Flowserve HPX Instructions For Installation, Operation And Maintenance

INSTRUCTIONS FOR

INSTALLATION,OPERATION

AND MAINTENANCE

___________________________________________

Centrifugal pumps

Type HPX

CE-HPX-R-FLOW.DOC – rev. 0

Pump Division

Worthington S.r.l.

2

FOREWORD

FLOWSERVE products are the result of more than a century of progressive study and

development. Advanced design, proper selection of materials, and precision construction reflect

this wide experience. FLOWSERVE products will give trouble-free efficient operation with

minimum maintenance and repair.

This instruction book will familiarize management and operating personnel with pertinent details

and proper procedures for the installation, operation and maintenance of one of these products.

Designate below your identification of the equipment for which this book applies.

Unit Size

Identification No.

STUDY THIS INSTRUCTION BOOK

The descriptions and instructions included in this book cover the standard design of the equipment

and any common deviations when possible. This book does not cover all design details and

variations nor does it provide for every possible contingency which may be encountered. When

information can not be found in this book, contact the nearest FLOWSERVE Service Centre.

WARNING

Do not operate this equipment in excess of its rated capacity, speed, pressure and

temperature, nor otherwise than in accordance with the instructions contained in this

Manual.

This equipment has been shop tested and found satisfactory for the conditions for which it

was sold, but its operation in excess of these conditions will subject it to stresses and

strains which it was not designed to withstand.

Failure to heed this warning may result in an accident causing personal injury.

3

TABLE OF CONTENTS

I INTRODUCTION 5

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

1.10

1.11

1.12

1.13

1.14

1.15

1.16

1.17

1.18

1.19

1.20

1.21

1.22

1.23

1.24

1.25

1.26

1.27

1.28

Safety

Installation, Operation and Maintenance Safety Procedures

Installation Safety Procedures

Operation Safety Procedures

Maintenance Safety Procedures

Construction

Parts description

Casing

Impeller

Casing cover

Shaft

Bearing housing

Bearings

Inducer

Coupling/Coupling guards

Baseplate

Check upon arrival

Care during storage

Long term storage

Inspection upon arrival

Storage

Inspection and maintenance

Painting and preservation

Associated equipment

Lifting equipment

To lift unit

To lift driver

To lift complete pump only

II INSTALLATION 15

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

2.10

2.11

2.12

2.13

2.14

2.15

Location

Foundation

Level the baseplate

Method of levelling baseplate using wedges or shims

Grouting

Shaft/Coupling alignment

Types of misalignment

Alignment using the Reverse Alignment method

Alignment using a graph (Reverse Alignment)

Assemble Coupling

Dowel Pump and Driver

Hot Alignment Check

Installation Check List

Piping

- Suction and Discharge Piping

- Bypass Line

Suction Strainer

4

III OPERATION 32

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

3.9

3.10

3.11

3.12

3.13

3.14

3.15

3.16

3.17

3.18

3.19

3.20

3.21

Technical Data

Effects of Specific Gravity

Effect of Viscosity

Changing the Pump Speed

Net Positive Suction Head (NPSH)

Minimum Continuous Stable Flow

Minimum Flow Control

Control Notes

Thermal Control

Pressure and/or Flow Control

Continuous Bypass Control

Operating Precautions

Pre-Operational Checks

Initial Start Up Procedure

Operating Checks

Normal Start Up

Securing the Pump

General Maintenance

Routine Maintenance

Trouble Shooting

Trouble Shooting Chart

IV LUBRICATION 43

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

Preparing Bearing Housing

Inspection

Replenishment

Oil Change

Lubrication Specification

Trico Oiler Setting

Bearing Housing Oil Fill Capacities

Bearing Housing Oil Limitations

V MECHANICAL SEALS 47

5.1

5.2

Description

Servicing Mechanical Seal

VI MAINTENANCE, DISMANTLING 48

6.1

6.2

6.3

Dismantling – General

Pump Disassembly Instructions

Disassembly of Pull Out Element

VII INSPECTION AND RENEWAL OF PARTS 53

7.1

7.2

7.3

7.4

7.5

7.6

7.7

7.8

7.9

7.10

7.11

7.12

General

Wear Rings (Impeller)

Case Wear Ring (and Casing Cover Wear Ring when Fitted)

Mechanical Seal

Throat Bush (If Fitted)

Bearing Handling Information

Bearing handling

Bearing Installation

Bearing Removal

Bearing Cleaning

Assembly

Torque Value Supplement

5

SECTION I

INTRODUCTION

This manual contains instructions for installation, operation and maintenance for your

FLOWSERVE Centrifugal Pump. The instructions are written for the use of personnel with a

general training in the operation and maintenance of Centrifugal Pumps.

Your pump has been designed to provide safe and reliable service. However, it is both a pressure

vessel and a piece of rotating machinery so that operators must exercise good judgement and

observe correct safety practices to avoid damage to the equipment and surroundings and to

prevent personal injury.

The pump has been designed for the duty specified in the customers order. F.P.D should be

consulted prior to any significant change of duty.

1.1 Safety

It is assumed that your safety department has established a safety programme based upon a

thorough analysis of industrial hazards. Before installing and operating or performing maintenance

on the pump and associated components in this manual, it is suggested that the safety

programme be reviewed to ensure that it covers the hazards arising from high speed rotating

machinery.

It is also important that due consideration be given to those hazards which arise from the presence

of electrical power, hot oil, high pressure and temperature liquids, toxic liquids and gases,

flammable liquid and gases. Correct installation and care of protective guards, shut down devices

and over pressure protection equipment should also be considered an essential part of any safety

programme.

Also essential are special precautionary measures to prevent the possibility of applying power to

the equipment at any time when maintenance work is in progress. The prevention of rotation due

to reverse flow should not be overlooked.

In general, all personnel should be guided by all the basic rules of safety associated with the

equipment and the process.

1.2 Installation, Operation and Maintenance Safety Procedures

In the following safety procedures you will encounter the words WARNING, CAUTION and NOTE.

These are intended to emphasize certain areas in the interest of personal and satisfactory pump

operation and maintenance. The definitions are as follows:

WARNING: An operating procedure, practice, etc, which if not correctly followed, could result in

personal injury, or loss of life.

CAUTION: An operating procedure, practice, etc, which, if not correctly observed, could result

in damage to, or destruction of equipment.

NOTE: An operating procedure, etc, which is essential to highlight.

These safety procedures are to be used in conjunction with the installation, operation and

maintenance instructions contained in the pump manual.

6

1.3 Installation Safety Procedures

1. Lifting equipment

Make sure that any equipment used to lift pump or any of its components is capable of supporting

the weights encountered. Make sure that all parts are correctly rigged before attempting to lift.

2. Coupling alignment CAUTION

Coupling alignment must be correct for successful operation. Flexible couplings will not

compensate for any appreciable misalignment, and rapid wear, noise, vibration and actual

damage to the equipment may be caused by misalignment. Therefore, the coupling must be

aligned within the limits given.

3. Driver rotation WARNING

The driver rotation must be checked before making up coupling. Actual damage to the

equipment and personal injury could result from operating the unit with incorrect rotation.

4. Suction and discharge piping

Provisio

n must be made to support suction and discharge piping to the pump to prevent excessive

nozzle loads and maintain pump to driver alignment.

1.4 Operation Safety Procedures

1. Operating conditions WARNING

In the interest of operator safety the unit must not be operated above the nameplate

conditions. such operation could result in unit failure causing injury to operating

personnel. Consult instruction book for correct operation and maintenance of the pump

and its supporting components.

2. Pumps handling heavy viscous liquids CAUTION

When pump is handling heavy viscous liquid, the temperature of the liquid must allow it to

be pumped easily. Liquid may have to be heated prior to pump start-up.

7

3. Pump priming CAUTION

Before starting or while operating the pump, the casing and suction line must be

completely filled with the liquid being pumped. The rotating parts depend on this liquid for

lubrication and the pump may seize if operated without liquid.

4. Pump by pass line CAUTION

When operating for some time at reduced capacity, much of the pump horsepower will go

into the liquid in the form of heat. A by pass must be provided under these conditions to

prevent the liquid in the pump from becoming hot enough to vaporize.

5. Operation at reduced capacity CAUTION

Damage to pump may result from prolonged operations at capacities less than 25% of the

best efficiency point

6. Bearing lubrication WARNING

Operation of the unit without correct lubrication can result in overheating of the bearings,

Bearing failures, pump seizures and actual breakup of the equipment, exposing operating

personnel to injury.

7. Operation inspections WARNING

Do not attempt any maintenance, inspection, repair or cleaning in the vicinity of rotating

equipment. Such action could result in injury to operating personnel.

8. Coupling guards WARNING

The unit must not be operated unless coupling guard is in place. Failure to observe this

warning could result in injury to operating personnel.

1.5 Maintenance safety procedures

1. Tagging for inspection or repair WARNING

Before attempting any inspection or repair on the pump the driver controls must be in the

"off" position, locked and tagged to prevent injury to personnel performing service to the

pump.

8

2. Isolating the pump WARNING

Before attempting to disassemble the pump, the pump must be isolated from the system,

by closing suction and discharge system valves, drained of liquid and cooled, if pump is

handling hot liquid.

3. Draining pump handling hot liquids WARNING

When pump is handling "hot" liquid extreme care must be taken to ensure safety of

personnel when attempting to drain pump. Hot pumps must be allowed to cool before

draining.

4. Draining pump handling caustic liquid WARNING

When pump is handling "caustic" liquid extreme care must be taken to ensure safety of

personnel when attempting to drain the pump. Protective devices of suitable protective

materials must be worn when draining the pump.

It should be understood that the information contained in this manual does not relieve

operating and maintenance personnel of the responsibility of exercising normal good

judgement in operation and care of the pump and its components.

5. Pumps on vacuum service WARNING

Before attempting any maintenance work on pumps in vacuum service, the pumps must be

isolated from suction and discharge system then carefully vented to return pressure in

pump casing to atmospheric pressure.

6. Oil ring inspection (where applicable) CAUTION

Remove the pipe plug(s) from the top of the bearing housing(s) and check to see that oil

rings are riding free on the pump shaft and are not hung up. Failure to observe this caution

could result in damage to or destruction of equipment.

9

1.6 Construction

1.7 Parts description

The type 'HPX' are horizontally mounted, vertically split, back pull out single stage, single suction

overhung process pumps, constructed to the requirements of API 610 specifications, for

continuous duty service in all process industries and industrial application within the pressure and

temperature limitations.

1.8 Casing

The casing is centre line supported with end suction and top discharge. It provides for the

immediate containment of liquid being pumped as the liquid is directed from the suction nozzle

through the impeller and then through the volute to the discharge nozzle. The casing also provides

the centre line attachment to the baseplate or support. A wear ring is mounted in the casing to

provide a close running clearance with the impeller wear ring.

1.9 Impeller

The impeller is a single suction, radial flow, closed design. The impeller is dynamically balanced,

keyed to the shaft and secured by locknut and lockscrew. Renewable wear rings are a press fit

onto the impeller hub and positively secured with radial screws.

1.10 Casing cover

The casing cover is designed to accommodate single, tandem or double elastomer and metal

bellow cartridge seals to the dimensional requirements of API 682. On certain models a wear ring

may be mounted in the cover to provide a close running clearance with the impeller back wear

ring.

1.11 Shaft

A high strength shaft is of stiff shaft design, machined over its entire length to close tolerances.

The shaft transmits the required power without vibration.

1.12 Bearing housing

The bearing housing is air cooled with fan type flingers provided at inboard and outboard ends.

The bearing housing contains the thrust and radial bearings and, for other than pure mist type

lubrication, serves as the oil reservoir for the bearing lubricating oil. For other than pure mist

applications, a constant level oiler is provided for maintaining required oil level. Labyrinth type

flingers help to seal the bearing housing to prevent contamination of the lubricating oil.

A finned type cooling insert is available as an option for the cooling of the lubricating oil. Provision

for purge oil mist is standard whilst pure oil mist lubrication is optional.

10

1.13 Bearings

Heavy duty, single row radial bearing and duplex angular contact thrust bearings arranged back to

back ensure long life under the most severe operating conditions. The bearings are a sliding fit in

the bearing housing and a light interference fit on the shaft in accordance with AFBMA

recommendations.

Lubrication of the bearings is provided by oil rings, thrower, purge mist or pure mist as a customer

option.

1.14 Inducer

Inducers are available on most pump models for low NPSH conditions. The inducer replaces the

standard impeller locknut and lockscrew. It is secured by proper cap nut and security washer.

1.15 Coupling/Coupling guards

Flexible spacer couplings are provided in various makes and models to suit customer preference.

(Fabricated heavy gauge sheet metal, or aluminium hinged or non- hinged guards are provided)

1.16 Baseplate

Standard baseplates are welded steel, drain pan type in conformance with API 610 standardized

dimensions, forces and moments. Horizontal driver alignment screws and vertical baseplate

levelling screws are provided as an option.

Special baseplates can be supplied to suit individual installation circumstances.

1.17 Check upon arrival

Your pump was carefully checked at the factory prior to shipment to assure its meeting the

requirements of your order.

It is suggested that the pump be inspected upon arrival and that any irregularities arising due to

shipping be reported immediately to the carrier and FLOWSERVE

1.18 Care During Storage

If the equipment is not to be installed immediately it should be stored in a clean, dry, vibration free

area and covered. Add "disessicant" between the covering and the pump.

Replace nozzle covers. Turn rotor in direction of rotation once a week.

Secure coverings after each check.

Electric Motors (Pump Driver) should not be stored in damp places without special protection

(Refer to Motor manufacturers instructions).

11

1.19 Long term storage

General

During extended periods of storage prior to installation, precautions must be taken to protect the

pump from deterioration. The various parts of the pump are protected prior to shipment by

applying varying grades of preservative to the parts. However, during shipment and handling the

preservatives are subjected to conditions that can cause their removal. Also, during extended

periods of time the preservatives may deteriorate. The listed procedures should be followed to

prevent deterioration of the pump during the extended storage period. These procedures may also

be supplemented by the experience of the person(s) performing the tasks.

1.20 Inspection upon arrival

When the pump is received it should be inspected for damage or other signs of rough handling. If

any damage is found it should be reported to the carrier immediately.

Inspect the preservative coating on various parts. If necessary, renew preservative in areas where

it has been rubbed or scraped.

Inspect all painted surfaces. If necessary, touch up the areas where paint has been chipped or

scraped.

Inspect all covers over pump openings and piping connections. If covers or seals for the covers

are damaged or loose, they are to be removed, and a visual inspection made of the accessible

interior areas for accumulation of foreign materials or water. If necessary, clean and preserve the

interior parts as noted above to restore the parts to the "as shipped" condition. Install or replace

covers and fasten securely.

1.21 Storage

If at all possible, the pump and its component parts should be stored indoors where they will be

protected from the elements. In no case should any pump element be subjected to extended

periods of submergence or wetting prior to start up. If it is not possible to store the pump and its

components indoors, precautions must be taken to protect them from the elements. Regardless of

whether storage is indoors or outside, the storage area should be vibration free. All boxes marked

for indoor storage should be stored indoors. When stored outdoors the pump and its components

should be protected from dirt, dust, rain, snow, or other unfavourable conditions by heavy plastic

sheets, canvas, waterproof burlap or other suitable coverings.

All equipment must be placed upon skids or blocks to prevent contact with the ground and surface

contaminants. Equipment must be adequately supported to prevent distortion and bending.

The pump shaft should be rotated, in the direction of rotation, at least 11/4 turns each week during

the storage period and any other periods of stand by.

When selecting a storage area the following should be taken into

consideration.

1. The deterioration of the equipment will be proportionate to the class of storage provided.

2. The expenses involved in restoring the equipment at time of installation will be proportionate

to the class of storage provided.

12

1.22 Inspection and maintenance

The stored equipment is to be placed on a periodic inspection schedule by the purchaser.

The responsibility for setting up an inspection schedule rests with the purchaser and will be

dependent upon the class of storage provided. It would be expected initially, inspection would

occur weekly, then depending upon the inspection reports being favourable or unfavourable,

inspection would continue weekly, monthly, or quarterly, as may be determined.

Each inspection should consist of a general surface inspection to assure that:

1. Pump supports are firmly in place.

2. Pump covers over openings are firmly in place.

3. Pump coverings, plastic or tarps are firmly in place. Any holes or tears must be repaired to

prevent entrance of dirt or water.

4. Pump covers are periodically removed from openings and interior accessible areas

inspected. If surface rusting has occurred, clean or coat with preservative.

5. If rusting occurs on exterior surfaces clean and repaint or coat with preservative.

6. Check individually wrapped parts for signs of deterioration. If necessary, renew preservative

and wrapping.

Six months prior to the scheduled installation date, an FLOWSERVE representative is to be

employed to conduct an inspection. This inspection may include, not necessarily in its entirety and

not limited to the following:

1. An inspection of all periodic inspection records as kept on file by the purchaser, and all

inspection reports that have been compiled during the storage period.

2. An inspection of the storage area to determine the "as stored" condition of the equipment

prior to any protection covers being removed.

3. An inspection of the equipment with protective covers and flange covers removed.

4. Depending upon the length of time the equipment was stored, the type of storage provided

(i.e. Indoor: heated, unheated, ground floor, concrete floor. Outdoors: under roof, no roof,

waterproof coverings, on concrete, on ground) and as a result of the inspection of 1,2 & 3

above the FLOWSERVE representative may require a partial or complete dismantling of the

equipment.

5. Dismantling may necessitate restoration of painted or preserved surfaces, and, or

replacement of gaskets, "O" rings, packing and bearings.

6. All costs involved during inspection, dismantling, restoration, replacement of parts and

reassembly will be to the account of the purchaser. All necessary labour, tools and cranes

will be supplied by the purchaser.

13

Upon completion of the inspection the FLOWSERVE representative shall submit a report to the

purchaser, and to the Manager of Customer Service, stating in detail the results of the inspection.

One month prior to installation of the equipment, an FLOWSERVE representative is to be

employed to conduct a final inspection. This inspection will be made to assure that the

requirements of the six months inspection report were satisfactorily completed and that the

equipment is ready for installation.

Upon completion of this inspection the FLOWSERVE representative shall submit a final report to

the purchaser, and to the Manager of Customer Service, advising the results of the final

inspection.

All costs involved in conducting the final inspection will be to the account of the purchaser.

Prior to and during start up, any requirements for the services of an FLOWSERVE representative

will revert back to the original contract agreement for equipment purchased, with revised costing.

1.23 Painting and preservation

Paints and preservatives used are either FLOWSERVE standard or 'special' as required by the

contract specification. Refer to your branch office through which the order was placed, or

FLOWSERVE for the description of paints and preservatives used on this order.

1.24 Associated equipment

Motors, Turbines, Gears, etc., being supplied by FLOWSERVE.

Generally rotors of associated equipment should be blocked to relieve bearing loads. Storage

should be indoors and dry. See the specific manufacturers storage requirements.

1.25 Lifting equipment

WARNING

Make sure that any equipment used to lift the pump or any of its components is capable of

supporting the weights encountered. Make sure that all parts are correctly rigged before

attempting to lift.

1.26 To Lift unit

Pump, driver and baseplate can be lifted as a unit. Sling from all four (4) eye bolts provided on

baseplate side rails. Failure to use all four (4) could result in permanent distortion of the baseplate.

Use as long a sling as possible, or use a spreader arrangement.

WARNING

Coupling bolting and spacer piece must be removed from between pump and driver half

couplings before lifting baseplate with pumping element.

To lift pump and baseplate, less driver, or baseplate alone, sling from all four (4) eye bolts.

14

WARNING

Do not lift pump, motor, baseplate unit by slinging from pump casing and/or eye bolt on

motor.

1.27 To lift driver

Refer to Manufacturers Instructions.

1.28 To lift complete pump only

Rig lifting straps at coupling end of bearing housing and at stuffing box extension. Make sure

straps are adjusted to obtain an even lift.

15

SECTION II

INSTALLATION

2.1 Location

Install the unit close to the source of the liquid to be pumped.

It is desired to have a straight length of suction pipe (approx. 8 to 10 times the pipe diameter) just

upstream of suction nozzle (No double turns).

When selecting the location, be sure to allow adequate space for operation as well as for

maintenance operations involving dismantling and inspections of parts.

Head room is an important consideration as an overhead lift of some type is required.

2.2 Foundation

The foundation should be sufficiently rigid and substantial to prevent any pump vibration and to

permanently support the baseplate at all points.

The most satisfactory foundations are made of reinforced concrete. These should be poured well

in advance of the installation to allow sufficient time for drying and curing.

The General Arrangement Drawing (In the last section of this manual) will furnish anchor bolt

locations, size of bolts, etc. See Figure 1 below.

GROUTING UNDER BASEPLATE

MAKE THIS DISTANCE

EQUAL TO LUG ON BASEPLATE

TEMPLATE FOR HANGING FOUNDATION BOLTS

BOLT

PIPE

WASHER

ALLOW BOLTS TO PROJECT FOR

Figure 1

Figure 2 below illustrates a recommended foundation bolt arrangement which can be used in lieu

of standard foundation bolts. Notice the large washer with lugs at the bottom. It should be welded

to the bolt and pipe sleeve to prevent turning.

Allow a little more than the specified threaded bolt length above the rail of the baseplate. The

excess can always be cut off if it is not needed.

A rough finish top surface is best when applying grout.

16

ALLOW AMPLE THREADED

BOLT LENGTH ABOVE

ROUGH CONCRETE

STUFF WASTE AROUND

BOLT WHILE POURING

CONCRETE

PIPE SLEEVE TO BE

THREE TIMES DIAMETER

OF ANCHOR BOLT

ROUGH FINISH

FOR GROUT

WELD A LARGE WASHER

WITH LUGS TO THE

BOTTOM OF BOLT

AND PIPE SLEEVE TO

PREVENT TURNING

Fig. 2 Arrangement of foundation bolt in foundation

2.3 Level the baseplate

Before putting the unit on the foundation, thoroughly clean the top of the foundation. Break off any

loose pieces of cement and roughen the top with a chisel to afford a good hold for grout.

NOTE

Coupling bolting and spacer piece must be removed from between the pump and driver half

couplings before lifting baseplate with pumping element

NOTE

When lifting baseplate with pumping element, sling baseplate from all lifting eyes provided.

Refer to Section 1.26.

Prepare sufficient steel plates to be placed below each baseplate jacking screw furnished with the

baseplate. The purpose of the plate is to spread the load of the screw without crushing the

concrete below.

17

Figure 3

2.4 Method of levelling baseplate using wedges or shims

Level the baseplate by using a machinist's level on the machined surfaces of the pump and driver

pads. Levelling is best achieved by adjusting the shim pack thickness under each holding bolt.

Carefully raise the baseplate by using either the baseplate jacking screws provided or by levering

with a suitable pinch bar or by installing a low level hydraulic jack.

Adjust the shim pack thickness and lower the baseplate.

Repeat this procedure in a logical manner at each bolt position until the baseplate is both straight

and level. A degree of 0.0035 inch per foot (.25mm per metre) length is achievable on most units

with a maximum of 0.005 inch per foot. (.40mm per metre length).

When the baseplate is level, pull down the foundation bolts so they are snug. This may have

disturbed the baseplate, so re-check the levels.

Ensure that shaft alignment per Section 2.6 can be achieved prior to grouting the baseplate.

18

2.5 Grouting

Build a dam around the foundation as shown in Figure 4 after levelling the baseplate. It is a matter

of personal preference whether the levelling wedges under the baseplate should be removed after

grouting. If you do not want to remove the wedges, carefully mark their locations before pouring

grout.

CAUTION

Before grouting, level machined pads of baseplate in both directions and perform a rough

shaft/coupling alignment. Alignment after grout has set will not be possible if above is not

satisfactorily completed.

GROUTING 1 TO 2

INCHES DEEP

CONCRETE

LEAVE TOP OF

FOUNDATION ROUGH

DO NOT FINISH

WITH TROWEL

FINISHED GROUT

DAM

Figure 4

Use a good, high strength, non shrink grout mix and install as per manufacturer's instructions.

Holes are provided in the baseplate to permit pouring the grout and stirring while acting as air

vents. Fill under the baseplate completely, stirring to assure correct distribution of the grout. Check

to see that the grout flows under the edges of the baseplate evenly.

NOTE

Do not vibrate baseplate when grouting, making sure baseplate is vented correctly and all areas

are thoroughly puddled to prevent any reasonant problems.

When the grout is thoroughly hardened, remove the dam and wedges, if desired, filling in the

holes they leave with grout.

NOTE

Pour grout until level reaches top of dam. Allow to dry sufficiently to prevent grout from overflowing

while completing the remaining grouting.

19

2.6 Shaft/Coupling alignment

CAUTION

Shaft alignment must be correct for successful operation. Rapid wear, noise, vibration and

actual damage to the equipment may be caused by shaft misalignment. The shafts must be

aligned within the limits given within this section.

NOTE

Adjustment to correct the alignment in one direction may alter the alignment in another direction.

Always check in all directions after making any adjustment.

Coupled equipment must be aligned to minimize unnecessary stresses in shafts, bearings and

coupling. Flexible couplings will not compensate for appreciable misalignment. Foundation settling,

thermal expansion or nozzle loads resulting in baseplate/foundation deflection and vibration during

operation may require the full coupling misalignment capability.

2.7 Types of misalignment

There are two types of shaft misalignment: angular and offset. Therefore, two sets of

measurements and corrections are required. Both types of misalignment can occur in horizontal

and vertical planes and are present in most applications.

A. Angular misalignment

In angular misalignment, the centre line of the shafts intersect, but are not on the same axis.

ANGULAR MISALIGNMENT

20

B. Offset misalignment

OFFSET MISALIGNMENT

COMBINATION OFFSET

AND

ANGULAR MISALIGNMENT

In offset misalignment, the shaft centre lines are parallel but do not intersect.

2.8 Alignment using the Reverse Alignment Method

The following practices are recommended when using the reverse method of alignment. These

should be carried out prior to main alignment.

CHECK FOR SOFT FOOT

This is a check to ensure that there is no undue

stress on the driver holding down bolts; owing

to non-level baseplate or twisting

To check, remove all shims and clean surfaces

and tighten down driver to the baseplate. Set a

dial indicator as shown in sketch and loosen off

the holding down bolt while noting any deflection

reading on the Dial Test Indicator - a maximum

of 0.05 mm (0.002”) is considered acceptable

but any more will have to be corrected by adding

shims, for example, if the Dial Test Indicator

shows the foot

lifting 0.15 mm (0.006") then this is the

thickness of shim to be placed under that foot.

Tighten down and repeat the same procedure

on all other feet until all are within tolerance.

NOTE

If the driver is an electric motor with sleeve bearings then the magnetic centre at which the rotor

will run must be set. This is usually done by lining up a groove in the shaft to a pointer fixed to the

motor body (refer to Motor Manufacture’s instructions).

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Flowserve HPX Instructions For Installation, Operation And Maintenance

Flowserve HPX Instructions For Installation, Operation And Maintenance

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