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Pump Division

I.O.M.
Installation,
Operation and
Maintenance

Durco Mark III


Alloy Pumps
ANSI Standard
Sealmatic
Unitized Self-Priming
Recessed Impeller
Lo-Flo

Bulletin P-10-502e (E)

Pump Division

TABLE OF CONTENTS
1.0 Introduction .....................................................................1
2.0 Safety considerations .....................................................2
3.0 Overview
3.1 Warranty statement................................................4
3.2 Nameplate ..............................................................4
3.3 Storage
Short term..............................................................4
Long term ..............................................................5
3.4 Lifting pumps and assemblies................................5
4.0 Mark III ANSI Standard Pump
4.1 General description of pump ..................................7
4.2 Installation
Protection of openings and threads .......................8
Rigid baseplates overview...................................8
Installation and Alignment
Factory Alignment
Procedure........................................................8
Recommended Procedure for
Baseplate Installation and
Final Field Alignment .......................................9
New Grouted Baseplates ..........................9
Existing Grouted Baseplates...................10
Stilt Mounted Baseplates........................10
Zirconium Components........................................11
Piping connection Suction/discharge ................11
Mechanical Seal ...................................................12
Packing ................................................................13
Piping connection Seal/packing
support system .............................................13
Piping connection Bearing housing
cooling system ..............................................13
Piping connection Support leg cooling
for centerline mounting option ......................13
Piping connection Heating/cooling fluid
for jacketed cover/casing ...............................14
Piping connection Oil mist lubrication
system...........................................................14
Coupling...............................................................15
Coupling guard maintenance.........................15
C-flange motor adapter
Special considerations..............................15
4.3 Operation
Rotation check .....................................................16
Pre start-up checks ..............................................16
(See Maintenance Section for details)
Impeller setting .............................................16
Shaft seal ......................................................16
Seal/packing support system ........................16
Bearing lubrication ........................................16
Bearing housing cooling system ...................16

Support leg cooling for centerline


mounting option .......................................16
Heating/cooling fluid for jacketed
cover/casing .............................................16
4.4 Start-up considerations
Ensuring proper NPSHA.......................................17
Minimum flow ......................................................17
Starting the pump and adjusting flow ..................17
Operation in sub-freezing conditions....................18
Shutdown considerations.....................................18
Troubleshooting ...................................................18
4.5 Maintenance
Preventive maintenance .......................................22
Need for maintenance records .............................22
Need for cleanliness .............................................22
Disassembly.........................................................22
Cleaning/inspection..............................................25
Critical measurements and tolerances..................25
Assembly .............................................................26
Power end assembly
Bearing installation........................................27
Lip seals 29
Labyrinth seals ..............................................29
Magnetic seals ..............................................29
Bearing carrier/power end
assembly ..................................................29
Wet end assembly
Cartridge mechanical seals
Seal installation ........................................30
Rear cover plate installation .....................30
Impeller installation and
clearance setting..................................30
Component-type mechanical seal
Determination of seal location ..................30
Gland installation......................................30
Seal installation ........................................30
Rear cover plate installation .....................31
Impeller installation and
clearance setting..................................31
Packing with split gland
Rear cover plate installation .....................31
Impeller installation and
clearance setting..................................31
Packing/gland installation.........................31
Packing with one-piece gland
Gland installation......................................31
Impeller installation and
clearance setting..................................32
Packing installation...................................32
Bearing lubrication
Oil bath ........................................................32

Pump Division

Grease
Regreaseable bearings .............................33
Shielded bearings .....................................33
Sealed bearings ........................................33
Oil mist ........................................................33
Reinstallation .......................................................33
4.6 Spare parts ........................................................34
How to order spare parts .....................................34

Appendix A.
Appendix B.
Appendix C.
Appendix D.
Appendix E.
Appendix F.

5.0 Mark III Sealmatic Pump


5.1 General description of pump ................................38
5.2 Overview
Repeller function ..................................................39
Design difference .................................................39
Seal options
Packing - Option A ........................................40
Checkmatic - Option B...................................40
Dry Running Seals - Option C........................41
5.3 Operation
General information..............................................41
Start-Up ...............................................................41
5.4 Maintenance
Disassembly of Group 2 Pumps...........................42
Disassembly of Group 3 Pumps...........................42
Reassembly - Sealmatic
with Packing..................................................42
Reassembly - Sealmatic with
Checkmatic Seal ............................................42
Reassembly - Sealmatic with
Dry Running Seal ..........................................42
5.5 Miscellaneous information ...................................43
Repeller selection instructions .............................43
5.6 Spare parts...........................................................44
6.0 Mark III Unitized Self-Priming Pump
6.1 General description of pump ................................45
6.2 Pump installation and operation...........................46
6.3 Spare parts...........................................................48
7.0 Mark III Recessed Impeller Pump
7.1 General description of pump ................................49
7.2 Setting the impeller ..............................................50
7.3 Spare parts...........................................................50
8.0 Mark III Lo-Flo Pump
8.1 General description of pump ................................51
8.2 Setting the impeller ..............................................51
8.3 Spare parts...........................................................52

Appendix G.
Appendix H.
Appendix I.
Appendix J.
Appendix K.

IOM for C-flange motors adapters


Assembly of stilt and spring mounted
baseplates
Critical measurements and tolerances
Installation/clearance setting of reverse vane
impeller
Installation/clearance setting of front vane
open impeller
Removal/installation of seals with
SealSentry FMI seal chamber
Bearing isolation maintenance instructions
Installation of repeller cover, repeller, cover,
impeller for Sealmatic Pump
Allowable nozzle loads
ClearGuard Trimming and Assembly
Instructions
Sources of additional information

Pump Division
Section 1.0

Section 1.0 INTRODUCTION


This bulletin contains instructions and guidelines for the
installation, operation, and maintenance of the Durco Mark III
ANSI Standard Pump, the Mark III Sealmatic Pump, the Mark III
Unitized Self-Priming Pump, the Mark III Recessed Impeller
Pump and the Mark III Lo-Flo Pump.
These pumps all use the Mark IIIA standard power end, or the
ANSI 3A upgraded power end. The A designation signifies
that both of these power ends are the new improved design that
was released in 1995. Information concerning the older Mark III
and ANSI 3 power ends is also available in the IOM.
There are many factors affecting the successful installation,
operation, and maintenance of a pump. From one pump to the
next there is typically significant variation in these factors. This
makes it impossible to create a bulletin that covers all situations.
Therefore, the information contained herein is meant to serve
only as a general guideline. If detailed questions or problems
arise, contact the nearest Flowserve Regional Sales Office or
Distributor/Representative.
It is extremely important that this entire bulletin be read prior
to installation or start-up of the pump. This is important for
safety, for proper performance of the pump, and for maximum
Mean Time Between Planned Maintenance (MTBPM).

THE COMPANY
Among Flowserve Corporations brands, Durco has long been
recognized as the leading name in chemical process pumps.
Durco pumps are manufactured at Flowserves modern
facilities, utilizing state-of-the-art equipment and sophisticated
quality control techniques. Flowserve provides technical
support and special services specific to the needs of its
customers. Flowserve is proud of earning preferred supplier
status with many of the world's leading processing companies.
Engineered and manufactured, sold and serviced to ISO 9001
quality certification, Durco process pumps are truly world class
products. And with more than 120 years of experience in
serving the needs of the worldwide process industries,
Flowserve has become the unchallenged leader in hydraulic
design engineering, materials expertise, and application knowhow. Committed to continuous quality improvement, Flowserve
controls the complete product life cycle from melting and
casting, to cellular manufacturing to assembly and testing, to
supply of aftermarket products, repair and diagnostic services.
The advanced design and precision manufacture of the rugged,
heavy-duty Mark III chemical service pump significantly
enhance bearing and seal life, thereby extending mean time
between planned maintenance (MTBPM). Its exclusive features
provide significant performance benefits for chemical pump
users. Most notable among these are:
1. The exclusive reverse vane impeller offers important
performance-enhancing, maintenance-reducing advantages.
2. The exclusive external micrometer shaft adjustment provides
dead accurate setting of impeller clearance in seconds.
3. The ANSI 3A power end, SealSentry family of seal
chambers, Ultralign pump/motor shaft alignment system
and the BaseLine family of baseplates are building blocks
for improved MTBPM.
A Flowserve Sales Engineer, Representative or Distributor will
be happy to review the advanced product features that make the
Mark III the leader in chemical pumping technology.

Pump Division
Section 2.0

Section 2.0 SAFETY CONSIDERATIONS


The Durco Mark III process pump has been designed and
manufactured for safe operation. In order to ensure safe
operation, it is very important that this manual be read in its
entirety prior to installing or operating the pump. Flowserve
shall not be liable for physical injury, damage or delays caused
by a failure to observe the instructions for installation, operation
and maintenance contained in this manual.
Remember that every pump has the potential to be dangerous,
because of the following factors:
parts are rotating at high speeds
high pressures may be present
high temperatures may be present
highly corrosive and/or toxic chemicals may be present
Paying constant attention to safety is always extremely
important. However, there are often situations that require
special attention. These situations are indicated throughout this
book by the following symbols:

DANGER
DANGER Immediate hazards which WILL result in severe
personal injury or death.

Several important general precautions are listed below:


1. DO NOT RUN EQUIPMENT DRY OR START THE PUMP
WITHOUT THE PROPER PRIME (Casing Flooded).
2. DO NOT EXCEED THE MAXIMUM DESIGN PRESSURE
(MDP) AT THE TEMPERATURE SHOWN ON PUMP
NAMEPLATE. See Figure 1 for general pressure versus
temperature ratings of common alloys.
3. ALWAYS LOCK OUT POWER TO THE DRIVER BEFORE
PERFORMING PUMP MAINTENANCE.
4. NEVER OPERATE THE PUMP WITHOUT COUPLING GUARD
AND ALL OTHER SAFETY DEVICES CORRECTLY INSTALLED.
5. DO NOT APPLY HEAT TO DISASSEMBLE THE PUMP OR TO
REMOVE THE IMPELLER. Entrapped liquid could cause an
explosion.
6. NEVER OPERATE THE PUMP FOR MORE THAN A SHORT
INTERVAL WITH THE DISCHARGE VALVE CLOSED. The length
of the interval depends on several factors including the nature
of the fluid pumped and its temperature. This interval must be
determined by the customers Engineering personnel.
7. NEVER OPERATE THE PUMP WITH THE SUCTION VALVE
CLOSED.

WARNING
WARNING Hazards or unsafe practices which COULD result in
severe personal injury or death.

CAUTION
CAUTION Hazards or unsafe practices which COULD result in
minor personal injury or product or property damage.

8. EXCESSIVE PUMP NOISE OR VIBRATION may indicate a


dangerous condition. The pump must be shut down
immediately.
9. DO NOT OPERATE THE PUMP FOR AN EXTENDED PERIOD
BELOW THE RECOMMENDED MINIMUM FLOW (Figure 20).
10. THE PUMP SHAFT MUST TURN CLOCKWISE WHEN
VIEWED FROM THE MOTOR END. It is absolutely essential that
the rotation of the motor be checked before installation of the
coupling spacer and starting the pump. Incorrect rotation of the
pump for even a short period of time can unscrew the impeller,
which can cause severe damage.

NOTE: ALWAYS COORDINATE REPAIR ACTIVITY WITH OPERATIONS PERSONNEL, AND FOLLOW ALL PLANT SAFETY
REQUIREMENTS AND APPLICABLE SAFETY AND HEALTH LAWS/REGULATIONS.

Pump Division
Section 2.0

FIGURE 1 Pressure-Temperature Limits By Alloy

CD4M
DS

300

100
DC2
DC3

MAX DISCHARGE PRESSURE - lbf /in2

200

TEMPERATURES C

250

300

D4
D4L

1500

DINC
D20

1250
DNI

150

1000
DS
DCI LOW TEMPERATURE
LIMIT

100

CLASS 150 MARK III PUMPS


BASED ON ANSI B16.5

50

CR29
CD4M
UPPER LIMIT
DCI
UPPER LIMIT

100

300

300

500

700

Ductile Iron
High Chrome Iron
High Chrome Iron
High Chrome Iron
Carbon Steel
Durco CF8
Durco CF3
Durco CF8M
Durco CF3M
Durcomet 100
Durimet 20
Durcomet 5
Durco CY40
Durco M35
Nickel
Chlorimet 2
Chlorimet 3
Duriron
Durichlor 51
Superchlor
Durco DC8
Titanium
Titanium-Pd
Zirconium

DCI
CR28
CR29
CR35
DS
D2
D2L
D4
D4L
CD4M
D20
DV
DIN
DM
DNI
DC2
DC3
D
D51
SD51
DC8
Ti
Ti-Pd
Zr

None
None
None
None
None
CF8
CF3
CF8M
CF3M
CD4MCu
CN7M
None
CY40
M351
CZ100
N7M
CW6M
None
None
None
None
None
None
None

300

DS

DINC
DC2
DC3

2250

2000

D2 D4
D2L D4L
D20
CD4M
UPPER LIMIT

200

1500

1250

GROUP I & II
CLASS 300 MARK III PUMPS
BASED ON ANSI B16.5
GROUP III
CLASS 300 MARK III PUMPS
LIMITED TO CLASS 150 RATINGS

150

CLASS 300
FLANGES
-100

100

1000

TI
TIP
ZR

750

500

CURVE NO. 2505-7


200

300

400

500

600

700

TEMPERATURES F

Equivalent Wrought Designation

ASTM Specifications

None
None
None
None
Carbon Steel
304
304L
316
316L
Ferralium
Alloy 20
None
Inconel 600
Monel 400
Nickel 200
Hastelloy B
Hastelloy C
None
None
None
None
Titanium
Titanium-Pd
Zirconium

A395
A532 class III
None
None
A216 Gr. WCB
A744, Gr. CF8
A744, Gr. CF3
A744, Gr. CF8M
A744, Gr. CF3M
A744, Gr. CD4MCu
A744, Gr. CN7M
None
A744, Gr. CY40
A744, Gr. M351
A744, Gr. CZ100
A494, Gr. N7M
A494, Gr. CW6M
A518
A518
A518
None
B367, Gr. C3
B367, Gr. C8A
B752, Gr. 702C

Duriron, Durichlor 51 and Superchlor are registered trademarks of Flowserve Corporation Ferralium is a registered trademark of Langley Alloys
Hastelloy is a registered trademark of Haynes International, Inc. Inconel and Monel are registered trademarks of International Nickel Co. Inc.

350

1750

TEMPERATURES F

FIGURE 2 Alloy Cross-Reference Chart


Designation
Symbol
ACI Designation

250

D4

500

600

200

250

100

400

150

DS
LOW
TEMPERATURE
LIMIT
DNI

CURVE NO. 2505-7


200

100

CD4M

250

CLASS 150
FLANGES
-100

750

50

DM

1750
D2
D2L

350

2000

DM

200

-50

350

TI
TIP
ZR

DCI
250

150

MAX DISCHARGE PRESSURE - lbf /in2

50

MAX DISCHARGE PRESSURE - kPa

MAX DISCHARGE PRESSURE - kPa

TEMPERATURES C
-50

Pump Division
Section 3.0

Section 3.0 OVERVIEW


3.1 WARRANTY STATEMENT

3.3 STORAGE

The warranty on a Durco pump is provided in a statement which


was sent with the Order Acknowledgement. Please call the
Flowserve Regional Sales Office or Distributor/Representative
for a copy of this warranty statement.

SHORT TERM STORAGE

3.2 NAMEPLATE
An example of the nameplate used on the Mark III pump is
shown below. This nameplate, which is always mounted on the
Mark III bearing housing, is shown in Figure 3.
FIGURE 3
How To Identify Durco Mark III Process Pump
Pump Division

Serial No.
Equipment No.
Purchase Order
Model
Size

2K6X4M-13A/124RV

MDP
Material
Date, DD/MMM/YY

Flowserves pump size code is used to indicate the size of the pump.
For example, consider the following:
2K6X4M13A/124RV
2 indicates a medium size pump
frame - in this example, a Group 2
1=Group 1 (small frame)
2=Group 2 (medium frame)
3=Group 3 (large frame)
K = Mark 3 style power end
J = Mark 3 style PE arranged for
Mark 2 wet end
No letter and no preceding number
indicates a Mark 2 power end
Nominal suction port size
Nominal discharge port size
Modifier for specialty pumps
blank or no letter = Standard pump
M = Sealmatic
L = Non-metallic wet end
R = Recessed impeller
H = High silicon iron
US = Unitized self-priming S = Old style self-priming
V = Vertical in-line
T = Teflon lined wet end
LF = Lo-Flo
E = Durcon wet end
Nominal maximum impeller diameter
13 = 13 inch
Pump design variation
A = This pump has been redesigned from an earlier
version. The impeller and casing are no longer
interchangeable with the earlier version.
H = This pump is designed for a higher flow capacity than
another pump with the same basic designation.
Examples: 4X3-10 and 4X3-10H; 6X4-10 and 6X4-10H;
10X8-16 and 10X8-16H. In each case the pump with
the H is designed for a higher flow capacity.
HH = This pump is designed for a higher head than another
pump with the same basic designation.
Example: 4X3-13 and 4X3-13HH
Actual impeller size
124 = 124/8 or 121/2 in diameter; 83 = 83/8 in; 106 = 106/8 or 103/4 in
Impeller style
RV = Reverse vane impeller; OP = Open impeller

Normal packaging is designed to protect the pump during


shipment and for dry, indoor storage for up to two months or
less. The procedure followed for this short term storage is
summarized below:
Standard Protection for Shipment :
a. Loose unmounted items, including, but not limited to,
oilers, packing, coupling spacers, stilts, and mechanical
seals are packaged in a water proof plastic bag and
placed under the coupling guard. Larger items are
cartoned and metal banded to the baseplate. For pumps
not mounted on a baseplate, the bag and/or carton is
placed inside the shipping carton. All parts bags and
cartons are identified with the Flowserve order number,
the customer purchase order number, and the pump item
number (if applicable).
b. Inner surfaces of the bearing housing, shaft (area
through bearing housing), and bearings are coated with
Cortec VCI-329 rust inhibitor, or equal.
Note: Bearing housings are not filled with oil prior to
shipment.
c. Regreasable bearings are packed with grease (Chevron
SRI #2).
d. After a performance test, if required, the pump is tipped
on the suction flange for drainage (some residual water
may remain in the casing). Then, internal surfaces of
ferrous casings, covers, flange faces, and the impeller
surface are sprayed with Calgon Vestal Labs RP-743m,
or equal. Exposed shafts are taped with Polywrap.
e. Flange faces are protected with plastic covers secured
with plastic drive bolts. 3/16 in (7.8 mm) steel, or 1/4 in
(6.3 mm) wood covers with rubber gaskets, steel bolts,
and nuts are available at extra cost.
f. All assemblies are bolted to a wood skid which confines
the assembly within the perimeter of the skid.
g. Assemblies with special paint are protected with a plastic
wrap.
h. Group 1 and Group 2 bare pumps, when not mounted on
baseplates, are packed in hard paper cartons mounted on
wood skids.
i. Group 3 bare pumps, when not mounted on baseplates,
are bolted to wood skids.
j. All pump assemblies utilizing polycrete baseplates are
mounted on wood skids.
k. All assemblies having external piping (seal flush and
cooling water plans), etcare packaged and braced to
withstand normal handling during shipment. In some
cases components may be disassembled for shipment.
The pump must be stored in a covered, dry location.

Pump Division
Section 3.4

LONG TERM STORAGE

LIFTING

Long term storage is defined as more than two months, but


less than 12 months. The procedure Flowserve follows for long
term storage of pumps is given below. These procedures are in
addition to the short term procedure.

The following describes how to lift pump components,


assembled pumps, or pump, motor and baseplate assemblies.
Do not attempt to lift a pump mounted on a baseplate by itself.
Only a pump-motor assembly may be lifted once installed on a
baseplate.

Solid wood skids are utilized. Holes are drilled in the skid to
accommodate the anchor bolt holes in the baseplate, or the
casing and bearing housing feet holes on assemblies less
baseplate. Tackwrap sheeting is then placed on top of the skid
and the pump assembly is placed on top of the Tackwrap. Metal
bolts with washers and rubber bushings are inserted through
the skid, the Tackwrap, and the assembly from the bottom of
the skid and are then secured with hex nuts. When the nuts are
snugged down to the top of the baseplate or casing and
bearing housing feet, the rubber bushing is expanded, sealing
the hole from the atmosphere. Desiccant bags are placed on
the Tackwrap. The Tackwrap is drawn up around the assembly
and hermetically (heat) sealed across the top. The assembly is
completely sealed from the atmosphere and the desiccant will
absorb any entrapped moisture. A solid wood box is then used
to cover the assembly to provide protection from the elements
and handling. This packaging will provide protection up to
twelve months without damage to mechanical seals, bearings,
lip seals, etc. due to 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 shaft should be rotated
approximately 10 revolutions.

3.4 LIFTING PUMPS AND PUMP


ASSEMBLIES
Lifting should only be done by trained personnel. Pumps and
motors often have integral lifting eyes or eye bolts. These are
intended for use in lifting the individual piece of equipment.

CAUTION
Do not use eye bolts or cast-in lifting lugs to lift pump, motor,
and baseplate assemblies.
Before lifting the equipment refer to the pump data sheet for the
complete assembly weight.

Pump Components:
Casing (#100): Use a choker hitch pulled tight around the
discharge nozzle.
Rear cover (#106): Insert an eye hook in the drilled and
tapped hole at the top of the cover. Use either a sling or
hook through the eye bolt.
Bearing housing (#119): Group I. Insert a sling between the
upper and lower support ribs between the housing barrel
and the casing attachment flange. Use a choker hitch
when slinging. Caution, make sure there are no sharp
edges on the bottom side of the ribs which could cut
the sling.
Group 2 and 3. Insert either a sling or hook through the
lifting lug located on the top of the housing.
Power end: Same as bearing housing.
Bare Pump: Sling around the pump discharge nozzle, and
around the outboard end of the bearing housing with
separate slings. Choker hitches must be used at both
attachment points and pulled tight. Make sure the
completion of the choker hitch on the discharge nozzle is
toward the coupling end of the pump shaft as shown in
Figure 4. The sling lengths should be adjusted to balance
the load before attaching the lifting hook.
Pump, motor and baseplate assembly: If the baseplate has
lifting holes cut in the sides at the end, (Type A Group 3,
Type D, and Type E bases) insert lifting S hooks at the
four corners and use slings or chains to connect to the
lifting eye as shown in Figure 5. Do not use slings
through the lifting holes.
For other baseplates sling around the pump discharge
nozzle, and around the outboard end of the motor frame
using choker hitches pulled tight (Figure 6). The sling
should be positioned so the weight is not carried through
the motor fan housing. Make sure the completion of the
choker hitch on the discharge nozzle is toward the
coupling end of the pump shaft as shown in Figure 6.

Pump Division
Section 3.4

FIGURE 4

FIGURE 5

FIGURE 6

Pump Division
Section 4.0

Section 4.0 MARK III ANSI STANDARD PUMP


Note: Throughout this book all references to pump parts are
followed by an item number in parentheses. These item
numbers are listed and shown pictorially in the Spare Parts
section.

4.1 GENERAL DESCRIPTION OF PUMP


The Durco Mark III chemical process pump is a horizontal, end
suction, single stage, centerline discharge, centrifugal pump. It
is an ANSI standard pump, which means it conforms to the
ASME B73.1M ANSI standard.

Pump Division
Section 4.2

4.2 INSTALLATION
PROTECTION OF OPENINGS AND THREADS
When the pump is shipped all threads and all openings are
covered. This protection/covering should not be removed until
installation. If, for any reason, the pump is removed from
service, this protection should be reinstalled.

RIGID BASEPLATES OVERVIEW


The function of a baseplate is to provide a rigid foundation
under a pump and its driver that maintains alignment between
the two. Baseplates may be, generally, classified into two types:
Foundation-mounted, grouted design (Figure 7)
Stilt mounted, or free-standing (Figure 8)
FIGURE 7

we supply our standard baseplate. Some users may desire


an even flatter surface which can facilitate installation and
alignment. Flowserve will supply flatter baseplates upon
request at extra cost. For example, mounting surface
flatness of 0.002 in/ft (0.17 mm/m) is offered on Durco Type
E Ten Point baseplate shown in Figure 7.
3. The baseplate must be designed to allow the user to final
field align the pump and driver to within their own particular
standards and to compensate for any pump or driver
movement that occurred during handling. Normal industry
practice is to achieve final alignment by moving the motor to
match the pump. Flowserves 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.

INSTALLATION AND ALIGNMENT


Factory Preliminary Alignment Procedure

FIGURE 8

Baseplates intended for grouted installation are designed to use


the grout as a stiffening member. Stilt mounted baseplates, on
the other hand, are designed to provide their own rigidity. Therefore, the designs of the two baseplates are usually different.
Regardless of the type of baseplate used, it must provide
certain functions that ensure a reliable installation. Three of
these requirements are:
1. The baseplate must provide sufficient rigidity to assure the
assembly can be transported and installed, given reasonable
care in handling, without damage. It must also be rigid
enough when properly installed to resist operating loads.
2. The baseplate must provide a reasonably flat mounting
surface for the pump and driver. Uneven surfaces will result
in a soft-foot condition that may make alignment difficult, or
impossible. Flowserves experience indicates that a baseplate that has a top surface flatness of 1/16 in (1.6 mm)
across the diagonal corners of the baseplate provides such a
mounting surface. Therefore, this is the tolerance to which

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 this, the factory alignment
procedure specifies that the pump be aligned in the horizontal
plane to the motor, with the motor foot bolts centered in the
motor holes. This procedure ensures that there is sufficient
clearance in the motor holes for the customer to field align the
motor to the pump, to zero tolerance. This philosophy requires
that the customer be able to place the base in the same
condition as the factory. Thus the factory alignment will be
done with the base sitting in an unrestrained condition on a flat
and level surface. This standard also emphasizes the need to
ensure the shaft spacing is adequate to accept the specified
coupling spacer.
The factory alignment procedure is summarized below:
1. The baseplate is placed on a flat and level work bench in a
free and unstressed position.
2. The baseplate is leveled as necessary. Leveling is accomplished by placing shims under the rails (or, feet) of the base
at the appropriate anchor bolt hole locations. Levelness is
checked in both the longitudinal and lateral directions.
3. The motor and appropriate motor mounting hardware is
placed on the baseplate and the motor is checked for any
planar soft-foot condition. If any is present it is eliminated
by shimming.
4. The motor feet holes are centered around the motor mounting fasteners. This is done by using a centering nut as
shown in Figure 9.

Pump Division
Section 4.2

FIGURE 9

Shims
(For Vertical
Alignment)

5. The motor is fastened in place by tightening the nuts on


two diagonal motor mounting studs.
6. The pump is put onto the baseplate and leveled. The foot
piece under the bearing housing is adjustable. It is used to
level the pump, if necessary.
Mark IIIA design
If an adjustment is necessary, we add or delete shims
(#109A) between the foot piece and the bearing housing.
Old style Mark III design
If an adjustment is necessary, the adjuster nut (#136B) is
used to adjust the footpiece up or down.
7. The spacer coupling gap is verified.
8. The parallel and angular vertical alignment is made by
shimming under the motor.
9. The motor feet holes are again centered around the motor
mounting studs using the centering nut. At this point the
centering nut is removed and replaced with a standard nut.
This gives maximum potential mobility for the motor to be
horizontally moved during final, field alignment. All four
motor feet are tightened down.
10. The pump and motor shafts are then aligned horizontally,
both parallel and angular, by moving the pump to the fixed
motor. The pump feet are tightened down.
11. Both horizontal and vertical alignment are again final
checked as is the coupling spacer gap.

Recommended Procedure for Baseplate


Installation and Final Field Alignment
New Grouted Baseplates
1. The pump foundation should be located as close to the
source of the fluid to be pumped as practical. There should
be adequate space for workers to install, operate, and
maintain the pump. The foundation should be sufficient to
absorb any vibration and should provide a rigid support for
the pump and motor. Recommended mass of a concrete
foundation should be three times that of the pump, motor
and base. Refer to Figure 10. Note that foundation bolts are
imbedded in the concrete inside a sleeve to allow some
movement of the bolt.
2. Level the pump baseplate assembly. If the baseplate has
machined coplanar mounting surfaces, these machined
surfaces are to be referenced when leveling the baseplate.
9

This may require that the pump and motor be removed


from the baseplate in order to reference the machined
faces. If the baseplate is without machined coplanar
mounting surfaces, the pump and motor are to be left on
the baseplate. The proper surfaces to reference when
leveling the pump baseplate assembly are the pump
suction and discharge flanges. DO NOT stress the
baseplate. Do not bolt the suction or discharge flanges of
the pump to the piping until the baseplate foundation is
completely installed. If equipped, use leveling jackscrews to
level the baseplate. If jackscrews are not provided, shims
and wedges should be used (see Figure 10). Check for
levelness in both the longitudinal and lateral directions.
Shims should be placed at all base anchor bolt locations,
and in the middle edge of the base if the base is more than
five feet long. Do not rely on the bottom of the baseplate to
be flat. Standard baseplate bottoms are not machined, and
it is not likely that the field mounting surface is flat.
Figure 10
Baseplate Foundation

Baseplate

Plastic Tubing
Around Bolt

Grout

Dam
Wedge
Packing

Sleeve
Locking Tab
Welded to Bolt

Anchor
Bolt

Washer

Concrete
Foundation

3. After leveling the baseplate, tighten the anchor bolts. If


shims were used, make sure that the baseplate was
shimmed near each anchor bolt before tightening. Failure to
do this may result in a twist of the baseplate, which could
make it impossible to obtain final alignment. Check the
level of the baseplate to make sure that tightening the
anchor bolts did not disturb the level of the baseplate. If the
anchor bolts did change the level, adjust the jackscrews or
shims as needed to level the baseplate. Continue adjusting
the jackscrews or shims and tightening the anchor bolts
until the baseplate is level.
4. Check initial alignment. If the pump and motor were
removed from the baseplate proceed with step 5 first, then
the pump and motor should be reinstalled onto the baseplate using Flowserves Factory Preliminary Alignment
Procedure, 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

Pump Division
Section 4.2

5.

6.

7.

8.

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 been no transit
damage, and also if the above steps where done properly,
the pump and driver should be within 0.015 in (0.38 mm)
FIM (Full Indicator Movement) parallel, and 0.0025 in/in
(0.0025 mm/mm) FIM angular. If this is not the case first
check to see if the driver mounting fasteners are centered
in the driver feet holes. If not, recenter the fasteners and
perform a preliminary alignment to the above tolerances by
shimming under the motor for vertical alignment, and by
moving the pump for horizontal alignment.
Grout the baseplate. A non-shrinking grout should be
used. Make sure that the grout fills the area under the
baseplate. After the grout has cured, check for voids and
repair them. Jackscrews, shims and wedges should be
removed from under the baseplate at this time. If they were
to be left in place, they could rust, swell, and cause
distortion in the baseplate.
Run piping to the suction and discharge of the pump. There
should be no piping loads transmitted to the pump after
connection is made. Recheck the alignment to verify that
there are no significant loads.
Perform final alignment. Check for soft-foot under the
driver. An indicator placed on the coupling, reading in the
vertical direction, should not indicate more than 0.002 in
(0.05 mm) movement when any driver fastener is
loosened. Align the driver first in the vertical direction by
shimming underneath its feet. When satisfactory alignment
is obtained the number of shims in the pack should be
minimized. It is recommended that no more than five
shims be used under any foot. Final horizontal alignment is
made by moving the driver. Maximum pump reliability is
obtained by having near perfect alignment. Flowserve
recommends no more than 0.002 in (0.05mm) parallel, and
0.0005 in/in (0.0005 mm/mm) angular misalignment.
Operate the pump for at least an hour, or until it reaches
final operating temperature. Shut the pump down and
recheck alignment while the pump is hot. Piping thermal
expansion may change the alignment. Realign pump as
necessary.

Existing Grouted Baseplates


When a pump is being installed on an existing grouted
baseplate, the procedure is somewhat different from the
previous section New Grouted Baseplates.
1. Mount the pump on the existing baseplate.
2. Level the pump by putting a level on the discharge flange. If
not level, adjust the footpiece as follows:
Mark IIIA design
Add or delete shims (#109A) between the footpiece and the
bearing housing.

3.
4.
5.
6.

Old style Mark III design


Use the adjuster nut (#136B) to adjust the footpiece up or
down.
Check initial alignment. (Step 4 above)
Run piping to the suction and discharge flanges of the
pump. (Step 6 above)
Perform final alignment. (Step 7 above)
Recheck alignment after pump is hot. (Step 8 above)

Stilt Mounted Baseplates


Refer to Appendix B for instructions for assembling stilt or
spring mounted baseplates. The low vibration levels of Durco
pumps allows 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. The
procedure for motor alignment on stilt or spring mounted
baseplates is similar to grouted baseplates. The difference is
primarily in the way the baseplate is levelled.
1. Level the baseplate by using the stilt adjusters. (Shims are
not needed as with grouted baseplates.) After the base is
level, it is locked in place by locking the stilt adjusters.
2. Next the initial pump alignment must be checked. The
vertical height adjustment provided by the stilts allows the
possibility of slightly twisting the baseplate. If there has
been no transit damage or twisting of the baseplate during
stilt height adjustment, the pump and driver should be
within 0.015 in (0.38 mm) parallel, and 0.0025 in/in
(0.0025 mm/mm) angular alignment. If this is not the case,
check to see if the driver mounting fasteners are centered
in the driver feet holes.
3. If the fasteners are not centered there was likely shipping
damage. Recenter the fasteners and perform a preliminary
alignment to the above tolerances by shimming under the
motor for vertical alignment, and by moving the pump for
horizontal alignment.
4. If the fasteners are centered, then the baseplate may be
twisted. Slightly adjust (one turn of the adjusting nut) the
stilts at the driver end of the baseplate and check for
alignment to the above tolerances. Repeat as necessary
while maintaining a level condition as measured from the
pump discharge flange. Lock the stilt adjusters.
The remaining steps are as listed for new grouted baseplates
(Steps 6, 7 and 8).

ZIRCONIUM 702 OR HIGH CHROME IRON COMPONENTS


If any of the components of the pump have been made of
zirconium or high chrome iron, the following precautionary
measures should be followed:
Use hand wrenches rather than impact wrenches.
This equipment should not be subjected to sudden changes
in temperature or pressure.
Avoid striking this equipment with any sharp blows.
10

Pump Division
Section 4.2

WARNING
Zirconium 702 and high chrome iron have relatively low impact
strengths. These materials could crack if subjected to excessive
temperature changes, pressure changes or impacts.

ZIRCONIUM 705 AND HIGH CHROME IRON COMPONENTS

FIGURE 11
Mark III Pump Installation Using Expansion Joints
Fixed axial supports must
be designed to resist the
collapsing forces of the
expansion joint selected
and to permit adjustment
to pump flanges without
loading or creating
forces on flanges.

Short spools for


axial supports

Avoid any repair or fabrication welds on Zirconium 705 and


high chrome iron components.

Expansion joint

PIPING CONNECTION SUCTION/DISCHARGE


All piping must be independently supported, accurately aligned
and preferably connected to the pump by a short length of
flexible piping. The pump should not have to support the weight
of the pipe or compensate for misalignment. It should be
possible to install suction and discharge bolts through mating
flanges without pulling or prying either of the flanges. All piping
must be tight. Pumps may air-bind if air is allowed to leak into
the piping. If the pump flange(s) have tapped holes, select
flange fasteners with thread engagement at least equal to the
fastener diameter but that do not bottom out in the tapped
holes before the joint is tight.

WARNING
Piping Forces: Take care during installation and operation to
minimize pipe forces and/or moments on the pump casing.
Forces and moments must be kept within the limits given in
Appendix I.
Many bellows type joints have an effective area larger than the
pipe area. The force resulting from application of system
pressure over the effective area when combined with other live
and dead loads must not exceed the values given in Appendix I.
If the combined forces and moments are greater than the
values from Appendix I, a piping system as shown in Figure 11
must be used.

Suction Piping
To avoid NPSH and suction problems, suction pipe sizes must
be at least as large as the pump suction connection. Never use
pipe or fittings on the suction that are smaller in diameter than
the pump suction size.
Figure 12 illustrates the ideal piping configuration with a
minimum of 10 pipe diameters between the source and the
pump suction. In most cases, horizontal reducers should be
eccentric and mounted with the flat side up as shown in Figure
13 with a maximum of one pipe size reduction. Never mount
eccentric reducers with the flat side down. Horizontally
mounted concentric reducers should not be used if there is
any possibility of entrained air in the process fluid. Vertically
mounted concentric reducers are acceptable. In applications
where the fluid is completely deaerated and free of any vapor or
suspended solids, concentric reducers are preferable to
eccentric reducers.
FIGURE 12
Good Piping Practice

DIAMETERS

FIGURE 13
Good Piping Practice
SUCTION

11

Pump Division
Section 4.2

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 Appendix K)

FIGURE 14
Suction pressure limits
MAXIMUM ALLOWABLE SUCTION PRESSURE kPa

Mark III
REVERSE VANE IMPELLER
MAXIMUM ALLOWABLE
SUCTION PRESURE
1750 RPM

SPECIFIC GRAVITY

Avoid the use of throttling valves and strainers in the suction


line. Start up strainers must be removed shortly after start up.
When the pump is installed below the source of supply, a valve
should be installed in the suction line to isolate the pump and to
permit pump inspection and maintenance. However, never
place a valve directly on the suction nozzle of the pump.

Suction pressure limits for Mark III pumps with reverse vane
impellers are given in Figure 14. The curves show maximum
allowable suction pressure at various specific gravities. Note
that Class 300 flanges may be necessary. Note also that for
front vane open impellers the suction pressure is limited only
by the pressure/ temperature curves shown in Figure 1.

SUCTION PRESSURE IS LIMITED ONLY BY THE PRESSURE


TEMPERATURE RATINGS FOR ALL OPEN IMPELLER PUMP
SIZES AT ALL SPECIFIC GRAVITIES AND FOR SEMI-OPEN
IMPELLER PUMP SIZES
10X8-14, 8X6-16A, 10X8-16 AND 10X8-16H THROUGH 2.0
SPECIFIC GRAVITY. CONSULT DURCO SALES ENGINEERS FOR
SPECIFIC GRAVITIES ABOVE 2.0

MAXIMUM ALLOWABLE SUCTION PRESSURE lbf / in2


MAXIMUM ALLOWABLE SUCTION PRESSURE kPa

Mark III GROUP I & II


REVERSE VANE IMPELLER MAX.
SUCTION PRESSURE
3500 RPM

The pressure temperature ratings shown in Figure 1 must not


be exceeded. Suction pressure is limited only by the pressure
temperature ratings, for pump sizes 10 x 8-14, 8 x 6-16A, 10
x 8-16 and 10 x 8-16H up through 2.0 specific gravity. Consult
factory for specific gravity greater than 2.0.

SPECIFIC GRAVITY

WARNING
Discharge Piping
Install a valve in the discharge line. This valve is required for
regulating flow and/or to isolate the pump for inspection and
maintenance.

WARNING
When fluid velocity in the pipe is high, for example, 10 f/s
(3 m/s) or higher, a rapidly closing discharge valve can cause a
damaging pressure surge. A dampening arrangement should be
provided in the piping.

Pump and Shaft Alignment Check


After connecting piping, rotate the pump drive shaft clockwise
(view from motor end) by hand several complete revolutions to
be sure there is no binding and that all parts are free. Recheck
shaft alignment. If piping caused unit to be out of alignment,
correct piping to relieve strain on the pump.

FOR ALL OPEN IMPELLER PUMPS


SUCTION PRESSURE IS LIMITED ONLY
BY THE PRESSURE TEMPERATURE RATINGS

MAXIMUM ALLOWABLE SUCTION PRESSURE lbf / in2

MECHANICAL SEAL
When the pump is intended to be equipped with a mechanical
seal, it is Flowserves 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
supplied. It is the pump installers responsibility to determine if
a seal was installed. If a seal was supplied but not installed, the
seal and installation instructions will be shipped with the pump.

WARNING
Failure to ensure that a seal is installed may result in serious
leakage of the pumped fluid.
Seal and seal support system must be installed and operational
as specified by the seal manufacturer.

12

Pump Division
Section 4.2

The stuffing box/seal chamber/gland may have ports that have


been temporarily plugged at the factory to keep out foreign
matter. It is the installers responsibility to determine if these
plugs should be removed and external piping connected. Refer
to the seal drawings and/or the local Flowserve representative
for the proper connections.

Abrasive Packing Arrangement The installation procedures


are the same as the standard packing with some exceptions. A
special lip seal is installed first, followed by two seal cage
assemblies, then two of the packing rings provided (Figure 16).
A flush line from a clean external source should be connected
via Tap V, in the top of the stuffing box.

PACKING

FIGURE 16

When the pump is intended to be equipped with shaft packing,


it is not Flowserves standard practice to install the packing in
the stuffing box prior to shipment. The packing is shipped with
the pump. It is the pump installers responsibility to install the
packing in the stuffing box.

WARNING
Failure to ensure that packing is installed may result in serious
leakage of the pumped fluid.

PIPING CONNECTION
SEAL/PACKING SUPPORT SYSTEM

Tap V

Lip Seal
Seal Cage
Packing

PIPING CONNECTION
BEARING HOUSING COOLING SYSTEM
Make connections as shown below. Liquid at less than 90F
(32C) should be supplied at a regulated flow rate of at least
1 gpm (0.06 l/s).

WARNING
If the pump has a seal support system, it is mandatory that this
system be fully installed and operational before the pump is
started.
If packing is used:
Packing Lubrication Water, when compatible with the pumpage, should be introduced into Tap V (Figure 15) at pressure 10
to 15 lbf/in2 (69 to 103 kPa) above the stuffing box 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 1-2 gpm (0.06-0.13 l/s).
FIGURE 15
Tap V

1/2 in O.D. Tubing

PIPING CONNECTION SUPPORT LEG COOLING


FOR CENTERLINE MOUNTING OPTION
If the casing is centerline mounted, and the process
temperature is over 350F (178C), then the casing support
legs may need to be cooled. Cool water (less than 90F (32C) )
should be run through the legs at a flow rate of at least 1 gpm
(0.06 l/s) as shown below.
Outlet

Outlet

Inlet

Inlet

Grease lubrication, when compatible with the pumpage, may be


used. Again, introduced into Tap V.
In non-abrasive applications the pumpage itself may be
sufficient to lubricate the packing without need for external
lines. Tap V should be plugged.
13

Pump Division
Section 4.2

PIPING CONNECTION HEATING/COOLING FLUID


FOR JACKETED COVER/CASING
The piping connections for jacketed covers and casings are
shown below. The flow rate of the cooling water (less than
90F (32C) ) should be at least 2 gpm (0.13 l/s).
Discharge
Outlet

3/4 NPT Inlet/Vent/Outlet

Suction Inlet

Inlet for Steam or Self


Venting Outlet for Liquid

Valve

3/4 NPT Inlet/Vent/Outlet

Inlet for Liquid or Self


Draining Outlet for Steam
Condensate

Drain
Plug

Suggested Plumbing to
Obtain Drain When
Using Liquid

Notes:
1. When circulating steam, use top hole for inlet. Both
bottom holes must be plumbed together for outlet, to
ensure draining both sides of jacket.
2. When circulating liquid, use both bottom holes as inlets.
Use top hole as outlet.

PIPING CONNECTION
OIL MIST LUBRICATION SYSTEM
The piping connections for an oil mist lubrication system are
shown below.
OIL MIST READY HOUSING WET SUMP
Locate Vent Fitting
Above Horizontal CL At
Assy

Locate Pipe Plug


Below Horizontal CL At
Assy

OIL MIST READY HOUSING DRY SUMP


Locate Vent Fitting
Above Horizontal CL At
Assy

1/2 NPT

1/4 NPT
Opp Side

Locate Pipe Plug


Below Horizontal CL At
Assy

1/2 NPT

1 NPT

1/4 NPT
Opp Side

14

Pump Division
Section 4.2

COUPLING

Coupling Guard Maintenance

CAUTION
A direction arrow is cast on the front of the Casing (See
Figure 17) and on the Bearing Housing. Make sure the motor
rotates in the same direction before coupling the motor to the
Pump. 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 the
impeller which may cause serious damage to the pump. All
Durco pumps turn clockwise as viewed from the motor end or,
conversely, counterclockwise when viewed from the suction
end as shown in Figure 17.

WARNING
Power must never be applied to the driver when the coupling
guard is not installed.
The Durco coupling guard is of the clam shell design and is
shown in Figure 19. It is hinged at the top. It can be removed by
loosening one of the foot bolts and sliding the support leg out
from under the cap screw (note that the foot is slotted). The leg
can then be rotated upward and half of the guard can be disengaged (unhinged) from the other. Note that only one side of
the guard needs to be removed. To reassemble simply reverse
the above procedure.

FIGURE 17
Refer to Appendix J for trimming and assembly instructions for
the ClearGuard coupling guard.
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.
The Durco coupling guard shown in Figure 19 conforms to the
U.S.A. standard ASME B15.1, Safety Standard for Mechanical
Power Transmission Apparatus. Flowserve manufacturing
facilities worldwide conform to local coupling guard
regulations.
FIGURE 19

The coupling (Figure 18) should be installed as advised by the


coupling manufacturer. Pumps are shipped without the spacer
installed. If the spacer has been installed to facilitate alignment,
then it must be removed prior to checking rotation. Remove
protective material from the coupling and any exposed portions
of the shaft before installing the coupling.
FIGURE 18

Typical
Non-Spacer
Coupling

15

Typical Spacer
Coupling

C-flange motor adapter special considerations


If the pump is equipped with a C-flange motor adapter, refer to
Appendix A for guidelines on installation, operation, and
maintenance.

Pump Division
Section 4.3

4.3 OPERATION
ROTATION CHECK

CAUTION
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 Durco
pumps turn clockwise as viewed from the motor end. A
direction arrow is cast on the front of the casing as shown in
Figure 17. Make sure the motor rotates in the same direction.

PRE START-UP CHECKS


Prior to starting the pump it is essential that the following
checks are made. These checks are all described in detail in the
Maintenance Section of this booklet.
Pump and Motor properly secured to the baseplate
All fasteners tightened to the correct torques
Coupling guard in place and not rubbing
Rotation check, see above, section 4.3
THIS IS ABSOLUTELY ESSENTIAL.
Impeller clearance setting
Shaft seal properly installed
Seal support system operational
Bearing lubrication
Bearing housing cooling system operational
Support leg cooling for centerline mounting option operational
Heating/cooling for jacketed casing/cover operational
Pump instrumentation is operational
Pump is primed
Rotation of shaft by hand
As a final step in preparation for operation, it is important to
rotate the shaft by hand to be certain that all rotating parts move
freely, and that there are no foreign objects in the pump casing.

16

Pump Division
Section 4.4

4.4 START-UP CONSIDERATIONS

FIGURE 20

ENSURING PROPER NPSHA


Net Positive Suction Head Available (NPSHA) is the measure
of the energy in a liquid above the vapor pressure. It is used to
determine the likelihood that a fluid will vaporize in the pump. It
is critical because a centrifugal pump is designed to pump a
liquid, not a vapor. Vaporization in a pump will result in damage
to the pump, deterioration of the Total Differential Head (TDH),
and possibly a complete stopping of pumping.
Net Positive Suction Head Required (NPSHR) is the decrease
of fluid energy between the inlet of the pump, and the point of
lowest pressure in the pump. This decrease occurs because of
friction losses and fluid accelerations in the inlet region of the
pump, and particularly accelerations as the fluid enters the
impeller vanes. The value for NPSHR for the specific pump
purchased is given in the pump data sheet, and on the pump
performance curve.
For a pump to operate properly the NPSHA must be greater than
the NPSHR. Good practice dictates that this margin should be at
least 5 ft (1.5 m) or 20%, whichever is greater.

CAUTION
Ensuring that NPSHA is larger than NPSHR by the suggested
margin will greatly enhance pump performance and reliability.
It will also reduce the likelihood of cavitation, which can
severely damage the pump.

MINIMUM FLOW
Minimum continuous stable flow is the lowest flow at which the
pump can operate and still conform to the bearing life, shaft
deflection and bearing housing vibration limits of ANSI/ASME
B73.1M-1991. Pumps may be operated at lower flows, but it
must be recognized that the pump may not conform to one or
more of these limits. For example, vibration may exceed the
limit set by the ASME standard. The size of the pump, the
energy absorbed, and the liquid pumped are some of the
considerations in determining the minimum flow.
Typically, limitations of 10% of the capacity at the best
efficiency point (BEP) should be specified as the minimum flow.
However, Flowserve has determined that several pumps must
be limited to higher minimum flows to provide optimum
service. The following are the recommended minimum flows
for these specific pumps:

17

Pump Size
1K3X2-6
2K3X2-8
2K4X3-8
2K3X2-10
2K4X3-10
2K6X4-10
2K3X2-13
2K4X3-13
2K6X4-13
ALL GROUP 3 PUMPS*
ALL OTHER SIZES

60 Hz
Minimum
flow
RPM (% of BEP)

50 Hz
Minimum
flow
RPM (% of BEP)

3500
3500
3500
3500
3500
3500
3500
3500
1750
1750
ANY

2900
2900
2900
2900
2900
2900
2900
2900
1450
1450
ANY

25%
25%
25%
33%
33%
50%
50%
50%
50%
50%
10%

21%
21%
21%
28%
28%
42%
42%
42%
42%
42%
10%

*In some cases, the 3K6X4-16 can be used at lower than 50% of BEP, by making a
modification. Contact Flowserve Engineering if this pump is to be used at a lower flow.

Note: Minimum intermittent flow value of 50% of the minimum


continuous flow as long as that flow is greater than the
minimum thermal flow.
Note: The Lo-Flo pump is not covered by this table. See Section
8.0 for a discussion of the Lo-Flo pump.
All Mark III pumps also have a Minimum Thermal Flow. This
is defined as the minimum flow that will not cause an excessive
temperature rise. Minimum Thermal Flow is application
dependent.

WARNING
Do not operate the pump at below Minimum Thermal Flow, as
this could cause an excessive temperature rise. Contact a
Flowserve Sales Engineer for determination of Minimum
Thermal flow.

STARTING THE PUMP AND ADJUSTING FLOW


1. 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.

DANGER
Never operate pump with both the suction and discharge valves
closed. This could cause an explosion.
2. A standard 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 completely filled with
liquid. Open discharge valve a slight amount. This will allow
any entrapped air to escape and will normally allow the

Pump Division
Section 4.4

pump to prime, if the suction source is above the pump.


(See Section 6.0 for special information regarding Durco
Unitized Self Priming pumps.) When a condition exists
where the suction pressure may drop below the pumps
capability, it is advisable to add a low pressure control
device to shut the pump down when the pressure drops
below a predetermined minimum.
3. All cooling, heating, and flush lines must be started and
regulated.
4. Start the driver (typically, the electric motor).
5. Slowly open the discharge valve until the desired flow is
reached, keeping in mind the minimum flow restrictions
listed above.

DANGER

Safeguards should also be taken against possible operation


with a closed discharge valve, such as installing a bypass
back to the suction source. The size of the bypass line and
the required bypass flow rate is a function of the input
horsepower and the allowable temperature rise.
7. Reduced Head
Note that when discharge head drops, the pumps flow rate
usually increases rapidly. Check motor for temperature rise
as this may cause overload. If overloading occurs, throttle
the discharge.
8. Surging Condition
A rapidly closing discharge valve can cause a damaging
pressure surge. A dampening arrangement should be
provided in the piping.

OPERATION IN SUB-FREEZING CONDITIONS


It is important that the discharge valve be opened within a short
interval after starting the driver. Failure to do this could cause a
dangerous build up of heat, and possibly an explosion.
6. Reduced capacity
Avoid running a centrifugal pump at drastically reduced
capacities or with discharge valve closed for extended
periods of time. This can cause severe temperature rise and
the liquid in the pump may reach its boiling point. If this
occurs, the mechanical seal will be exposed to vapor, with
no lubrication, and may score or seize to the stationary
parts. Continued running under these conditions when the
suction valve is also closed, can create an explosive condition due to the confined vapor at high pressure and
temperature.

When using the pump in sub-freezing conditions where the


pump is periodically idle, the pump should be properly drained
or protected with thermal devices which will keep the liquid in
the pump from freezing. High chrome iron pumps are not
recommended for applications below 0F (-18C).

SHUTDOWN CONSIDERATIONS
When the pump is being shutdown, the procedure should be
the reverse of the start-up procedure. First, slowly close the
discharge valve, shutdown the driver, then close the suction
valve. Remember, closing the suction valve while the pump is
running is a safety hazard and could seriously damage the
pump and other equipment.

Thermostats may be used to safeguard against over heating


by shutting down the pump at a predetermined temperature.

TROUBLESHOOTING
The following is a guide to troubleshooting problems with Durco pumps. Common problems are analyzed and solutions are 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 the Sources of Additional Information section or contact a local Flowserve Sales Engineer or
Distributor/Representative for assistance.
PROBLEM

POSSIBLE CAUSE

RECOMMENDED REMEDY

Problem #1
Pump not reaching design
flow rate

1.1
Insufficient NPSH. (Noise may
not be present.)

Recalculate NPSH available. It must be greater


than the NPSH required by pump at desired flow.
If not, redesign suction piping, holding number of elbows and
number of planes to a minimum to avoid adverse flow rotation
as it approaches the impeller.

1.2
System head greater than
anticipated.

Reduce system head by increasing pipe size and/


or reducing number of fittings. Increase impeller
diameter.
NOTE: Increasing impeller diameter may require use of a larger
motor.

18

Pump Division
Section 4.4

PROBLEM

POSSIBLE CAUSE

RECOMMENDED REMEDY

Cont: Problem #1.0


Pump not reaching design
flow rate.

1.3
Entrained air. Air leak from
atmosphere on suction side.

1. Check suction line gaskets and threads for tightness.


2. If vortex formation is observed in suction tank, install
vortex breaker.
3. Check for minimum submergence.

1.4
Entrained gas from process.

Process generated gases may require larger pumps.

1.5
Speed too low.

Check motor speed against design speed.

1.6
Direction of rotation wrong.

After confirming wrong rotation, reverse any two of three


leads on a three phase motor.
The pump should be disassembled and inspected before it is
restarted.

1.7
Impeller too small.

Replace with proper diameter impeller.


NOTE: Increasing impeller diameter may require use of a larger
motor.

1.8
Impeller clearance too large.

Reset impeller clearance.

1.9
Plugged impeller, suction line or casing
which may be due to a product or large
solids.

1. Reduce length of fiber when possible.


2. Reduce solids in the process fluid when possible.
3. Consider larger pump.

1.10
Wet end parts (casing cover, impeller)
worn, corroded or missing.

Replace part or parts.

Problem #2.0
Pump not reaching design
head (TDH).

2.1
Refer to possible causes under
Problem #1.0.

Refer to remedies listed under Problem #1.0 and #3.0.

Problem #3.0
No discharge or flow with

3.1
Not properly primed.

Repeat priming operation, recheck instructions. If pump has


run dry, disassemble and inspect the pump before operation.

3.2
Direction of rotation wrong.

After confirming wrong rotation, reverse any two of three


leads on a three phase motor.
The pump should be disassembled and inspected before
operation.

3.3
Entrained air. Air leak from
atmosphere on suction side.

Refer to recommended remedy under Problem #1.0,


Item #1.3.

3.4
Plugged impeller, suction line or
casing which may be due to a
fibrous product or large solids.

Refer to recommended remedy under Problem #1.0,


Item #1.9.

3.5
Damaged pump shaft, impeller.

Replace damaged parts.

4.1
Insufficient NPSH.

Refer to recommended remedy under Problem #1.0,


Item #1.1.

4.2
Entrained air. Air leak from
atmosphere on suction side.

Refer to recommended remedy under Problem #1.0,


Item #1.3.

Problem #4.0
Pump operates for short
period, then loses prime.

19

Pump Division
Section 4.4

PROBLEM

POSSIBLE CAUSE

RECOMMENDED REMEDY

Problem #5.0
Excessive noise from
wet end.

5.1
Cavitation - insufficient NPSH available.

Refer to recommended remedy under Problem #1.0,


Item #1.1.

5.2
Abnormal fluid rotation due to
complex suction piping.

Redesign suction piping, holder number of elbows and


number of planes to a minimum to avoid adverse fluid
rotation as it approaches the impeller.

5.3
Impeller rubbing.
Problem #6.0
Excessive noise from
power end.

1. Check and reset impeller clearance.


2. Check outboard bearing assembly for axial end play.

6.1
Bearing contamination appearing
on the raceways as scoring, pitting,
scratching, or rusting caused by
adverse environment and
entrance of abrasive contaminants
from atmosphere.

1. Work with clean tools in clean surroundings.


2. Remove all outside dirt from housing before
exposing bearings.
3. Handle with clean dry hands.
4. Treat a used bearing as carefully as a new one.
5. Use clean solvent and flushing oil.
6. Protect disassembled bearing from dirt and moisture.
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.

6.2
Brinelling of bearing identified by
indentation on the ball races, usually
caused by incorrectly applied forces in
assembling the bearing or by shock
loading such as hitting the bearing or
drive shaft with a hammer.

When mounting the bearing on the drive shaft use a


proper size ring and apply the pressure against the
inner ring only. Be sure when mounting a bearing to
apply the mounting pressure slowly and evenly.

6.3
False brinelling of bearing identified
again by either axial or circumferential
indentations usually caused by
vibration of the balls between the races
in a stationary bearing.

1. Correct the source of vibration.


2. Where bearings are oil lubricated and employed in
units that may be out of service for extended periods,
the drive shaft should be turned over periodically to
relubricate all bearing surfaces at intervals of one-tothree months.

6.4
Thrust overload on bearing identified 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 III
pumps.) These thrust failures are caused
by improper mounting of the bearing or
excessive thrust loads.
6.5
Misalignment identified by fracture of
ball retainer or a wide ball path on the
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.

1. Follow correct mounting procedures for bearings.

Handle parts carefully and follow recommended mounting


procedures. Check all parts for proper fit and alignment.

20

Pump Division
Section 4.4

PROBLEM

POSSIBLE CAUSE

RECOMMENDED REMEDY

Cont.: Problem #6.0


Excessive noise from
power end.

6.6
Bearing damaged by electric
arcing identified as electroetching of both inner and outer
ring as a pitting or cratering.
Electrical arcing is caused by a
static electrical charge eminating from belt drives, electrical
leakage or short circuiting.

1. Where current shunting through the bearing cannot be


corrected, a shunt in the form of a slip ring assembly
should be incorporated.
2. Check all wiring, insulation and rotor windings to be
sure that they are sound and all connections are
properly made.
3. Where pumps are belt driven, consider the elimination
of static charges by proper grounding or consider belt
material that is less generative.

6.7
Bearing damage due to improper
lubrication, identified by one or
more of the following:
1. Abnormal bearing temperature
rise.
2. A stiff cracked grease
appearance.
3. A brown or bluish discoloration
of the bearing races.

1. Be sure the lubricant is clean.


2. Be sure proper amount of lubricant is used.
The constant level oiler supplied with Durco pumps will
maintain the proper oil level if it is installed and operating
properly. In the case of greased lubricated bearings, be
sure that there is space adjacent to the bearing into which
it can rid itself of excessive lubricant, otherwise the bearing may overheat and fail prematurely.
3. Be sure the proper grade of lubricant is used.

21

Pump Division
Section 4.5

4.5 MAINTENANCE

DISASSEMBLY

PREVENTIVE MAINTENANCE

Refer to the parts list shown in Figure 52 for item number


references used throughout this section.
1. Before performing any maintenance, disconnect the driver
from its power supply and lock it off line.

The following sections of this manual give instructions on how


to perform a complete maintenance overhaul. However, it is
also important to periodically repeat the Pre start-up checks
listed on page 16. These checks will help extend pump life as
well as the length of time between major overhauls.

NEED FOR MAINTENANCE RECORDS


A procedure for keeping accurate maintenance records is a
critical part of any program to improve pump reliability. There
are many variables that can contribute to pump failures. Often
long term and repetitive problems can only be solved by
analyzing these variables through pump maintenance records.

NEED FOR CLEANLINESS


One of the major causes of pump failure is the presence of
contaminants in the bearing housing. This contamination can
be in the form of moisture, dust, dirt and other solid particles
such as metal chips. Contamination can also be harmful to the
mechanical seal (especially the seal faces) as well as other parts
of the pumps. For example, dirt in the impeller threads could
cause the impeller to not be seated properly against the shaft.
This, in turn, could cause a series of other problems. For these
reasons, it is very important that proper cleanliness be
maintained. Some guidelines are listed below.
After draining the oil from the bearing housing, periodically
send it out for analysis. If it is contaminated, determine the
cause and correct. The work area should be clean and free from
dust, dirt, oil, grease, etc. Hands and gloves should be clean.
Only clean towels, rags, and tools should be used. To simplify
maintenance, it is recommended that the Durco Tool Kit,
shown in Figure 21, to used. This tool kit includes a handy
impeller wrench, which simplifies installation and removal of
the impeller. It also contains nose cones which protect shaft
threads and O-rings during maintenance.
FIGURE 21
Durco Tool Kit

DANGER
Lock out power to driver to prevent personal injury.
2. Close the discharge and suction valves, and drain all liquid
from the pump.
3. Close all valves on auxiliary equipment and piping, then
disconnect all auxiliary piping.
4. Decontaminate the pump as necessary.

DANGER
If Durco pumps contain dangerous chemicals, it is important to
follow plant safety guidelines to avoid personal injury or death.
5. Remove the coupling guard. (See page 15 on Coupling
Guards.)
6. Remove the spacer from the coupling.
7. Remove casing fasteners (#115A).
8. Remove the fasteners holding the bearing housing foot to
the baseplate.
9. Move the power end, rear cover, and seal chamber
assembly away from the casing. Discard the casing/ cover
gasket (#107).

CAUTION
The power end and rear cover assembly is heavy. It is
important to follow plant safety guidelines when lifting it.
10. Transport the assembly to the maintenance shop.
11. Remove the coupling hub from the pump shaft (#105).
12. Using the shaft key (#130), mount the impeller wrench
from the Durco Tool Kit (Figure 21) to the end of the
shaft. With the wrench handle pointing to the left when
viewed from the impeller end, grasp the impeller (#103)
firmly with both hands (wear heavy gloves), by turning the
impeller in the clockwise direction move the wrench handle
to the 11:00 oclock position and then spin the impeller
quickly in a counterclockwise 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.
22

Pump Division
Section 4.5

Unscrew the impeller and remove from the shaft. Discard


the impeller gasket (#104).

FIGURE 23

DANGER
Do not apply heat to the impeller. If liquid is entrapped in the
hub, an explosion could occur.
Refer to Appendix F for instructions on removing the seal,
sleeve, and rear cover plate if pump is equipped with a
SealSentry FMI seal chamber. This is the Durco seal
chamber that does not have a separate gland. The gland is
integral to the seal chamber.
13. Remove the seal or packing gland nuts (#111A).
14. Remove the two cap screws (#140) which attach the rear
cover plate to the adapter. Carefully remove the rear cover
plate (#106).
FIGURE 22

18. If packing (#113) is used, remove it and the seal cage


(lantern ring)(#112). Remove the gland (#110).
19. If the pump has a hook type sleeve (#177) it can now be
removed. Unit now appears as shown in Figure 24.
FIGURE 24

15. If a cartridge type mechanical seal (#153) is used (Figure


22), loosen the set screws which lock the unit to the shaft
and remove the complete seal assembly. If the seal is be
be reused, the spacing clips or tabs should be reinstalled
prior to loosening the set screws. This will ensure that the
proper seal compression is maintained.
16. If a component type inside mechanical seal (#153) is used,
loosen the set screws on the rotating unit and remove it
from the shaft, see Figure 23. Then pull the gland (#190)
and stationary seat off the shaft. Remove the stationary
seat from the gland. Discard all O-rings and gaskets.
17. If a component type outside mechanical seal is used,
remove the gland and the stationary seat. Remove the
stationary seat from the gland. Loosen the set screws in
the rotating unit and remove it. Discard all O-rings and
gaskets.

23

20. If the power end is oil lubricated, remove the drain plug
(#134) and drain the oil from the bearing housing (#119).
21. If the pump has lip seals, a deflector (#114) will be
present. Remove it.
22. Loosen the three set screws (#201A) on the bearing carrier
(#201). The bearing carrier must be completely unscrewed
from the bearing housing. Note: Do not pry against the
shaft.
Mark IIIA design
The face of the bearing carrier has three square lugs that
protrude from the surface. The bearing carrier is turned by
using an open end wrench on one of the square lugs as
shown in Figure 25.

Pump Division
Section 4.5

FIGURE 25

Old style Mark III design


On Group 1 and 2 pumps the bearing carrier is turned by
using a strap wrench, with the strap located around the
O.D. of the carrier face. On Group 3 pumps, the bearing
carrier is turned by using a spanner wrench to engage the
cogs on the O.D. of the bearing carrier.
23. Because the O-rings (#201B) 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 25A. Further
disassembly is not required unless the bearings are to
be replaced.

FIGURE 26

Note: Group 1 and 2 pumps equipped with duplex angular


contact bearings use a bearing retainer (#201D) instead of
the snap ring. Remove the carrier from the bearing.
25. The bearing locknut (#124) and lockwasher (#125) may
now be removed from the shaft (#105). Discard the
lockwasher.
26. An arbor or hydraulic press may be used to remove the
bearings (#120 and #121) from the shaft. It is extremely
important to apply even pressure to the inner bearing race
only. Never apply pressure to the outer race as this exerts
excess load on the balls and causes damage.

CAUTION
Applying pressure to the outer race could permanently damage
the bearings.

FIGURE 25A

24. Remove the snap ring (#201C) (Figure 26) on Group 1


and 2 pumps, or the bearing retainer (#201D) on Group 3
pumps.

27. The Mark IIIA design has an optional oil slinger (#122)
located between the bearings. If present, inspect it for
damage or looseness. Remove if it needs to be replaced.
28. On Group 2 and 3 pumps, the bearing housing (#119)
must be separated from the bearing housing adapter
(#108).
Mark IIIA design
This is accomplished by removing the capscrews (#139)
which thread into the bearing housing.
Old style Mark III design
This is accomplished by removing the hexnuts (#139A)
and the capscrews (#139). The adapter O-ring (#131)
should be discarded.
29. If lip seals (#118) and (#129) (Figure 27) are used, they
should be removed from the bearing housing and adapter
and discarded.

24

Pump Division
Section 4.5

FIGURE 27

FIGURE 30

30. If bearing isolators are used, refer to Appendix G.


31. If magnetic seals are used, maintain the seals as specified
by the manufacturer.
32. If present, the Trico oiler (#133) (Figure 28) should be
removed from the bearing housing.
FIGURE 28

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.

WARNING
It is important that only non-flammable, non-contaminated
cleaning fluids are used. These fluids must comply with plant
safety and environmental guidelines.

CRITICAL MEASUREMENT AND TOLERANCES


33. The sight gage (#200) (Figure 29) should be removed from
the bearing housing. The Mark IIIA design will have the tag
shown in Figure 30 attached to the sight gage. Remove
this tag and save it to be re-installed later.
FIGURE 29

25

To maximize reliability of pumps, it is important that certain


parameters and dimensions are measured and maintained
within specified tolerances. Please refer to Appendix C for a
summary of these various physical parameters and the
associated tolerances which are vital for maximizing pump
reliability. It is very important that all parts be checked as
specified in Appendix C. Any parts that do not conform to the
specifications should be replaced with new Flowserve parts.

Pump Division
Section 4.5

ASSEMBLY
Note: Refer to Figure 31 for all bolt torque information.
It is very important that all pipe threads be sealed properly.
PTFE tape provides a very reliable seal over a wide range of
fluids, but it has a serious shortcoming if not used 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 off
when threaded into the female fitting. This string can then tear
away and lodge in the piping system. 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 sealants and


has identified two that provide an effective seal, have the same
chemical resistance as the tape, and will not plug flush
systems. These are La-co Slic-Tite and Bakerseal. Both
products contain finely ground PTFE particles in an oil based
carrier. They are supplied in a paste form which is brushed on
the male pipe threads. Flowserve recommends using one of
these paste sealants.
Full thread length engagement is required for all fasteners.

FIGURE 31
Recommended Bolt Torques (US Customary Units)
Item

Description

Group 1
Non-lubricated

Group 2
Non-lubricated

Group 3
Non-lubricated

201E
201E
139
111
111
115

Bearing retainer capscrews - standard bearings


Bearing retainer capscrews - duplex bearings
Bearing housing/adapter capscrews and nuts
Mechanical seal gland studs/nuts, with gasket
Mechanical seal gland studs/nuts, with O-ring
Casing studs/nuts

N/A
3/16 in - 2 ft lbf
N/A
3/8 in - 10 ft lbf
3/8 in - 40 ft lbf
1/2 in - 25 ft lbf

5/16 in - 6 ft lbf
5/16 in - 6 ft lbf
5/8 in - 53 ft lbf
1/2 in - 25 ft lbf
1/2 in - 97 ft lbf
3/4 in - 75 ft lbf

140
201A
136
195

Capscrew cover/adapter (token bolts)


Bearing carrier set screws
Capscrew foot
Capscrews - repeller cover to cover

3/8 in - 11 ft lbf
3/8 in - 11 ft lbf
1/2 in - 27 ft lbf
N/A

N/A
3/16 in - 2 ft lbf
1/2 in - 27 ft lbf
3/8 in - 10 ft lbf
3/8 in - 40 ft lbf
1/2 in - 25 ft lbf
5/8 in - 45 ft lbf
3/8 in - 11 ft lbf
1/2 in - 27 ft lbf
3/4 in - 94 ft lbf
3/8 in - 10 ft lbf

1/2 in - 27 ft lbf
1/2 in - 27 ft lbf
1 in - 228 ft lbf
1/2 in - 25 ft lbf

Note: For lubricated or PTFE-coated threads, use 75% of the values given.
Recommended Bolt Torques (Metric)
Item

Description

Group 1
Non-lubricated

Group 2
Non-lubricated

Group 3
Non-lubricated

201E
201E
139
111
111
115

Bearing retainer capscrews - standard bearings


Bearing retainer capscrews - duplex bearings
Bearing housing/adapter capscrews and nuts
Mechanical seal gland studs/nuts, with gasket
Mechanical seal gland studs/nuts, with O-ring
Casing studs/nuts

N/A
3/16 in - 3 N m
N/A
3/8 in - 13 N m
3/8 in - 54 N m
1/2 in - 34 N m

5/16 in - 8 N m
5/16 in - 8 N m
5/8 in - 72 N m
1/2 in - 34 N m
1/2 in - 130 N m
3/4 in - 102 N m

140
201A
136
195

Capscrew cover/adapter (token bolts)


Bearing carrier set screws
Capscrew foot
Capscrews - repeller cover to cover

3/8 in - 15 N m
3/8 in - 15 N m
1/2 in - 37 N m
N/A

N/A
3/16 in - 3 N m
1/2 in - 37 N m
3/8 in - 13 N m
3/8 in - 54 N m
1/2 in - 34 N m
5/8 in - 61 N m
3/8 in - 15 N m
1/2 in - 37 N m
3/4 in - 130 N m
3/8 in - 13 N m

1/2 in - 37 N m
1/2 in - 37 N m
1 in - 300 N m
1/2 in - 34 N m

Note: For lubricated or PTFE-coated threads, use 75% of the values given.
26

Pump Division
Section 4.5

POWER END ASSEMBLY


The Mark IIIA design has an optional oil slinger. If the slinger
was removed during disassembly, install a new slinger (#122).
FIGURE 32

Outboard
Bearing

Slinger

Inboard
Bearing

Bearing installation
Mounting of bearings on shafts must be done in a clean
environment. Bearing and power end life can be drastically
reduced if even very small foreign particles work their way into
the bearings.

bearing refers to the bearing nearest to the casing. Outboard


bearing refers to the bearing nearest to the motor.
1. Install the inboard bearing (#120) on the shaft (#105).
Mark IIIA design
The inboard bearing must be positioned against the shoulder
as shown in Figure 36.
Old style Mark III design
The correct position for the inboard bearing is given in
Figure 34. It is important to note that on Group 1 and 2
pumps, the inboard bearing is not located against a
shoulder. The position must be determined from the chart.
On Group 3 shafts the inboard bearing is positioned against
a shoulder.
If the power end is equipped with single shield regreaseable
bearings, the shields should be oriented as shown in
Figure 32A.

Bearings should be removed from their protective packaging


only immediately before assembly to limit exposure to possible
contamination. After removing the packaging they should only
come in contact with clean hands, fixtures, tools and work
surfaces.

FIGURE 32A

The chart shown in Figure 33 gives the SKF part numbers for
bearings in Durco Mark III pumps. Note that the term inboard

Outboard
Bearing

Shield

Inboard
Bearing

FIGURE 33
Durco Mark III Bearings
Group
1

Type of Bearings
Oil bath/mist Open1
Regreasable Single Shielded2
Greased for life Double Shielded3
Sealed for life Double Sealed4

Inboard
Single Row,
Deep Groove5
6207-C3
6207-ZC3
6207-2ZC3
6207-2RSIC3

Oil bath/mist Open1


Regreasable Single Shielded2
Greased for life Double Shielded3
Sealed for life Double Sealed4

6310-C3
6310-ZC3
6310-2ZC3
6310-2RSIC3

5310-AHC3
5310-AZC3
5310-A2ZC3
5310-A2RSC3

7310-BECBY
NA6
NA7
NA7

Oil bath/mist Open1


Regreasable Single Shielded2
Greased for life Double Shielded3
Sealed for life Double Sealed4

6314-C3
6314-ZC3
6314-2ZC3
6314-2RSIC3

5314-AC3
5314-AZC3
5314-A2ZC3
5314-A2RSC3

7314-BECBY
NA6
NA7
NA7

1
2

27

Outboard Double Row,


Angular Contact,
Deep Groove5
5306-AC3
5306-AZC3
5306-A2ZC3
5306-A2RSC3

Optional Outboard
Duplex Angular
Contact5
7306-BECBY
NA6
NA7
NA7

These bearings are open on both sides. They are lubricated by oil bath or oil mist.
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.
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.
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
RPM.
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.
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.
Not available.

Pump Division
Section 4.5

BEARING INSTALLATION
FOR POWER END ASSEMBLY (CONTD)
Both bearings have a slight interference fit which requires
that they be pressed on the shaft with an arbor or hydraulic
press. A chart giving bearing fits is shown in Figure 35. Even
force should be applied to the inner race only. Never press
on the outer race, as the force will damage the balls and
races. An alternate method of installing bearings is to heat
the bearings to 200F (93C) in an oven or induction heater.
Then place them quickly in position on the shaft.

CAUTION
Never heat the bearings above 230F (110C). To do so will
likely cause the bearing fits to permanently change, leading to
early failure.
FIGURE 34
Bearing Position Old Style Mark III Design

MARK III
MARK III
STANDARD SHAFT
DUPLEX BRG SHAFT
GROUP
A
GROUP
A
1
211/16 in (68 mm)
1
23/8 in (61 mm)
2
515/32 in (139 mm)
2
53/32 in (129 mm)
3
*
3
*
*Inboard bearing located against shoulder
FIGURE 35
Bearing Fits (inches)*

OB brg/shaft Bearing
Shaft
Fit
IB brg/shaft Bearing
Shaft
Fit
OB brg/hsg Bearing
Housing
Fit
IB brg/hsg Bearing
Housing
Fit

Group 1
1.1811/1.1807
1.1816/1.1812
0.0009T/0.0001T
1.3780/1.3775
1.3785/1.3781
0.0010T/0.0001T
2.8346/2.8341
2.8346/2.8353
0.0012L/0.0000L
2.8346/2.8341
2.8346/2.8353
0.0012L/0.0000L

Group 2
1.9685/1.9680
1.9690/1.9686
0.0010T/0.0001T
1.9685/1.9680
1.9690/1.9686
0.0010T/0.0001T
4.3307/4.3301
4.3310/4.3316
0.0015L/0.0003L
4.3307/4.3301
4.3310/4.3316
0.0015L/0.0003L

*See Appendix C for metric system fits

Group 3
2.7559/2.7553
2.7565/2.7560
0.0012T/0.0001T
2.7559/2.7553
2.7565/2.7560
0.0012T/0.0001T
5.9055/5.9047
5.9056/5.9067
0.0020L/0.0001L
5.9055/5.9047
5.9058/5.9065
0.0018L/0.0003L

2. Place the snap ring (#201C) or the bearing retainer (#201D)


onto the outboard end of the shaft and slide down to the
inboard bearing. Note the proper orientation of the bearing
retainer or snap ring must be assured in this step. The flat
side of the snap ring and the small side of the retainer must
face away from the inboard bearing.
FIGURE 36

Outboard
Bearing

Inboard
Bearing

3. Using clean gloves, install the outboard bearing (#121)


firmly against the shoulder as shown in Figure 36. If hot
bearing mounting techniques are used, steps must be taken
to ensure the outboard bearing is firmly positioned against
the shaft shoulder. The outboard bearing, while still hot, is to
be positioned against the shaft shoulder. After the bearing
has cooled below 100F (38C) the bearing should be
pressed against the shaft shoulder. An approximate press
force needed to seat the bearing is listed in Figure 37. This
value may be used if the press has load measuring
capability.

CAUTION
It must be understood that fixtures and equipment used to press
the bearing must be designed so no load is ever transmitted
through the bearing balls. This would damage the bearing.
The locknut (#124) and lockwasher (#125) should be
installed. The locknut should be torqued to the value shown
in Figure 37. At this point the lockwasher tang must be bent
into the locknut.
FIGURE 37
Pump

Press Force
lbf (N)

Locknut Torque
ftlbf (Nm)

Group 1
Group 2
Group 3

1300 (5,780)
2500 (11,100)
4500 (20,000)

20 +5/-0 (27 +4/-0)


40 +5/-0 (54 +7/-0)
70 +5/-0 (95 +7/-0)

4. If the outboard bearing is cold pressed against the shaft


shoulder, it should be secured with the lockwasher and locknut torqued with the locknut torque value listed in Figure
32. The lockwasher tang must then be bent into the locknut.
28

Pump Division
Section 4.5

5. Duplex angular contact bearings must be mounted back-toback with the wider thrust sides of the outer races in
contact with each other as shown in Figure 38. Only
bearings designed for universal mounting should be used.
SKFs designation is BECB. NTNs designation is G.
Note: A special shaft is required when using duplex angular
contact bearings.
FIGURE 38

OUTER
RACE

THRUST SIDES

Lip seals
If lip seals were used (see Figure 28), install new lip seals in the
bearing carrier (#201) and the housing (#119) (Group 1) or the
adapter (#108) (Group 2 and 3). The lip seals (#118 and #129)
are double lip style, the cavity between the lips should be 1/2 to
2/3 filled with grease.

Labyrinth seals
Refer to Appendix G.

Magnetic seals
Follow the installation instructions provided by the
manufacturer.

Bearing carrier/power end assembly


6. Install new O-rings (#201B) onto the bearing carrier. Be
sure to use the correct size O-rings. (The Mark III and
Mark IIIA bearing carriers use different O-rings.) Slide the
bearing carrier (#201) over the outboard bearing (#121).
7. On Group 1 and 2 pumps, if standard outboard bearings
are used, slide the snap ring (#201C) in place with its flat
side against the outboard bearing and snap it into its
groove in the bearing carrier.

WARNING
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.

29

8. On Group 1 and 2 pumps, if duplex angular contact


bearings are used, slide the bearing retainer (#201D) in
place, install, and tighten the socket head capscrews
(#201E). See Figure 31 for correct torque values.
9. On Group 3 pumps slide the bearing retainer (#201D)
against the outboard bearing and install and tighten the
socket head capscrews (#201E). See Figure 31 for correct
torque values.
10. The shaft, bearings, and bearing carrier assembly (Figure
25) can now be installed into the bearing housing (#119).
The bearing carrier (#201) should be lubricated with oil on
the O-rings and threads before installing the assembly into
the bearing housing. Thread the bearing carrier into the
bearing housing by turning it clockwise to engage the
threads. Thread the carrier onto the housing until the
carrier flange is approximately 1/8 in (3 mm) from the
housing. Install the set screws (#201A) loosely.
11. Install a sight gage (#200) into the bearing housing. For the
Mark IIIA design, first install the oil level message tag,
shown in Figure 31.
12. If one was present, install a Trico oiler (#133) into the bearing housing. If not used, install a plug into the hole. When
using a Trico oiler it is very important that a vent/breather
be installed in the tapped hole on top of the bearing
housing.
13. Install a drain plug (#134) into the bearing housing. Be sure
to install the optional magnetic drain plug (#134M), if
appropriate.
14. On Group 2 and 3 pumps, assemble the bearing housing
adapter (#108) to the bearing housing (#119). Be sure to
install a new O-ring (#131).
Mark IIIA design
Thread the capscrews (#139) through the adapter and into
the tapped holes in the bearing housing.
Old style Mark III design
Use the capscrews (#139) and hexnuts (#139A). Orient the
bearing housing adapter with the two holes for capscrews
(#139) on a horizontal line.
15. If the pump has lip seals, install the deflector (#114).
16. If the pump is equipped with a hook type sleeve (#177),
slip it into place over the impeller end of the shaft (#105).

WET END ASSEMBLY


Cartridge mechanical seals
Seal installation
Slide the cartridge seal (#153) onto the shaft using a seal guide
until it lightly touches the bearing housing (#119) or adapter
(#108). See Figure 39.

Pump Division
Section 4.5

FIGURE 39

Impeller/rear cover removal


Remove the impeller following instructions given in the
Disassembly section on Page 22. Remove the rear cover
following instructions given in the Disassembly section on
Page 23.
FIGURE 40

Rear cover plate installation


Install the rear cover plate (#106) to the bearing housing
(Group 1) or the bearing housing adapter (Group 2 and 3) by
using the capscrews (#140). Now install the cartridge seal
gland to the rear cover plate (#106) using studs (#111) and
nuts (#111A).
Impeller installation and clearance setting
Install the impeller (#103) as instructed in Appendix D, if
reverse vane, or Appendix E, if a front vane open style impeller
(See Figure 42). Care should be taken in the handling of high
chrome iron impellers.
Lock seal in place
Tighten set screws on the seal to lock the rotating unit to the
shaft. Finally, remove centering clips from the seal.

Gland installation
Install the gland (#190) and stationary seal components
following the seal manufacturers instructions. Slide the gland
and stationary seal components onto the shaft until it lightly
touches the bearing housing or adapter. Install the gland gasket
(#190G) into the gland. See Figure 41.
FIGURE 41

Component type mechanical seal


Determination of seal location
In order to properly set a component seal it is necessary to first
locate the shaft in its final axial position. This is accomplished
in the following manner.
Install the rear cover plate (#106) to the bearing housing
(Group 1) or the bearing housing adapter (Group 2 and 3) by
using the capscrews (#140). Install the impeller (#103) as
instructed in Appendix D, if reverse vane, or Appendix E, if a
front vane open style impeller. Put blueing on the shaft in the
area near the face of the seal chamber (rear cover #106). Scribe
a mark on the shaft at the face of the seal chamber (Figure 40).
Now the location of the seal can be determined by referring to
the seal drawing supplied by the seal manufacturer.

Seal installation
Install the rotating unit onto the shaft (or sleeve) using a seal
guide following the seal manufacturers instructions (Figure 43).

30

Pump Division
Section 4.5

FIGURE 42

Front Vane Open


Style Impeller

FIGURE 45

Reverse Vane
Impeller

FIGURE 43

Impeller final installation


Install the impeller (#103) as instructed in Appendix D, if
reverse vane, or Appendix E, if a front vane open style impeller.
Remember that the impeller clearance is already set. It cannot
be changed at this point without resetting the seal.

Packing with split gland


Rear cover plate installation
Install the rear cover plate (#106) to the bearing housing
(Group 1) or the bearing housing adapter (Group 2 and 3) by
using the capscrews (#140).
Impeller installation and clearance setting
Install the impeller (#103) as instructed in Appendix D,
if reverse vane, or Appendix E, if a front vane open style
impeller. Care should be taken in the handling of high chrome
iron impellers.
Rear cover plate installation
Install the rear cover plate (#106) to the bearing housing
(Group 1) or the bearing housing adapter (Group 2 and 3) by
using the capscrews (#140) (Figure 44). Now, install the gland
(#190) to the rear cover plate (#106) using studs (#111) and
nuts (#111A) (Figure 40).
FIGURE 44

Packing/gland installation
Install the packing rings (#113) and seal cage halves (#112)
into the stuffing box as shown in Figure 16. Always stagger the
end gaps 90 to ensure a better seal. To speed installation of
each ring, have an assistant turn the pump shaft in one
direction. This movement of the shaft will tend to draw the rings
into the stuffing box. A split gland (#110) is an assembly of two
matched gland halves that are bolted together. Unbolt the gland
halves and install the gland halves around the shaft. Bolt the
halves together to form a gland assembly. Now, install the
gland assembly (#110) using studs (#111) and nuts (#111A).
Lightly snug up the gland. Final adjustments must be made
after the pump has begun operation.

Packing with one piece gland


Gland installation
Slip gland over shaft and slide back to the bearing housing.

31

Pump Division
Section 4.5

PACKING WITH ONE PIECE GLAND (CONTD)


Rear cover plate installation
Install the rear cover plate (#106) to the bearing housing
(Group 1) or the bearing housing adapter (Group 2 and 3) by
using the capscrews (#140).
Impeller installation and clearance setting
Install the impeller (#103) as instructed in Appendix D, if
reverse vane, or Appendix E, if a front vane open style impeller.
Packing installation
Install the packing rings (#113) and seal cage halves (#112)
into the stuffing box as shown in Figure 16. Always stagger the
end gaps 90 to ensure a better seal. To speed installation of
each ring, have an assistant turn the pump shaft in one
direction. This movement of the shaft will tend to draw the rings
into the stuffing box. Now, attach the gland (#110) to the cover
using studs (#111) and nuts (#111A). Lightly snug up the
gland. Final adjustments must be made after the pump has
begun operation.

BEARING LUBRICATION
Oil bath
The standard bearing housing bearings are oil bath lubricated
and are not lubricated by Flowserve. Before operating the
pump, fill the bearing housing to the center of the oil sight glass
with the proper type oil. (See Figure 46 for approximate amount
of oil required do not overfill.)

above, proper oil level is the center of the bulls eye sight
glass (#200) (Figure 29).
In many pumping applications lubricating oil becomes
contaminated before it loses its lubricating qualities or breaks
down. For this reason it is recommended that the first oil
change take place after approximately 160 hours of operation,
at which time, the used oil should be examined carefully for
contaminants. During the initial operating period monitor the
bearing housing operating temperature. Record the external
bearing housing temperature. See Figure 49 for maximum
acceptable temperatures. The normal oil change interval is
based on temperature and is shown in Figure 50.
FIGURE 46
Amount of Oil Required
Pump Size
Group 1
Group 2
Group 3

See Figure 47 for recommended lubricants. DO NOT USE


DETERGENT OILS. The oil must be free of water, sediment,
resin, soaps, acid and fillers of any kind. It should contain rust
and oxidation inhibitors. The proper oil viscosity is determined by
the bearing housing operating temperature as given in Figure 48.
To add oil to the housing, clean and then remove the vent plug
(#135) at the top of the bearing housing, pour in oil until it is
visually half way up in the sight glass (#200). Fill the constant
level oiler bottle (Trico), if used, and return it to its position. The
correct oil level is obtained with the constant level oiler in its
lowest position, which results in the oil level being at the top of
the oil inlet pipe nipple, or half way up in the sight glass
window. Oil must be visible in the bottle at all times.Note that
on ANSI 3A power ends there is no Trico oiler. As stated

MK IIIA Amount
8.5 oz (251 ml)
32 oz (946 ml)
48 oz (1419 ml)

FIGURE 47
Recommended Lubricants
Mineral Oil

Synthetic
On the Mark IIIA design, an optional oil slinger is available. The
oil slinger is not necessary; however, if used, it provides an
advantage by allowing a larger tolerance in acceptable oil level.
Without an oil slinger, the oil level in the bearing housing must
be maintained at 1/8 in (3 mm) from the center of the sight
glass. The sight glass has a 1/4 in (6 mm) hole in the center of
its reflector. The bearing housing oil level must be within the
circumference of the center hole to ensure adequate lubrication
of the bearings.

MK III Amount
5 oz (148 ml)
19 oz (560 ml)
48 oz (1419 ml)

Grease

Quality mineral oil with rust and oxidation


inhibitors. Mobil DTE Heavy/Medium ISO VG 68
or equivalent.
Royal Purple or Conoco SYNCON 68 or
equivalent. Some synthetic lubricants require
Viton O-rings.
Chevron SRI #2 (or compatible)

FIGURE 48
Oil Viscosity Grades
Maximum Oil
Temperature
Up to 160F (71C)
160-175F (71-80C)
175-200F (80-94C)

ISO
Viscosity Grade
46
68
100

Minimum
Viscosity Index
95
95
95

FIGURE 49
Maximum External Housing Temperatures
Lubrication
Oil bath
Oil mist
Grease

Temperature
180F* (82C)
180F* (82C)
200F* (94C)

* Synthetic oil and grease will allow higher temperatures.

Maximum bearing temperature is 220F (105C).

32

Pump Division
Section 4.5

FIGURE 50
Relubrication Intervals*
Lubricant
Grease
Mineral Oil
Synthetic Oil**

Under 160F
(71C)
6 mo
6 mo
18 mo

160-175F
(71-80C)
3 mo
3 mo
18 mo

175-200F
(80-94C)
1.5 mo
1.5 mo
18 mo

* Assuming good maintenance and operation practices, and


no contamination.
** May be increased to 36 months with ANSI 3A power end.

Grease
Single shielded regreasable bearings
When the grease lubrication option is specified, single shielded
bearings, grease fittings and vent pipe plugs are installed
inboard and outboard. The bearings are packed with Esso
Unirex N3 grease prior to assembly. For relubrication, a grease
with the same type base (non-soap polyuride) and oil (mineral)
should be used. To regrease, remove the pipe plug from both
the inboard and outboard bearing location. See Figure 51.

WARNING
To regrease bearings under coupling guard, stop pump, lock
the motor, remove coupling guard, then regrease the bearings.
Apply grease through the fittings until it comes out of the vent
holes, then reinstall the pipe plugs.
Bearings configured as shown in Figure 32A will draw grease
across the shield as needed.
FIGURE 51
Regreaseable Configuration
1/8 NPT
Tap Drill Thru
(2) Places

33

CAUTION
Do not fill the housing with oil when greased bearings are used.
The oil will leach the grease out of the bearings and the life of
the bearings may be drastically reduced.
Double shielded or double sealed bearings
These bearings are packed with grease by the bearing manufacturer and should not be relubricated. Maintenance intervals
for these bearings are greatly affected by their operating
temperature and pump speed. However, the shielded bearing
typically operates cooler, thus extending its life. Refer to Figure
50 for recommended maintenance intervals.

Oil mist
When optional oil mist lubricated bearings are specified, the
bearing housing is furnished with a plugged 1/2 in NPT top inlet
for connection to the users oil mist supply system, a vent
fitting in the bearing carrier, and a plugged 1/4 in NPT bottom
drain. See Oil Mist Lubrication System on Page 14.
Do not allow oil level to remain above the center of the bearing
housing sight glass window with purge mist (wet sump)
systems.
The optional oil slinger must not be used with an oil mist
system.

REINSTALLATION
The pump is now ready to be returned to service. It should be
reinstalled as described in the installation section.

Pump Division
Section 4.6

4.6 SPARE PARTS


RECOMMENDED SPARE PARTS
STANDARD MARK III PUMP
The decision on what spare parts to stock varies greatly
depending on many factors such as the criticality of the
application, the time required to buy and receive new spares,
the erosive/corrosive nature of the application, and the cost of
the spare part. Figures 52, 53, and 54 give the parts list for a
typical Mark III pump. Please refer to the Durco Pump Parts
Catalog for more information. Prior to resizing impellers in
high chrome iron and nickel, please consult your local
Flowserve sales representative.

HOW TO ORDER SPARE PARTS


Spare parts can be ordered from the local Flowserve Sales
Engineer, or from the Flowserve Distributor or Representative.
The pump size and type can be found on the name plate on the
bearing housing. See Figure 3. Please provide the item number,
description, and alloy for the part(s) to be ordered.
To make parts ordering easy, Flowserve has created a catalog
titled Durco Pump Parts Catalog. A copy of this book can be
obtained from the local Flowserve Sales Engineer or
Distributor/Representative.

34

Pump Division
Section 4.6

FIGURE 52 - Group 1

Option for duplex angular


contact bearings

35

ITEM

DESCRIPTION

100

CASING

103

IMPELLER

104

IMPELLER GASKET

105

SHAFT

106

REAR COVER PLATE

107

REAR COVER GASKET

108

BEARING HOUSING ADAPTER

109

BEARING HOUSING FOOT

109A

SHIM

110

GLAND - PACKING

111

STUD - GLAND

111A

HEXNUT - GLAND

112

PACKING SEAL CAGE HALVES

113

PACKING

OPT.

114

DEFLECTOR INBOARD

OPT.

115

STUD - CASING

115A

HEXNUT - CASING

118

OIL SEAL INBOARD

119

BEARING HOUSING

120

BEARING INBOARD

121

BEARING OUTBOARD

122

OIL SLINGER

124

LOCKNUT - BEARING

125

LOCKWASHER - BEARING

129

OIL SEAL OUTBOARD

130

KEY - SHAFT/COUPLING

131

O-RING - ADAPTER

133

TRICO OILER (Not Shown)

134

BEARING HOUSING DRAIN PLUG

135

BEARING HOUSING VENT PLUG

136

CAPSCREW - FOOT

139

CAPSCREW - BEARING HOUSING

140

CAPSCREW - COVER/ADAPTER

153

MECHANICAL SEAL

177

HOOK SLEEVE

190

GLAND - MECHANICAL SEAL

190G

GLAND GASKET

200

SIGHT GAGE - BEARING HOUSING

201

BEARING CARRIER

201A

SET SCREW - BEARING CARRIER

201B

O-RING - BEARING CARRIER

201C

BEARING CARRIER RETAINER

N/A

OPT.

OPT.

OPT.

N/A

N/A

OPT.

201D

CLAMP RING BEARING HOUSING

OPT.

201E

SOC-CAPSCREW CLAMP

OPT.

Pump Division
Section 4.6

FIGURE 53 - Group 2
ITEM

DESCRIPTION

100

CASING

103

IMPELLER

104

IMPELLER GASKET

105

SHAFT

106

REAR COVER PLATE

107

REAR COVER GASKET

108

BEARING HOUSING ADAPTER

109

BEARING HOUSING FOOT

109A

SHIM

110

GLAND - PACKING

111

STUD - GLAND

111A

HEXNUT - GLAND

112

PACKING SEAL CAGE HALVES

113

PACKING

OPT.

114

DEFLECTOR INBOARD

OPT.

115

STUD - CASING

115A

HEXNUT - CASING

118

OIL SEAL INBOARD

119

BEARING HOUSING

120

BEARING INBOARD

121

BEARING OUTBOARD

122

OIL SLINGER

124

LOCKNUT - BEARING

125

LOCKWASHER - BEARING

129

OIL SEAL OUTBOARD

130

KEY - SHAFT/COUPLING

131

O-RING - ADAPTER

133

TRICO OILER (Not Shown)

134

BEARING HOUSING DRAIN PLUG

135

BEARING HOUSING VENT PLUG

136

CAPSCREW - FOOT

139

CAPSCREW - BEARING HOUSING

140

CAPSCREW - COVER/ADAPTER

153

MECHANICAL SEAL

177

HOOK SLEEVE

190

GLAND - MECHANICAL SEAL

190G

GLAND GASKET

200

SIGHT GAGE - BEARING HOUSING

201

BEARING CARRIER

201A

SET SCREW - BEARING CARRIER

201B

O-RING - BEARING CARRIER

201C

BEARING CARRIER RETAINER

OPT.

OPT.

OPT.

OPT.

201D

CLAMP RING BEARING HOUSING

OPT.

201E

SOC-CAPSCREW CLAMP

OPT.

Option for duplex angular


contact bearings

36

Pump Division
Section 4.6

FIGURE 54 - Group 3

Option for duplex angular


contact bearings

37

ITEM

DESCRIPTION

100

CASING

103

IMPELLER

104

IMPELLER GASKET

105

SHAFT

106

REAR COVER PLATE

107

REAR COVER GASKET

108

BEARING HOUSING ADAPTER

109

BEARING HOUSING FOOT

109A

SHIM

110

GLAND - PACKING

111

STUD - GLAND

111A

HEXNUT - GLAND

112

PACKING SEAL CAGE HALVES

113

PACKING

OPT.

114

DEFLECTOR INBOARD

OPT.

115

STUD - CASING

115A

HEXNUT - CASING

118

OIL SEAL INBOARD

119

BEARING HOUSING

120

BEARING INBOARD

121

BEARING OUTBOARD

122

OIL SLINGER

124

LOCKNUT - BEARING

125

LOCKWASHER - BEARING

129

OIL SEAL OUTBOARD

130

KEY - SHAFT/COUPLING

131

O-RING - ADAPTER

133

TRICO OILER (Not Shown)

134

BEARING HOUSING DRAIN PLUG

135

BEARING HOUSING VENT PLUG

136

CAPSCREW - FOOT

139

CAPSCREW - BEARING HOUSING

140

CAPSCREW - COVER/ADAPTER

153

MECHANICAL SEAL

177

HOOK SLEEVE

190

GLAND - MECHANICAL SEAL

190G

GLAND GASKET

200

SIGHT GAGE - BEARING HOUSING

201

BEARING CARRIER

201A

SET SCREW - BEARING CARRIER

201B

O-RING - BEARING CARRIER

201C

BEARING CARRIER RETAINER

201D

CLAMP RING BEARING HOUSING

201E

SOC-CAPSCREW CLAMP

OPT.

OPT.

OPT.

OPT.

Pump Division
Section 5.0

Section 5.0 MARK III SEALMATIC PUMP


5.1 GENERAL DESCRIPTION OF THE PUMP
The Mark III Sealmatic pump is an extension of the Mark III
Standard ANSI pump with a special rear cover, repeller and
repeller cover interchanged for the Standard pump rear cover.
The repeller provides a dynamic seal and keeps the seal
chamber area clear of liquid when the pump is operating. A
static seal is required to prevent leakage when the pump is not
operating. There are three optional static sealing devices
offered. The optimal choice is determined by the application.

standard family of shafts. The repeller slips over the end of the
standard shaft with a hook coming against the end of the shaft.
The hook is squeezed and held in place by the impeller.
The Sealmatic can be supplied on any Group 2 or Group 3
Mark III pump.

An important feature of the Mark III Sealmatic pump is that it


utilizes the standard Durco Mark IIIA power end with the

38

Pump Division
Section 5.2

5.2 OVERVIEW

FIGURE 56 Group 2

REPELLER FUNCTION
This pump differs from the conventional Mark III in that it has a
repeller (#181). The repeller is a hydro-dynamic sealing device.
When the pump is operating, it pumps the fluid out of the seal
chamber.

DESIGN DIFFERENCE
The rear cover/repeller cover design is different for Group 2 and
Group 3 pumps. Figure 56 shows the Group 2 design and
Figure 57 shows the Group 3 design. Note: Only the reverse
vane impeller can be used in the Sealmatic pump. The front
vane open style impeller should not be used.

SEAL OPTIONS
When the pump is not operating, a static seal is required. Three
designs are available. The choice of design depends on the
application.
FIGURE 55
Item
100
103
104
106
107
110
111
111A
112
113
115
115A
140
180
181
181A
182
183
190
195
297
298
299
330

39

Part Name
Casing
Impeller
Impeller Gasket
Rear Cover
Rear Cover Gasket
Gland
Stud
Hex Nut
Seal Cage
Packing
Casing Studs
Casing Studs Nuts
Capscrews - Adapter to Cover
Cover Repeller
Repeller
Repeller O-ring
Gasket - Repeller Cover
Repeller O-ring
Gland
Capscrews - Repeller Cover to Cover
Seat
Lip Seal
Lip Seal O-ring
Mechanical Seal

FIGURE 57 Group 3

Pump Division
Section 5.2

SEAL OPTIONS (CONTD)


Packing Option A

Checkmatic Option B

This option utilizes graphite packing to obtain a static seal. The


standard packed unit as shown in Figure 57 and 58 is
recommended for clear fluids and requires no lubrication or
flushing. For applications where the pumpage contains solids
that may crystalize or settle out when the pump is idle, the 1/4
in NPT flush port and packing arrangement as show in Figure
59 can be utilized to purge flush prior to start-up or shut-down.

This design utilizes the packed box cover and consists of a


gland, ceramic seat and opposing rotating lips which contact the
ceramic seat faces. The inboard lip seals at shut-down and the
outboard lip seals against air intake during operation. Available
on all Sealmatic pumps. See Figure 60 and 61.
FIGURE 60

FIGURE 58

FIGURE 61

FIGURE 59

Shaft

40

Pump Division
Section 5.3

Dry Running Seals Option C


Dry running gas seals utilize special seal face configurations
that create a hydrodynamic film of air between the seal faces
when the pump is operating. This film forms a seal, prevents
face contact, and eliminates heat generation. When the pump is
not running, springs keep the faces in contact, thereby
providing a static seal. The dynamic seal is maintained by the
repeller. See Figure 56 and 62.
FIGURE 62

5.3 OPERATION
GENERAL INFORMATION
The Durco Mark III Sealmatic pump was designed and sized to
specific operating requirements. The Flowserve sales person
has carefully selected the correct Sealmatic pump for the
customers system. Under no circumstance should a Sealmatic
pump be operated under any conditions other than those for
which it was intended without the recommendation of a
Flowserve sales representative.

START-UP
When starting a Sealmatic pump for the first time make certain
that the suction valve is completely open, the discharge valve is
throttled and that there is liquid in the pump. Determine that
there will be a positive head at the suction when start-up is
made. Check the technical data and nameplate to make certain
that the repeller is capable of handling the suction head.

41

Pump Division
Section 5.4

5.4 MAINTENANCE
DISASSEMBLY OF GROUP 2 PUMPS
1. Remove the impeller (#103).
2. Remove the gland nuts (#111A).
3. Remove the capscrews (#195) that hold the rear cover (106)
to the repeller cover (#180). Remove the cover.
4. The repeller (#181) is now exposed and should be free to
slip from the shaft. If not, take two flat tools such as heavy
screwdrivers and insert between the repeller and repeller
cover at two points 180 apart and exert firm pressure
against the repeller. This should break it free from the shaft.
5. Remove the repeller cover (#180).
6. Remove shaft seal components and gland.

DISASSEMBLY OF GROUP 3 PUMPS


1. Remove the impeller (#103).
2. Remove the gland nuts (#111A).
3. Remove the capscrews (#195) that hold the rear cover (106)
to the repeller cover (#180). Remove the cover.
4. The repeller (#181) is now exposed and should be free to
slip from the shaft. If not, use the Durco impeller wrench
and the techniques described on Page 22. This should break
it free from the shaft.
5. Remove the repeller cover (#180).
6. Remove shaft seal components and gland.

6. The Checkmatic gland must now be moved forward toward


the impeller, pushing the forward lip ahead of it. It is
important that the forward lip be firmly loaded against the
seat when the gland is seated. Care must be taken to
maintain even pressure on both sides of the gland, keeping
the lip seal/ceramic seal faces perpendicular to the shaft.
Tighten the gland nuts evenly. Finally, the rear lip must be
slipped forward and tight against the seat. Care should be
taken so as not to damage the seal face.

REASSEMBLY SEALMATIC WITH DRY RUNNING SEAL


Note: The John Crane 28LD seal is used as an example.
1. Lubricate shaft and 28LD internal O-ring with non-abrasive
liquid hand soap.
2. Slide 28LD all the way back to bearing housing.
3. Place repeller cover (#180) face down on work bench and
install 28LD seat with gland gasket and attach gland.
4. Install repeller cover, repeller, rear cover, and impeller as
instructed in Appendix H except this time do not adjust
the shaft.
5. Slide rotary of 28LD seal forward until its disc and scribe
line line up. Then tighten set screws. Pump power unit is
ready for casing installation.

REASSEMBLY SEALMATIC WITH PACKING


1. Reinstall repeller cover, repeller, rear cover, and impeller as
instructed in Appendix H.
2. Reinstall packing.
3. Attach gland (#110) to repeller cover (#180) using studs
(#111) and nuts (#111A).

REASSEMBLY SEALMATIC WITH CHECKMATIC SEAL


1. Remove any sharpness of edge at wet end of shaft with
#400 emery cloth. Clean all exposed surfaces of the wet end
of the shaft. Install a shaft guide tool from the Durco Tool
Kit, Figure 21. Do not lubricate surfaces. Slide one lip seal
onto the shaft with a lip facing away from the bearing
housing. Position the O-ring (#299) over the tail of the lip
seal. See Figure 61. Slide it all the way to the bearing
housing.
2. Clean all surfaces of the gland, and install the ceramic into
the gland.
3. Slide gland/ceramic seat assembly onto the shaft and move
it back to the lip seal.
4. Slide a second lip seal onto the shaft, with the lip facing the
bearing housing, all the way to the ceramic seat. Position the
O-ring (#299) over the tail of the lip seal. See Figure 61.
5. Reinstall the repeller cover, repeller, rear cover, and impeller
as instructed in Appendix H.

42

Pump Division
Section 5.5

In certain applications of Sealmatic pumps, air may be


entrained in the liquid being pumped. Figure 63 shows the
typical rate of air ingress for the 71/2 in (191 mm) diameter
dual head repeller in a 10 in (254 mm) pump at 1800 rpm.
Approximately the same rate of ingress should be expected with
other repellers. Note that air ingress can be kept to an extremely
low level by selecting a repeller to operate near its maximum
suction head capability.
Horsepower consumed by the repeller is shown on the repeller
performance characteristic curves. This horsepower is added to
the horsepower taken from the standard pump performance
curve to determine the total water horsepower requirement for
the Sealmatic pump.
43

STATIC SUCTION PRESSURE IN METERS


3
0
.6 1.2 1.8 2.4 3.0 3.6

100
90
80
70
60
50
40
30
20
10
0
30

20

10
0
2
4
6
8
STATIC SUCTION PRESSURE IN FEET

10

12

FIGURE 63A
Temperature Rise in Repeller Chamber
vs. Static Suction Head
9

STATIC SUCTION PRESSURE IN METERS


3
0
6
12

18

22.4

40

30

20

10

10 GPM (2 m3/h)

20 GPM (4 m3/h)

16.8

11.2

5.6

100 GPM (23 m3/h)


0
30

0
20

10
0
20
40
STATIC SUCTION PRESSURE IN FEET

60

TEMPERATURE C ABOVE PUMPAGE

Caution must be exercised in applying Sealmatic pumps for


liquids having surface tensions below 50 dynes per cm at 3600
rpm and below 30 dynes per cm at 1800 rpm. Such liquids
have a greater tendency to be atomized by the repeller vanes
moving through the air-liquid interface. The resultant vapor may
then condense on the non-wetted internal surfaces and drip
from the shaft area. Consult a Flowserve Sales Engineer for
assistance with applications involving low surface tensions.

MAX. POS. HD. - REPELLER OVERDRIVEN

Some liquids have physical properties which tend to reduce the


stability of the air-liquid interface created by the repeller in the
repeller chamber. This instability may lead to a misting of liquid
which can result in a small stream of leakage or a constant
dripping from the shaft area. Generally, selecting a repeller
which will operate toward the high end of its suction head
capability will assure a more stable air-liquid interface and
thus avoid this problem.

MAX. NEG. SUCT. BROKEN PRIME

To select a repeller, compare the range of suction pressures


expected in each application to the repeller characteristic
curves. The curves show the range of static suction heads for
which the repeller has been tested and found to prevent
leakage. These curves are published in the Repeller Selection
Curves brochure.

MAX. NEG. SUCT. BROKEN PRIME

REPELLER SELECTION INSTRUCTIONS

FIGURE 63
Air Ingress into Product at Standard Atmosphere
vs. Static Suction Head

APPROX. AIR INGESTED INTO PUMP


CC/MIN. AT STD. ATMOSPHERE

There are two basic repeller configurations, one to accommodate only positive suction heads of fairly large magnitude
and another dual head repeller that will accommodate suction
heads that may be negative as well as positive; while the pump
is in operation, however, the magnitude of its positive head
capability is reduced. It should be understood that under no
circumstances can the pump be started and primed unless the
suction piping is flooded with liquid. This requirement would
preclude the use of a SEALMATIC pump as a normally
employed self-priming pump. Performance capabilities of the
available repellers are given in the Flowserve bulletin Sealmatic
Repeller Selection Curves.

Some of the horsepower consumed by the repeller is imparted


to the liquid in the repeller chamber as heat. The amount of heat
imparted during 1800 rpm operation is negligible; however, it
may be significant at 3600 rpm. The repeller hub is designed to
promote circulation of liquid between the repeller chamber and
the casing and prevent temperature build-up by dissipating the
heat throughout the volume of liquid passing through the
casing. Figure 63A shows anticipated temperature rise in the
repeller chamber for various flow rates through the casing.
Where temperature rise may be critical, contact a Flowserve
Sales Engineer. Note: The Sealmatic must be flooded at time
of start-up.

TEMPERATURE F ABOVE PUMPAGE

5.5 MISCELLANEOUS INFORMATION

Pump Division
Section 5.6

5.6 SEALMATIC SPARE PARTS


Note: Group 2 pump is shown. See Figure 54 to see a Group 3 power end. See Figures 55, 56, 57
for additional wet end drawings.

ITEM

DESCRIPTION

100

CASING

103

IMPELLER

104

IMPELLER GASKET

105

SHAFT

106

REAR COVER PLATE

107

REAR COVER GASKET

108

BEARING HOUSING ADAPTER

109

BEARING HOUSING FOOT

109A

SHIM

110

GLAND - PACKING

111

STUD - GLAND

111A

HEXNUT - GLAND

112

PACKING SEAL CAGE HALVES

113

PACKING

OPT.

114

DEFLECTOR INBOARD

OPT.

115

STUD - CASING

115A

HEXNUT - CASING

118

OIL SEAL INBOARD

OPT.

119

BEARING HOUSING

120

BEARING INBOARD

121

BEARING OUTBOARD

122

OIL SLINGER

124

LOCKNUT - BEARING

125

LOCKWASHER - BEARING

129

OIL SEAL OUTBOARD

130

KEY - SHAFT/COUPLING

131

O-RING - ADAPTER

133

TRICO OILER (Not Shown)

134

BEARING HOUSING DRAIN PLUG

135

BEARING HOUSING VENT PLUG

136

CAPSCREW - FOOT

139

CAPSCREW - BEARING HOUSING

140

CAPSCREW - COVER/ADAPTER

153

MECHANICAL SEAL

177

HOOK SLEEVE

180

COVER - REPELLER

OPT.

OPT.

OPT.

181

REPELLER

190

GLAND - MECHANICAL SEAL

190G

GLAND GASKET

200

SIGHT GAGE - BEARING HOUSING

201

BEARING CARRIER

201A

SET SCREW - BEARING CARRIER

201B

O-RING - BEARING CARRIER

201C

BEARING CARRIER RETAINER

201D

CLAMP RING BEARING HOUSING*

201E

SOC-CAPSCREW CLAMP*

330

MECHANICAL SEAL

*OPTIONAL GROUP 2

44

Pump Division
Section 6.0

Section 6.0 MARK III UNITIZED SELF-PRIMING PUMP


6.1 GENERAL DESCRIPTION OF THE PUMP
Mark III Unitized Self-Priming pumps combine the best design
features of Mark III Standard pumps with efficient self-priming
casings. These specific-purpose wet end parts fit the basic
building block philosophy in that they utilize the Standard pump
components from the impeller on back to the bearing housing.
The self-priming casings were designed to pump from liquid
sources which do not flow naturally to the pumps suction,
such as from sumps or from the tops of tank cars.

45

Pump Division
Section 6.2

6.2 PUMP INSTALLATION AND OPERATION

FIGURE 64

Installation of the self-priming pump is perhaps more critical


than any other of the Durco centrifugal pumps. The suction
piping must be as short as possible and be as close to the
diameter of the pumps suction nozzle as is practical.
The pump works by removing the air contained in the suction
piping. Once removed, it operates exactly the same as a flooded
suction Standard pump. The longer the suction pipe, the greater
the volume of air that has to be removed. The larger the
diameter of the pipe, the greater the volume of air. The suction
piping and the seal chamber/stuffing box must be airtight, for
any leak will destroy the partial vacuum which is created by
the impeller. This vacuum is what allows the liquid to enter
the pump.
Initial priming liquid must be added to the pump casing until
the liquid level has reached the bottom of the suction nozzle
(See Figure 64). Once the initial prime is in place, the pump will
automatically replenish itself and additional priming liquids are
not normally necessary. If the pump sits idle in the hot sun for
extended periods, additional priming liquid might have to be
added to make up for evaporation losses. Another important
dimension to check is the minimum submergence of the
suction pipe into the sump, S as shown in Figure 64. See
Figure 68 for the acceptable minimum values for S.
The priming cycle begins pump operation. When the pump is
turned on, the spinning impeller quickly moves the priming
liquid out of the suction nozzle creating a partial vacuum in the
suction line. The sump liquid begins to rise in the suction line,
or the liquid in the tank car begins its ascent up the dip tube
(See Figure 67). The liquid passes from the impeller and back
into the casing where any entrained air is vented out the
discharge nozzle. There must be a way for this air to vent. Our
typical recommendation is to provide a small diameter air bleed
line from discharge pipe to sump if the air is not able to freely
vent out the discharge pipe as shown in Figure 66. The liquid
falls to the bottom of the priming chamber where it passes
through a bypass slot connecting the priming chamber with the
volute. The liquid then returns to the impeller where it is mixed
with air from the suction pipe. This mix of liquid and air is
pumped to the priming chamber again until all of the air is
removed from the suction piping. This process may take
anywhere from 15 seconds to several minutes depending upon
the amount of air to be removed.

FIGURE 65
PRIMING CHAMBER FILL

TAP II
TAP III
TAP I

FIGURE 66

Air Bleed Line

Normal operation commences as soon as the suction piping


and the priming chamber are void of air (See Figure 67). Liquid
from the impeller then passes through the discharge passage
and into the priming chamber. At the same time, liquid from the

46

Pump Division
Section 6.2

.6

MINIMUM SUBMERGENCE (S), m


1.2
1.8
2.4
3.0
3.6
4.2

4.8

16

293

12

220

146

73

6
8
10
12
14
MINIMUM SUBMERGENCE (S), ft

SUCTION PIPE VELOCITY, m/min

FIGURE 67

FIGURE 68

SUCTION PIPE VELOCITY, f/s

impeller also passes through the bypass slot in the bottom of


the casing and into the priming chamber. These two flows join
and pass out of the priming chamber through the discharge
nozzle located at the top of the chamber.

16

It is usually recommended that a bypass line be installed from


the casing Tap III (See Figure 65) to the seal chamber or the
gland. The purpose of this line is to keep the seal faces wet
during the priming cycle. The seal chamber is under negative
pressure during priming cycle. It pulls liquid from the flood
casing.
When possible, it is recommended that the suction piping be
sloped slightly downward to the casing suction flange. This will
ensure that no priming fluid is lost down the suction line while
the pump is priming.
Shut down occurs when the pump is turned off either by a float
switch in the sump or manually by the pump operator. The
liquid in the discharge piping falls back into the priming
chamber and washes back through the impeller and suction
nozzle. The backwash creates a siphon effect in the casing and
suction nozzle until the liquid falls below the nozzle level and
the siphon is broken. The inertia of the liquid flowing
backwards pulls the level of the priming chamber to a lower
level than achieved with the initial fill. Though the level is lower,
there is still sufficient liquid in the priming chamber to allow the
pump to reprime itself during the next pumping cycle.

47

Special Note: The clearance between the outside diameter of the


impeller and the casing cutwater is crucial. The clearance must
be 1/8 in (3 mm) or less. If this close clearance is not
maintained the pump may not prime.

Pump Division
Section 6.3

6.3 SPARE PARTS


The parts diagram is the same as the Mark III standard pump
with the exception of the special casing. The pump shown below

is a Group 2. Refer to Figure 52 to see a Group 1 pump, or to


see the duplex angular contact bearing option.

FIGURE 69
ITEM

DESCRIPTION

100

CASING

103

IMPELLER

104

IMPELLER GASKET

105

SHAFT

106

REAR COVER PLATE

107

REAR COVER GASKET

108

BEARING HOUSING ADAPTER*

109

BEARING HOUSING FOOT

109A

SHIM

110

GLAND - PACKING

111

STUD - GLAND

111A

HEXNUT - GLAND

112

PACKING SEAL CAGE HALVES

113

PACKING

OPT.

114

DEFLECTOR INBOARD

OPT.

115

STUD - CASING

115A

HEXNUT - CASING

118

OIL SEAL INBOARD

OPT.

119

BEARING HOUSING

120

BEARING INBOARD

121

BEARING OUTBOARD

122

OIL SLINGER

124

LOCKNUT - BEARING

125

LOCKWASHER - BEARING

129

OIL SEAL OUTBOARD

130

KEY - SHAFT/COUPLING

131

O-RING - ADAPTER*

133

TRICO OILER (Not Shown)

134

BEARING HOUSING DRAIN PLUG

135

BEARING HOUSING VENT PLUG

136

CAPSCREW - FOOT

139

CAPSCREW - BEARING HOUSING*

140

CAPSCREW - COVER/ADAPTER

153

MECHANICAL SEAL

177

HOOK SLEEVE

190

GLAND - MECHANICAL SEAL

OPT.

OPT.

OPT.

190G

GLAND GASKET

200

SIGHT GAGE - BEARING HOUSING

201

BEARING CARRIER

201A

SET SCREW - BEARING CARRIER

201B

O-RING - BEARING CARRIER

201C

BEARING CARRIER RETAINER

201D

CLAMP RING BEARING HOUSING

OPT.

201E

SOC-CAPSCREW CLAMP

OPT.

*GROUP 2 ONLY

48

Pump Division
Section 7.0

Section 7.0 MARK III RECESSED IMPELLER PUMP


7.1 GENERAL DESCRIPTION OF THE PUMP
The Recessed Impeller is an open-vane design that has the
shroud attached to the rear of the vanes. The impeller is located
a distance of two inches or so from the suction face of the
casing. When the impeller spins, it sets up a vortex within the
casing. This swirling liquid is fed from the center via the suction
nozzle and exits tangentially from the vortex through the
discharge nozzle.
Very little of any solids that may be contained in the liquid
actually touch the impeller. Rather, they are swept up in the
swirling motion and conducted in direct fashion to the
discharge nozzle. The discharge nozzle is placed at a tangent

49

to the swirling flow so that the fluid flows smoothly out of the
pump. Top, center-line discharge is not desirable as the extra
bends in the discharge nozzle necessary to locate the flange in
the center would disrupt the flow and increase the possibility of
wearing out the casing.
Except for the impeller and casing, all other parts are identical
to the standard Mark III pump.

Pump Division
Section 7.2

7.2 SETTING THE IMPELLER

7.3 SPARE PARTS

The impeller is set off of the rear cover plate, just like the
reverse vane impeller on the Mark III standard pump. Refer
to Appendix D for instructions on setting the impeller.

The parts diagram is the same as the Mark III standard pump
with the exception of the casing and impeller. The pump shown
below is a Group 2. Refer to Figure 52 to see a Group 1 pump,
or to see the duplex angular contact bearing option.

FIGURE 70
ITEM

DESCRIPTION

100

CASING

103

IMPELLER

104

IMPELLER GASKET

105

SHAFT

106

REAR COVER PLATE

107

REAR COVER GASKET

108

BEARING HOUSING ADAPTER*

109

BEARING HOUSING FOOT

109A

SHIM

110

GLAND - PACKING

111

STUD - GLAND

111A

HEXNUT - GLAND

112

PACKING SEAL CAGE HALVES

113

PACKING

OPT.

114

DEFLECTOR INBOARD

OPT.

115

STUD - CASING

115A

HEXNUT - CASING

118

OIL SEAL INBOARD

OPT.

119

BEARING HOUSING

120

BEARING INBOARD

121

BEARING OUTBOARD

122

OIL SLINGER

124

LOCKNUT - BEARING

125

LOCKWASHER - BEARING

129

OIL SEAL OUTBOARD

130

KEY - SHAFT/COUPLING

131

O-RING - ADAPTER*

133

TRICO OILER (Not Shown)

134

BEARING HOUSING DRAIN PLUG

135

BEARING HOUSING VENT PLUG

136

CAPSCREW - FOOT

139

CAPSCREW - BEARING HOUSING*

140

CAPSCREW - COVER/ADAPTER

153

MECHANICAL SEAL

177

HOOK SLEEVE

190

GLAND - MECHANICAL SEAL

OPT.

OPT.

OPT.

190G

GLAND GASKET

200

SIGHT GAGE - BEARING HOUSING

201

BEARING CARRIER

201A

SET SCREW - BEARING CARRIER

201B

O-RING - BEARING CARRIER

201C

BEARING CARRIER RETAINER

201D

CLAMP RING BEARING HOUSING

OPT.

201E

SOC-CAPSCREW CLAMP

OPT.

*GROUP 2 ONLY

50

Pump Division
Section 8.0

Section 8.0 MARK III LO-FLO PUMP


8.1 GENERAL DESCRIPTION OF THE PUMP

8.2 SETTING THE IMPELLER

The Durco Mark III Lo-Flo Pump has a special design casing
and impeller which allows it to work very reliably at low flows.
The pump has an impeller with radial vanes that twist around
the hub, and a circular, concentric casing. This design ensures
that, at low flows, no significant hydraulic radial forces are
transmitted to the shaft. Minimum flow on this pump is
Minimum Thermal Flow. This is defined as the minimum flow
that will not cause an excessive temperature rise.

The impeller for his pump is set off the casing, just like the
standard front vane open style impeller. Refer to Appendix E for
instructions on how to install, remove, and set this impeller.

WARNING
Do not operate the Lo-Flo pump below Minimum Thermal Flow,
as this could cause an excessive temperature rise. Contact a
Flowserve Sales Engineer for determination of Minimum
Thermal flow.
Only the impeller and casing are special, all other parts are
standard Mark III parts. Note: The adapter on the 13 in pump is
the standard adapter but with 16 holes drilled in it for
attachment to the casing.

51

Pump Division
Section 8.3

8.3 SPARE PARTS


The parts diagram is the same as the Mark III standard pump
with the exception of the casing and impeller. The pump shown
below is a Group 2. Refer to Figure 52 to see a Group 1 pump,
or to see the duplex angular contact bearing option.
FIGURE 71
ITEM

DESCRIPTION

100

CASING

103

IMPELLER

104

IMPELLER GASKET

105

SHAFT

106

REAR COVER PLATE

107

REAR COVER GASKET

108

BEARING HOUSING ADAPTER*

109

BEARING HOUSING FOOT

109A

SHIM

110

GLAND - PACKING

111

STUD - GLAND

111A

HEXNUT - GLAND

112

PACKING SEAL CAGE HALVES

113

PACKING

OPT.

114

DEFLECTOR INBOARD

OPT.

115

STUD - CASING

115A

HEXNUT - CASING

118

OIL SEAL INBOARD

OPT.

119

BEARING HOUSING

120

BEARING INBOARD

121

BEARING OUTBOARD

122

OIL SLINGER

124

LOCKNUT - BEARING

125

LOCKWASHER - BEARING

129

OIL SEAL OUTBOARD

130

KEY - SHAFT/COUPLING

131

O-RING - ADAPTER*

133

TRICO OILER (Not Shown)

134

BEARING HOUSING DRAIN PLUG

135

BEARING HOUSING VENT PLUG

136

CAPSCREW - FOOT

139

CAPSCREW - BEARING HOUSING*

140

CAPSCREW - COVER/ADAPTER

153

MECHANICAL SEAL

177

HOOK SLEEVE

190

GLAND - MECHANICAL SEAL

OPT.

OPT.

OPT.

190G

GLAND GASKET

200

SIGHT GAGE - BEARING HOUSING

201

BEARING CARRIER

201A

SET SCREW - BEARING CARRIER

201B

O-RING - BEARING CARRIER

201C

BEARING CARRIER RETAINER

201D

CLAMP RING BEARING HOUSING

OPT.

201E

SOC-CAPSCREW CLAMP

OPT.
* GROUP 2 ONLY

52

Pump Division
Appendix A

APPENDIX A
desired, it can be accomplished by use of our C-Plus
optional alignment feature, described in Section 3. If
desired, alignment may be checked with indicators as
shown:

IOM FOR C-FLANGE MOTOR ADAPTERS


INTRODUCTION
1.1

1.2

C-flange motor adapters provide a means of obtaining


pump to motor alignment. A C-flange type motor is
mounted on the pump bearing housing with the use of an
intermediate adapter. Alignment is achieved through the
use of machined locating and piloting surfaces on the
bearing housing and adapter. Care should be taken to
ensure these surfaces are kept free from handling
damage defects or dirt which will affect alignment. The
drawings at the end of this bulletin show typical crosssectional views of Mark III Group I and II pumps with the
C-flange adapter option. Group III pumps are not
available with this option.
Motors used may range from 182TC frames to 405TSC.
Motors 324TSC to 405TSC (inclusive) must be short
shaft (TSC) type. Motors from 182TC to 286TC
(inclusive) may be either standard (TC) or short shaft
(TSC) type. Motor frames smaller than 182TC can not be
accommodated.

PUMP INSTALLATION
2.1

2.2
2.3
2.4

Refer to standard pump foundation discussion for


installation of grouted and stilt mounted baseplates. It
may be necessary to remove the pump from the baseplate to access the grout hole.
Refer to standard pump piping discussion for piping
recommendations.
Temporary supports (installed for shipping only) should
be removed from under the motor.
It is necessary to wire the electric motor with a flexible
conduit of sufficient length to allow the motor/power end
assembly to be moved back from the casing for
maintenance.

FIGURE A-1

Coupling Hub
Motor Shaft

Item
1

Reqd.
1

Matl.

SR

SR

SR

5A
5B
6
7

1
1
1
1

SR
SR
SR
SR

It is absolutely essential that the motor rotation be checked


before connecting the shaft coupling. Incorrect rotation of the
pump for even a short time can unscrew and damage the
impeller, casing and shaft. The pump must turn clockwise
when viewed from the motor end.
The coupling sleeve has been purposely left out to aid in
checking motor rotation without endangering the pump.

53

Alignment between the pump shaft and motor shaft is


built-in by the precise machining of the parts that
position these shafts. Parallel alignment of 0.007 in
(0.18 mm) and angular alignment of 0.002 in/in (0.002
mm/mm) can be expected. If a more refined alignment is

Pump Shaft

Description
Miniature Indicator,
Lug Back Starrett *80-144J
3/8 dia x 2-1/2 post with
1/4-20 x 5/8 thd. &
3/8-16x3/4 thd.
1/4 x 1/4 Starrett
*657S Sleeve
3/8 x 1/4 Starrett
*196L Sleeve
1/4-20 Hex nut
3/8-16 Hex nut
1/4 dia x 5 rod
Indicator attachment,
Starrett *657Y

a. Install one half of the Rexnord Omega coupling sleeve.


b. Mount post (2) into an unused hole in the coupling hub
and lock in place with hex nut (5).
c. Assemble the rest of the indicator as shown with the
indicator in contact with the other coupling hub.
d. Zero the indicator.
e. Rotate the entire assembly 360 degrees. Note the
indicator readings as the shaft is rotated. Both shafts
will rotate together.
f. The shaft to shaft parallel misalignment should be
within 0.007 in (0.18 mm) FIM (Full Indicator
Movement).
g. It is necessary to be aware of the affects of indicator
sag and to take them into account when making
measurements.

CAUTION

2.5

Coupling Hub

2.6

The indicator kit should be removed. The coupling sleeve


should be installed using the capscrews provided by
Rexnord for that purpose. Observe and follow the torque
instructions provided by Rexnord.

Pump Division
Appendix A

WARNING
Failure to secure capscrews properly could cause coupling
component(s) to become dislodged during operation resulting
in personal injury.
2.7

Install coupling guards (#402).

C-PLUS ALIGNMENT FEATURE


3.1

If the C-Plus alignment feature is desired the spacer ring


must be installed before the motor is assembled. The
drawing below shows the components of the C-Plus
feature.

RETROFIT OF EXISTING PUMPS

FIGURE A-2

Motor
Adjuster
Jam Nut
Spacer
Ring

3.1.1 With the C-Plus alignment feature and the indicator kit in
place, alignment is changed by moving the motor radially
using the four adjustment screws. Adjusting screws are
located to push on four of the motor mounting studs as
shown in Figure A-2.
3.2 The motor mounting screws must be snug but not tight
when attempting to adjust motor location. Depending on
the size of motor it may be necessary to check the
alignment with the motor fasteners tight. Corrections
may be made until 0.002 in (0.05 mm) FIM (or the
desired) alignment is achieved. The adjusters, adjuster
jam nuts and the motor fasteners should all be tightened.
3.3 The indicator kit should be removed, the coupling and
coupling guard installed as described in paragraphs 2.6
and 2.7.

Nut
Motor
Mounting
Stud

Motor
Adapter

4.1

Any pump to be retrofitted with the C-flange motor


adapter must have machined motor adapter piloting and
locating surfaces on the bearing housing. The baseplate
must be drilled for the motor adapter.
4.2 Referring to the cross section drawing, mount motor
adapter (#400) with adjustable foot (#401) installed onto
the bearing housing using three hex cap screws (#403).
Loosely install motor adapter mounting fasteners
(#405A) along with any necessary mounting blocks.
Remove the bearing housing foot (#109) and related
hardware.
4.2 Level the pump shaft by adjusting the foot height. Hold a
bubble level axially on the pump shaft extension or on the
top of the discharge flange, and rotate hex foot adjuster
(#401) until the pump is level and parallel with the
baseplate.
4.2.1 A soft foot is to be avoided at the casing and the motor
adapter feet. Check for any gap with a feeler gage. If the
feeler gage indicates a gap, slight adjustment of the hex
foot adjusters and/or tapping down on the discharge
flange with a soft mallet should correct this condition.
Tighten the four pump to baseplate fasteners and tighten
the adjuster locking set screws (#401A).
4.3 Proceed to step 2.4.

54

Pump Division
Appendix A

MARK III 1K PROCESS PUMP C FACE ADAPTER


CROSS SECTIONAL PARTS LIST

Optional
Front Vane
Open
Impeller

Standard
Reverse
Vane
Impeller

ITEM
100
103
104
105
106
107
110
111
111A

DESCRIPTION
CASING
IMPELLER
GASKET, IMPELLER
SHAFT
COVER PLATE
GASKET, COVER
GLAND
STUD, GLAND
HEXNUT, GLAND

ITEM
120
121
124
125
129
130
133
134
135

DESCRIPTION
BEARING I.B.
BEARING O.B.
LOCKNUT, BEARING
LOCKWASHER, BEARING
OIL SEAL O.B.
KEY SHAFT/CPLG
OILER, TRICO
PLUG, DRAIN
PLUG, VENT

112
113

SEAL CAGE HALVE


PACKING

140
153

114
115

DEFLECTOR IL.B.
STUD, CASING

115A
118
119

HEXNUT, CASING
OIL SEAL I.B.
HOUSING, BEARING

* USE C-FACE MOTOR WITH FEET

55

ITEM
201B
201C
400
401
401A
402
402A
403
405

DESCRIPTION
O-RING
RING, SNAP
ADAPTER, C-FACE
FOOT, ADJUSTABLE
SET SCREW
GUARD, COUPLING
SCREW, HEX HEAD
SCREW, HEX HEAD
MOTOR

CAPSCREW, CVR-HSG
SEAL, STUFF BOX

405A
405B

STUD, MOTOR
HEXNUT, MOTOR

177
190

SLEEVE, HOOK
FLANGE, FOLLOWER

406
408

RING SPACER
ADJUSTER SCREW

200
201
201A

SIGHT GLASS
CARRIER, BEARING
SET SCREW

411

ADJUSTER JAM NUT

Pump Division
Appendix A

MARK III 2K PROCESS PUMP C FACE ADAPTER (182TC TO256TC MOTORS)


CROSS SECTIONAL PARTS LIST

Optional
Front Vane
Open
Impeller

Standard
Reverse
Vane
Impeller

ITEM
100
103
104
105
106
107
108
110

DESCRIPTION
CASING
IMPELLER
GASKET, IMPELLER
SHAFT
COVER PLATE
GASKET, COVER
ADAPTER, BRG-HSG
GLAND

ITEM
120
121
124
125
129
130
131
133

DESCRIPTION
BEARING I.B.
BEARING O.B.
LOCKNUT, BEARING
LOCKWASHER, BEARING
OIL SEAL O.B.
KEY SHAFT/CPLG
O-RING, ADAPTER
OILER, TRICO

ITEM
201
201A
201B
201C
400
401
401A
402

DESCRIPTION
CARRIER, BEARING
SET SCREW
O-RING
RING, SNAP
ADAPTER, C-FACE
FOOT, ADJUSTABLE
SET SCREW
GUARD, COUPLING

111
111A
112

STUD, GLAND
HEXNUT, GLAND
SEAL CAGE HALVE

134
135
139

PLUG, DRAIN
PLUG, VENT
CAPSCREW, ADAPTER

402A
403
405

SCREW, HEX HEAD


SCREW, HEX HEAD
MOTOR

113
114
115

PACKING
DEFLECTOR IL.B.
STUD, CASING

139A
140
153

HEXNUT, BRG HSG


CAPSCREW, CVR-ADTR
SEAL - MECHANICAL

405A
405B
406

STUD, MOTOR
HEXNUT, MOTOR
RING SPACER

115A

HEXNUT, CASING

177

SLEEVE

408

ADJUSTER SCREW

118
119

OIL SEAL I.B.


HOUSING, BEARING

190
200

FLANGE, FOLLOWER
SIGHT GLASS

411

ADJUSTER JAM NUT

* USE C-FACE MOTOR WITH FEET

56

Pump Division
Appendix A

MARK III 2K PROCESS PUMP C FACE ADAPTER (284TC & Larger Motors)
CROSS SECTIONAL PARTS LIST
Optional
Front Vane
Open
Impeller

Standard
Reverse
Vane
Impeller

ITEM
100
103
104
105
106
107
108
110
111

DESCRIPTION
CASING
IMPELLER
GASKET, IMPELLER
SHAFT
COVER PLATE
GASKET, COVER
ADAPTER, BRG-HSG
GLAND
STUD, GLAND

ITEM
120
121
124
125
129
130
131
133
134

DESCRIPTION
BEARING I.B.
BEARING O.B.
LOCKNUT, BEARING
LOCKWASHER, BEARING
OIL SEAL O.B.
KEY SHAFT/CPLG
O-RING, ADAPTER
OILER, TRICO
PLUG, DRAIN

111A
112

HEXNUT, GLAND
SEAL CAGE HALVE

135
139

PLUG, VENT
CAPSCREW, ADAPTER

113
114

PACKING
DEFLECTOR IL.B.

139A
140

115
115A
118

STUD, CASING
HEXNUT, CASING
OIL SEAL I.B.

119

HOUSING, BEARING

* USE C-FACE MOTOR WITH FEET

57

ITEM
201
201A
201B
201C
400
401
401A
402
402A

DESCRIPTION
CARRIER, BEARING
SET SCREW
O-RING
RING, SNAP
ADAPTER, C-FACE
FOOT, ADJUSTABLE
SET SCREW
GUARD, COUPLING
SCREW, HEX HEAD

403
405

SCREW, HEX HEAD


MOTOR

HEXNUT, BRG HSG


CAPSCREW, CVR-ADTR

405A
405B

STUD, MOTOR
HEXNUT, MOTOR

153
177
190

SEAL - MECHANICAL
SLEEVE
FLANGE, FOLLOWER

406
408
411

RING SPACER
ADJUSTER SCREW
ADJUSTER JAM NUT

200

SIGHT GLASS

Pump Division
Appendix B

APPENDIX B
ASSEMBLY OF STILT AND SPRING
MOUNTED BASEPLATES
Flowserve offers stilt and spring mounted baseplates. (See
Figure B-1 for stilt mounted option.) General instructions for
assembling these baseplates are given below. For dimensional
information, please refer to the appropriate Flowserve
Sales Print.
FIGURE B-1

FIGURE B-2

STILT BOLT
NUTS
LOCK WASHER
FLOOR CUP

STILT MOUNTED BASEPLATE ASSEMBLY INSTRUCTIONS


Refer to Figure B-2
1. Raise or block up baseplate/pump above the floor to allow
for the assembly of the stilts.
2. Predetermine or measure the approximate desired height
for the baseplate above the floor.
3. Set the bottom nuts (Item ) above the stilt bolt head
(Item ) to the desired height.
4. Assemble lock washer (Item ) down over the stilt bolt.

5. Assemble the stilt bolt up through hole in the bottom plate


and hold in place.
6. Assemble the lock washer (Item ) and nut (Item ) on
the stilt bolt. Tighten the nut down on the lock washer.
7. After all four stilts have been assembled, position the
baseplate in place, over the floor cups (Item ) under each
stilt location, and lower the baseplate to the floor.
8. Level and make final height adjustments to the suction and
discharge pipe by first loosening the top nuts and turning
the bottom nuts to raise or lower the baseplate.
9. Tighten the top and bottom nuts at the lock washer (Item
) first then tighten the other nuts.
10. It should be noted that the connecting pipe lines must be
individually supported, and that the stilt mounted baseplate
is not intended to support total static pipe load.
58

Pump Division
Appendix B

FIGURE B-3
STILT BOLT
BOTTOM SPRING
(31/4 in (83 mm) OD X 4 in (102 mm) FL/CUPS)

TOP SPRING
(2 in (51 mm) OD X 4 in (102 mm) FL/CUPS)

NUTS
FLAT WASHER
LOCK WASHER
FLOOR CUP

1 in (25 mm) Approx. Initial Height

STILT/SPRING MOUNTED BASEPLATE ASSEMBLY


INSTRUCTIONS
Refer to Figure B-3
1. Raise or block up baseplate/pump above the floor to allow
for the assembly of the stilts.
2. Set the bottom nuts (Item ) above the stilt bolt head
(Item ). This allows for 2 in (51 mm) upward movement
for the final height adjustment of the suction/ discharge
flange.
3. Assemble the lock washer (Item ) flat washer (Item )
and bottom spring/cup assembly (Item ) down over the
stilt bolt (Item ).
4. Assemble the stilt bolt/bottom spring up through hole in
the bottom plate and hold in place.
5. Assemble top spring/cup assembly (Item ) down over
stilt bolt.
6. Assemble flat washer (Item ), lock washer (Item ) and
nuts (Item ) on the stilt bolt.

59

7. Tighten down top nuts, compressing the top spring


approximately 1 in (25 mm).
8. After all four stilts have been assembled, position the
baseplate in place, over the floor cups (Item ) under each
stilt location, and lower the baseplate down to the floor.
9. Level and make final height adjustments to the suction and
discharge pipe by first loosening the top nuts, and turning
the bottom nuts to raise or lower the baseplate.
10. To make the stilt bolts more stable, tighten down on the
top nuts, compressing the top spring approximately 1 in
(25 mm), and lock the nuts in place.
11. It should be noted that the connecting pipe lines must be
individually support, and that the spring mounted baseplate
is not intended to support total static pipe loads.

Pump Division
Appendix C

APPENDIX C
CRITICAL MEASUREMENTS AND
TOLERANCES FOR MAXIMIZING MTBPM
PARAMETERS THAT SHOULD BE CHECKED BY USERS
Flowserve recommends that the user check the following
measurements and tolerances whenever pump maintenance is
performed. Each of these measurements is described in more
detail on the following pages.

Topic

Shaft
Diameter tolerance,
under bearings

ASME
B73.1M
Std.
in (mm)

Suggested
By Major
Seal
Vendors
in (mm)

N.S.

Suggested
And/Or
Provided
By Flowserve
in (mm)

0.0002 (0.005)

Impeller
Balance
Bearing Housing
Diameter (ID) tolerance
at bearings
Power End Assembly
Shaft Runout
Shaft Sleeve Runout
Radial Deflection - Static
Shaft Endplay
Seal Chamber
Face Squareness to Shaft
Register Concentricity
Complete Pump
Shaft movement caused
by pipe strain
Alignment
Vibration at bearing
housing

See Note 1

N.S.

0.0005 (0.013)

0.002 (0.05)
0.002 (0.05)

0.001 (0.03)
0.002 (0.05)

0.001 (0.03)
0.002 (0.05)

N.S.
N.S.

0.003 (0.076)
0.002 (0.05)

0.002 (0.05)
0.002 (0.05)

0.003 (0.08)

0.001 (0.03)

0.003 (0.08)

0.005 (0.13)

0.005 (0.13)

0.005 (0.13)

N.S.
N.S.
0.25 in/s
(6.3 mm/s)

0.002 (0.05)

0.002 (0.05)
See Note 2
See Note 3

N.S. = Not specified


Note 1: The maximum values of acceptable unbalance are: 1800 rpm: 0.021 ozin/lb
(1500 rpm: 40 gmm/kg) of mass; 3600 rpm: 0.011 ozin/lb (2900 rpm: 20 gmm/kg)
of mass. Flowserve performs a single plane spin balance on most impellers. The
following impellers are exceptions: 10X8-14 and 10X8-16H. On these Flowserve
performs a two plane dynamic balance, as required by the ASME B73.1M standard.
All balancing, whether single or two plane, is performed to the ISO 1940 Grade 6.3
tolerance criteria.
Note 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 0.002 in (0.05 mm) parallel F.I.M. (Full Indicator Movement) and 0.0005 in/in
(0.0005 mm/mm) angular F.I.M. Closer alignment will extend MTBPM. For a detailed
discussion of this subject see the Alignment section of this IOM.
Note 3: The ASME B73.1M standard for vibration at the bearing housing is 0.25 in/s
(6.3 mm/second) peak velocity or 0.0025 (63 m) peak-to-peak displacement.
Flowserve recommends the following peak velocities, in in/s (mm/second): Group 1 =
0.1 (2.5), Group 2 = 0.15 (3.8), Group 3 = 0.25 (6.3).

ADDITIONAL PARAMETERS CHECKS BY FLOWSERVE


The parameters listed below are somewhat more 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. These parameters are
described at the end of this appendix.

Topic
Shaft - Maximum roughness
at seal chamber
Bearing Housing - Bore
Concentricity
Complete Pump - Dynamic
Shaft Deflection*

ASME
B73.1M
Std.
32in
(0.80 m)

0.005 in
(0.13 mm)

Suggested
By Major
Seal
Vendors

0.002 in
(0.05 mm)

Suggested
And/Or
Provided
By Flowserve
16in
(0.40 m)
0.001 in
(0.025 mm)
0.002 in
(0.05 mm)

*The ASME standard recommends 0.005 in (0.13 mm) max deflection at the impeller,
while Flowserve provides 0.002 in (0.05 mm) max deflection at the mechanical seal.
The two recommendations are essentially equivalent.

OVERVIEW
When Flowserve introduced the ANSI 3 Power End, a new
concept called The Signature Program was announced. The
objective of this program is to provide our customers with a
complete pumping system with at least three years MTBPM.
Obtaining this objective requires a major commitment from
Flowserve, the seal manufacturer and other suppliers, and
the customer.
First of all, the reliability of a process pump largely depends
upon the correct selection of equipment, including the pump,
seal, and accessories. However, proper handling, installation,
maintenance, and operation are equally important. To maximize
reliability certain parameters must be measured and maintained
within certain specified tolerances.
The primary purpose of this appendix is to provide a summary
of these various physical parameters and the associated
tolerances which Flowserve feels are vital to maximizing pump
MTBPM. (A secondary benefit of controlling these parameters
can be a reduction of seal emissions.) When appropriate, the
appendix also shows pictorially how to take the various
measurements.

SHAFT
Before installing the shaft into the power end it is important to
check the following parameters.

Diameter tolerance, under bearings


In order to ensure that the bearings fit around the shaft
properly, it is important that the shaft diameter is consistently

60

Pump Division
Appendix C

within the min/max values given below. A micrometer should be


used to check the dimension of the OD of the shaft.
US Customary Units
OB bearing/ Bearing
shaft - Shaft
in
Fit

Group 1
1.1811/1.1807

Group 2
1.9685/1.9680

Group 3
2.7559/2.7553

1.1816/1.1812
0.0009T/0.0001T

1.9690/1.9686
0.0010T/0.0001T

2.7565/2.7560
0.0012T/0.0001T

1.3780/1.3775
1.3785/1.3781

1.9685/1.9680
1.9690/1.9686

2.7559/2.7553
2.7565/2.7560

0.0010T/0.0001T

0.0010T/0.0001T

0.0012T/0.0001T

IB bearing/
shaft
in

Bearing
Shaft

Metric
OB bearing/
shaft mm

Bearing

Group 1
30.000/29.990

Group 2
50.000/49.987

Group 3
70.000/69.985

Shaft
Fit
Bearing
Shaft
Fit

30.013/30.003
0.023T/0.003T
35.000/34.989
35.014/35.004
0.025T/0.004T

50.013/50.003
0.026T/0.003T
50.000/49.987
50.013/50.003
0.026T/0.003T

70.015/70.002
0.030T/0.002T
70.000/69.985
70.015/70.002
0.030T/0.002T

IB bearing/
shaft mm

Fit

US Customery Units
OB bearing/ Bearing
housing - Housing
in
Fit
IB bearing/ Bearing
housing - Housing
in
Fit

Group 1
2.8346/2.8341

Group 2
4.3307/4.3301

Group 3
5.9055/5.9047

2.8346/2.8353
0.0012L/0.0000L

4.3310/4.3316
0.0015L/0.0003L

5.9056/5.9067
0.0020L/0.0001L

2.8346/2.8341
2.8346/2.8353

4.3307/4.3301
4.3310/4.3316

5.9055/5.9047
5.9058/5.9065

0.0012L/0.0000L

0.0015L/0.0003L

0.0018L/0.0003L

Metric
OB bearing/ Bearing
housing - Housing
mm
Fit

Group 1
71.999/71.986

Group 2
110.000/109.985

Group 3
150.000/149.979

71.999/72.017
0.031L/0.000L

110.007/110.022
0.037L/0.007L

150.002/150.030
0.051L/0.002L

IB bearing/ Bearing
housing - Housing
mm
Fit

71.999/71.986
71.999/72.017
0.031L/0.000L

110.000/109.985
110.007/110.022
0.037L/0.007L

150.000/149.979
150.007/150.025
0.046L/0.007L

The OD of the bearings should also be checked and should


conform to the min/max values given above.

The ID of the bearings should also be checked and should


conform to the min/max values given above.

POWER END ASSEMBLY


Shaft/Shaft Sleeve Runout

Impeller Balancing

Shaft runout is the amount the shaft is out of true when


rotated in the pump. It is measured by attaching a dial indicator
to a stationary part of the pump so that its contact point
indicates the radial movement of the shaft surface as the shaft
is rotated slowly. If a shaft sleeve is used then shaft sleeve
runout must be checked. It is analogous to shaft runout.
Measurement of shaft runout/ shaft sleeve runout will disclose
any out of roundness of the shaft, any eccentricity between the
shaft and the sleeve, any permanent bend in the shaft, and/or
any eccentricity in the way the shaft or bearings are mounted in
the bearing housing.

Shaft whip is deflection where the centerline of the impeller is


moving around the true axis of the pump. It is not caused by
hydraulic force but rather by an imbalance with the rotating
element. Shaft whip is very hard on the mechanical seal
because the faces must flex with each revolution in order to
maintain contact. To minimize shaft whip it is imperative that
the impeller is balanced. All impellers manufactured by
Flowserve are balanced after they are trimmed. If for any
reason, a customer trims an impeller, it must be re-balanced.
The maximum values of acceptable unbalance are:
1800 rpm: 0.021 ozin/lb (1500 rpm: 40 gmm/kg) of mass
3600 rpm: 0.011 ozin/lb (2900 rpm: 20 gmm/kg) of mass
Flowserve performs a single plane spin balance on most
impellers. The following impellers are exceptions: 10X8-14 and
10X8-16H. On these, a two plane dynamic balance is performed,
as required by the ASME B73.1M standard. All balancing,
whether single or two plane, is performed to the ISO 1940
Grade 6.3 tolerance criteria.

Shaft runout can shorten the life of the bearings and the
mechanical seal. The following diagram shows how to measure
shaft/shaft sleeve runout. Note that both ends need to be
checked. The runout should be 0.001 in (0.025 mm) FIM or less.
FIGURE C-1

BEARING HOUSING
Diameter (ID) tolerance at bearings
An inside caliper should be used to check the dimension of the
ID of the housing and bearing carrier. The diameter must be
within the following min/max values given in order to provide
the proper bearing tightness.

61

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
ten pounds to the impeller end of the shaft. While applying this
force, the movement of an indicator is observed as shown in the
following diagram. The movement should be checked at a point

Pump Division
Appendix C

as near as possible to the location of the seal faces. A movement


of more than 0.002 in (0.05 mm) is not acceptable.
FIGURE C-2

Register Concentricity
An eccentric seal chamber bore or gland register can 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 concentricity should be less than 0.005 in (0.13 mm). The diagram
below shows how to measure this concentricity.
FIGURE C-5

Shaft Endplay
The maximum amount of axial shaft movement, or endplay, on
a Durco pump should be 0.001 in (0.03 mm) and is measured
as shown below. Observe indicator movement while tapping the
shaft from each end in turn with a soft mallet. Shaft endplay can
cause several problems. It can cause fretting or wear at the
point of contact between the shaft and the secondary sealing
element. It can also cause seal overloading or underloading and
possibly chipping of the seal faces. It can also cause the faces
to separate if significant axial vibration occurs.
FIGURE C-3

COMPLETE PUMP
Shaft Movement Caused by Pipe Strain
Pipe strain is any force put on the pump casing by the piping.
Pipe strain should be measured as shown below. Install the
indicators as shown before attaching the piping to the pump.
The suction and discharge flanges should now be bolted to the
piping separately while continuously observing the indicators.
Indicator movement should not exceed 0.002 in (0.05 mm).
FIGURE C-6

Pump Shaft
SEAL CHAMBER
Face Squareness to Shaft
Also referred to as Seal Chamber Face Run-Out. This runout
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 runout should be less than 0.003 in (0.08 mm) and should
be measured as shown below:
FIGURE C-4

Alignment
Misalignment of the pump and motor shafts can cause the
following problems:
Failure of the mechanical seal
Failure of the motor and/or pump bearings
Failure of the coupling
Excessive vibration/noise
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 flanges are loaded, and at typical
operating temperatures. If proper alignment cannot be
maintained a C-flange motor adapter and/or stilt/spring
mounting should be considered.
62

Pump Division
Appendix C

FIGURE C-7

Parallel

SPECIAL PARAMETERS CHECKED BY FLOWSERVE


Shaft Maximum roughness at seal chamber
The ASME B73.1M standard requires that the surface finish of
the shaft (or sleeve) through the stuffing box and at rubbing
contact bearing housing seals shall not exceed a roughness of
32 in (0.8 m). Durco shafts do not exceed 16 in (0.4 m)
at these areas. Flowserve audits smoothness by using a
profilometer surface finish gauge.

Angular
Many companies today are using laser alignment which is a
more sophisticated and accurate technique. With this method a
laser and sensor measure misalignment. This is fed to a
computer with a graphic display which shows the required
adjustment for each of the motor feet.

Vibration Analysis
Vibration Analysis is a type of condition monitoring where a
pumps vibration signature is monitored on 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 the 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, misalignment, defective bearings,
resonance, hydraulic forces, cavitation, and recirculation. Once
identified, the problem can be corrected, leading to increased
MTBPM for the pump.
Flowserve does not make vibration analysis equipment, however Flowserve strongly urges customers to work with an
equipment supplier or consultant to establish an on-going
vibration analysis program.
The ASME standard for vibration at the bearing housing is
0.25 inches/second (6.35 mm/sec) peak velocity or 0.0025
inches (0.064 mm) peak-to-peak displacement. Flowserve
recommends the following peak velocities:
Group 1
Group 2
Group 3

0.1 in/s
0.15 in/s
0.25 in/s

(2.5 mm/s)
(3.8 mm/s)
(6.4 mm/s)

for best practice of a properly installed and operated pump.

63

Bearing Housing Bore Concentricity


If the bore for holding the bearing is eccentric, the bearing will
be shifted off center. This will contribute to shaft runout.
Flowserve measures this concentricity by using computerized
measuring equipment. The concentricity should not exceed
0.001 in (0.03 mm).

Complete Pump Dynamic Shaft Deflection


In regards to pump operation, a very important factor for
maximizing pump MTBPM is the avoidance of off-design pump
operation. In order to maximize the life of the seal and bearings,
a process pump should be run as close as possible to its Best
Efficiency Point (BEP).
Dynamic shaft deflection is a deflection of the shaft caused by
unbalanced hydraulic forces acting on the impeller. Dynamic
shaft deflection will change as the pump is operated on various
points along the curve. When the pump is operated at BEP, the
shaft deflection is zero. This deflection is very difficult to
measure. The ASME B73.1M standard states that dynamic shaft
deflection at the impeller centerline shall not exceed 0.005 in
(0.13 mm) at maximum load (shutoff) for pump sizes A70 and
smaller and at design load for pump sizes A80 and larger. The
chart on page 61 shows that Durco pumps are below this limit.
At a given point on the curve, the shaft deflection is constant
and is constantly in the same direction. The centerline of the
impeller, though bent from parallel, does not move. For this
reason, in many cases, shaft deflection is not particularly hard
on mechanical seals. It is, however, hard on bearings, since the
force which causes shaft deflection can be a tremendous load
on them. The amount of deflection depends on three factors:
how the shaft is supported, the strength of the shaft and the
amount of unbalanced hydraulic force experienced by the shaft/
impeller. If there seems to be a shaft deflection problem, refer
to the Durco Pump Engineering Manual for a detailed
discussion on how to calculate deflection.

Pump Division
Appendix D

APPENDIX D
INSTALLATION/CLEARANCE SETTING FOR
REVERSE VANE IMPELLER

FIGURE D-3

Install the impeller (#103) by screwing it onto the shaft (use


heavy gloves) until it firmly seats against the shaft shoulder.

WARNING
The impeller could have sharp edges which could cause an
injury. It is very important to wear heavy gloves.
Tighten the impeller with the impeller wrench from the Durco
tool kit. To do this, grasp the impeller in both hands and, with
the impeller wrench handle to the left (viewed from the impeller
end of the shaft) (Figure D-1), spin the impeller forcefully in a
clockwise direction to impact the impeller wrench handle on
the work surface to the right (Figure D-2).
FIGURE D-1

Indicator
Pattern

Rotation Equipment To
0.004 in (0.1 mm) Axial
Movement

CAUTION
Do not attempt to tighten the impeller on the shaft by hitting
the impeller with a hammer or any other object or by inserting
a pry bar between the impeller vanes. Serious damage to the
impeller may result from such actions.

FIGURE D-2

Now set the impeller clearance by loosening the set screws


(#201A) and rotating the bearing carrier (#201) to obtain the
proper clearance. Turn the bearing carrier counterclockwise
until the impeller comes into light rubbing contact with the rear
cover. Rotating the shaft at the same time will accurately
determine this zero setting. Now, rotate the bearing carrier
clockwise to get the proper clearance. Refer to Figure D-4 for
the proper impeller clearance. Rotating the bearing carrier the
width of one of the indicator patterns cast into the bearing
carrier moves the impeller axially 0.004 in (0.1 mm).
(See Figure D-3.)

CAUTION
It is recommended that two people install a Group 3 impeller.
The weight of a Group 3 impeller greatly increases the chance
of thread damage and subsequent lock-up concerns.

64

Pump Division
Appendix D

Determine how far to rotate the bearing carrier by dividing the


desired impeller clearance by 0.004 (one indicator pattern).
Tightening the set screws (#201A) will cause the impeller to
move 0.002 in (0.05 mm) closer to the rear cover because of
the internal looseness in the bearing carrier threads. This must
be considered when setting the impeller clearance. Rotate the
bearing carrier clockwise the required amount to get the
desired clearance to the cover. Lastly, tighten the set screws
(#201A) to lock the bearing carrier in place.
FIGURE D-4
Impeller Clearance Settings
Temperature F (C)
<200
200 to 250
251 to 300
301 to 350
351 to 400
401 to 450
>450

(93)
(93 to 121)
(122 to 149)
(150 to 176)
(177 to 204)
(205 to 232)
(232)

Clearance to cover in (mm)


0.018 0.003 (0.46 0.08)
0.021 (0.53)
0.024 (0.61)
0.027 (0.69)
0.030 (0.76)
0.033 (0.84)
0.036 (0.91)

Notes
1. For 3 x 1.5-13 and 3x2-13 at 3500 rpm add 0.003 in
(0.08 mm).
2. Rotation of bearing carrier from center of one lug to center
of next results in axial shaft movement of 0.004 in
(0.1 mm).
3. Reverse vane impeller set to cover, open impeller to casing.
FIGURE D-5

Example: For an impeller setting of 0.020 in (0.5 mm) off the


rear cover plate, it is necessary to add 0.002 in (0.05 mm) for
the movement caused by tightening the set screws; therefore,

65

an adjustment of 0.022 in (0.56 mm) is needed. First, turn the


bearing carrier counterclockwise until the impeller comes into
light rubbing contact with the rear cover. Now rotate the
bearing carrier clockwise 5-1/2 indicator patterns to get the
0.022 in (0.56 mm) clearance (0.004 x 5-1/2 = 0.022).
Flowserve suggests that a felt tip pen be used to mark an initial
reference point on the bearing housing and the bearing carrier
as shown in Figure D-5. Then make a second mark on the
bearing carrier 5-1/2 indicator patterns counterclockwise from
the initial reference point. Now rotate the bearing carrier clockwise until the second mark on the bearing carrier lines up with
the initial reference point mark on the bearing housing. The
impeller is now set correctly.

Pump Division
Appendix E

APPENDIX E
INSTALLATION/CLEARANCE SETTING FOR
FRONT VANE OPEN STYLE IMPELLER
Install the impeller (#103) by screwing it onto the shaft (use
heavy gloves) until it firmly seats against the shaft shoulder.

WARNING
The impeller could have sharp edges which could cause an
injury. It is very important to wear heavy gloves.

WARNING
Care should be taken in the handling of high chrome iron
impellers.
Tighten the impeller with the impeller wrench from the Durco
tool kit. To do this, grasp the impeller in both hands and, with
the impeller wrench handle to the left (viewed from the impeller
end of the shaft) (Figure E-1), spin the impeller forcefully in a
clockwise direction to impact the impeller wrench handle on the
work surface to the right (Figure E-2).
FIGURE E-1

CAUTION
Do not attempt to tighten the impeller on the shaft by hitting the
impeller with a hammer or any other object or by inserting a
pry bar between the impeller vanes. Serious damage to the
impeller may result from such actions.
Like all front vane open style impellers, the Durco open impeller
clearance must be set off the casing. The casing must be
present to accurately set the impeller clearance. (Realizing that
this can be very difficult, Flowserve strongly promotes the use
of reverse vane impellers, which do not require the presence of
the casing to be properly set.)
Attach the power end/rear cover plate assembly to the casing.
Now set the impeller clearance by loosening the set screws
(#201A) and rotating the bearing carrier (#201) to obtain the
proper clearance. Turn the bearing carrier clockwise until the
impeller comes into light rubbing contact with the casing.
Rotating the shaft at the same time will accurately determine
this zero setting. Now, rotate the bearing carrier counterclockwise to get the proper clearance. Refer to Figure E-4 for
the proper impeller clearance. Rotating the bearing carrier the
width of one of the indicator patterns cast into the bearing
carrier moves the impeller axially 0.004 in (0.1 mm). (See
Figure E-3.)
FIGURE E-3

FIGURE E-2

Indicator
Pattern

Rotation Equipment To
0.004 in (0.1 mm) Axial
Movement

Determine how far to rotate the bearing carrier by dividing the


desired impeller clearance by 0.004 in (0.1 mm) (one indicator
pattern). Tightening the set screws (#201A) will cause the
impeller to move 0.002 in (0.05 mm) away from the casing
because of the internal looseness in the bearing carrier threads.
This must be considered when setting the impeller clearance.
Rotate the bearing carrier counterclockwise the required
amount to get the desired clearance to the casing. Lastly, tighten
the set screws (#201A) to lock the bearing carrier in place.
66

Pump Division
Appendix E

FIGURE E-4
Impeller Clearance Settings
Temperature F (C)
<200
200 to 250
251 to 300
301 to 350
351 to 400
401 to 450
>450

(93)
(93 to 121)
(122 to 149)
(150 to 176)
(177 to 204)
(205 to 232)
(232)

Clearance to casing in (mm)


0.018 0.003 (0.46 0.08)
0.021 (0.53)
0.024 (0.61)
0.027 (0.69)
0.030 (0.76)
0.033 (0.84)
0.036 (0.91)

Notes
1. For 3 x 1.5-13 and 3x2-13 at 3500 rpm add 0.003 in
(0.08 mm).
2. Rotation of bearing carrier from center of one lug to center
of next results in axial shaft movement of 0.004 in
(0.1 mm).
3. Reverse vane impeller set to cover, open impeller to casing.

setting will be 0.018 in (0.46 mm). Tightening the set screws


will cause a 0.002 in (0.05 mm) draw of the bearing carrier
threads, which will give the final setting of 0.020 in (0.5 mm).
The above procedure is fairly straightforward when doing the
final setting of the impeller. However, it can be quite laborious
when doing the preliminary setting in order to establish the
location of the mechanical seal. For this reason, some
companies will take the following shortcut. Before the pump is
taken out of service, they adjust the impeller until it touches the
casing. The impeller is then backed off by 0.020 in (0.5 mm), or
whatever is the desired clearance. Now, the impeller is adjusted
all the way back to the rear cover, and this distance is recorded.
The pump is now removed from the casing and taken to the
shop for maintenance. When it is time to set the seal, the
impeller is simply set off the rear cover by the same distance
recorded earlier.
Note that if the casing, cover, impeller or shaft need to be
replaced this short cut method will not work.

FIGURE E-5

CAUTION
It is recommended that two people install a Group 3 impeller.
The weight of a Group 3 impeller greatly increases the chance
of thread damage and subsequent lock-up concerns.

Example: For an impeller setting of 0.020 in (0.5 mm) off the


casing, it is necessary to subtract 0.002 in (0.05 mm) for the
movement caused by tightening the set screws; therefore, an
adjustment of 0.018 in (0.46 mm) is needed. First, turn the
bearing carrier clockwise until the impeller comes into light
rubbing contact with the casing. Now rotate the bearing carrier
counterclockwise 4-1/2 indicator patterns to get the 0.018 in
(0.46 mm) clearance (0.004 x 4-1/2 = 0.018). Flowserve
suggests that a felt tip pen be used to mark an initial reference
point on the bearing housing and the bearing carrier as shown
in Figure E-5. Then make a second mark on the bearing carrier
4-1/2 indicator patterns clockwise from the initial reference
point. Now rotate the bearing carrier counterclockwise until the
second mark on the bearing carrier lines up with the initial
reference point mark on the bearing housing. At that point, the

67

Pump Division
Appendix F

APPENDIX F
REMOVAL/INSTALLATION OF SEALS WITH
SEALSENTRY FMI SEAL CHAMBER

FIGURE F-1

REMOVAL
After removing the impeller, slide the hook sleeve off the shaft.
Remove the rotating unit from the sleeve. Remove cover.
Remove the stationary seat from the seal chamber counter
bore.

INSTALLATION
1.
2.
3.
4.
5.

6.

7.
8.

Set the impeller as instructed in Appendix D or E.


Remove the impeller.
Install stationary seat into seal chamber counterbore.
Refer to Figure F-1. Measure distance TL from the seal face
on the stationary seat to the end of the hook sleeve.
The seal working length, WL, is determined from the seal
drawing provided by the seal manufacturer. Subtract the seal
working length WL from TL.
The distance remaining, RL, is the distance from the end of
the hook sleeve to the rotating unit. Install the rotating unit
at this location.
Install the hook sleeve onto the shaft.
Install the impeller to the shaft, locking the hook sleeve into
position.

68

Pump Division
Appendix G

APPENDIX G
DURCO MARK III MAINTENANCE
INSTRUCTIONS BEARING HOUSING OIL
SEALS (LABYRINTH TYPE) INPRO/SEAL
VBXX BEARING ISOLATORS

3.

INTRODUCTION
Flowserve Corporation provides pumps fitted with a variety of
labyrinth oil seals. While these instructions are written specifically for the Inpro/Seal VBXX labyrinth, they also apply to seals
of other manufacturers. Specific installation instructions
included with the seal, regardless of manufacturer, should be
observed.
The Inpro VBXX Bearing Isolator is a labyrinth type seal which
isolates the bearings from the environment (uncontaminated),
and retains the oil in the bearing housing. The bearing isolator
consists of a rotor and a stator. The rotor revolves with the
shaft, driven by a close fitted drive ring that rotates with the
shaft. the stator is a stationary component that fits into the
housing bore with a press fit (nominal 0.002 in (0.05 mm)
interference) and with an O ring gasket seal. The two pieces
are assembled as a single unit, and are axially locked together
by an O ring. There is no mechanical contact between the
rotor and stator when the isolator is running.
Stator
Stator

4.

5.

Rotor
Rotor

Vapor Block
Ring
Vapor
Block
Ring

Drive
Ring
Drive Ring

6.

Lube
LubeReturn
Return

The VBXX is not intended to be separated from the bearing


housing/adapter/carrier unless being replaced.
1. If the VBXX is removed from the housing, for any reason, it
must be replaced with a new VBXX to ensure a perfect seal
with the housing bore.
2. Repair or replacement of the seals is only necessary when
excessive oil leakage is evident. However, if for any other
reason, the bearing housing is to be disassembled or the
pump shaft removed, it is recommended that the rotor
O rings (which seal on the shaft) be replaced. Spare or
replacement O rings may be obtained from Inpro
distributors.
69

The Inpro VBXX bearing isolator is a one piece


assembly. The rotor must not pull out of the stator. If the
rotor can be removed, the complete seal assembly must be
replaced.
If the bearing housing or bearing carrier with bronze VBXX
seals is washed or cleaned using a caustic type bath, the
bronze material may discolor (turn black). If this happens,
the complete seal assembly must be replaced. Note: This
may occur if the housing is left in a caustic bath over a long
period of time (more than 8 hours).
To remove the VBXX bearing isolator:
A. Remove the pump shaft as described in the pump
disassembly instructions.
B. From the inside of the bearing housing or bearing carrier,
place a bar (made from a soft material such as wood or
plastic) against the inside face of the seal. Push the seal
out by tapping the bar with a soft mallet or an arbor
press.
To install a new VBXX bearing isolator, in the impeller end
of the bearing housing/adapter:
A. Position the impeller end (inboard) seal in the bore of the
adapter or bearing housing with the single expulsion
port at the 6 oclock position, (carefully keep aligned
with the bore).
B. The seal stator O.D. press fits into the bore. Use an arbor
press. Place a block or bar (large enough to protect the
rotor flange) between the arbor press ram and seal face.
Press the seal down into the bore stopping at the
shoulder on the stator O.D.
The elastomer O ring acts as a gasket to ensure damming
up of small imperfections in the housing bore. The O ring
is designed to be compressed to the point of overfilling its
groove. The overfilled material is sheared off during
assembly. Remove any sheared O ring material which
may extrude from the bore.
To install a new VBXX bearing isolator in the drive end
(outboard) side of the bearing carrier:
A. Position the outboard seal in the bore of the bearing
carrier (no orientation of the multiple expulsion ports is
necessary) and carefully keep aligned with the bore.
If the outboard seal has only one explusion port, that
port must be oriented at the 6 oclock position. Because
the bearing carrier rotates for impeller adjustment, take
the necessary steps to ensure the explusion port is
oriented at 6 oclock when the pump is installed and
operating.
B. The seal stator O.D. press fits into the bore. Use an arbor
press. Place a block or bar (large enough to protect the
rotor flange) between the arbor press ram and seal face.
Press the seal down into the bore stopping at the
shoulder on the stator O.D. Remove any sheared o-ring
material which may extrude from the bore.

Pump Division
Appendix G

7. Assemble the bearing carrier/VBXX bearing isolator on to the


shaft:
A. On GP1 and GP2 pumps, the outboard double row
bearing is nested inside of the bearing carrier, and
retained in place by a snap ring. This snap ring has a
tapered edge on one side. The snap ring must be
installed with the flat face of the snap ring against the
bearing and the tapered edge away from the bearing. On
GP3 pumps, the bearing is held in place with a retaining
ring fastened with cap screws.
B. Using sand paper, remove burrs and break any sharp
edges off the keyway at end of the shaft.
C. It is important to prevent the corners of the keyway from
cutting the O rings during assembly. This can be
accomplished with the use of a half key or a thin flexible
sleeve. Lightly lubricate the shaft and slide the bearing
carrier on to the shaft, pushing on the VBXX rotor, until
the bearing is seated. Assemble the bearing retainer
snap ring.
D. Check the position of the rotor (make sure rotor and
stator have not separated) and seat the rotor snugly into
the stator by hand.
8. Assemble the shaft/bearings into the bearing housing:
A. Screw a tapered cone into the impeller end of the shaft
to act as a guide and to prevent from cutting the rotor
O ring.
B. Lightly lubricate the shaft and assemble the shaft into the
bearing housing, sliding the shaft through the rotor,
keeping the rotor seated snugly into the stator by hand.
C. After the bearing carrier is screwed in place, rotate the
shaft and check to make sure that both seal rotors are
positioned snugly inside of the stators. If for some
reason, the rotor becomes disengaged or is pushed
completely out of the stator, the VBXX bearing isolator
must be replaced. It is not advisable to force the rotor
back into the stator.

70

Pump Division
Appendix H

APPENDIX H
SEALMATIC PUMP: INSTALLATION OF
REPELLER COVER, REPELLER, COVER,
IMPELLER.
GROUP 2 PUMPS:

GROUP 3 PUMPS:

1. Install the repeller cover to the adapter using capscrews


(#140).
2. Install a new repeller O-ring (#181A) into the repeller
groove. Lubricate the O-ring with liquid soap.
3. Install the repeller. Hold the repeller firmly against the end
of the shaft by temporarily installing a seal guide (nose
guide), or the impeller. The seal guide is available in the
Durco Tool Kit shown in Figure 21.
4. Loosen the set screw (#201A) in the bearing carrier.
5. The repeller may now be set to the repeller cover. Rotate
the bearing carrier counterclockwise until the repeller
contacts the repeller cover. Now rotate the bearing carrier
clockwise to obtain a 0.015 to 0.020 in (0.38-0.51 mm)
clearance. (Refer to Appendix D for information on how
bearing carrier rotation affects axial shaft movement.) The
repeller gap can be checked with a feeler gage.
6. Remove the temporarily installed seal guide, or impeller.
7. Install the repeller cover/cover gasket (#182).
8. Install the cover (#106). Attach to the repeller cover using
capscrews (#195).
9. Snug the set screws (#201A) against the housing to lock
the setting.
10. Install the impeller gasket (#104) into the impeller and
install the impeller firmly to the shaft. (Refer to Appendix D
for information on how to tighten impeller to shaft.) The
correct repeller setting should correctly set the impeller.
This can be checked with a feeler gage, check the closest
impeller vane clearance. This gap should be 0.015 to 0.020
in (0.38-0.51 mm). If the impeller gap is outside of the
correct setting, it may be readjusted to get the best gap at
the repeller and impeller.

1. Install the repeller cover (#180) over the shaft and push it
all the way back until it touches the bearing housing.
2. Install the repeller cover/cover gasket (#182).
3. Install a new repeller O-ring (#181A) to the repeller groove.
Lubricate the O-ring with liquid soap.
4. Install the slip-on repeller (#181) onto the shaft.
5. Install the cover (#106) to the adapter. Attach to the
adapter using capscrews (#140).
6. Attach the repeller cover to the cover using the capscrews
(#195).
7. Loosen the set screws (#201A) in the bearing carrier.
8. The repeller may now be set to the repeller cover. Hold the
repeller firmly against the end of the shaft by temporarily
installing a seal guide. Rotate the bearing carrier
counterclockwise until the repeller contacts the repeller
cover. Now rotate the bearing carrier clockwise to obtain a
0.015 to 0.020 in (0.38-0.51 mm) clearance. (Refer to
Appendix D for information on how bearing carrier rotation
affects axial shaft movement.)
9. Finally, snug the set screws (#201A) against the housing to
lock the setting.
10. Install the impeller gasket (#104) into the impeller and
install the impeller firmly to the shaft, after removing the
seal guide. (Refer to Appendix D for information on how to
tighten impeller to shaft.) The correct repeller setting
should correctly set the impeller. This can be checked with
a feeler gage, check the closest impeller vane clearance.
This gap should be 0.015 to 0.020 in (0.38-0.51 mm). If
the impeller gap is outside of the correct setting, it may be
readjusted to get the best gap at the repeller and impeller.

71

Pump Division
Appendix I

APPENDIX I
ALLOWABLE NOZZLE LOADS DURCO PUMPS (ASME B73.1M)
FIGURE I-1: Axis System

The allowable nozzle loads listed in Figure I-2 may be applied to


any Mark III Standard Horizontal, Sealmatic, Lo-Flo, Recessed
Impeller, or Unitized Self-Priming pumps in Ductile cast iron, all
Durco 18-8 alloys, Chlorimet, Durimet 20, Carbon Steel, Monel,
and Inconel. The allowable loads must be multipled by
0.70 for pumps made of nickel, titanium, zirconium and high
chrome iron.

The loads listed in Figure I-2 are the combined values resolved
to the center of the pump, except for the Fr + Mr/3 limits, which
apply to the separate suction and discharge flanges. Some
piping analysis programs calculate forces and moments on
each flange, and do not translate them to a common point at
the center of the pump. The formulas in Figure I-3 and Dimensions in Figure I-4 can be used to translate the forces and
moments on each flange to the common center point.

FIGURE I-2: Allowable Forces and Moments (U.S. Customary Units)


Pump
Nozzle
Sizes

Combined Loading at Center of Pump


Forces (lbf)
Moments (lbf ft)
Fy
Fz
Mx
My

Fx

1.5 x 1

120

295

235

590

295

295

325

220

1.5 x 1.5

120

295

235

590

295

295

325

325

2x1

145

365

285

730

365

365

435

220

Mz

Flange
Suction
Frs+Mrs/3

Loading
Discharge
Frd+Mrd/3

2 x 1.5

165

405

325

815

405

405

435

325

2x2

175

435

350

875

435

435

435

435

3 x 1.5

220

545

435

1090

545

545

650

325

3x2

235

590

470

1170

590

590

650

435

3x3

260

650

520

1300

650

650

650

650

4x3

325

815

650

1625

815

815

865

650

6x4

470

1170

940

2345

1170

1170

1300

865

8x6

610

1520

1215

3030

1520

1520

1730

1300

10 x 8

670

1670

1335

3350

1670

1670

1870

1730

72

Pump Division
Appendix I

FIGURE I-2: Allowable Forces and Moments (Metric Units)


Pump
Nozzle
Sizes

Fx

1.5 x 1

534

Combined Loading at Center of Pump


Forces (N)
Moments (Nm)
Fy
Fz
Mx
My
1313

1046

802

401

Mz
401

Flange
Suction
Frs+Mrs*1.09

Loading
Discharge
Frd+Mrd*1.09

1446

979
1446

1.5 x 1.5

534

1313

1046

802

401

401

1446

2x1

645

1624

1268

993

496

496

1936

979

2 x 1.5

734

1802

1446

1108

551

551

1936

1446
1936

2x2

779

1936

1558

1190

592

592

1936

3 x 1.5

979

2425

1936

1482

741

741

2893

1446

3x2

1046

2626

2092

1591

802

802

2893

1936

3x3

1157

2893

2314

1768

884

884

2893

2893

4x3

1446

3627

2893

2210

1108

1108

3849

2893

6x4

2093

5207

4183

3189

1591

1591

5785

3849

8x6

2715

6764

5407

4121

2067

2067

7699

5785

10 x 8

2982

7432

5941

4556

2271

2271

8322

7699

FIGURE I-3: Load Translation Formulae


Formula for all pumps except Recessed

Formula for Recessed Impeller

Fx = Fxs + Fxd

Same

Fy = Fys + Fyd

Same

Fz = Fzs + Fzd

Same

Mx = Mxs + Mxd + (Fzd*H) + (Fzs*M)

Mxs + Mxd + (Fzd*H) + (Fyd*M)

My = Mys + Myd + (-Fzs*L)

Mys + Myd + (-Fzs*L) + (-Fxd*M)

Mz = Mzs + Mzd + (Fys*L) - (Fxd*H) - (Fxs*M)

Mzs + Mzd + (Fys*L) - (Fxd*dH)

Frs = (Fxs2 + Fys2 + Fzs 2)

Same

Mrs = (Mxs2 + Mys2 + Mzs2)


Frd = (Fxd + Fyd + Fzd )

Same
Same

Suction Loading (US Customary) = Frs + Mrs/3

Same

Discharge Loading (US Customary) = Frd + Mrd/3

Same

Suction Loading (Metric) = Frs + Mrs*1.09

Same

Discharge Loading (Metric) = Frd + Mrd*1.09

Same

Where:
Forces are expressed lbf or N and moments are expressed in
lbfft or Nm.
Forces and Moments are positive in the directions shown on
Figure I-1.
Fx = Calculated total force in the x direction at the center of the
pump.
Fxs = Force in the x direction applied to the suction nozzle.
Fxd = Force in the x direction applied to the discharge nozzle.
Mx = Calculated total moment about the x-axis at the center of
the pump.
Mxs = Moment about the x-axis applied to the suction nozzle.
Frs = Resultant force applied to the suction.
Mrs = Resultant moment applied to the suction.
73

Same

Mrd = (Mxd2 + Myd2 + Mzd2)

H = Vertical distance from the centerline of the pump to the top


of the discharge flange.
L = Horizontal distance from the centerline of the discharge to
the front of the suction flange.
M = Vertical distance from the centerline of the pump to the
centerline of the suction on Unitized Self-priming pumps
or the horizontal distance from the centerline of the
pump to the centerline of the discharge on Recessed
Impeller pumps.
These dimensions are listed in Figure I-4 and are shown in
Figure I-5.

Pump Division
Appendix I

FIGURE I-4: Dimensional Data


U.S. Customary (inches)

Metric (meters)

Pump Size
H
L
M
H
1K1.5 x 1-6
6.5
4
0
0.165
1K3 x 1.5-6
6.5
4
0
0.165
1K3 x 2-6
6.5
4
0
0.165
1K1.5 x 1LF-4
6.5
4
0
0.165
1K1.5 x 1LF-8
6.5
4
0
0.165
11K1.5 x 1-8
6.5
4
0
0.165
1K3 x 1.5-8
7.5
4
0
0.191
2K3 x 2-8
9.5
4
0
0.241
2J4 x 3-8
11
4
0
0.279
2K2 x 1-10A
8.5
4
0
0.216
2J2 x 1LF-10
8.5
4
0
0.216
2K3 x 1.5-10A
8.5
4
0
0.216
2K3 x 2-10A
9.5
4
0
0.241
2K4 x 3-10
11
4
0
0.279
2K4 x 3-10H
12.5
4
0
0.318
2K6 x 4-10
13.5
4
0
0.343
2K6 x 4-10H
13.5
4
0
0.343
2K3 x 1.5-13
10.5
4
0
0.267
2K3 x 1.5LF-13
10.5
4
0
0.267
2K3 x 2-13
11.5
4
0
0.292
2K4 x 3-13
12.5
4
0
0.318
2K4 x 3-13HH
12.5
4
0
0.318
2K6 x 4-13A
13.5
4
0
0.343
3K8 x 6-14A
16
6
0
0.406
3K10 x 8-14
18
6
0
0.457
3K6 x 4-16
16
6
0
0.406
3K8 x 6-16A
18
6
0
0.457
3K10 x 8-16
19
6
0
0.483
3K10 x 8-16H
19
6
0
0.483
3K10 x 8-17
20
6
0
0.508
1J1x5 x 1US-6
7.25
4
2.5
0.184
1K1.5 x 1.5US-8
7.875
5
4
0.200
2K2 x 1.5US-10
10
5.25
4
0.254
2K3 x 2US-10
10.5
5.25
4
0.267
2K4 x 3US-10H
12.5
5.75
5
0.318
2K3 x 2US-13
12
5.25
4
0.305
2K4 x 3US-13
13.5
5.75
5
0.343
2K6 x 4US-13A
15
6
5
0.381
1J2 x 2R-6
6.5
3.25
2.75
0.165
2K2 x 2R-10
8.5
3.5
5.25
0.216
2K3 x 3R-10
9
4.25
5.125
0.229
2K4 x 3R-13
10.5
4.125
6.625
0.267
2K6 x 4R-13
11.5
4.75
6.625
0.292
Sealmatic versions have the same dimensions and allowable loads as the above standard pumps.

L
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.102
0.152
0.152
0.152
0.152
0.152
0.152
0.152
0.102
0.127
0.133
0.133
0.146
0.133
0.146
0.152
0.083
0.089
0.108
0.105
0.121

M
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0.064
0.102
0.102
0.102
0.127
0.102
0.127
0.127
0.070
0.133
0.130
0.168
0.168

FIGURE I-5
M

H
M

Unitized Self-Priming

Recessed Impeller

L
Standard, Lo-Flo, Sealmatic

74

Pump Division
Appendix J

APPENDIX J
CLEARGUARD TRIMMING AND
ASSEMBLY INSTRUCTIONS

In order to correctly fit the pump/motor configuration,


each ClearGuard must be trimmed to a specific length.
This trimming is done on the motor end of the guard as
described below.

Trimming Instructions
1. Measure minimum distance from the center of mounting
hole in the baseplate to the motor at diameter as shown
above.
2. Locate a reference center of the slot in the coupling guard
flange. Transfer measurement from Step 1 to the guard
using this reference center.
3. Trim the motor end of guard according to the above
measurement. Trimming is best done with a band saw, but
most other types of manual or power saws give acceptable
results. Care must be taken to ensure that there is no gap
larger than 0.24 in (6 mm) between the motor and the
coupling guard.
4. Note: If motor diameter is smaller than guard diameter, trim
guard so that it extends over the end of the motor as far as
possible.
5. Deburr the trimmed end with a file or a sharp knife. Care
must be taken to eliminate all sharp edges.

75

Assembly Instructions
6. Place the bottom and top halves of the ClearGuard around
the coupling.
7. Install the support legs by inserting and then rotating the top
flange of the leg through the slot in the shell flange until it
comes all the way through and locks the top and bottom
together.
8. Attach the support legs to the baseplate using the fasteners
and washers provided.
9. Install fasteners in the holes provided to secure the guard
flanges together.

Pump Division
Appendix K

APPENDIX K
ADDITIONAL SOURCES OF INFORMATION
The following are excellent sources for additional information
on Durco Mark III pumps, and centrifugal pumps in general.
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, 1991.
American National Standard for Centrifugal Pumps for
Nomenclature, Definitions, Application and Operation, Hydraulic
Institute, 9 Sylvan Way, Parsippany, New Jersey 07054-3802.
Durco Pump Parts Catalog
Durco Mark III Sales Bulletin
Durco Mark III Technical Bulletin
RESP73H Application of ASME B73.1M-1991, Specification for
Horizontal End Suction Centrifugal Pumps for Chemical
Process, Process Industries Practices, Construction Industry
Institute, The University of Texas at Austin, 3208 Red River
Street, Suite 300, Austin, Texas 78705.
Pump Handbook, 2nd edition, Igor J. Karassik et al, McGrawHill, Inc., New York, NY, 1986.
Centrifugal Pump Sourcebook, John W. Dufour and William E.
Nelson, McGraw-Hill, Inc., New York, NY, 1993.
Pumping Manual, 9th edition, T.C. Dickenson, Elsevier
Advanced Technology, Kidlington, United Kingdom, 1995.

76

Hydraulic Engineering

Mechanical Design

Materials Expertise

Smart Technology

Manufacturing Technology

USA and Canada


Flowserve Corporation
Pump Division
Millennium Center
222 Las Colinas Blvd., 15th Floor
Irving, TX 75039-5421 USA
Telephone: 1 972 443 6500
Telefax: 1 972 443 6800
Europe, Africa, Middle East
Flowserve Ltd.
Pump Division
Harley House
94 Hare Lane, Claygate, Esher
Surrey KT10 ORB, UK
Telephone: 44 1372 463700
Telefax: 44 1372 463801
Printed in U.S.A.
August 2000
Flowserve Corporation

Pump Division
Your local Flowserve representative:

Flowserve has numerous manufacturing, sales,


and service operations throughout the world.
Please contact one of the regional centers to
determine the location of the nearest office.

Latin America
Flowserve de Venezuela S.A.
Pump Division
Torre Ejecutiva No. 75-51
Ave. 4 Bella Vista entre calles 75 y 76
1 er Piso Ofic. 1B, Maracaibo
Edo. Zulia 4002-010. Venezuela
Telephone: 58 61 932 767
Telefax: 58 61 933 114
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Flowserve Pte. Ltd.
Pump Division
12 Tuas Avenue 20
Singapore 638824
Republic of Singapore
Telephone: 65 862 3332
Telefax: 65 868 4603