Centrifugal pumps Installation, operation maintenance(IOM) manuals

Doc. No.: 09035-00-OPM-VD-MR001-002
Job No.: 2009035

Installation, operation & maintenance(IOM) manuals

PROJECT : DINH VU POLYESTER PLANT PROJECT
LOCATION : DVIZ, HAI PHONG CITY, VIETNAM
09035-00-PPO-MR001

001

OWNER : PVTEX., JSC
PO NO. : 09035-00-PPO-MR001
DOCUMENT NO. : 09035-00-OPM-VD-MR001-002

Document Class : Z

01

Jun. 23, 2011

Issue for Approval

J.H.YUN

J.D.KIM

J.W.LEE

REV.

DATE

DESCRIPTION

PREPARED

CHECKED

APPROVED

Young Poong Precision Corporation


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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
• In-Line

Bulletin P-10-502g (E)


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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


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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
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

9.0

Mark III In-Line Pump.................................................53
9.1 General Description of the Pump.......................53
9.2 Installation.........................................................53
9.3 Operation...........................................................55
9.4 Start-Up Considerations ....................................55
9.5 Maintenance ......................................................57
9.6 Spare Parts........................................................60

Appendix A.
Appendix B.
Appendix C.
Appendix D.
Appendix E.
Appendix F.
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
Part 1 – Allowable nozzle loads
Part 2 – Mark IIIA In-Line allowable nozzle
loads
ClearGuard trimming and assembly
instructions
Sources of additional information


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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 Corporation’s brands, Durco has long been
recognized as the leading name in chemical process pumps.
Durco pumps are manufactured at Flowserve’s 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.

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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 customer’s 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.

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Section 2.0

FIGURE 1 – Pressure-Temperature Limits By Alloy
50
CD4M
DS

300

100
DC2
DC3

MAX DISCHARGE PRESSURE - lbf /in2

200

250

300

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

DCI
UPPER LIMIT

0

100

300

400

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

0

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.

3

350

1750

TEMPERATURES – °F

FIGURE 2 – Alloy Cross-Reference Chart
Designation
Symbol
ACI Designation

250

D4

500

600

200

250

250

300

150

DS
LOW
TEMPERATURE
LIMIT
DNI

CURVE NO. 2505-7
200

100

CD4M

100

CLASS 150
FLANGES
-100

750

CD4M
UPPER LIMIT

50

DM

1750
D2
D2L

0

350

2000

DM

200

-50

350

D4
D4L

DCI
250

150
TI
TIP
ZR

MAX DISCHARGE PRESSURE - lbf /in2

0

MAX DISCHARGE PRESSURE - kPa

-50

TEMPERATURES – °C

MAX DISCHARGE PRESSURE - kPa

TEMPERATURES – °C

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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/12.5RV

MDP
Material
Date, DD/MMM/YY

Flowserve’s pump size code is used to indicate the size of the pump.
For example, consider the following:
2 K 6 X 4 M – 1 3 A / 12.5 R V
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
12.5 = 121/2 in diameter; 8.13 = 81/8 in; 10.75 = 106/8 or 103/4 in
Previous annotation: 124 = 124/8 or 121/2 in diameter; 83 = 83/8 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), etc…are 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.

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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.

5

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.


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Section 3.4

FIGURE 4

FIGURE 5

FIGURE 6

6


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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.

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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. Flowserve’s 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. Flowserve’s 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.

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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 Flowserve’s 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


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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.
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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

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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 Flowserve’s 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 installer’s 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.

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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 installer’s 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 Flowserve’s standard practice to install the packing in
the stuffing box prior to shipment. The packing is shipped with
the pump. It is the pump installer’s 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 90°F
(32°C) 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 350°F (178°C), then the casing support
legs may need to be cooled. Cool water (less than 90°F (32°C) )
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.
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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
90°F (32°C) ) 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

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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.


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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.

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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


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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 pump’s
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 pump’s 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 0°F (-18°C).

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.

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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.

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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.

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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