed may result in serious leakage of the pumped Make connections as shown below. Liquid at less
fluid. than 32 °C (90 °F) should be supplied at a regulated
flow rate of at least 0.06 l/s (1 US gpm).
4.6.6.3 Piping connection – seal/packing support
system
If the pump has a seal support system

it is mandatory that this system be fully installed and
operational before the pump is started.
Figure 4-13
If packing is used:
4.6.6.3a Packing lubrication 4.6.6.5 Piping connection - Oil mist lubrication
Water, when compatible with the pumpage, should be system
introduced into tap 5 (figure 4-11) at pressure 69 to The piping connections for an oil mist lubrication
103 kPa (10 to 15 lbf/in.2) above the stuffing box system are shown below.
pressure. The gland should be adjusted to give a flow
rate of 20 to 30 drops per minute for clean fluid. For
abrasive applications, the regulated flow rate should
be 0.06 to 0.13 l/s (1 to 2 US gpm)
Page 18 of 48
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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.
If not level, adjust the footpiece as follows:
Mark 3A and ANSI 3 design
Add or delete shims [109A] between the
footpiece and the bearing housing.
Figure 4-14 Mark 3 design
Use the adjuster nut [6570.4B] to adjust the
footpiece up or down.
c) Check initial alignment. If pump and driver have
been remounted or the specifications given below
are not met, perform an initial alignment as
described in section 4.5. This ensures there will
be sufficient clearance between the motor hold
down bolts and motor foot holes to move the
motor into final alignment. The pump and driver
should be within 0.38 mm (0.015 in.) FIM (full
Figure 4-15 indicator movement) parallel, and 0.0025 mm/mm
(0.0025 in./in.) FIM angular.
4.7 Electrical connections Stilt mounted baseplates
If initial alignment cannot be achieved with the
Electrical connections must be made by motor fasteners centered, the baseplate may be
a qualified Electrician in accordance with relevant twisted. Slightly adjust (one turn of the adjusting
local national and international regulations. nut) the stilts at the driver end of the baseplate and
check for alignment to the above tolerances.
It is important to be aware of the EUROPEAN Repeat as necessary while maintaining a level
DIRECTIVE on potentially explosive areas where condition as measured from the pump discharge
compliance with IEC60079-14 is an additional flange.
requirement for making electrical connections. d) Run piping to the suction and discharge to the
pump. There should be no piping loads
It is important to be aware of the EUROPEAN transmitted to the pump after connection is made.
DIRECTIVE on electromagnetic compatibility when Recheck the alignment to verify that there are no
wiring up and installing equipment on site. significant changes.
e) Perform final alignment. Check for soft-foot under
Attention must be paid to ensure that the techniques the driver. An indicator placed on the coupling,
used during wiring/installation do not increase reading in the vertical direction, should not indicate
electromagnetic emissions or decrease the more than 0.05 mm (0.002 in.) movement when
electromagnetic immunity of the equipment, wiring or any driver fastener is loosened. Align the driver
any connected devices. If in any doubt contact first in the vertical direction by shimming
Flowserve for advice. underneath its feet.
f) When satisfactory alignment is obtained the
The motor must be wired up in number of shims in the pack should be minimized.
accordance with the motor manufacturer's It is recommended that no more than five shims be
instructions (normally supplied within the terminal used under any foot. Final horizontal alignment is
box) including any temperature, earth leakage, made by moving the driver. Maximum pump
current and other protective devices as appropriate. reliability is obtained by having near perfect
The identification nameplate should be checked to alignment. Flowserve recommends no more than
ensure the power supply is appropriate. 0.05 mm (0.002 in.) parallel, and 0.0005 mm/mm
(0.0005 in./in.) angular misalignment. (See
See section 5.4, Direction of rotation section 6.8.7.2.)
before connecting the motor to the electrical supply.
Page 19 of 48
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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
is hot. Piping thermal expansion may change the • Support leg cooling for centerline mounting option
alignment. Realign pump as necessary. operational
• Heating/cooling for jacketed casing/cover
4.9 Protection systems operational
• Pump instrumentation is operational
The following protection systems are • Pump is primed
recommended particularly if the pump is installed in a • Rotation of shaft by hand
potentially explosive area or is handling a hazardous
liquid. If in doubt consult Flowserve. As a final step in preparation for operation, it is
important to rotate the shaft by hand to be certain that
If there is any possibility of the system allowing the all rotating parts move freely, and that there are no
pump to run against a closed valve or below foreign objects in the pump casing.
minimum continuous safe flow a protection device
should be installed to ensure the temperature of the
liquid does not rise to an unsafe level.
5.2 Pump lubricants
5.2.1 Oil bath
If there are any circumstances in which the system
Oil bath is available on all product lines with the
can allow the pump to run dry, or start up empty, a
exception of the In-Line pump. The standard bearing
power monitor should be fitted to stop the pump or
housing bearings are oil bath lubricated and are not
prevent it from being started. This is particularly
lubricated by Flowserve. Before operating the pump,
relevant if the pump is handling a flammable liquid.
fill the bearing housing to the center of the oil sight
glass with the proper type oil. (See figure 5-2 for
If leakage of product from the pump or its associated
approximate amount of oil required - do not overfill.)
sealing system can cause a hazard it is
recommended that an appropriate leakage detection
On the Mark 3A design, an optional oil slinger is
system is installed.
available. The oil slinger is not necessary; however,
if used, it provides an advantage by allowing a larger
To prevent excessive surface temperatures at
tolerance in acceptable oil level. Without an oil
bearings it is recommended that temperature or
slinger, the oil level in the bearing housing must be
vibration monitoring is carried out.
maintained at ±3 mm (±1/8 in.) from the center of the
sight glass. The sight glass has a 6 mm (¼ in.) hole
5 COMMISSIONING, STARTUP, in the center of its reflector. The bearing housing oil
OPERATION AND SHUTDOWN level must be within the circumference of the center
hole to ensure adequate lubrication of the bearings.
These operations must be carried
out by fully qualified personnel. See Figure 5-3 for recommended lubricants. DO
NOT USE DETERGENT OILS. The oil must be free
5.1 Pre-commissioning procedure of water, sediment, resin, soaps, acid and fillers of
any kind. It should contain rust and oxidation
5.1.1 Pre start-up checks inhibitors. The proper oil viscosity is determined by
Prior to starting the pump it is essential that the the bearing housing operating temperature as given
following checks be made. These checks are all in figure 5-4.
described in detail in the Maintenance section of this
manual. To add oil to the housing, clean and then remove the
• Pump and motor properly secured to the vent plug [6521] at the top of the bearing housing, pour
baseplate in oil until it is visually half way up in the sight glass
• All fasteners tightened to the correct torque [3856]. Fill the constant level oiler bottle, if used, and
• Coupling guard in place and not rubbing return it to its position. The correct oil level is obtained
• Rotation check, see section 5.4. with the constant level oiler in its lowest position, which
This is absolutely essential results in the oil level being at the top of the oil inlet pipe
• Impeller clearance setting nipple, or half way up in the sight glass window. Oil
must be visible in the bottle at all times.
• Shaft seal properly installed
Page 20 of 48
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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.
is the center of the “bull’s eye” sight glass [3856].
(See figure 5-1.) Figure 5-2: Amount of oil required
Pump Mark 3 Mark 3A
Figure 5-1 Group 2 560 ml (19 fl. oz.) 946 ml (32 fl. oz.)
Figure 5-3a: Recommended lubricants -

Descriptions
Quality mineral oil with rust and oxidation
Mineral
inhibitors. Mobil DTE heavy/medium (or
oil
equivalent)
Royal Purple or Conoco SYNCON (or equivalent).
Synthetic
Some synthetic lubricants require Viton O-rings.
EXXON POLYREX EM (or compatible)
Grease Polyurea base with mineral oil
In many pumping applications lubricating oil becomes
contaminated before it loses its lubricating qualities or
breaks down. For this reason it is recommended that Figure 5-4: Oil viscosity grades
the first oil change take place after approximately 160 Maximum oil ISO viscosity Minimum
hours of operation, at which time, the used oil should be temperature grade viscosity index
examined carefully for contaminants. During the initial Up to 71 °C (160 °F) 46 95
71-80 °C (160-175 °F) 68 95
operating period monitor the bearing housing operating
80-94 °C (175-200 °F) 100 95
temperature. Record the external bearing housing
temperature. See figure 5-5 for maximum acceptable
Figure 5.3b Recommended oil lubricants

Oil Splash lubrication Oil mist lubrication
Centifugal pump
lubrication
Viscosity
32 68 46
mm²/s 40 ºC
Temp. max. ºC (ºF) 65 (149) 80 (176) -
Designation
according to HL/HLP 32 HL/HLP 68 HL/HLP 46
DIN51502 ISO VG
BP Energol HL32 BP Energol HL68 BP Energol HL46
BP
BP Energol HLP32 BP Energol HLP68 BP Energol HLP46
Anstron HL32 Anstron HL68 Anstron HL46
DEA
Anstron HLP32 Anstron HLP68 Anstron HLP46
OLNA 32
Oil companies and lubricants
HYDRELEF 32 TURBELF SA68 TURBELF SA46

Elf
TURBELF 32
ELFOLNA DS32 ELFOLNA DS68 ELFOLNA DS46
TERESSO 32 TERESSO 68 TERESSO 46
Esso
NUTO H32 NUTO H68 NUTO H46
Mobil DTE oil light Mobil DTE oil heavy medium Mobil DTE oil medium
Mobil
Mobil DTE13 Mobil DTE26 Mobil DTE15M
MobilDTE24 Mobil DTE25
Q8 Verdi 32 Q8 Verdi 68 Q8 Verdi 46
Q8
Q8 Haydn 32 Q8 Haydn 68 Q8 Haydn 46
Shell Tellus 32 Shell Tellus 01 C 68 Shell Tellus 01 C 46
Shell
Shell Tellus 37 Shell Tellus 01 68 Shell Tellus 01 46
Rando Oil HD 32 Rando Oil 68 Rando Oil 46
Texaco
Rando Oil HD-AZ-32 Rando Oil HD C-68 Rando Oil HD B-46
Wintershall Wiolan HN32 Wiolan HN68 Wiolan HN46
(BASF Group) Wiolan HS32 Wiolan HS68 Wiolan HS46
Page 21 of 48
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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).
Figure 5-6: Lubrication intervals*

Lubricant Under 71 °C 71-80 °C 80-94 °C
(160 °F) (160-175 °F) (175-200 °F)
Grease 6 months 3 months 1.5 months
Mineral oil 6 months 3 months 1.5 months
Synthetic oil** 18 months 18 months 18 months
* Assuming good maintenance and operation practices, and no
contamination.
** May be increased to 36 months with ANSI 3A™ power end.
*** Bearing Temperatures up to 16°C (30 °F) higher than housing. Figure 5-9: Horizontal lubrication amounts
Housing Initial lube Relubrication
5.2.2 Grease Group 2 inboard
Until grease 3
17 cm (1.0 in. )
3
comes out of plug
5.2.2.1 Regreasable Until grease 3 3
Group 2 outboard 28 cm (1.7 in. )
comes out of plug
3 3 3 3
Group 2 duplex 68 cm (4.1 in. ) 34 cm (2.1 in. )
Single shielded regreasable bearings
When the grease lubrication option is specified,
single shielded bearings, grease fittings and vent pipe
Do not fill the housing with oil when
plugs are installed inboard and outboard.
greased bearings are used. The oil will leach the
grease out of the bearings and the life of the bearings
Figure 5-7: Horizontal pump shield orientation
may be drastically reduced.
5.2.2.1 Grease for life
Double shielded or double sealed bearings

These bearings are packed with grease by the
bearing manufacturer and should not be relubricated.
The replacement interval for these bearings is greatly
Horizontal pump bearings are packed with Exxon affected by their operating temperature and speed.
POLYREX EM grease prior to assembly. For Shielded bearings typically operate cooler.
relubrication, a grease with the same type base
(polyurea) and oil (mineral) should be used. To 5.2.3 Oil mist
regrease, remove the pipe plug from both the inboard The inlet port for all horizontal pumps is the plugged
and outboard bearing location. (See figure 5-9.) ½ in. NPT located at the top of the bearing housing.
After relubricating the bearings three times, it is A vent fitting has been supplied on the bearing carrier
typically recommended that the bearing housing is as well as a plugged ¼ in. NPT bottom drain on the
cleaned out. bearing housing. See section 4.6.6.5, Oil mist
lubrication system. Do not allow oil level to remain
To regrease bearings under coupling above the center of the bearing housing sight glass
guard, stop pump, lock the motor, remove coupling window with purge mist (wet sump) systems.
guard, and then regrease the bearings.
The optional oil slinger must not be used with an oil
mist system.
Page 22 of 48
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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). If the process temperature changes
the impeller clearance must be reset, see section 6.6.
Figure 5-12
Figure 5-10: Impeller clearance settings
Temperature °C (°F) Clearance mm (in.)
5.5 Guarding
< 93 (200) 0.46 ± 0.08 (0.018 ± 0.003)
93 to 121 (200 to 250) 0.53 (0.021) Power must never be applied to the
122 to 149 (251 to 300) 0.61 (0.024)
driver when the coupling guard is not installed.
150 to 176 (301 to 350) 0.69 (0.027)
177 to 204 (351 to 400) 0.76 (0.030)
205 to 232 (401 to 450) 0.84 (0.033)
5.5.1 Clam shell guard - standard
>232 (450) 0.91 (0.036) The standard coupling guard for all Mark 3 pumps is
Notes: the “clam shell” design and is shown in figure 5-13. It
1. Rotation of bearing carrier from center of one lug to center of is hinged at the top and it can be removed by
next results in axial shaft movement of 0.1 mm (0.004 in.). loosening one of the foot bolts and sliding the support
2. Open impeller set to suction cover.
leg out from under the cap screw. Note that the foot
is slotted. The leg can then be rotated upward and
5.4 Direction of rotation half of the guard can be disengaged (unhinged) from
the other. Only one side of the guard needs to be
5.4.1 Rotation check removed. To reassemble simply reverse the above
procedure.
It is absolutely essential that the
rotation of the motor be checked before connecting
the shaft coupling. Incorrect rotation of the pump, for
even a short time, can dislodge and damage the
impeller, casing, shaft and shaft seal. All Mark 3
pumps turn clockwise as viewed from the motor end.
A direction arrow is cast on the front of the casing as
shown in figure 5-11. Make sure the motor rotates in
the same direction. Figure 5-13
Flowserve coupling guards are safety devices intended
to protect workers from inherent dangers of the rotating
pump shaft, motor shaft and coupling. It is intended to
prevent entry of hands, fingers or other body parts into a
point of hazard by reaching through, over, under or
around the guard. No standard coupling guard provides
complete protection from a disintegrating coupling.
Flowserve cannot guarantee their guards will
completely contain an exploding coupling.
Figure 5-11 The coupling guard shown in figure 5-13 conforms to

the USA standard ASME B15.1, “Safety standard for
5.4.2 Coupling installation mechanical power transmission apparatus.”
Flowserve manufacturing facilities worldwide conform
The coupling (figure 5-12) should be to local coupling guard regulations.
installed as advised by the coupling manufacturer.
Pumps are shipped without the spacer installed. If 5.5.2 ClearGuard™ - optional
the spacer has been installed to facilitate alignment, Flowserve offers as an option a ClearGuard™, which
then it must be removed prior to checking rotation. allows you to see the condition of the coupling (see
Remove all protective material from the coupling and figure 5-14). This guard can be used in place of the
shaft before installing the coupling. existing clamshell guard described above. The
Page 23 of 48
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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.
h) Attach the support legs to the baseplate using
the fasteners and washers provided.
i) Install fasteners in the holes provided to secure
the guard flanges together.
5.6 Priming and auxiliary supplies

The Mark 3 HSI centrifugal pump will not move liquid
unless the pump is primed. A pump is said to be
“primed” when the casing and the suction piping are
Figure 5-14 completely filled with liquid. Open discharge valves a
slight amount. This will allow any entrapped air to
5.5.2.1 Trimming and assembly instructions escape and will normally allow the pump to prime, if the
In order to correctly fit the pump/motor configuration, suction source is above the pump. When a condition
each ClearGuard must be trimmed to a specific exists where the suction pressure may drop below the
length. This trimming is done on the motor end of the pump’s capability, it is advisable to add a low-pressure
guard as described below. (See figure 5-15.) control device to shut the pump down when the
pressure drops below a predetermined minimum.
5.7 Starting the pump

a) Open the suction valve to full open position. It is
very important to leave the suction valve open while
the pump is operating. Any throttling or adjusting of
flow must be done through the discharge valve.
Partially closing the suction valve can create
serious NPSH and pump performance problems.
THERMAL SHOCK
Rapid changes in the temperature of the liquid within
the pump can cause thermal shock, which can result
Figure 5-15 in damage or breakage of components and should be
avoided. High Silicon Iron should be heated and
a) Measure minimum distance from the center of cooled at a maximum rate of 55˚C (100˚F) per hour.
mounting hole in the baseplate to the motor at
diameter as shown above. b) Never operate pump with both the
b) Locate a reference center of the slot in the coupling suction and discharge valves closed. This could
guard flange. Transfer measurement from step 1 to cause an explosion.
the guard using this reference center. c) Ensure the pump is primed. (See section 5.6.)
c) Trim the motor end of guard according to the above d) All cooling, heating, and flush lines must be
measurement. Trimming is best done with a band started and regulated.
saw, but most other types of manual or power saws e) Start the driver (typically, the electric motor).
give acceptable results. Care must be taken to f) Slowly open the discharge valve until the desired
ensure that there is no gap larger than 6 mm flow is reached, keeping in mind the minimum
(0.24 in.) between the motor and the coupling guard. continuous flow listed in section 3.4.
d) If motor diameter is smaller than guard g) It is important that the discharge valve
diameter, trim guard so that it extends over the be opened within a short interval after starting the
end of the motor as far as possible. driver. Failure to do this could cause a dangerous
e) Deburr the trimmed end with a file or a sharp build up of heat, and possibly an explosion.
knife. Care must be taken to eliminate all sharp
edges. 5.8 Running or operation
f) Place the bottom and top halves of the
ClearGuard around the coupling. 5.8.1 Minimum continuous flow
g) Install the support legs by inserting and then Minimum continuous stable flow is the lowest flow at
rotating the top flange of the leg through the slot which the pump can operate and still meet the bearing
Page 24 of 48
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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 When using the pump in sub-freezing conditions
recognized that the pump may exceed one or more of where the pump is periodically idle, the pump should
these limits. For example, vibration may exceed the be properly drained or protected with thermal devices
limit set by the ASME standard. The size of the pump, which will keep the liquid in the pump from freezing.
the energy absorbed, and the liquid pumped are some High Silicon Iron pumps are not recommended for
of the considerations in determining the minimum applications below -29 °C (-20 °F).
continuous flow (MCF).
5.9 Stopping and shutdown
The minimum continuous flow (capacity) is established
as a percentage of the best efficiency point (BEP). (See THERMAL SHOCK
section 3.4.4.) Rapid changes in the temperature of the liquid within
the pump can cause thermal shock, which can result
5.8.2 Minimum thermal flow in damage or breakage of components and should be
All Mark 3 pumps also have a minimum thermal flow. avoided. High Silicon Iron should be heated and
This is defined as the minimum flow that will not cooled at a maximum rate of 55˚C (100˚F) per hour.
cause an excessive temperature rise. Minimum
thermal flow is application dependent. 5.9.1 Shutdown considerations
When the pump is being shutdown, the procedure
Do not operate the pump below
should be the reverse of the start-up procedure.
minimum thermal flow, as this could cause an excessive
First, slowly close the discharge valve, shut down the
temperature rise. Contact a Flowserve sales engineer
driver, and then close the suction valve. Remember
for determination of minimum thermal flow.
that closing the suction valve while the pump is
Avoid running a centrifugal pump at drastically reduced running is a safety hazard and could seriously
capacities or with discharge valve closed for extended damage the pump and other equipment.
periods of time. This can cause severe temperature
rise and the liquid in the pump may reach its boiling 5.10 Hydraulic, mechanical and electrical
point. If this occurs, the mechanical seal will be duty
exposed to vapor, with no lubrication, and may score or
seize to the stationary parts. Continued running under 5.10.1 Net positive suction head (NPSH)
these conditions when the suction valve is also closed Net positive suction head - available (NPSHA) is the
can create an explosive condition due to the confined measure of the energy in a liquid above the vapor
vapor at high pressure and temperature. pressure. It is used to determine the likelihood that a
fluid will vaporize in the pump. It is critical because a
Thermostats may be used to safeguard against over centrifugal pump is designed to pump a liquid, not a
heating by shutting down the pump at a predetermined vapor. Vaporization in a pump will result in damage to
temperature. the pump, deterioration of the Total differential head
(TDH), and possibly a complete stopping of pumping.
Safeguards should also be taken against possible
operation with a closed discharge valve, such as
Net positive suction head - required (NPSHR) is the
installing a bypass back to the suction source. The size
decrease of fluid energy between the inlet of the
of the bypass line and the required bypass flow rate is a
pump, and the point of lowest pressure in the pump.
function of the input horsepower and the allowable
This decrease occurs because of friction losses and
temperature rise.
fluid accelerations in the inlet region of the pump and
particularly accelerations as the fluid enters the
5.8.3 Reduced head impeller vanes. The value for NPSHR for the specific
Note that when discharge head drops, the pump’s
pump purchased is given in the pump data sheet, and
flow rate usually increases rapidly. Check motor for
on the pump performance curve.
temperature rise as this may cause overload. If
overloading occurs, throttle the discharge.
For a pump to operate properly the NPSHA must be
greater than the NPSHR. Good practice dictates that
5.8.4 Surging condition
this margin should be at least 1.5 m (5 ft) or 20%,
A rapidly closing discharge valve can cause a
whichever is greater.
damaging pressure surge. A dampening
arrangement should be provided in the piping.
Page 25 of 48
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Ensuring that NPSHA is larger than Oil and grease leaks may make the ground
NPSHR by the suggested margin will greatly enhance slippery. Machine maintenance must always
pump performance and reliability. It will also reduce begin and finish by cleaning the ground and the
the likelihood of cavitation, which can severely exterior of the machine.
damage the pump.
If platforms, stairs and guard rails are required for
5.10.2 Specific gravity (SG) maintenance, they must be placed for easy access to
Pump capacity and total head in meters (feet) of areas where maintenance and inspection are to be
liquid do not change with SG, however pressure carried out. The positioning of these accessories
displayed on a pressure gauge is directly proportional must not limit access or hinder the lifting of the part to
to SG. Power absorbed is also directly proportional be serviced.
to SG. It is therefore important to check that any
change in SG will not overload the pump driver or When air or compressed inert gas is used in the
over pressurize the pump. maintenance process, the operator and anyone in the
vicinity must be careful and have the appropriate
5.10.3 Viscosity protection.
For a given flow rate the total head reduces with
increased viscosity and increases with reduced Do not spray air or compressed inert gas on skin.
viscosity. Also for a given flow rate the power
absorbed increases with the increased viscosity, and Do not direct an air or gas jet towards other people.
reduces with reduced viscosity. It is important that
checks are made with your nearest Flowserve office if Never use air or compressed inert gas to clean
changes in viscosity are planned. clothes.
5.10.4 Pump speed Before working on the pump, take measures to

Changing the pump speed affects flow, total head, prevent the pump from being accidentally started.
power absorbed, NPSHR, noise and vibration levels. Place a warning sign on the starting device:
Flow varies in direct proportion to pump speed. Head "Machine under repair: do not start."
varies as speed ratio squared. Power varies as speed
ratio cubed. If increasing speed it is important to ensure With electric drive equipment, lock the main switch
the maximum pump working pressure is not exceeded, open and withdraw any fuses. Put a warning sign on
the driver is not overloaded, NPSHA > NPSHR and that the fuse box or main switch:
noise and vibration are within local requirements and "Machine under repair: do not connect."
regulations.
Never clean equipment with flammable solvents or
6 MAINTENANCE carbon tetrachloride. Protect yourself against toxic
fumes when using cleaning agents.
It is the plant operator's responsibility to ensure
that all maintenance, inspection and assembly work Refer to the parts list shown in section 8 for item
is carried out by authorized and qualified personnel number references used throughout this section.
who have adequately familiarized themselves with
the subject matter by studying this manual in detail. 6.1 Maintenance schedule
(See also section 1.6.2.)
It is recommended that a maintenance plan and
Any work on the machine must be performed when it schedule be implemented, in accordance with these
is at a standstill. It is imperative that the procedure User Instructions, to include the following:
for shutting down the machine is followed, as a) Any auxiliary systems installed must be monitored,
described in section 5.9. if necessary, to ensure they function correctly.
b) Gland packing must be adjusted correctly to give
On completion of work all guards and safety devices visible leakage and concentric alignment of the
must be re-installed and made operative again. gland follower to prevent excessive temperature
of the packing or follower.
Before restarting the machine, the relevant c) Check for any leaks from gaskets and seals. The
instructions listed in section 5, Commissioning, start correct functioning of the shaft seal must be
up, operation and shut down must be observed. checked regularly.
Page 26 of 48
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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. Please refer to the Flowserve Mark 3
operating range for the pump. Pump Parts Catalog for more information. A copy of
f) Check vibration, noise level and surface this book can be obtained from your local Flowserve
temperature at the bearings to confirm sales engineer or distributor/representative.
satisfactory operation.
g) Check dirt and dust is removed from areas Prior to resizing impellers in high
around close clearances, bearing housings and chrome iron and nickel, please consult your local
motors. Flowserve sales representative.
h) Check coupling alignment and re-align if
necessary 6.2.1 Ordering of spare parts
Flowserve keeps records of all pumps that have been
6.1.1 Preventive maintenance supplied. Spare parts can be ordered from your local
The following sections of this manual give instructions Flowserve sales engineer or from a Flowserve
on how to perform a complete maintenance overhaul. distributor or representative. When ordering spare
However, it is also important to periodically repeat the parts the following information should be supplied:
Pre start-up checks listed in section 5.1. These 1) Pump serial number
checks will help extend pump life as well as the 2) Pump size and type
length of time between major overhauls. 3) Part name – see section 8
4) Part item number – see section 8
6.1.2 Need for maintenance records 5) Material of construction (alloy)
A procedure for keeping accurate maintenance 6) Number of parts required
records is a critical part of any program to improve
pump reliability. There are many variables that can The pump size and serial number can be found on
contribute to pump failures. Often long term and the nameplate located on the bearing housing. See
repetitive problems can only be solved by analyzing figure 3-1.
these variables through pump maintenance records.
6.3 Recommended spares and
6.1.3 Cleanliness consumable items
One of the major causes of pump failure is the Mechanical process fluid seals, bearing housing lip
presence of contaminants in the bearing housing. seals, bearings, shafting, impeller, and gaskets.
This contamination can be in the form of moisture,
dust, dirt and other solid particles such as metal
6.4 Tools required
chips. Contamination can also be harmful to the
A typical range of tools that will be required to
mechanical seal (especially the seal faces) as well as
maintain these pumps is listed below.
other parts of the pump. For example, dirt in the
impeller threads could cause the impeller to not be
Standard hand tools SAE
seated properly against the shaft. This, in turn, could
• Hand wrenches
cause a series of other problems. For these reasons,
it is very important that proper cleanliness be • Socket wrenches
maintained. Some guidelines are listed below. • Allen wrenches
• After draining the oil from the bearing housing, • Soft mallet
periodically send it out for analysis. If it is • Screwdrivers
contaminated, determine the cause and correct.
• The work area should be clean and free from Specialized equipment
dust, dirt, oil, grease etc. • Bearing pullers
• Hands and gloves should be clean. • Bearing induction heaters
• Only clean towels, rags and tools should be • Dial indicators
used. • Spanner wrench
• Flowserve Mark 3 tool kit (see below)
6.2 Spare parts
The decision on what spare parts to stock varies greatly To simplify maintenance, it is recommended that the
depending on many factors such as the criticality of the Flowserve Mark 3 tool kit (shown in figure 6-1) is
application, the time required to buy and receive new used. This tool kit includes a handy impeller wrench,
spares, the erosive/corrosive nature of the application, which simplifies installation and removal of the
Page 27 of 48
®
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.
Figure 6-3
Figure 6-1
6.5 Fastener torques

Figure 6-2: Recommended bolt torques Figure 6-4
Item Description Group 2 non-lubricated
[6570.2] Bearing retainer cap screws
3
⁄16 in. – 6 Nm (4 lbf•ft) Figure 6-5
- duplex bearings
[6570.5] Bearing housing/adapter cap ½ in. – 54 Nm (40 lbf•ft)
screws and nuts
[6570.6] Mechanical seal gland ⅜ in. – 16 Nm (12 lbf•ft)
studs/nuts
[6570.7] Split gland yoke screws/nuts ⅜ in. – 22 Nm (16 lbf•ft)
[6570.1] Casing screws/nuts ⅝ in. – 47 Nm (35 lbf•ft)
[6570.3] Bearing carrier set screws ½ in. – 41 Nm (30 lbf•ft)
[6570.4] Cap screw foot ¾ in. – 217 Nm (160 lbf•ft)
Indicator
[3712] Bearing Locknut 54 +7 / -0 Nm Rotation Equivalent To
Pattern
(40 +5 / -0 lbf•ft) 0.1 mm (0.004 in) Axial
Note: Movement
1. For lubricated or PTFE-coated threads, use 75% of the values
given. Figure 6.6
6.6 Setting impeller clearance and

impeller replacement
A new impeller gasket [4590] must be installed
whenever the impeller has been removed from the
shaft. Impeller clearance settings may be found in
section 5.3. Impeller balancing instruction may be
found in section 6.8.
6.6.1 Installation and clearance setting for front

vane open style impeller
Install the impeller [2200] by screwing it onto the shaft
(use heavy gloves) until it firmly seats against the
shaft shoulder.
Page 28 of 48
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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
Care should be taken in the handling impeller setting would be 0.69 mm (0.027 in.) off the
of high chrome iron impellers. suction cover. Since it is necessary to subtract 0.05
mm (0.002 in.) for the movement caused by
Tighten the impeller with the impeller wrench from the tightening the set screws an adjustment of 0.64 mm
Flowserve Mark 3 tool kit. To do this, grasp the (0.025 in.) is needed. First, turn the bearing carrier
impeller in both hands and, with the impeller wrench clockwise until the impeller comes into light rubbing
handle to the left (viewed from the impeller end of the contact with the suction cover. To determine the
shaft - figure 6-3), spin the impeller forcefully in a number of indicator patterns that you will need to
clockwise direction to impact the impeller wrench rotate the carrier, divide 0.10 into the desired setting;
handle on the work surface to the right (figure 6-4). 0.64 / 0.10 = 6.4 (.025 / 0.004 = 6.3). Rotate the
bearing carrier counter-clockwise 6.5 indicator
Do not attempt to tighten the impeller patterns which will give a clearance of 0.65 mm
on the shaft by hitting the impeller with a hammer or (0.026 in.). Flowserve suggests that a felt tip pen be
any other object or by inserting a pry bar between the used to mark an initial reference point on the bearing
impeller vanes. Serious damage to the impeller may housing and the bearing carrier as shown in figure 6-6.
result from such actions. Then make a second mark on the bearing carrier
indicator patterns clockwise from the initial reference
Like all front vane open style impellers, the Flowserve point. Rotate the bearing carrier counter-clockwise until
open impeller clearance must be set off the front. the second mark on the bearing carrier lines up with the
The suction cover must be installed to accurately set initial reference point mark on the bearing housing.
the impeller clearance. Lastly, uniformly tighten the set screws [6570.3] in
incremental steps up to the final torque value to lock
Attach the suction cover plate to the casing. Now set the bearing carrier in place. The impeller is now set for
the impeller clearance by loosening the set screws an impeller setting of 0.7 mm (0.028 in.) off the
[6570.3] and rotating the bearing carrier [3240] to obtain casing.
the proper clearance. Turn the bearing carrier
clockwise until the impeller comes into light rubbing The above procedure is fairly straightforward when
contact with the suction cover. Rotating the shaft at the doing the final setting of the impeller. However it can
same time will accurately determine this zero setting. be quite laborious when doing the preliminary setting
Now, rotate the bearing carrier counter-clockwise to get in order to establish the location of the mechanical
the proper clearance. Refer to figure 5-10 for the proper seal. For this reason, the following practice is
impeller clearance. recommended. Before the pump is taken out of
service, adjust the impeller until it touches the suction
Rotating the bearing carrier the width of one of the cover and then rotate the bearing carrier until the
indicator patterns cast into the bearing carrier moves the desired impeller clearance is obtained. Identify this
impeller axially 0.1 mm (0.004 in.). (See figure 6-5.) location on the bearing carrier and then rotate the
bearing carrier until the impeller contacts the casing.
Determine how far to rotate the bearing carrier by Record the distance from the desired impeller
dividing the desired impeller clearance by 0.1 mm clearance setting to when the impeller contacts the
(0.004 in.) (one indicator pattern). Tightening the set casing. The pump is now removed and taken to the
screws [6570.3] will cause the impeller to move 0.05 shop for maintenance. When it is time to set the seal,
mm (0.002 in.) away from the suction cover because of the impeller is simply set off the casing by the same
the internal looseness in the bearing carrier threads. distance recorded earlier.
This must be considered when setting the impeller
clearance. Rotate the bearing carrier counter-clockwise The above technique is only applicable if all
the required amount to get the desired clearance to the of the original pump components are reinstalled. If
casing. the casing, suction cover, impeller or shaft is replaced
this method must not be used.
Lastly, uniformly tighten the set screws
[6570.3] in incremental steps up to the final torque
value to lock the bearing carrier in place.
Page 29 of 48
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Unscrew the impeller and remove from the shaft.

6.7 Disassembly Discard the impeller gasket [4590].
6.7.1 Pump removal

a) Before performing any maintenance, disconnect the Do not apply heat to the
driver from its power supply and lock it off line. impeller. If liquid is entrapped in the hub, an
explosion could occur.
Lock out power to driver to prevent
personal injury. The casing [1100] is not directly
b) Close the discharge and suction valves, and attached to the power end. It is only held in
drain all liquid from the pump. place by the impeller and seal. Support the
c) Close all valves on auxiliary equipment and casing until removal is required.
piping, then disconnect all auxiliary piping.
d) Decontaminate the pump as necessary.
If Flowserve Mark 3 pumps

contain dangerous chemicals, it is important to
follow plant safety guidelines to avoid personal
injury or death.
e) Remove the coupling guard. (See section 5.5.)
f) Remove the spacer from the coupling.
g) Remove the suction and discharge flange bolting. Figure 6-7
n) Remove the seal or packing gland nuts [6580.2]
Exercise extreme care as the pump
o) Cartridge type mechanical seal [4200]
casing will contain process fluid. Residual process
(figure 6-7), The spacing clips or tabs should be
fluid should be neutralized or drained as allowed
installed prior to loosening the set screws which
by plant procedures.
attaches the seal to the shaft or removing it from
h) Remove the fasteners holding the bearing
the casing seal chamber. This will ensure that
housing foot and adapter feet to the baseplate.
the proper seal compression is maintained.
i) Move the assembly away from the piping. Discard
p) Remove the casing seal chamber [1100].
the flange gaskets.
q) Component type inside mechanical seal [4200]
The pump assembly is heavy. It is Loosen the set screws on the rotating unit and
important to follow plant safety guidelines when remove it from the shaft (see figure 6-8). Then
lifting it. pull the gland [4120] and stationary seat off the
j) Transport the assembly to the maintenance shop. shaft. Remove the stationary seat from the
gland.
6.7.2 Pump Disassembly Component type outside mechanical seal [4200]
k) Remove the coupling hub from the pump shaft Remove the gland and the stationary seat.
[2100]. Remove the stationary seat from the gland.
l) Remove casing nuts [6580.1] from bolts [6570.1]. Loosen the set screws in the rotating unit and
Removing the clamping ring [1240] and suction remove it from the shaft.
cover [1223]. Discard the cover gasket [4590.1]. Packing [4130] Remove it and the seal cage
m) Using the shaft key [6700], mount the impeller [lantern ring, 4134]. Remove the gland [4120].
wrench from the Flowserve Mark 3 tool kit (figure r) Discard all O-rings, gaskets and packing.
6-1) to the end of the shaft. With the wrench s) If the pump has a hook type sleeve [2400] it can
handle pointing to the left when viewed from the now be removed. Unit now appears as shown in
impeller end, grasp the impeller [2200] firmly with figure 6-9.
both hands (wear heavy gloves). By turning the t) If the power end is oil lubricated, remove the
impeller in the clockwise direction move the drain plug [6469] and drain the oil from the
wrench handle to the 11 o’clock position and then bearing housing [3200].
spin the impeller quickly in a counter-clockwise
direction so that the wrench makes a sudden
impact with a hard surface on the bench. After
several sharp raps, the impeller should be free.
Page 30 of 48
®
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. The bearing carrier assembly with
the shaft and bearings should come free. This unit
will appear as shown in figure 6-11. Further
disassembly is not required unless the bearings are
to be replaced.
Figure 6-8
Figure 6-11
x) Remove the snap ring [2530.1] (see figure 6-12)
Figure 6-9
u) If the pump has lip seals, a deflector [2540] will
be present. Remove it. Figure 6-12
v) Loosen the three set screws [6570.3] on the
bearing carrier [3240]. The bearing carrier must be Pumps equipped with duplex angular
completely unscrewed from the bearing housing. contact bearings use a bearing retainer [2530.2]
instead of the snap ring. Remove the carrier from
Do not pry against the shaft. the bearing.
Mark 3A and ANSI 3A design y) The bearing locknut [3712] and lockwasher
The face of the bearing carrier has three square [6541.1] may now be removed from the shaft
lugs that protrude from the surface. The bearing [2100]. Discard the lockwasher.
carrier is turned by using an open end wrench on z) An arbor or hydraulic press may be used to
one of the square lugs as shown in figure 6-10. remove the bearings [3011 and 3012] from the
Mark 3 design shaft. It is extremely important to apply even
The bearing carrier is turned by using a strap pressure to the inner bearing race only. Never
wrench, with the strap located around the outside apply pressure to the outer race as this exerts
diameter of the carrier face. excess load on the balls and causes damage.
Applying pressure to the outer

race could permanently damage the bearings.
aa) The Mark 3A design has an optional oil slinger

[2540] located between the bearings. If present,
inspect it for damage or looseness. Remove if it
bb) The bearing housing [3200] must be separated from
the bearing housing adapter [1340]. The adapter O-
ring [4610.1] should be discarded.
Figure 6-10 Mark 3A and ANSI 3A design
Page 31 of 48
®
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]. If the yoke is removed, discard the
This is accomplished by removing the hex nuts gasket(s).
[6570.5A] and the cap screws [6570.5].
cc) If lip seals [4310.1] and [4310.2] (see figure 6-13) 6.8 Examination of parts
are used, they should be removed from the
bearing carrier and adapter and discarded. 6.8.1 Cleaning/inspection
All parts should now be thoroughly cleaned and
inspected. New bearings, O-rings, gaskets, and lip
seals should be used. Any parts that show wear or
corrosion should be replaced with new genuine
Flowserve parts.
It is important that only non-flammable,

non-contaminated cleaning fluids are used. These
Figure 6-13 fluids must comply with plant safety and environmental
dd) If the bearing isolators are removed from either guidelines.
the bearing carrier or adapter they must not be
reused, discard appropriately. 6.8.2 Critical measurements and tolerances
ee) If magnetic seals are used, maintain the seals as To maximize reliability of pumps, it is important that
specified by the manufacturer. certain parameters and dimensions are measured
ff) Mark 3 and Mark 3A design and maintained within specified tolerances. It is
Remove the Trico oiler/site gage [3855] important that all parts be checked. Any parts that do
(figure 6-14) and oil level tag (figure 6-15) from the not conform to the specifications should be replaced
bearing housing. with new Flowserve parts.
ANSI 3A design
Remove the site gage [3856] (figure 5-1) and oil 6.8.3 Parameters that should be checked by
level tag (figure 6-15) from the bearing housing. users
Flowserve recommends that the user check the
measurements and tolerances in figure 6-16
whenever pump maintenance is performed. Each of
these measurements is described in more detail on
the following pages.
6.8.4 Additional parameters checked by

Flowserve
The parameters listed below are somewhat more
Figure 6-14 difficult to measure and/or may require specialized
equipment. For this reason, they are not typically
checked by our customers, although they are
monitored by Flowserve during the manufacturing
and/or design process.
6.8.4.1 Shaft and sleeve (if fitted)

Replace if grooved, pitted or worn. Prior to mounting
bearings or installing the shaft into the bearing
housing, check the following parameters.
Diameter/tolerance, under bearings

Figure 6-15 - “Oil level In order to ensure proper fit between the shaft and
must be maintained at center of sight glass” bearings, verify that both the inboard (IB) and
outboard (OB) shaft diameter is consistently within
Save these parts for reuse. the minimum/maximum values shown in figure 6-17.
Page 32 of 48
®
A micrometer should be used to check these outside Figure 6-17

diameter (OD) dimensions on the shaft. Group 2
50.000/49.987
OB Bearing
Figure 6-16 (1.9685/1.9680)
bearing/
Suggested Suggested 50.013/50.003
ASME shaft Shaft
Topic by major and/or mm (in.) (1.9690/1.9686)
B73.1M 0.026T/0.003T
seal provided by Fit
standard (0.0010T/0.0001T)
mm (in.) vendors Flowserve
mm (in.) mm (in.) 50.000/49.987
IB Bearing
Shaft (1.9685/1.9680)
bearing/
Diameter tolerance, n/s 0.005 (0.0002) 50.013/50.003
shaft Shaft
under bearings mm (in.) (1.9690/1.9686)
Impeller 0.026T/0.003T
Fit
Balance See note 1 (0.0010T/0.0001T)
Bearing housing
Diameter (ID) tolerance n/s 0.013 (0.0005) Diameter/tolerance, outside diameter
at bearings
In order to ensure proper fit between bearings and
Power end assembly
Shaft runout 0.05 (0.002) 0.03 (0.001)
the bearing housing, verify that the OD on both the IB
Shaft sleeve runout 0.05 (0.002) 0.05 (0.002) 0.05 (0.002) and OB bearings are consistently within the
Radial deflection - static n/s 0.076 (0.003) 0.05 (0.002) minimum/maximum values shown in figure 6-18. A
Shaft endplay n/s 0.05 (0.002) 0.05 (0.002) micrometer should be used to check these outside
Seal chamber diameter (OD) dimensions on the bearings.
Face squareness to shaft 0.08 (0.003) 0.03 (0.001) 0.08 (0.003)
Register concentricity 0.13 (0.005) 0.13 (0.005)
Complete pump Figure 6-18
Shaft movement caused Group 2
by pipe strain n/s 0.05 (0.002) 0.05 (0.002) 110.000/109.985
Alignment n/s See note 2 OB Bearing
(4.3307/4.3301)
Vibration at bearing housing See note 3 See note 3 bearing/
carrier Carrier 110.007/110.022
n/s = not specified. (4.3310/4.3316)
1. The maximum values of acceptable unbalance are: mm (in.)
0.037L/0.007L
1500 r/min: 40 g·mm/kg (1800 r/min: 0.021 oz-in/lb) of mass. Fit
2900 rpm: 20 g·mm/kg (3600 rpm: 0.011 oz-in/lb) of mass. (0.0015/0.0003L)
Flowserve performs a single plane spin balance on most 110.000/109.985
IB Bearing
impellers. The following impellers are exceptions: 10X8-14, (4.3307/4.3301)
bearing/
10X8-16 and 10X8-16H. On these Flowserve performs a two housing Housing 110.007/110.022
plane dynamic balance, as required by the ASME B73.1M mm (in.) (4.3310/4.3316)
standard. All balancing, whether single or two plane, is 0.037L/0.007L
Fit
performed to the ISO 1940 Grade 6.3 tolerance criteria. (0.0015L/0.0003L)
2. The ASME B73.1M standard does not specify a recommended
level of alignment. Flowserve recommends that the pump and
motor shafts be aligned to within 0.05 mm (0.002 in.) parallel FIM 6.8.4.3 Impeller balancing
(full indicator movement) and 0.0005 mm/mm (0.0005 in./in.) Shaft whip is deflection where the centerline of the
angular FIM. Closer alignment will extend MTBPM. For a impeller is moving around the true axis of the pump.
detailed discussion of this subject see the Alignment section of It is not caused by hydraulic force but rather by an
this manual.
3. The ASME B73.1M, paragraph 5.1.4.
imbalance with the rotating element. Shaft whip is
very hard on the mechanical seal because the faces
6.8.4.2 Bearings must flex with each revolution in order to maintain
It is recommended that bearings not be re-used after contact. To minimize shaft whip it is imperative that
removal from the shaft. Prior to mounting bearings, the impeller is balanced. All impellers manufactured
check the following parameters. by Flowserve are balanced after they are trimmed. If
for any reason, a customer trims an impeller, it must
Diameter/tolerance, inside diameter be re-balanced. See note 1 under figure 6-16
In order to ensure proper fit between bearings and regarding acceptance criteria.
the shaft, verify that the inside diameter (ID) of both
the IB and OB bearing are consistently within the 6.8.4.4 Bearing housing/carrier
minimum/maximum values shown in figure 6-17. An Prior to installing the shaft into the bearing housing,
inside caliper should be used to check these ID check the following parameters.
diameters on the bearings.
Diameter/tolerance, at bearing surface
In order to ensure proper fit between the bearing
housing/carrier and the bearings, verify that the ID of
Page 33 of 48
®
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.
6.8.4.5 Power end

Assembled bearing housing, carrier, bearings, and
shaft.
Deflection
Shaft/shaft sleeve run-out
Shaft endplay
Shaft run-out is the amount the shaft is “out of true”
The maximum amount of axial shaft movement, or
when rotated in the pump. It is measured by
endplay, on a Durco pump should be 0.03 mm
attaching a dial indicator to a stationary part of the
(0.001 in.) and is measured as shown below.
pump so that its contact point indicates the radial
Observe indicator movement while tapping the shaft
movement of the shaft surface as the shaft is rotated
from each end in turn with a soft mallet. Shaft
slowly. If a shaft sleeve is used then shaft sleeve
endplay can cause several problems. It can cause
run-out must be checked. It is analogous to shaft
fretting or wear at the point of contact between the
run-out. Measurement of shaft run-out/shaft sleeve
shaft and the secondary sealing element. It can also
run-out will disclose any out of roundness of the
cause seal overloading or underloading and possibly
shaft, any eccentricity between the shaft and the
chipping of the seal faces. It can also cause the
sleeve, any permanent bend in the shaft, and/or any
faces to separate if significant axial vibration occurs.
eccentricity in the way the shaft or bearings are
mounted in the bearing housing.
Shaft run-out can shorten the life of the bearings and

the mechanical seal. The following diagram shows
how to measure shaft/shaft sleeve run-out. Note that
both ends need to be checked. The run-out should
be 0.025 mm (0.001 in.) FIM or less. Endplay
6.8.4.6 Seal chamber
Assembled power end and rear cover.
Face squareness to shaft

Also referred to as “Seal chamber face run-out.” This
run-out occurs when the seal chamber face is not
perpendicular to the shaft axis. This will cause the
gland to cock, which causes the stationary seat to be
cocked, which causes the seal to wobble. This run-
Runout
out should be less than 0.08 mm (0.003 in) and
should be measured as shown below:
Radial deflection - static
Radial movement of the shaft can be caused by a
loose fit between the shaft and the bearing and/or the
bearing and the housing. This movement is
measured by attempting to displace the shaft
vertically by applying an upward force of
approximately 4.5 kg (10 lb) to the impeller end of the
shaft. While applying this force, the movement of an
indicator is observed as shown in the following
Face squareness
diagram. The movement should be checked at a
point as near as possible to the location of the seal
Register concentricity
faces. A movement of more than 0.05 mm (0.002 in.)
An eccentric seal chamber bore or gland register can
is not acceptable.
interfere with the piloting and centering of the seal
components and alter the hydraulic loading of the
seal faces, resulting in reduction of seal life and
performance. The seal chamber register
Page 34 of 48
®
concentricity should be less than 0.13 mm (0.005 in.).

The diagram below shows how to measure this
concentricity.
Alignment
Concentricity Many companies today are using laser alignment

which is a more sophisticated and accurate
6.8.4.7 Installed pump technique. With this method a laser and sensor
Complete pump installed. measure misalignment. This is fed to a computer
with a graphic display that shows the required
Shaft movement caused by pipe strain adjustment for each of the motor feet.
Pipe strain is any force put on the pump casing by the
piping. Pipe strain should be measured as shown See section 4.8 for recommended final shaft
below. Install the indicators as shown before alignment limits.
attaching the piping to the pump. The suction and
discharge flanges should now be bolted to the piping Vibration analysis
separately while continuously observing the Vibration analysis is a type of condition monitoring
indicators. Indicator movement should not exceed where a pump’s vibration “signature” is monitored on
0.05 mm (0.002 in.). a regular, periodic basis. The primary goal of
vibration analysis is extension on MTBPM. By using
this tool Flowserve can often determine not only the
existence of a problem before it becomes serious, but
also the root cause and possible solution.
Modern vibration analysis equipment not only detects

if a vibration problem exists, but can also suggest the
cause of the problem. On a centrifugal pump, these
causes can include the following: unbalance,
Pipe strain movement misalignment, defective bearings, resonance,
hydraulic forces, cavitation and recirculation. Once
Alignment identified, the problem can be corrected, leading to
Misalignment of the pump and motor shafts can increased MTBPM for the pump.
cause the following problems:
• Failure of the mechanical seal Flowserve does not make vibration analysis
• Failure of the motor and/or pump bearings equipment, however Flowserve strongly urges
customers to work with an equipment supplier or
• Failure of the coupling
consultant to establish an on-going vibration analysis
• Excessive vibration/noise
program. See note 3 under figure 6-19 regarding
acceptance criteria.
The schematics below show the technique for a
typical rim and face alignment using a dial indicator.
It is important that this alignment be done after the 6.9 Assembly of pump and seal
flanges are loaded, and at typical operating
It is important that all pipe threads be
temperatures. If proper alignment cannot be
sealed properly. PTFE tape provides a very reliable
maintained a C-flange motor adapter and/or
seal over a wide range of fluids, but it has a serious
stilt/spring mounting should be considered.
shortcoming if not installed properly. If, during
application to the threads, the tape is wrapped over the
end of the male thread, strings of the tape will be formed
when threaded into the female fitting. These strings can
then tear away and lodge in the piping system.
Page 35 of 48
®
Figure 6-20: Flowserve Mark 3 bearings

Group Type of bearing Inboard single row, Outboard double row, angular Optional outboard
5 5&9 5
deep groove contact, deep groove duplex angular contact
1
2 Oil bath/mist - open 6310-C3 5310-AC3 (AHC3) or 3310-AC3 7310-BECBY
2 6
Regreasable – single shielded 6310-ZC3 5310-AZC3 or 3310-AZC3 NA
3 7
Greased for life - double shielded 6310-2ZC3 5310-A2ZC3 or 3310-A2ZC3 NA
4 7
Sealed for life - double sealed 6310-2RS1C3 5310-A2RSC3 or 3310-A2RS1C3 NA
Notes:
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. The shield protects the bearing from getting too much grease, which would generate heat. The grease
reservoir is initially filled with grease by Flowserve. Lubrication fittings are provided, to allow the customer to periodically replenish the
grease, as recommended by the bearing and/or grease manufacturer.
3. These bearings are shielded on both sides. They come pre-greased by the bearing manufacturer. The user does not need to regrease
these bearings. The shields do not actually contact the bearing race, so no heat is generated.
4. These bearings are sealed on both sides. They come pre-greased by the bearing manufacturer. The user does not need to regrease
these bearings. The seals physically contact and rub against the bearing race, which generates heat. These bearings are not
recommended at speeds above 1750 r/min.
5. The codes shown are SKF codes. Inboard and outboard bearings have the C3, greater than “normal” clearance. These clearances are
recommended by SKF to maximize bearing life.
6. Regreasable - single shielded bearings are not available in the duplex configuration; however, open oil bath-type bearings can be used
for the regreasable configuration. These bearings must be pre-greased during assembly. Lubrication fittings are provided, to allow the
user to periodically replenish the grease, as recommended by the bearing and/or grease manufacturer.
7. Not available.
8. All bearing configurations are supplied only with steel cages
9. SKF - the 5300 and 3300 bearing series are identical and therefore can be used interchangeably.
If this occurs in the seal flush system, small orifices can

become blocked effectively shutting off flow. For this
reason, Flowserve does not recommend the use of
PTFE tape as a thread sealant.
Flowserve has investigated and tested alternate Figure 6-19

sealants and has identified two that provide an 6.9.1.1 Bearing installation
effective seal, have the same chemical resistance as Mounting of bearings on shafts must be done in a
the tape, and will not plug flush systems. These are clean environment. Bearing and power end life can
La-co Slic-Tite and Bakerseal. Both products contain be drastically reduced if even very small foreign
finely ground PTFE particles in an oil based carrier. particles work their way into the bearings. Wear
They are supplied in a paste form which is brushed clean gloves.
onto the male pipe threads. Flowserve recommends
using one of these paste sealants. Bearings should be removed from their protective
packaging only immediately before assembly to limit
Full thread length engagement is required for all exposure to possible contamination. After removing
fasteners. the packaging they should only come in contact with
clean hands, fixtures, tools and work surfaces.
Refer to figure 6-2 for recommended bolt
The chart shown in figure 6-20 gives the SKF part
torques.
numbers for bearings in Flowserve Mark 3 pumps. Note
that the term “inboard bearing” refers to the bearing
6.9.1 Power end assembly
nearest to the casing. “Outboard bearing” refers to the
The Mark 3A design has an optional oil slinger. If the
bearing nearest to the motor. (See figure 6-19.)
slinger was removed during disassembly, install a
new slinger [2540]. (See figure 6-19.) Both bearings have a slight interference
fit which requires that they be pressed on the shaft with
an arbor or hydraulic press. Figure 6-17 identifies the
bearing fits. Even force should be applied to only the
inner race. Never press on the outer race, as the force
will damage the balls and races.
Page 36 of 48
®
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. The
or induction heater. With this approach the bearing outboard bearing, while still hot, is to be
must be quickly positioned on the shaft. positioned against the shaft shoulder.
Duplex angular contact bearings
Never heat the bearings above 110 °C (230 °F). To Duplex angular contact bearings must be
do so will likely cause the bearing fits to permanently mounted back-to-back with the wider thrust sides
change, leading to early failure. of the outer races in contact with each other as
shown in figure 6-22. Only bearings designed for
a) Install the inboard bearing [3011] on the shaft universal mounting should be used. The SKF
[2100]. designation is “BECB”. NTN’s designation is “G”.
Mark 3A and ANSI 3A design
The inboard bearing must be positioned against the A special shaft is required when using
shoulder as shown in figure 6-19. duplex angular contact bearings.)
Mark 3 design
The inboard bearing must be located as shown in
figure 6-21.
Figure 6-21: Bearing position - Mark 3 design
Figure 22
It must be understood that fixtures

and equipment used to press the bearing must be
Mark 3 standard shaft Mark 3 duplex bearing shaft designed so no load is ever transmitted through the
Group A Group A bearing balls. This would damage the bearing.
15 3
2 139 mm (5 /32 in.) 2 129 mm (5 /32 in.)
* Inboard bearing located against shoulder. d) After the bearing has cooled below 38 °C (100 °F)
the bearing should be pressed against the shaft
If the power end is equipped with single shielded shoulder. Figure 6-23 identifies the approximate
regreasable bearings, see figure 5-7 for proper force needed to seat the bearing against the shaft
orientation of the shields shoulder. If a press is not available the locknut
[3712] should be installed immediately after the
b) Install the outboard bearing retaining device onto bearing is placed on the shaft and tightened to
the shaft. ensure the bearing remains in contact with the shaft
Double row bearings shoulder. The locknut should then be retightened
Place the snap ring [2530.1] onto the outboard end repeatedly during the time the bearing is cooling.
of the shaft and slide down to the inboard bearing. Once cool the locknut should be removed.
The proper orientation of the snap ring Figure 6-23
must be assured in this step. The flat side of the Pump Press force Locknut torque
snap ring must face away from the inboard bearing. N (lbf) Nm (lbf·ft)
Duplex angular contact bearings Group 2 11 100 (2 500) 54 +7/-0 (40 +5/-0)
Place the bearing retainer [2530.2] onto the e) Install lockwasher [6541.1] and locknut [3712].
outboard end of the shaft and slide down to the The locknut should be torqued to the value
inboard bearing. shown in figure 6-23. One tang on the
lockwasher must be bent into a corresponding
The proper orientation of the bearing
groove on the locknut.
retainer must be assured in this step. The small
side of the retainer must face away from the
6.9.1.2 Bearing housing seals
inboard bearing.
c) Install the outboard bearing.
Lip seals
Double row bearings
If lip seals were used (see figure 6-13), install new lip
Install the outboard bearing [3012] firmly against
seals in the bearing carrier [3240] and the adapter
the shoulder as shown in figure 6-19. If hot
[1340]. The lip seals [4310.1 and 4310.2] are double lip
Page 37 of 48
®
style, the cavity between these two lips should be 1/2 to housing [3200]. The bearing carrier [3240] should
2
/3 filled with grease. When installing this part, the large be lubricated with oil on the O-rings and threads
metal face on the lip seal must face away from the before installing the assembly into the bearing
bearings. housing. Thread the bearing carrier into the
bearing housing by turning it clockwise to engage
Labyrinth seals the threads. Thread the carrier onto the housing
The following are general installation instructions until the carrier flange is approximately 3 mm (1/8 in.)
regarding the VBXX Inpro seal. Follow the from the housing. Install the set screws [6570.3]
instructions provided with the seal by the loosely.
manufacturer. e) Reinstall any tags, plugs, site gages and oiler.
Mark 3 and Mark 3A design
The elastomer O-ring located on the OD of the seal Install the following items onto the bearing housing;
has been sized to overfill the groove in which it is oil level tag (figure 6-15) and combination Trico
located. When installing the seal into its oiler/site gage [3855], vent/breather [6521] and
corresponding housing, in addition to compressing drain plug [6469].
the O-ring a certain amount of material may shear off. ANSI 3A design
This sheared material should be removed. An arbor Install the following items onto the bearing
press should be used to install the seal. housing; oil level tag (figure 6-15) and site gage
[3855], plug [6521] and magnetic drain plug
Install the inboard seal in the bore of the bearing [6469].
housing adapter with the single expulsion port f) Assemble the bearing housing adapter [1340] to
positioned at the 6 o’clock position. the bearing housing [3200]. Be sure to install a
new O-ring [4610.1].
Install the outboard seal in the bore of the bearing Mark 3A and ANSI 3A design
carrier. There are no orientation issues since this is a Thread the capscrews [6570.5] through the
multiport design seal. adapter and into the tapped holes in the bearing
housing.
Magnetic seals Mark 3 design
Follow the installation instructions provided by the Use the capscrews [6570.5] and hexnuts
manufacturer. [6570.5A]. Orient the bearing housing adapter
with the two holes for capscrews [6570.5] on a
6.9.1.3 Bearing carrier/power end assembly horizontal line.
a) Install new O-rings [4610.2] onto the bearing g) If the pump has lip seals, install the deflector [2540].
carrier. Be sure to use the correct size O-rings. h) If the pump is equipped with a hook type sleeve
(The Mark 3 and Mark 3A bearing carriers use [2400], slip it into place over the impeller end of
different O-rings.) the shaft [2100].
b) Slide the bearing carrier [3240] over the outboard
bearing [3012]. 6.9.2 Wet end assembly
c) Install the outboard bearing retaining device.
Double row bearings Slide the snap ring [2530.1] 6.9.2.1 Split Gland Yoke
in place with its flat side against the outboard Four basic configurations are available. Split Gland
bearing and snap it into its groove in the bearing Yokes are available tapped [4121.1] and un-tapped
carrier. [4121.2]. Gaskets [4590.4] are used for locations
Duplex angular contact bearings where the casing seal chamber has a hole. Spacers
Slide the bearing retainer [2530.2] against the [4590.5] are used when there is no casing seal
outboard bearing and install and tighten the chamber hole.
socket head capscrews [6570.2]. See figure 6-2
for correct torque values.
Never compress the snap ring

unless it is positioned around the shaft and between
the bearings. In this configuration, it is contained
therefore if it should slip off the compression tool it
is unlikely to cause serious injury.
d) The shaft, bearings, and bearing carrier assembly
(figure 6-11) can now be installed into the bearing
Page 38 of 48
®
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. Finally, remove centering clips
hole at top from the seal.
• 1 tapped split gland [4121.1] and 1 gasket
[4590.4] for top 6.9.2.3 Component type mechanical seal
• 1 un-tapped spit gland [4212.2]and 1 gasket Review the seal assembly instructions and drawings
spacer [4590.5] for bottom (seal set dimension) provided by the seal
manufacturer.
Configuration B: Elimination of Tap 5.
• Casing seal chamber [1100] with one chamber In order to properly set a component seal it is
hole at top necessary to first locate the shaft in its final axial
• 1 un-tapped split gland [4121.2] and 1 gasket position. This is accomplished in the following
[4590.4] for top manner.
• 1 un-tapped spit gland [4212.2]and 1 gasket a) Install the casing [1100] to the bearing housing
spacer [4590.5] for bottom and clamp in place.
b) Install and set the impeller [2200] clearance as
Configuration C: Tap 5 (top) and Tap 7 (bottom) outlined in section 6.6. Put blueing on the shaft/
• Casing seal chamber [1100] with 3 chamber sleeve in the area near the face of the casing seal
holes chamber [casing 1100]. Scribe a mark on the
shaft at the face of the seal chamber (figure 6-24).
• 2 tapped split gland [4121.1] and 2 gasket
[4590.4]
Configuration D: No taps
• Casing seal chamber [1100] with no holes
• 2 un-tapped spit gland [4212.2] and 2 gasket
spacer [4590.5]
a) Install gaskets [4590.4] and spacers [4590.5] to

split gland yokes [4121] as required. Figure 6-24
b) Install four gland fasteners [6570.6] through the c) Remove the impeller and seal chamber (casing)
split gland yoke holes. following the instructions given in section 6.7 and
c) Install split gland yoke halves around the casing install a nose cone onto the end of the shaft.
seal chamber [1100].
d) Install fasteners [6570.7], lockwashers [6541.2] Single internal seal installation
and hexnuts [6580.3] finger tight. d) Place the gland [4120] and stationary seat onto
e) Pull assembled split gland yoke against the the shaft until it lightly touches the bearing
casing seal chamber outer lip. Hold in position housing adapter.
while tightening fasteners [6570.7]. e) Install a gland gasket [4590.3] into the gland.
(See figure 6-25.)
6.9.2.2 Cartridge mechanical seals
Review the seal assembly instructions and drawings
provided by the seal manufacturer.
a) Install a nose cone on the end of the shaft and
then slide the cartridge seal [4200] onto the shaft
until it lightly touches the bearing housing [3200]
or adapter [1340]. See figure 6-7.
b) Install the casing [1100] to the bearing housing
adapter and clamp in place. Now install the
cartridge seal gland to the casing seal chamber Figure 6-25
[1100] using screws [6570.6] and nuts [6580.2]. f) Locate the rotary seal unit onto the shaft (or sleeve)
c) Install the impeller [2200] as instructed in section according to the set dimension provided by the seal
6.6. Care should be taken in the handling of high manufacture. Tighten set screws on the seal to
chrome iron impellers. lock the rotating unit to the shaft/sleeve.
g) Install the casing [1100] to the bearing housing
adapter and clamp in place.
Page 39 of 48
®
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
i) Install the impeller [2200] as instructed in section figures 4-11 and 4-12. Always stagger the end
6.6. Care should be taken in the handling of high gaps 90 degrees to ensure a better seal. To speed
chrome iron impellers. Remember that the installation of each ring, have an assistant turn the
impeller clearance is already set. It cannot be pump shaft in one direction. This movement of the
changed at this point without resetting the seal. shaft will tend to draw the rings into the stuffing box.
d) A split gland [4120] is an assembly of two
Single external seal installation matched gland halves that are bolted together.
Carry out steps a) to c), above. Unbolt the gland halves and install the gland
d) Locate the rotary seal unit onto the shaft/sleeve halves around the shaft. Bolt the halves together
according to the set dimension provided by the to form a gland assembly.
seal manufacturer. Tighten set screws on the e) Now install the gland assembly [4120] using
seal to lock the rotating unit to the shaft/sleeve. studs [6570.6] and nuts [6580.2].
e) Attach the gland [4120] and stationary seat onto f) Lightly snug up the gland. Final adjustments must
casing [1100] using studs [6570.6] and nuts be made after the pump has begun operation.
[6580.2] g) Install the impeller [2200] as instructed in section
f) Install the casing [1100] to the bearing housing 6.6. Care should be taken in the handling of high
adapter. chrome iron impellers.
g) Install the impeller [2200] as instructed in section
6.6. Care should be taken in the handling of high One piece Gland installation
chrome iron impellers. Remember that the a) Install the gland [4120] over shaft until it lightly
impeller clearance is already set. It cannot be touches the bearing housing adapter.
changed at this point without resetting the seal. b) Install the casing [1100] to the bearing housing
Double seal installation c) Install and set the impeller [2200] clearance as
Carry out steps a) to c), above. outlined in section 6.6.
d) Place the gland [4120] and stationary seat onto the d) Install the packing rings [4130] and seal cage
shaft until it lightly touches the bearing housing halves [4134] into the stuffing box as shown in
adapter. Install a gland gasket [4590.3] into the figure 4-12. Always stagger the end gaps 90
gland. (See figure 6-25.) degrees to ensure a better seal. To speed
e) Locate the rotary seal unit onto the shaft/sleeve installation of each ring, have an assistant turn the
according to the set dimension provided by the seal pump shaft in one direction. This movement of the
manufacturer. Tighten set screws on the seal to shaft will tend to draw the rings into the stuffing box.
lock the rotating unit to the shaft/sleeve. Install a e) Now attach the gland [4120] to the cover using
stationary seat into the casing seal chamber [1100]. studs [6570.6] and nuts [6580.2].
f) Install the casing [1100] to the bearing housing f) Lightly snug up the gland. Final adjustments must
adapter. be made after the pump has begun operation.
g) Attach the gland/seat to the casing [1100] using g) Install the impeller [2200] as instructed in section
studs [6570.6] and nuts [6580.2]. 6.6. Care should be taken in the handling of high
h) Install the impeller [2200] as instructed in section chrome iron impellers
6.6. Care should be taken in the handling of high
chrome iron impellers. Remember that the 6.9.3 Installation of front cover
impeller clearance is already set. It cannot be a) Install a new cover gasket [4590.1]. The gasket
changed at this point without resetting the seal. material must be overlapped at the joint.
b) Install the front cover [1223] and clamping ring
6.9.2.4 Packing [1240].
c) Uniformly tighten through bolts [6570.1] and nuts
Split gland installation [6580.1].
a) Install the casing [1100] to the bearing housing
b) Install and set the impeller [2200] clearance as
outlined in section 6.6.
Page 40 of 48
®
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.
FAULT SYMPTOM
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
⇓ Excessive noise from wet end
⇓ Excessive noise from power end
⇓
⇓
⇓
⇓
⇓ PROBABLE CAUSES POSSIBLE REMEDIES
Recalculate NPSH available. It must be greater than the NPSH
z z z z Insufficient NPSH. (Noise may not be
required by pump at desired flow. If not, redesign suction piping,
present.)
holding number of elbows and number of planes to a minimum to
avoid adverse flow rotation as it approaches the impeller.
Reduce system head by increasing pipe size and/or reducing
z z z System head greater than anticipated.
number of fittings. Increase impeller diameter. (nb: Increasing
impeller diameter may require use of a larger motor.)
1. Check suction line gaskets and threads for tightness.
z z z Entrained air. Air leak from
2. If vortex formation is observed in suction tank, install vortex
atmosphere on suction side.
breaker.
3. Check for minimum submergence
z z Entrained gas from process. Process generated gases may require larger pumps.
z z Speed too low. Check motor speed against design speed.
After confirming wrong rotation, reverse any two of three leads on
z z z Direction of rotation wrong.
a three phase motor. The pump should be disassembled and
inspected before it is restarted.
Replace with proper diameter impeller. (NOTE: Increasing
z z Impeller too small.
impeller diameter may require use of a larger motor.)
z z Impeller clearance too large. Reset impeller clearance.
Plugged impeller, suction line or 1. Reduce length of fiber when possible.
z z z
casing which may be due to a product 2. Reduce solids in the process fluid when possible.
or large solids. 3. Consider larger pump.
Wet end parts (casing cover, impeller)
z z Replace part or parts.
worn, corroded or missing.
Repeat priming operation, recheck instructions. If pump has run
z z Not properly primed.
dry, disassemble and inspect the pump before operation.
1. Check and reset impeller clearance.
z Impeller rubbing.
2. Check outboard bearing assembly for axial end play.
z z Damaged pump shaft, impeller. Replace damaged parts.
Redesign suction piping, holding the number of elbows and planes
z Abnormal fluid rotation due to
to a minimum to avoid adverse fluid rotation as it approaches the
complex suction piping.
impeller.
1. Work with clean tools in clean surroundings.
z Bearing contamination appearing on
2. Remove all outside dirt from housing before exposing bearings.
the raceways as scoring, pitting,
3. Handle with clean dry hands.
scratching or rusting caused by
4. Treat a used bearing as carefully as a new one.
adverse environment and entrance of
5. Use clean solvent and flushing oil.
abrasive contaminants from
6. Protect disassembled bearing from dirt and moisture.
atmosphere.
7. Keep bearings wrapped in paper or clean cloth while not in use.
8. Clean inside of housing before replacing bearings.
9. Check oil seals and replace as required.
10. Check all plugs and tapped openings to make sure that they
are tight.
Page 41 of 48
®
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
⇓ Excessive noise from wet end
⇓ Excessive noise from power end
⇓
⇓
⇓
⇓
⇓ PROBABLE CAUSES POSSIBLE REMEDIES
Brinelling of bearing identified by
z When mounting the bearing on the drive shaft use a proper size
indentation on the ball races, usually
ring and apply the pressure against the inner ring only. Be sure
caused by incorrectly applied forces
when mounting a bearing to apply the mounting pressure slowly
in assembling the bearing or by shock
and evenly.
loading such as hitting the bearing or
drive shaft with a hammer.
False brinelling of bearing identified 1. Correct the source of vibration.
z
again by either axial or circumferential 2. Where bearings are oil lubricated and employed in units that
indentations usually caused by may be out of service for extended periods, the drive shaft should
vibration of the balls between the be turned over periodically to relubricate all bearing surfaces at
races in a stationary bearing. intervals of one to three months.
Thrust overload on bearing identified
z Follow correct mounting procedures for bearings.
by flaking ball path on one side of the
outer race or in the case of maximum
capacity bearings, may appear as a
spalling of the races in the vicinity of
the loading slot. (Please note:
maximum capacity bearings are not
recommended in Mark 2I pumps.)
These thrust failures are caused by
improper mounting of the bearing or
excessive thrust loads.
Misalignment identified by fracture of
z Handle parts carefully and follow recommended mounting
ball retainer or a wide ball path on the
procedures. Check all parts for proper fit and alignment.
inner race and a narrower cocked ball
path on the outer race. Misalignment
is caused by poor mounting practices
or defective drive shaft. For example,
bearing not square with the centerline
or possibly a bent shaft due to
improper handling.
Bearing damaged by electric arcing 1. Where current shunting through the bearing cannot be
z
identified as electro- etching of both corrected, a shunt in the form of a slip ring assembly should be
inner and outer ring as a pitting or incorporated.
cratering. Electrical arcing is caused 2. Check all wiring, insulation and rotor windings to be sure that
by a static electrical charge they are sound and all connections are properly made.
emanating from belt drives, electrical 3. Where pumps are belt driven, consider the elimination of static
leakage or short circuiting. charges by proper grounding or consider belt material that is less
generative.
Bearing damage due to improper 1. Be sure the lubricant is clean.
z
lubrication, identified by one or more 2. Be sure proper amount of lubricant is used. The constant level
of the following: oiler supplied with Durco pumps will maintain the proper oil level if
1. Abnormal bearing temperature it is installed and operating properly. In the case of greased
rise. lubricated bearings, be sure that there is space adjacent to the
2. A stiff cracked grease appearance. bearing into which it can rid itself of excessive lubricant, otherwise
3. A brown or bluish discoloration of the bearing may overheat and fail prematurely.
the bearing races. 3. Be sure the proper grade of lubricant is used.
Page 42 of 48
®
BLANK
Page 43 of 48
®
8 PARTS LIST AND DRAWINGS
8.1 Mark 3 High Silicon Iron Pump, Group 2
Page 44 of 48
®
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 Flange – Split 4590.2 Gasket – Impeller
1245.2 Flange – Split 4590.3 Gasket – Seat to Gland
1340 Bearing Adapter 4590.4 Gasket – Gland
2100 Shaft 4590.5 Gasket Spacer
2200 Impeller 4610.1 O-ring – Adapter to Bearing Housing
2400 Sleeve – Shaft (optional) 4610.2 O-ring – Bearing Carrier
2530.1 Retainer – Snap Ring 6521 Vent / Plug
2530.2 Retainer – Duplex Bearing 6541.1 Lockwasher – Bearing
2540 Deflector 6541.2 Lockwasher – Spit Gland
2541 Slinger (optional) 6569 Plug – Housing Drain
3011 Bearing – Inboard 6570.1 Fastener – Casing
3013 Bearing – Outboard 6570.2 Fastener – Bearing Retainer
3126.1 Shim – Rear Foot 6570.3 Fastener – Carrier Setscrews
3134 Foot – Bearing Housing 6570.4 Fastener – Foot
3200 Bearing Housing 6570.5 Fastener – Bearing Housing to Adapter
3240 Bearing Carrier 6570.6 Fastener – Gland
3712 Locknut - Bearing 6570.7 Fastener – Spit Gland
3855 Oiler (optional) 6580.1 Hexnut – Casing
3856 Sight Gage – Bearing Housing 6580.2 Hexnut- Gland
4120 Gland 6580.3 Hexnut – Split Gland
4121.1 Split Gland Yoke – Tapped 6700 Key – Drive Shaft
4121.2 Split Gland Yoke – Un-tapped
4130 Packing
Page 45 of 48
®
8.2 General arrangement drawing

The typical general arrangement drawing and any American National Standard for Centrifugal Pumps
specific drawings required by the contract will be sent for Nomenclature, Definitions, Design and Application
to the Purchaser separately unless the contract (ANSI/HI 1.1-1.3)
specifically calls for these to be included into the User Hydraulic Institute, 9 Sylvan Way, Parsippany,
Instructions. If required, copies of other drawings New Jersey 07054-3802.
sent separately to the Purchaser should be obtained
from the Purchaser and retained with these User American National Standard for Vertical Pumps for
Instructions. Nomenclature, Definitions, Design and Application
(ANSI/HI 2.1-2.3)
Hydraulic Institute, 9 Sylvan Way, Parsippany,
9 CERTIFICATION New Jersey 07054-3802.
Certificates, determined from the contract
requirements are provided with these instructions American National Standard for Centrifugal Pumps for
where applicable. Examples are certificates for CE Installation, Operation, and Maintenance (ANSI/HI 1.4)
marking and ATEX marking etc. If required, copies of Hydraulic Institute, 9 Sylvan Way, Parsippany,
other certificates sent separately to the Purchaser New Jersey 07054-3802.
should be obtained from Purchaser for retention with
these User Instructions. Flowserve Durco Pump Parts Catalog.
10 OTHER RELEVANT Flowserve Mark 3 Sales Bulletin.

DOCUMENTATION AND MANUALS
Flowserve Mark 3 Technical Bulletin (P-10-501).
10.1 Supplementary User Instructions
Supplementary instructions such as for a driver, RESP73H Application of ASME B73.1M-1991,
instrumentation, controller, seals, sealant systems etc Specification for Horizontal End Suction Centrifugal
are provided as separate documents in their original Pumps for Chemical Process, Process Industries
format. If further copies of these are required they Practices
should be obtained from the supplier for retention Construction Industry Institute, The University of
with these User Instructions. Texas at Austin, 3208 Red River Street, Suite 300,
Austin, Texas 78705.
10.2 Change notes
If any changes, agreed with Flowserve Pump Pump Handbook
Division, are made to the product after it is supplied, 2nd edition, Igor J. Karassik et al, McGraw-Hill, Inc.,
a record of the details should be maintained with New York, NY, 1986.
these User Instructions.
Centrifugal Pump Sourcebook
John W. Dufour and William E. Nelson,
10.3 Additional sources of information McGraw-Hill, Inc., New York, NY, 1993.
The following are excellent sources for additional
information on Flowserve Mark 3 pumps, and Pumping Manual, 9th edition
centrifugal pumps in general. T.C. Dickenson, Elsevier Advanced Technology,
Kidlington, United Kingdom, 1995.
Pump Engineering Manual
R.E. Syska, J.R. Birk,
Flowserve Corporation, Dayton, Ohio, 1980.
Specification for Horizontal End Suction Centrifugal

Pumps for Chemical Process, ASME B73.1M
The American Society of Mechanical Engineers,
New York, NY.
Specification for Vertical In-Line Centrifugal Pumps

for Chemical Process, ASME B73.2M
The American Society of Mechanical Engineers,
New York, NY.
Page 46 of 48
®
BLANK
Page 47 of 48
®
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 Houston, Texas 77008, USA
Tel +1 972 443 6500 Tel +1 713 803 4434

Toll free 800 728 PUMP (7867) Fax +1 713 803 4497
Fax +1 972 443 6800
Europe, Middle East and Africa Asia Pacific

Flowserve Limited (Pump Division) Flowserve Pte Ltd (Pump Division)
Harley House, 94 Hare Lane 200 Pandan Loop, 06-03/04
Claygate, Esher, Surrey KT10 0RB Pantech 21, Singapore 128388
United Kingdom
Tel +65 775 3003
Tel +44 (0)1372 463 700 Fax +65 779 4607
Fax +44 (0)1372 460 190
Visit our web site at: www.flowserve.com
Your Flowserve factory contact: Your local Flowserve representative:
Flowserve Pump Division

3900 Cook Boulevard
Chesapeake, VA 23323-1626 USA
Telephone +1 757 485 8000
Fax +1 757 485 8149
Flowserve Pumps Limited

PO Box 17, Newark, Notts NG24 3EN
United Kingdom
Telephone (24 hours) +44 (0)1636 494 600

Sales & Admin Fax +44 (0)1636 705 991 To find your local Flowserve representative, please
Repair & Service Fax +44 (0)1636 494 833 use the Sales Support Locator System found at
E.mail [email protected] www.flowserve.com

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Mark 3 High Silicon Iron Pumps

These instructions must be read prior to installing,

CONTENTS 6.8 Examination of parts ..................................... 32

These instructions must always be kept 1.3 Disclaimer

1.6.2 Personnel qualification and training THERMAL SHOCK

immediate area. Note: bearing housings must not be

1.6.4.2 Marking Maximum permitted liquid temperature for pumps

1.6.4.6 Preventing leakage 1.7.2 Safety labels

Pumps with mechanical seal. The pump must

Avoid entrapment of liquid in the pump and associated

Bursting of liquid containing parts due to freezing

Where there is the potential hazard of a loss of a seal

DurcoShieldTM (Splash/Shaft Guard) only:

Typical sound pressure level, dBA, LpA at 1 m reference 20 µPa

2 TRANSPORT AND STORAGE 2.3.1.4 Bare pump

Check any crate, boxes or wrappings for any

Each product has a unique serial number. Check

This packaging will provide protection for up to twelve

After unpacking, protection will be the responsibility of

Figure 3-2: Alloy cross-reference chart

3.4.2 Pressure-temperature ratings 4 INSTALLATION

3.4.3 Suction pressure limits If any of the components of the pump

Refer to the general arrangement drawing for the

4.2 Part assemblies installed, given reasonable care in handling,

Figure 4-2 4.3.3 Stilt and spring mounted baseplates

General instructions for assembling these baseplates

4.3.3.3 Stilt/spring mounted baseplates - motor

j) Grout the baseplate. A non-shrinking grout Mark 3A and ANSI 3A design

4.5 Initial alignment

Figure 4-7 Figure 4-8

Refer to the Durco Pump Engineering Manual and

4.6.6 Auxiliary piping Figure 4-11

If the pump has a seal support system

4.8 Final shaft alignment check

Figure 5-3a: Recommended lubricants -

Figure 5.3b Recommended oil lubricants

HYDRELEF 32 TURBELF SA68 TURBELF SA46

Figure 5-5: Maximum external housing Figure 5-8: Regreasable configuration

The maximum temperature that the

Figure 5-6: Lubrication intervals*

5.2.2.1 Grease for life

Double shielded or double sealed bearings

5.3 Impeller clearance

Figure 5-11 The coupling guard shown in figure 5-13 conforms to

5.6 Priming and auxiliary supplies

5.7 Starting the pump

life, shaft deflection and bearing housing vibration limits

5.10.4 Pump speed Before working on the pump, take measures to

impeller. It also contains “nose cones” which protect

This tool kit can be ordered from your local Flowserve

6.5 Fastener torques

6.6 Setting impeller clearance and

6.6.1 Installation and clearance setting for front

Unscrew the impeller and remove from the shaft.

6.7.1 Pump removal

If Flowserve Mark 3 pumps

w) Because the O-rings [4610.2] will cause some

x) Remove the snap ring [2530.1] (see figure 6-12)

Applying pressure to the outer

aa) The Mark 3A design has an optional oil slinger

It is important that only non-flammable,

6.8.4 Additional parameters checked by

6.8.4.1 Shaft and sleeve (if fitted)