Bba Flowserve Lh8 71569282-E
Bba Flowserve Lh8 71569282-E
Bba Flowserve Lh8 71569282-E
CONTENTS
Page Page
1 INTRODUCTION AND SAFETY ........................ 3 6 MAINTENANCE ............................................... 27
1.1 General ........................................................ 3 6.1 Maintenance schedule ............................... 28
1.2 CE marking and approvals .......................... 3 6.2 Spare parts ................................................. 28
1.3 Disclaimer .................................................... 3 6.3 Recommended spares and
1.4 Copyright ..................................................... 3 consumable items ...................................... 29
1.5 Duty conditions ............................................ 3 6.4 Tools required ............................................. 29
1.6 Safety........................................................... 4 6.5 Fastener torques ........................................ 29
1.7 Warning labels ............................................. 7 6.6 Disassembly ............................................... 30
1.8 Specific machine performance .................... 7 6.7 Examination of parts .................................. 32
1.9 Noise level ................................................... 7 6.8 Assembly of pump and seal ....................... 33
2 TRANSPORT AND STORAGE .......................... 8 7 FAULTS; CAUSES AND REMEDIES ............... 39
2.1 Consignment receipt and unpacking ........... 8
8 PARTS LIST AND DRAWINGS ........................ 41
2.2 Handling....................................................... 9
2.3 Lifting ........................................................... 9 9 CERTIFICATION .............................................. 47
2.4 Extended storage ...................................... 10
10 OTHER RELEVANT DOCUMENTATION
2.5 Recycling and end of product life .............. 12
AND MANUALS................................................ 47
3 PUMP DESCRIPTION ..................................... 12 10.1 Supplementary user instruction manuals ... 47
3.1 Configurations............................................ 12 10.2 Change notes ............................................. 47
3.2 Name nomenclature .................................. 12 10.3 Additional sources of information ............... 47
3.3 Design of major parts ................................ 13 10.4 Customer data sheet .................................. 48
3.4 Performance and operating limits .............. 14
4 INSTALLATION ................................................ 14
4.1 Location ..................................................... 14
4.2 Foundation ................................................. 14
4.3 Grouting ..................................................... 15
4.4 Initial alignment .......................................... 17
4.5 Piping ......................................................... 20
4.6 Electrical connections ................................ 22
4.7 Final shaft alignment check ....................... 22
4.8 Protection systems .................................... 23
5 COMMISSIONING, START-UP,
OPERATION AND SHUTDOWN ..................... 23
5.1 Precommissioning procedure .................... 23
5.2 Pump lubricants ......................................... 24
5.3 Impeller wearring clearance ...................... 26
5.4 Direction of rotation ................................... 26
5.5 Guarding .................................................... 26
5.6 Priming and auxiliary supplies ................... 26
5.7 Starting the pump ...................................... 26
5.8 Running or operation ................................. 26
5.9 Stopping and shutdown ............................. 27
5.10 Hydraulic, mechanical and electrical duty . 27
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1 INTRODUCTION AND SAFETY Where applicable, the Directives and any additional
Approvals, cover important safety aspects relating to
1.1 General machinery and equipment and the satisfactory
provision of technical documents and safety
instructions. Where applicable this document
These Instructions must always be kept incorporates information relevant to these Directives
close to product's operating location or directly and Approvals. To confirm the Approvals applying
with the product. and if the product is CE marked, check the serial
number plate markings and the Certification, see
Flowserve's products are designed, developed and section 9, Certification.
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great
1.3 Disclaimer
care and commitment to continuous quality control,
Information in these User Instructions is believed
utilising sophisticated quality techniques, and safety
to be reliable. In spite of all the efforts of
requirements.
Flowserve to provide sound and all necessary
information the content of this manual may
Flowserve is committed to continuous quality
appear insufficient and is not guaranteed by
improvement and being at service for any further
Flowserve as to its completeness or accuracy.
information about the product in its installation and
operation or about its support products, repair and
Flowserve manufactures products to exacting
diagnostic services.
International Quality Management System Standards as
certified and audited by external Quality Assurance
These instructions are intended to facilitate
organisations. Genuine parts and accessories have
familiarization with the product and its permitted use.
been designed, tested and incorporated into the
Operating the product in compliance with these
products to help ensure continued product quality and
instructions is important to help ensure reliability in
performance in use. As Flowserve cannot test parts
service and avoid risks. The instructions may not
and accessories sourced from other vendors the
take into account local regulations; ensure such
incorrect incorporation of such parts and accessories
regulations are observed by all, including those
may adversely affect the performance and safety
installing the product. Always coordinate repair
features of the products. The failure to properly select,
activity with operations personnel, and follow all plant
install or use authorised Flowserve parts and
safety requirements and applicable safety and health
accessories is considered to be misuse. Damage or
laws and regulations.
failure caused by misuse is not covered by Flowserve's
warranty. In addition, any modification of Flowserve
These instructions must be read prior to products or removal of original components may impair
installing, operating, using and maintaining the the safety of these products in their use.
equipment in any region worldwide. The
equipment must not be put into service until all 1.4 Copyright
the conditions relating to safety, noted in the
All rights reserved. No part of these instructions may
instructions, have been met. Failure to follow
be reproduced, stored in a retrieval system or
and apply the present user instructions is
transmitted in any form or by any means without prior
considered to be misuse. Personal injury,
permission of Flowserve Corporation.
product damage, delay or failure caused by
misuse are not covered by the Flowserve
warranty. 1.5 Duty conditions
This product has been selected to meet the
specifications of your purchaser order. The
1.2 CE marking and approvals acknowledgement of these conditions has been sent
It is a legal requirement that machinery and
separately to the Purchaser. A copy should be kept
equipment put into service within certain regions of
with these instructions.
the world shall conform with the applicable CE
Marking Directives covering Machinery and, where
applicable, Low Voltage Equipment, Electromagnetic The product must not be operated beyond
Compatibility (EMC), Pressure Equipment Directive the parameters specified for the application. If
(PED) and Equipment for Potentially Explosive there is any doubt as to the suitability of the
Atmospheres (ATEX). product for the application intended, contact
Flowserve for advice, quoting the serial number.
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If the conditions of service on your purchase order are Always co-ordinate repair activity with operations and
going to be changed (for example liquid pumped, health and safety personnel, and follow all plant safety
temperature or duty) it is requested that the user seeks requirements and applicable safety and health laws
Flowserves written agreement before start up. and regulations.
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1.6.4.3 Avoiding excessive surface temperatures 1.6.4.4 Preventing the build-up of explosive
mixtures
ENSURE THE EQUIPMENT TEMPERATURE
CLASS IS SUITABLE FOR THE HAZARD ZONE ENSURE THE PUMP IS PROPERLY FILLED
AND VENTED AND DOES NOT RUN DRY
Pumps have a temperature class as stated in the ATEX
Ex rating on the nameplate. These are based on a Ensure the pump and relevant suction and discharge
maximum ambient temperature of 40 C (104 F); refer pipeline system is totally filled with liquid at all times
to Flowserve for higher ambient temperatures. during the pump operation, so that an explosive
atmosphere is prevented. In addition it is essential to
The temperature of the liquid handled influences the make sure that seal chambers, auxiliary shaft seal
surface temperature on the pump. The maximum systems and any heating and cooling systems are
permissible liquid temperature depends on the ATEX properly filled. If the operation of the system cannot
temperature class and must not exceed the values in avoid this condition, users shall fit an appropriate dry
the table that follows. run protection device (e.g. liquid detection or a power
monitor).
The temperature rise at the seals and bearings and
due to the minimum permitted flow rate is taken into To avoid potential hazards from fugitive emissions of
account in the temperatures stated. vapor or gas to atmosphere the surrounding area
shall be well ventilated.
Temperature class Maximum surface Temperature limit of
to EN 13463-1 temperature permitted liquid
1.6.4.5 Preventing sparks
T6 85 C (185 F) Consult Flowserve
T5 100 C (212 F) Consult Flowserve
T4 135 C (275 F) 115 C (239 F) * To prevent a potential hazard from mechanical
T3 200 C (392 F) 180 C (356 F) * contact, the coupling guard must be non-sparking
T2 300 C (572 F) 275 C (527 F) * and anti-static for Category 2.
T1 450 C (842 F) 400 C (752 F) *
* The table only takes the ATEX temperature class into consideration.
Pump design or material as well as component design or material To avoid the potential hazard from random induced
may further limit the maximum working temperature of the liquid. current generating a spark, the baseplate shall be
properly grounded.
The responsibility for compliance with the
specified maximum liquid temperature is with the Avoid electrostatic charge: do not rub non-metallic
plant operator. surfaces with a dry cloth; ensure cloth is damp.
If an explosive atmosphere exists during the The coupling must be selected to comply with 94/9/EC
installation, do not attempt to check the direction of and correct alignment must be maintained.
rotation by starting the pump unfilled. Even a short
run time may give a high temperature resulting from 1.6.4.6 Preventing leakage
contact between rotating and stationary components.
The pump shall only be used to handle liquids
Where there is any risk of the pump being run against for which it has been approved to have the correct
a closed valve generating high liquid and casing corrosion resistance.
external surface temperatures, the users shall fit an
external surface temperature protection device. Avoid entrapment of liquid in the pump and associated
piping due to closing of suction and discharge valves,
Avoid mechanical, hydraulic or electrical overload by which could cause dangerous excessive pressures to
using motor overload trips, temperature monitor or a occur if there is heat input to the liquid. This can occur if
power monitor and make routine vibration monitoring the pump is stationary or running.
checks.
Bursting of liquid containing parts due to freezing
In dirty or dusty environments, regular checks shall must be avoided by draining or protecting the pump
be made and dirt removed from areas around close and ancillary systems.
clearances, bearing housings and motors.
Where there is the potential hazard of a loss of a seal
barrier fluid or external flush, the fluid shall be
monitored.
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If leakage of liquid to atmosphere can result in a hazard, Where performance data has been supplied
then a liquid detection device shall be installed. separately to the purchaser these should be obtained
and retained with these User Instructions if required.
1.6.4.7 Maintenance to avoid the hazard
1.9 Noise level
CORRECT MAINTENANCE IS REQUIRED TO Attention must be given to the exposure of personnel
AVOID POTENTIAL HAZARDS WHICH GIVE A to the noise, and local legislation will define when
RISK OF EXPLOSION guidance to personnel on noise limitation is required,
and when noise exposure reduction is mandatory.
The responsibility for compliance with maintenance This is typically 80 to 85 dBA.
instructions is with the plant owner or operator.
The usual approach is to control the exposure time to
To avoid potential explosion hazards during the noise or to enclose the machine to reduce
maintenance, the tools, cleaning and painting emitted sound. You may have already specified a
materials used must not give rise to sparking or limiting noise level when the equipment was ordered,
adversely affect the ambient conditions. Where there however if no noise requirements were defined, then
is a risk from such tools or materials, maintenance attention is drawn to the following table to give an
must be conducted in a safe area. indication of equipment noise level so that you can
take the appropriate action in your plant.
A maintenance plan and schedule shall be adopted.
(See section 6, Maintenance.)
Pump noise level is dependent on a number of
operational factors, flow rate, pipework design and
1.7 Warning labels acoustic characteristics of the building, and so the
values given are subject to a 3 dBA tolerance and
cannot be guaranteed.
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For specific gravities less than 1.0, use 1.0 specific Difference between two Add to higher level to obtain
gravity. For specific gravities above 1.0, use the levels to be combined, dB combined level, dB
actual specific gravity. 0 3
1 2.5
2 2
When the required condition flow falls outside the
4 1.5
range of 75 % to 125 % of BEP, a part load 6 1
correction (PLC) must be added to the noise levels 9 0.5
as follows: 10 0
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2.2 Handling
Boxes, crates, pallets or cartons may be unloaded
using forklift vehicles or slings dependent on their
size and construction.
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Initially inspection would occur weekly then, The customer will supply all necessary labor, tools and
depending upon the inspection reports being cranes. This inspection will include (not necessarily in
favorable or unfavorable, inspection would continue its entirety) but not be limited to the following:
weekly, monthly or quarterly, as may be determined. a) An inspection of all periodic inspection records as
Inspection reports must be kept on file. kept on file by the customer, and all inspection
reports that have been compiled during the
Every inspection should consist of a general surface storage period.
inspection. b) An inspection of the storage area to determine
a) Pump supports are firmly in place. the as stored condition of the equipment prior to
b) Pump covers over openings are firmly in place. any protection being removed.
c) Pump coverings, plastics or tarps, are firmly in c) An inspection of the equipment with protection
place. Any holes or tears must be repaired to covers and flange covers removed.
prevent entrance of dirt or water. d) Depending upon the length of time the equipment
d) Pump covers are periodically removed from was stored, the class/type of storage provided,
openings and interior accessible areas inspected. (i.e: indoor, heated, unheated, ground floor,
If surface rusting has occurred, clean and repaint concrete floor, out-of-doors, under roof, no roof,
or re-coat with preservative. waterproof coverings, on concrete, on ground)
e) If rusting occurs on exterior surfaces, clean and and as a result of the inspection of a, b and c
repaint or re-coat with preservative. above, Flowserve representative may require a
f) Loosen casing drain plugs to allow seepage of partial or complete dismantling of the equipment.
any accumulated moisture. e) Dismantling may necessitate restoration of
g) If the rotor is stored horizontally, rotate pump painted or preserved surfaces, and or
1
rotor 1 /4 revolutions at least once a month to replacement of gaskets, O-rings and mechanical
prevent rotor from taking a permanent set. seals and bearings. Use only Flowserve
recommended replacement materials.
Make sure bearings have
adequate lubrication before turning rotor. Upon completion of the inspection, the Flowserve
representative shall submit a report to the customer,
The oil ring inspection plug on top and to the Manager of Customer Service, stating in
of the bearing housing is to be removed and a detail the result of the inspection.
small amount of oil poured over the journals
before turning. If there are any discrepancies identified, it is the
h) Periodically remove bearing covers and inspect customer's responsibility for correction before initial
for accumulation of moisture, rust and foreign startup.
material. As required, clean bearings and
bearing housing and re-preserve. Install bearing 2.4.4 Storage non-preferred (wet)
cover and secure to assure maximum protection. It is not recommended that the rotor be subjected to
Bearings removed for storage should be coated extended periods of submergence or wetting prior to
with preservative, wrapped in oil/wax paper, and start-up. However, it is recognized that in some
stored in a warm dry area. cases, a long period of time may lapse from
i) Check individually wrapped parts for signs of installation until commercial operation.
deterioration. If necessary, renew preservative
and wrapping. If the pump must be stored after being installed and
wetted, the following inspection and maintenance
If storage is over one month, should be performed:
instrumentation (controls, electrical devices, Isolate the pump with valving - tag (seal) all valves
temperature switches) should be removed and
Preserve the pump internals
placed in a climate controlled environment if
instrumentation is not powered up.
If storage is over one month,
instrumentation (controls, electrical devices,
2.4.3.3 Prior to installation maintenance
temperature switches) should be removed and
Six months prior to the scheduled installation date, a
placed in a climate controlled environment if
Flowserve representative is to be employed to conduct
instrumentation is not powered up.
an inspection. All costs involved during inspection,
dismantling, restoration, replacement of parts and Electric motors (pump driver) should not
reassembly will be the responsibility of the customer. be stored in damp places without special protection.
(Refer to motor manufacturers instructions).
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2.5 Recycling and end of product life The 10 is the nominal impeller size
At the end of the service life of the product or its parts,
the relevant materials and parts should be recycled or The DMX is pump type
disposed of using an environmentally acceptable
method and local regulations. If the product contains The 10 is the number of stages and depending on
substances which are harmful to the environment, these pump size, they go from 2 to 14 stages
should be removed and disposed of in accordance with
current regulations. This also includes the liquids and or DMX = single suction standard pressure
gases in the "seal system" or other utilities. DMXD = double suction standard pressure
DMXH = single suction high pressure
Make sure that hazardous substances or toxic DMXDH = double suction high pressure
fluids are disposed of safely and that the correct
personal protective equipment is used. The safety
specifications must be in accordance with the current
regulations at all times.
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3.3.6 Center bushing The plain ball bearings are a single-row deep-groove
The renewable center bushing is horizontally split, type, free to adjust axially in the bearing housing.
and the two halves are held together by socket head
cap screws and taper dowel pins. It is held in The thrust ball bearings are of the double row (mounted
position by the raised annular ring of the bushing back to back) angular contact type, and are of ample
engaging the annular groove in the casing. The size to carry the thrust loads encountered in service.
center bushing, in conjunction with the center sleeve,
divides the casing at the center (back to back) The pump bearings are renewable.
impellers.
3.3.13 Seal chambers
3.3.7 Throttling sleeve The seal chambers are cast integral with the casing.
A renewable type throttling sleeve is used under the The pump is typically shipped with the mechanical
throttling bushing. The throttling sleeve is tubular, seal already installed.
keyed, and has a shrink fit to the shaft. It is held in
position by a split ring. The mechanical seal is designed to suit each
application. This creates the correct seal loading
face when seal gland is bolted in place.
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Cartridge type mechanical seals are preset at the field of foundations, to ensure proper design/installation
seal manufacturers facility and require no field of the foundation.
settings. The seal installation should be checked
before start-up. The foundation should be properly prepared according
to the planned grouting method. See 4.3, Grouting, for
Refer to the mechanical seal manufacturers drawing details.
and instructions found in section 8 of this manual for
detailed information. The foundation should be rigid and substantial to
support the baseplate at all points to prevent any
3.4 Performance and operating limits pump vibration and to permanently support the
Refer to section 10.4 Customer data sheet. baseplate at all points.
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30-40 mm
c) Grout leveling space and baseplate as per
manufacturer's instructions. Holes are provided in
c the baseplate to permit pouring the grout and
Normal concrete b distributing. Vent holes are also provided in each
compartment. Fill under the baseplate completely,
stirring to assure proper distribution of the grout.
Check to see that the grout flows under the edges
25 50 mm unless 30-40 mm
as specified a of the baseplate evenly.
Pipe
Washer
Building dam around the foundation before pouring grout
Levelling Grout
Foundation complete description
screw levelling
b) Build a dam around the foundation to contain space
grout materials. Foundation
concrete
Before grouting, check level of Grout
bolt
machined pads of baseplate in both directions Foundation holes
and perform a rough shaft/coupling alignment. bolts
Alignment after grout has set will not be possible
if above is not satisfactorily completed.
Foundation and grouting description
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b) Build a dam around the foundation to contain Coupled equipment must be aligned to minimize
grout materials. unnecessary stresses in shafts, bearings and couplings.
c) Grout the foundation bolt holes as per the Flexible couplings will not compensate for appreciable
manufacturer's instructions. Ensure that the misalignment. Foundation settling, thermal expansion
grout fills all open space and eliminates all air or nozzle loads resulting in baseplate/foundation
pockets. deflection and vibration during operation may require
the full coupling misalignment capability.
Before grouting levelling space
and baseplate, check level of pads of baseplate 4.4.1.1 Types of misalignment
in both directions and perform a rough There are two types of shaft misalignment: angular
shaft/coupling alignment. Alignment after grout and offset. Both types of misalignment can occur in
has set will not be possible if above is not horizontal and vertical planes and are present in most
satisfactorily completed. applications.
d) Grout leveling space and baseplate as per
manufacturer's instructions. Holes are provided In angular misalignment, the centerline of the shafts
in the baseplate to permit pouring the grout and intersects, but is not on the same axis.
distributing. Vent holes are also provided in each
compartment. Fill under the baseplate
completely, stirring to assure proper distribution
of the grout. Check to see that the grout flows
under the edges of the baseplate evenly.
Angular misalignment
Pour grout until level reaches top of
dam. Allow drying sufficiently to prevent grout In offset misalignment, the shaft centerlines are
from overflowing while completing the remaining parallel but do not intersect.
grouting.
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a) Prior to alignment process the baseplate must be A gib-block running parallel to the length of the pump
leveled. foot at each of the outboard feet controls the horizontal
b) Check for soft foot condition. Uneven base movement. The gib-blocks are bolted and doweled to
height, dirty or corroded foot or other irregularities the pedestal. A 0.254 mm (0.010 in.) gap is maintained
c) Rough align the pump and motor shafts with a between the gib-block and pump foot.
straight edge.
d) Mount the laser emitter on the pump shaft, and The self-locking nuts, which hold the pump
the laser target on the motor shaft. from moving in a vertical motion, are clamped
e) Link the shaft ends so they rotate together. tight to the pump foot at the time of shipment.
f) Adjust shim stack heights for vertical parallelism The 0.051 mm (0.002 in.) clearance must be
and angular alignment per laser units output. established at time of installation.
Make the necessary corrections by adding or by DOWEL PIN (TYP) FLEX LOCK NUT 0.002"
removing shims at the motor feet. CLEARANCE
GIB GIB
g) Adjust the motor position sideways for horizontal BLOCK BLOCK
and angular alignment per the laser units output
by using a soft mallet or adjusting screws.
h) Tighten all pump and motor feet fasteners. 0.010"
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4.4.8 Hot alignment check Elbows in more than one plane should not be used
A hot check can only be made after the unit has been in without splitters.
operation a sufficient length of time to assume its
NORMAL operating temperature and conditions. If the Splitters are placed in the elbow in the mean radius
unit has been correctly cold set, the offset misalignment line perpendicular to the plane of the elbow.
will be within 0.076 mm (0.003 in.) TIR and the angular
misalignment will be within 0.0254 mm (0.001 in.) TIR Provision must be made to support
when in operation. If not, make adjustments. piping external to the pump to prevent excessive
nozzle loads, maintain pump/driver alignment and
Do not attempt any maintenance, avoid pipe-induced vibrations.
inspection, repair or cleaning in the vicinity of
rotating equipment. Such action could result in Install a check valve and a gate valve in the
injury to operating personnel. discharge pipe of the pump. When the pump is
stopped, the check valve will protect the pump
Before attempting any inspection or repair against excessive pressure and will prevent the pump
on the pump the driver controls must be in the from running backwards. The check valve should be
"off" position, locked and tagged to prevent installed between the gate valve and the pump
restarting equipment and injury to personnel nozzle in order to permit its inspection. The gate
performing service on the pump. valve is also useful in priming and starting the pump.
4.5 Piping Keep the suction pipe short and direct. Use a suction
pipe equal to or one size larger than the pump suction
The following information regarding nozzle. Keep the suction pipe free of all air pockets.
piping is only offered as a general guideline to the
customer. Flowserve requires that all piping and A spool piece should be installed in the
related systems be designed/installed in accordance suction line so that the suction screen may be
with specifications set forth in chapter 6, Piping, from installed and removed.
API recommended practices 686/PIP REIE 686, First
Edition. Operation at low flow results in pump
power heating the liquid. A bypass may be required
The design of piping, and related systems, is not the to prevent vaporization and subsequent pump
responsibility of Flowserve. It is therefore damage. Mechanical damage may result from
recommended that the customer consult a competent continuous operation at flows less than the minimum
specialist skilled in the field of piping, to ensure flow of design operating point. (See section 10.4,
proper design/installation of all piping. Customer Data Sheet.)
4.5.1 Suction and discharge piping When pump is equipped with manifolded
These units are furnished for a particular service vent and drain lines, each line must be equipped
condition. Changes in the hydraulic system may with an individual valve to prevent any liquid from
affect performance adversely. This is especially true a high pressure line flowing into a low pressure
if the changes reduce the pressure at the suction or if line. These valves must be kept in the closed
the liquid temperature is increased. In case of any position during pump operation.
doubt contact the nearest Flowserve Office.
4.5.2 Suction strainer
Suction and discharge piping should be of ample In a new installation, great care should be taken to
size, be installed in direct runs, and have a minimum prevent dirt, scale and welding beads from entering
of bends. Eccentric reducers shall be flat on top the pump. Even when piping has been previously
(FOT). flushed, it is difficult to break loose the oxides and
mill scale, which will become free when the pipe
It is desirable to have at least seven (7) diameters of heats and cools several times. Numerous close
straight pipe between the first elbow and the pump running clearances within the pump are vulnerable to
suction. Elbows in the piping to the pump suction abrasive matter present in new piping. Foreign
nozzle should be of the long radius type. material may be large enough, or of sufficient
volume, to jam a pump, with probable damage to
Seven (7) diameters of straight pipe should be used both pump and drive equipment. Smaller size
between two elbows in series and the pump suction. material passing through the pump can cause rapid
pump wear and premature pump failure.
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4.8 Protection systems Isolate the pump from pipe work, flush out the
pipe work then flush the pump. This operation
The following protection systems are must be carried out thoroughly because the
recommended particularly if the pump is installed in a pump contains many close running clearances,
potentially explosive area or is handling a hazardous which will be damaged by dirt particles. Take all
liquid. If in doubt consult Flowserve. possible care not to contaminate your system.
b) Clean and flush bearing housings. Fill reservoir
If there is any possibility of the system allowing the with oil to the proper level. (See section 5.2,
pump to run against a closed valve or below Pump lubricants.)
minimum continuous safe flow a protection device
should be installed to ensure the temperature of the Check that oil rings are properly
liquid does not rise to an unsafe level. positioned and not hung-up by looking through
vent.
If there are any circumstances in which the system c) Turn rotor by hand or with strap to make sure it
can allow the pump to run dry, or start up empty, a turns freely.
power monitor should be fitted to stop the pump or d) Ensure that the mechanical seal is properly
prevent it from being started. This is particularly assembled and tightened.
relevant if the pump is handling a flammable liquid.
Most cartridge seals are equipped
with a spacer between the gland plate and drive
If leakage of product from the pump or its associated
collar. This spacer must be removed before
sealing system can cause a hazard it is
starting unit.
recommended that an appropriate leakage detection
e) Ensure coupling is properly aligned and
system be installed.
lubricated; and pump and driver are properly
doweled. (Refer to 4.1.1, Shaft /coupling
To prevent excessive surface temperatures at
alignment procedure).
bearings it is recommended that temperature or
f) Ensure coupling guard is in place.
vibration monitoring are carried out.
g) Check torque of all bolting and plugs for
tightness.
5 COMMISSIONING, START-UP,
OPERATION AND SHUTDOWN 5.1.2 Pump instrumentation set points
The following set points apply to DMX pumps, which
Commissioning of all equipment must be use the ball/ball bearing arrangement:
performed in accordance with specifications set forth in a) Bearing metal temperature
chapter 9, Commissioning, from API Recommended Normal - 60 to 82 C (140 to 180 F)
Practices 686/PIP REIE 686, First Edition. Alarm - 88 C (190 F)
Shutdown - 93 C (200 F)
These operations must be carried b) Bearing housing vibration
out by fully qualified personnel.
Normal - 2.5 to 7.6 mm/s (0.1 to 0.3 in./sec)
Alarm - 10.2 mm/s (0.4 in./sec)
5.1 Precommissioning procedure Shutdown - 12.7 mm/s (0.5 in./sec)
a) Never operate the pump with suction valve closed.
b) Never operate pump unless it is filled with liquid 5.1.3 Initial start-up procedure
and vented. a) Close discharge valve if a bypass system is
c) Never operate the pump unless a liquid source is used. If not, crack open the discharge valve.
available. b) Prepare the driver for start-up in accordance with
d) Never operate the pump without proper lubrication. the manufacturers instructions.
c) Warm-up pump (if required).
5.1.1 Pre-operational checks Avoid severe thermal shocks to the pump as a
At initial start-up and after the equipment has been result of sudden liquid temperature changes.
overhauled: The pump must be preheated prior to start-up.
a) Ensure pump and piping are clean. Before Unless otherwise specified, the external
putting the pump into operation, it should be temperature of the casing must be within 55.6 C
thoroughly flushed to remove the rust preventive (100 F) of the temperature of the liquid to be
as well as any foreign matter, which may have pumped at time of start-up.
accumulated during installation.
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5.2.3 Oil temperature To clean the lubrication system refer to the sectional
Oil temperature should be maintained between 16 C drawings and proceed as follows:
(60 F) and 82 C (180 F). a) Loosen the bearing end covers and flingers and
remove drain plugs.
The minimum bearing oil temperature b) Flush out the bearing housings with kerosene or
is 16 C (60 F). If necessary, prior to start-up, one of other suitable solvent.
the following procedures should be employed: c) Flush the bearing housing with oil. Oil should be
a) Drain the oil in the bearing housing(s) and compatible with lubricating oil that will be used.
replace with warm oil. d) After flushing, replace drain plugs. Reassemble
b) Heat the bearing housing(s) using heat tape (or bearings and torque end cover bolting. (Refer to
other suitable means). section 5, Maintenance.)
c) Circulate warm liquid through the cooling jacket e) Refer to driver instruction book for instructions
or immersion cooler (if supplied). covering flushing of driver bearings.
d) Utilize oil with a lower viscosity, or VG number, or
consider using a synthetics hydrocarbon oil with 5.2.5 Trico oiler setting
a low pour point to give a viscosity similar to that
of ISO 46 (for maximum oil operating
temperatures of 180 F) or ISO 32 (for maximum
oil operating temperatures of 120 F).
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Operation of the unit without appropriate 5.10.3 Changing the pump speed
lubrication can result in overheating of the Changing the speed of a centrifugal pump changes the
bearings, bearing failures, pump seizures and capacity, total head and brake horse power. The
actual breakdown of the equipment, exposing capacity will vary in a direct ratio with the speed,
operating personnel to injury. whereas the total head will vary as the ratio of the
speed squared. The brake horse power will vary as the
5.9 Stopping and shutdown ratio of the speed cubed except in cases where the
If motor driven, de-energize driver circuit. If turbine speed change also affects the efficiency of the pump.
driven, stop the pump by manually tripping the over-
speed trip. When contemplating speeds other than of the original
condition, refer to Flowserve for recommendations.
If pump stops abruptly when driver is shut
down, investigate for pump binding. Take necessary 5.10.4 Net positive suction head (NPSH)
remedial action before restarting pump. Any liquid, hot or cold, must be forced into the impeller
of the pump without vaporization by the pressure of the
If pump is subjected to freezing vessel from which the pump takes its suction.
temperatures, the pump must be drained of liquid to
prevent damage to pump. The head of liquid necessary to force the required
a) Close the pump suction and discharge valve. flow into the pump is called the Net Positive Suction
b) Close valve in bypass line. Head. This value, more commonly called NPSH, is
c) Drain the pump. the head above the vapor pressure of the liquid at the
pumping temperature.
5.10 Hydraulic, mechanical and electrical
There are two kinds of NPSH: the NPSHR by the
duty
pump, as shown on the pump curve, is the head
These pumps are furnished for a particular service
needed to cover the losses in the pump suction. The
condition. Changes in the operating system design
second NPSH is that available in the system, taking
may adversely affect the pump performance. This is
into account the friction loss in suction piping, valves,
especially true if the changes reduce the pressure at
fittings etc. In all cases the NPSHA (measured above
the suction flange or if the liquid temperature is
vapor pressure) must exceed the NPSHR in order to
increased. In case of doubt, contact the nearest
push the liquid into the pump.
Flowserve office.
Failure to have an adequate margin of NPSHA over
5.10.1 Specific gravity (SG)
NPSHR will cause a reduction of pump performance
The capacity and total head in m (ft) of liquid developed
and internal damage to the pump.
by a centrifugal pump are fixed for every point on the
curve and are always at the same speed. Neither
capacity nor total head will be affected by a change in 6 MAINTENANCE
the specific gravity of the liquid pumped. However, This pump is a precision machine. Take every
since the developed pressure in bar (psi) and the power precaution to avoid damage or slight burrs to the
to drive the pump are a function of the specific gravity of shaft bearing areas, as well as any other ground,
the liquid, both will be affected in direct proportion by finished surface when dismantling the pump.
any change in specific gravity. Therefore, a change in
specific gravity will affect the discharge gauge pressure It should be understood that the information
and power. Any changes should be noted, in that they contained in this manual does not relieve operating
may overload the pump driver. and maintenance personnel of the responsibility of
exercising normal good judgment in operation and
care of the pump and its components.
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The recommended spare parts are divided into three The above torque values will be applied
classifications, which are defined below. only when the casing hydro test pressure is equal to
a) Class 1 (minimum): covers recommended spare or less than the values showing in the following table.
parts for a single unit where additional spare parts Any hydro test pressure exceeding these values must
are ordinarily available from branch or dealer stock. have torque values cleared by Flowserve.
Suggested for domestic service handling non-
Max. hydro pressure
corrosive liquids where interruptions in service are Pump type
not objectionable. This include gaskets and bar psi
3x8DMX 207 3 000
bearings that are not reusable.
3x10DMX 276 4 000
b) Class 2 (average): covers recommended spare 3x10DMXH 414 6 000
parts for a single unit where additional spare 4x10DMX/DMXD 276 4 000
parts are not readily available. Suggested for 4x10DMXH/DMXDH 414 6 000
domestic service handling abrasive or corrosive 4x11DMX/DMXD 276 4 000
liquids where some interruptions in service are 4x11DMXH/DMXDH 414 6 000
6x11DMX/DMXD 276 4 000
permissible. This includes Class 1 spares plus 6x11DMXH/DMXDH 379 5 500
all renewable wear parts. 6x13DMX/DMXD 224 3 250
c) Class 3 (maximum): covers recommended spare 6x13DMXH/DMXDH 345 5 000
parts for a single unit where maximum protection 8x13DMX/DMXD 224 3 250
from major shutdown must be considered. 8x13DMXH/DMXDH 248 3 600
8x14DMX/DMXD 224 3 250
Suggested for export service or domestic service 8x14DMXH/DMXDH 248 3 600
where minimum loss of service is essential. This 8x15DMX/DMXD 207 3 000
includes Class 1 and 2 spares plus a spare 8x15DMXH/DMXDH 248 3 600
rotating assembly. 10x16DMXD 186 2 700
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Casing wearing rings [1500], channel After impeller is heated, it will have to be pushed
rings [1500], throttle bushing [1630], center towards the center of the pump, the split rings
bushing [1600], seal chamber bushings [4132] [2531] removed and quickly pulled from the end
(and crossover bushing [1600] if double suction of the shaft.
design - DMXD and DMXDH) will be removed
with the rotor. The shaft is step machined at each
impeller fit to ease the disassembly process. It is
Block to prevent rolling. recommended that each impeller be marked with
d) Remove seal chamber bushings [4132] and its stage number to ensure proper reassembly.
throttle bushing [1630] from shaft ends.
e) Remove casing rings [1500] from the two outer 6.6.8 Heating impellers for removal
impellers at each end of the rotor. a) Apply heat (torch with fine tip) to periphery [outer
38 mm (1.5 in.)] of impeller until temperature
In case of double suction pumps reaches 191 C (375 F) (minimum) to 204 C
(DMXD and DMXDH), remove crossover bushing (400 F) (maximum). Use "tempilstick" to
[1600]. Crossover bushing is horizontally split determine temperature.
and held together by dowel pins [6810]. b) Maintaining temperature between (191 C to 204 C
f) Remove channel rings [1500] from impeller back (375 F to 400 F) at the periphery, apply heat down
ring at each impeller. Channel rings are through the vane passages, thus heating the hub.
horizontally split and are held together by c) Do not apply heat directly to the shaft; this will
shoulder screws or dowel pins. cause it to expand.
d) With periphery, shroud and hub at temperature,
Channel rings are precision machined remove impeller.
as a set, after being dowelled. They should be e) If the impeller does not move freely off the shaft,
match marked and numbered for reassembly additional heat may be necessary. This heating
purposes. It is suggested that the two halves be should be started at the periphery of the impeller,
placed back together immediately. not the hub. (Additional heating of the hub area
g) Remove center bushing [1600] from center (back at this time will tighten the impeller on the shaft,
to back) impellers. Center bushing is horizontally not loosen it). If the impeller still fails to come
split and held together by socket head cap- free, the impeller and shaft should be allowed to
screws [6570] and dowel pins [6810]. cool completely and the heating process
repeated, starting at step a).
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b) Heat the new ring to 148 C (300 F) in a f) Continue to assemble remaining inboard
convection oven to allow for uniform heating. Do impellers [2200] as in steps a), c) and e).
not use a torch as this may cause local re-
tempering of the material. In case of double suction pumps
c) After the rings are thoroughly heated, they can be (DMXD and DMXDH), install crossover sleeve
assembled on the impeller hubs. Only one of the [2450] before assembling the first stage impeller.
internal edges has been machined with a lead in
chamfer. Radial location is unimportant as there is Let entire rotor cool after removing
a uniform cross-section around the circumference. several components with heat as there may be a
The ring must fit up against the shoulder provided build-up of heat in the rotor. It is recommended
on the hubs for proper assembly. that shaft runout is checked.
d) After cooling tighten all the set-screws with an g) Assemble outboard impellers [2200] as in steps
Allen wrench. a), c) and e).
e) Rings are machined to final size. They do not h) Install throttling sleeve key [6700] to shaft and
have to be turned after assembly. pre-fit split rings [2531] in shaft to fit snug in
groove. Heat the throttling sleeve and slide onto
6.8.4 Rebuilding rotor shaft far enough to expose split ring groove.
Install split ring and pull sleeve back to seat
Before up-staging or de-staging a pump against the split ring.
(adding or removing impellers), contact Flowserve
Customer Service department for instructions, to avoid 6.8.5 Dynamically balance rotor
permanent damage to the pump rotor. a) Place the rotor assembly on V-blocks or rollers.
The runout of all impeller wear rings and bushings
Split rings and keys should be pre-fitted is not to exceed 0.05 mm (0.002 in.) TIR.
and marked for proper location before assembling the b) All pump rotors are to be dynamically balanced.
rotor. Impellers should be marked for proper location
prior to heating for assembling on the rotor. Refer to section 6.7.2 for grinding for balance
a) Install center stage impeller key [6700], into key information.
way in shaft and pre-fit split rings [2531] to shaft.
Split rings to fit snug in groove. 6.8.6 Installing rotor in casing
b) All impeller bores and shaft outside diameters are a) The seal chamber bushing [4132], throttle bushing
to be dimensionally inspected. [1630], channel rings [1500] and center bushing
[1600] should be checked to make sure they seat in
Impeller-to-shaft fit must be a both the upper and lower half casing and that the
minimum of 0.0254 mm (0.001 in.) to 0.0762 mm anti-rotating pins [2923] can be properly located in
(0.003 in.) interference fit. the slot on the lower half casing parting flange.
c) Heat the center impeller [2200] in the suction side b) Install main parting flange gasket [4590]. (Refer
in an oven, and assemble to the shaft, moving to section 6.6.10, Parting flange gasket.)
the impeller past the split ring groove in the shaft. c) Place lower half of the center bushing [1600] into
Quickly install split ring [2531] and pull impeller the lower half casing [1210], making sure the
back to seat against the split ring. A constant anti-rotation pins are properly located in the slot
heat source is preferred to a torch; a torch is not on the lower half casing parting flange.
recommended.
In case of double suction pumps
Make sure impellers are installed for (DMXD and DMXDH), place lower half of the
proper rotation and location. crossover bushing [1600] into the lower half
d) Install center sleeve [2450] from the opposite end casing [1210], making sure the anti-rotation pins
of the shaft. The center sleeve is to be seated are properly located in the slot on the lower half
against the impeller hub installed in step c). casing parting flange.
e) Place casing ring [1500] on impeller front ring. d) Place the lower half of all channel rings [1500] in
lower half casing, in the same sequence as they
Put the case ring on the previous were removed, making sure the anti-rotation pins
impeller before assembling the next impeller. are properly located in the slot on the lower half
Failure to do so will require complete casing parting flange.
dismantling of the rotor.
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6.8.9 Horizontal and vertical shaft alignment Install dowel pins [6810] and bearing housing
to casing cap-screws [6570] and snug down
The rotor must be initially aligned using cap-screws. Install both the vertical and
dummy bearings. Do not put on mechanical seals at horizontal adjusting screws [6570] in the
this time, as the seal chamber bore must be exposed to bearing housing mounting flange. Remove
centralize the rotor. Dummy bearings (not furnished) dowel pins [6810].
will ease the assembly process of adding shims and the c) Using a dial indicator and the adjusting screws
mechanical seals. Dummy bearings can be made by [6570], adjust the horizontal and vertical position
taking a used set of ball bearings and opening up the of the shaft inside the seal chamber to within
bore so it has a 0.0127 mm (0.0005 in.) to 0.0254 mm 0.0254 mm (0.001 in.) radially.
(0.001 in.) loose fit to the shaft. d) Repeat step c) on thrust end, then recheck plain
end. Pump shaft should turn freely with no
a) Assemble plain bearing: indication of binding or rubbing. This should be
Assemble dummy bearing to shaft. Install taken into account when making adjustments.
journal sleeve [2400], bearing lock-washer e) If rubs occur, adjust the rotor upwards in 0.025 mm
[6541] and bearing nut [3712] and tighten. (0.001 in.) increments. Check alignment at both
ends after each movement. After adjustment,
Do not set locking tab of lock- check for rubs.
washer at this time. Dummy bearings will f) When vertical and horizontal alignment is
have to be removed. obtained, tighten bearing housing bolting (except
Assemble bearing housing [3200] into position the two top bolts at the adjusting screws). Ream
over the plain ball bearing. Install dowel pins the dowel holes and install dowel pins [6810].
[6810] and snug down cap-screws [6570]. Loosen adjusting screws and tighten the two top
Install both the horizontal and vertical adjusting bearing housing bolts.
screws [6570] in the bearing housing mounting
flange. Remove dowel pins [6810]. 6.8.10 Centralize rotor axially
b) Assemble thrust bearing: a) Make sure center mark on masking tape is in line
Slide pump side end cover [3260] with with seal chamber face as in step e) of section
0.051 mm (0.002 in.) shims [3126] onto shaft. 6.8.8, Check rotor axial float.
Install shims [3126] against shaft shoulder if b) Install dial indicator on thrust bearing housing
amount was recorded at disassembly. If shim [3200] so indicator contacts end of shaft. Set
thickness was not recorded at disassembly, or indicator at zero.
if rotor was rebuilt completely, do not install c) Push rotor outboard to ensure contact between
any shims at this time. thrust ball bearing [3013] and bearing housing
Assemble "dummy bearing to shaft. [3200].
Compare width of outside bearing races with d) Read the distance the shaft moved on the dial
new bearing races. Differences must be indicator. This is the amount of shims [3126] to
compensated when adjusting for 0.127 mm be installed between thrust ball bearing [3013]
(0.005 in.) to 0.254 mm (0.010 in.) end-play. and shaft.
Install journal sleeve [2400], bearing lock-washer
[6541] and bearing nut [3712] and tighten. 6.8.11 Set thrust bearing end-play
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If distance indicated is between 0.127 mm e) Remove tape from shaft at seal chamber area
(0.005 in.) to 0.254 mm (0.010 in.) no further and install mechanical seal [4200]. Tighten gland
shim adjustment is required nuts [6580] of both mechanical seals as in the
If distance indicated is above 0.254 mm seal chamber section.
(0.010 in.) remove inboard end cover [3260]
and remove amount of shims [3126], which Do not tighten lock collar set-
will reduce axial end-play to 0.127 mm screws at this time.
(0.005 in.) to 0.254 mm (0.010 in.)
If distance indicated is below 0.127mm 6.8.14 Final thrust bearing assembly
(0.005 in.), remove inboard end cover [3260] a) Position flinger [2540], end cover [3260], O-ring
and add shims [3126], which will increase [4610] and end cover shims [3126] in their
axial end-play to 0.127 mm (0.005 in.) to approximate positions on the pump shaft.
0.254 mm (0.010 in.). (Shims may be cut for b) Install shaft shims [3126]. Make sure shims are
ease of assembly.) correctly seated against shaft shoulder.
c) Heat thrust bearing [3013] and install on the shaft
6.8.12 Final plain bearing assembly in the back-to-back position (stamping will be
a) If pump is installed with a mechanical seal, install face to face) as shown here.
completely assembled mechanical seals [4200]
to the shaft. Insert into seal chamber.
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c) Install coupling key, pump half coupling, coupling 6.8.17 Parting flange torque procedure
nut and set coupling nut set-screws. (Refer to Assemble upper half casing to lower half casing and
section 6.6.3, Coupling removal.) secure with washers and cap-nuts listed on the parts
d) Check coupling/shaft alignment as described in list of the casing. Torque the cap-nuts in three or
section 4.4.1, Shaft/coupling alignment, and more complete passes of increasing torque values
assemble coupling. until the torque values in section 6.5.1 are achieved.
e) Install coupling guard.
f) Replace all auxiliary piping, instrumentation and Minimum recommended torque passes:
pipe plugs. First pass - 50% specified torque value
g) Fill bearing housing oil reservoir. (Refer to Second pass - 90% specified torque value
section 5.2, Pump lubricants.) Final pass - 100% specified torque value
h) Refer to section 5.8, Running or operation, for
starting procedure. Tighten the cap-nuts in the following sequence during
each pass:
6.8.16 Parting flange gasket a) Torque both center cap-nuts marked O.
1
a) Using proper recommended 0.397 mm ( /64 in.) b) Torque the cap-nuts shown in diagram below,
thick gasket material, locate and cut stud holes, casing quadrant 3. Start approximately in the
using upper half casing as a template. center of the pump and proceed towards the
b) Lay gasket on lower half casing, using either a suction nozzle.
gasket adhesive or a band of shellac c) Torque the cap-nuts on the opposite corner of the
1
approximately 13 mm ( /2 in.) wide on the outer pump as indicated in diagram below, casing
edge of lower casing. quadrant 4. Again, start at the center of the
c) Place upper half casing on top of gasket and pump and work towards the opposite end.
allow time for gasket adhesive or shellac to set. d) Torque the cap-nuts in diagram below, casing
d) Remove upper half casing. quadrant 5, in a similar manner.
e) Using a sharp knife, cut gasket with downward e) Torque the cap-nuts in diagram below, casing
strokes only. Make sure all cuts are neat and quadrant 6, in a similar manner.
exact, especially on internal edges of casing. If f) Repeat the same sequence two or more times
this is not done, the high-pressure liquid will using increasing torque values with each full
bypass and erode the ring fits. pass.
Discharge passage
Position of the parting flange gasket
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Fault symptom
Pump overheats and seizes
Bearings have short life
Pump vibrates or is noisy
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Impeller sub-assembly
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View A-A
Typical assembly of optional finned cooler
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View A-A
Typical assembly of optional finned cooler
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10.4 Customer data sheet Brake horse power (design/max) with pumped liquid:
Hydrotest pressure:
Location:
Maximum temperature:
Flowserve order:
Bearing lubrication:
Serial numbers:
Pump rating:
Total head:
Suction pressure:
Discharge pressure:
Minimum flow:
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Notes:
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Notes:
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Notes:
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FLOWSERVE REGIONAL
Your Flowserve factory contacts: SALES OFFICES: