Goulds Pumps 3196 User Manual
Installation, Operation,
and Maintenance Manual
Model 3196 i-FRAME
Table of Contents
Introduction and Safety .......................................................................................................... 4
Introduction ............................................................................................................................. 4
Safety ...................................................................................................................................... 4
Safety terminology and symbols ........................................................................................... 5
Environmental safety ............................................................................................................ 5
User safety ........................................................................................................................... 6
Ex-approved products .......................................................................................................... 7
Product approval standards .................................................................................................... 8
Product warranty ..................................................................................................................... 9
Transportation and Storage ................................................................................................. 10
Inspect the delivery ............................................................................................................... 10
Inspect the package ........................................................................................................... 10
Inspect the unit ................................................................................................................... 10
Transportation guidelines ...................................................................................................... 10
Pump handling ................................................................................................................... 10
Lifting methods ................................................................................................................... 10
Storage guidelines ................................................................................................................ 12
Pump storage requirements ............................................................................................... 12
Frostproofing ...................................................................................................................... 12
Table of Contents
Product Description .............................................................................................................. 13
General description 3196 ...................................................................................................... 13
Part description 3196 .......................................................................................................... 14
General description i-ALERT™ Condition Monitor ................................................................ 15
Nameplate information .......................................................................................................... 16
Installation ............................................................................................................................. 19
Preinstallation ....................................................................................................................... 19
Pump location guidelines .................................................................................................... 19
Foundation requirements ................................................................................................... 19
Baseplate-mounting procedures ........................................................................................... 20
Prepare the baseplate for mounting ................................................................................... 20
Install the baseplate using shims or wedges ...................................................................... 20
Install the baseplate using jackscrews ................................................................................ 21
Install the baseplate using spring mounting ........................................................................ 24
Install the baseplate using stilt mounting ............................................................................ 25
Baseplate-leveling worksheet ............................................................................................. 27
Install the pump, driver, and coupling .................................................................................... 28
Pump-to-driver alignment ...................................................................................................... 28
Alignment checks ............................................................................................................... 28
Permitted indicator values for alignment checks ................................................................ 29
Alignment measurement guidelines ................................................................................... 29
Attach the dial indicators for alignment ............................................................................... 29
Pump-to-driver alignment instructions ................................................................................ 30
C-face adapter .................................................................................................................... 33
Grout the baseplate .............................................................................................................. 33
Piping checklists ................................................................................................................... 34
General piping checklist ..................................................................................................... 34
Suction-piping checklist ...................................................................................................... 36
Discharge piping checklist .................................................................................................. 38
Model 3196 i-FRAME Installation, Operation, and Maintenance Manual 1
Table of Contents
Commissioning, Startup, Operation, and Shutdown ......................................................... 40
Preparation for startup .......................................................................................................... 40
Remove the coupling guard .................................................................................................. 40
Check the rotation ................................................................................................................. 43
Impeller-clearance check ...................................................................................................... 43
Impeller clearances (3196 and HT 3196) ........................................................................... 43
Impeller-clearance setting ..................................................................................................... 44
Set the impeller clearance - dial indicator method (all except CV 3196) ............................. 44
Set the impeller clearance - feeler gauge method (all except CV 3196) ............................. 45
Couple the pump and driver .................................................................................................. 45
Install the coupling guard .................................................................................................... 46
Bearing lubrication .............................................................................................................. 50
Shaft-sealing options ............................................................................................................ 52
Mechanical seal options ..................................................................................................... 52
Connection of sealing liquid for mechanical seals .............................................................. 52
Packed stuffing box option ................................................................................................. 52
Connection of sealing liquid for a packed stuffing box ........................................................ 53
Dynamic-seal option ........................................................................................................... 53
Set an elastomeric face seal ............................................................................................... 54
Pump priming ........................................................................................................................ 54
Prime the pump with the suction supply above the pump ................................................... 54
Prime the pump with the suction supply below the pump ................................................... 54
Other methods of priming the pump ................................................................................... 56
Start the pump ...................................................................................................................... 56
Activate the i-ALERT™ Condition Monitor ............................................................................ 57
i-ALERT™ Condition Monitor routine operation .................................................................... 58
Pump operation precautions ................................................................................................. 58
Shut down the pump ............................................................................................................. 59
Deactivate the i-ALERT™ Condition Monitor ........................................................................ 59
Reset the i-ALERT™ Condition Monitor ................................................................................ 59
Make the final alignment of the pump and driver ................................................................... 59
Maintenance ........................................................................................................................... 61
Maintenance schedule .......................................................................................................... 61
Bearing maintenance ............................................................................................................ 62
Lubricating-oil requirements ............................................................................................... 62
Regrease the grease-lubricated bearings .......................................................................... 63
Lubricate the bearings after a shutdown period .................................................................. 64
Shaft seal maintenance ........................................................................................................ 64
Mechanical-seal maintenance ............................................................................................ 64
Packed stuffing-box maintenance ...................................................................................... 65
Dynamic-seal maintenance ................................................................................................ 65
Disassembly ......................................................................................................................... 66
Disassembly precautions ................................................................................................... 66
Tools required .................................................................................................................... 66
Drain the pump ................................................................................................................... 66
Remove the coupling .......................................................................................................... 67
Remove the back pull-out assembly ................................................................................... 67
Remove the coupling hub ................................................................................................... 69
Impeller removal ................................................................................................................. 69
Seal-chamber cover removal .............................................................................................. 71
Remove the seal-chamber cover (3196, CV 3196, HT 3196, LF 3196, 3796) .................... 71
Remove the stuffing-box cover (3196, CV 3196, HT 3196, LF 3196, 3796) ....................... 72
Remove the dynamic seal .................................................................................................. 73
Remove the frame adapter (MTi, LTi, XLT-i, i17) ............................................................... 74
Remove the inboard labyrinth oil seal ................................................................................. 75
Power-end disassembly ..................................................................................................... 75
2 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual
Table of Contents
Disassemble the bearing frame .......................................................................................... 84
Guidelines for i-ALERT™ Condition Monitor disposal ........................................................ 85
Disassemble the C-face adapter ........................................................................................ 85
Pre-assembly inspections ..................................................................................................... 86
Replacement guidelines ..................................................................................................... 86
Shaft and sleeve replacement guidelines ........................................................................... 87
Bearing-frame inspection ................................................................................................... 88
C-face adapter inspection ................................................................................................... 89
Seal chamber and stuffing box cover inspection ................................................................ 89
Bearings inspection ............................................................................................................ 91
Bearing-housing inspection ................................................................................................ 91
Bearing fits and tolerances ................................................................................................. 93
Reassembly .......................................................................................................................... 93
Assemble the rotating element and the bearing frame (STi and MTi) ................................. 93
Assemble the rotating element and the bearing frame (STi and MTi with duplex
bearings) ............................................................................................................................ 96
Assemble the rotating element and the bearing frame (LTi) ............................................... 99
Assemble the rotating element and the bearing frame (XLT-i and i17) ............................. 102
Assemble the rotating element and the bearing frame (XLT-i and i17 with duplex
bearings) .......................................................................................................................... 105
Assemble the frame .......................................................................................................... 109
INPRO labyrinth oil seal description ................................................................................. 112
Assemble the INPRO labyrinth oil seal ............................................................................. 113
Assemble the C-face adapter ........................................................................................... 113
Shaft sealing ..................................................................................................................... 114
Install the impeller ............................................................................................................. 120
Attach the i-ALERT™ Condition Monitor to the pump ...................................................... 122
Post-assembly checks ...................................................................................................... 123
Install the back pull-out assembly (except HT 3196) ........................................................ 123
Assembly references ........................................................................................................ 125
Spare parts ....................................................................................................................... 126
Interchangeability drawings ................................................................................................ 126
3196 interchangeability .................................................................................................... 126
Lubrication conversion ........................................................................................................ 127
Frame lubrication conversion ........................................................................................... 127
Convert from greased-for-life or regreaseable to oil-lubricated bearings .......................... 128
Conversion from flood-oil to pure-oil mist ......................................................................... 129
Convert from flood oil to regreaseable .............................................................................. 129
Troubleshooting .................................................................................................................. 130
Operation troubleshooting ................................................................................................... 130
Alignment troubleshooting .................................................................................................. 131
Assembly troubleshooting ................................................................................................... 131
i-ALERT™ Condition Monitor troubleshooting .................................................................... 131
Parts Listings and Cross-Sectional Drawings .................................................................. 132
Parts list .............................................................................................................................. 132
Certification: CE or CE ATEX ............................................................................................. 141
Certificates of conformance ................................................................................................ 141
Other Relevant Documentation or Manuals ...................................................................... 147
Local ITT Contacts .............................................................................................................. 148
Regional offices .................................................................................................................. 148
Model 3196 i-FRAME Installation, Operation, and Maintenance Manual 3
Introduction and Safety
Introduction and Safety
Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product can
cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the unit.
Requesting other information
Special versions can be supplied with supplementary instruction leaflets. See the sales
contract for any modifications or special version characteristics. For instructions, situations, or
events that are not considered in this manual or in the sales documents, please contact the
nearest ITT representative.
Always specify the exact product type and identification code when requesting technical
information or spare parts.
Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is overpressurized. Take all necessary measures to avoid over-pressurization.
• Operating, installing, or maintaining the unit in any way that is not covered in this manual could
cause death, serious personal injury, or damage to the equipment. This includes any modification to
the equipment or use of parts not provided by ITT. If there is a question regarding the intended use of
the equipment, please contact an ITT representative before proceeding.
• This manual clearly identifies accepted methods for disassembling units. These methods must be
adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never
apply heat to impellers, propellers, or their retaining devices to aid in their removal.
• Do not change the service application without the approval of an authorized ITT representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result in physical
injury, damage, or delays.
4 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual
Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent these
hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
Hazard levels
Hazard level Indication
DANGER: result in death or serious injury
Introduction and Safety
A hazardous situation which, if not avoided, will
Hazard categories
WARNING: result in death or serious injury
CAUTION: result in minor or moderate injury
NOTICE:
A hazardous situation which, if not avoided, could
A hazardous situation which, if not avoided, could
• A potential situation which, if not avoided,
could result in undesirable conditions
• A practice not related to personal injury
Hazard categories can either fall under hazard levels or let specific symbols replace the
ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary hazard
levels and may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard
The Ex symbol
The Ex symbol indicates safety regulations for Ex-approved products when used in
atmospheres that are potentially explosive or flammable.
Environmental safety
The work area
Always keep the station clean to avoid and/or discover emissions.
Model 3196 i-FRAME Installation, Operation, and Maintenance Manual 5
Introduction and Safety
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable environmental
regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
WARNING:
Do NOT send the product to the ITT manufacturer if it has been contaminated by any nuclear radiation.
Inform ITT so that accurate actions can take place.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Recycling guidelines
Always follow local laws and regulations regarding recycling.
User safety
General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment within
the work area:
• Helmet
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
Electrical connections
Electrical connections must be made by certified electricians in compliance with all international, national, state, and local regulations. For more information about requirements, see sections
dealing specifically with electrical connections.
Precautions before work
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other chapters of this manual.
Observe these safety precautions before you work with the product or are in connection with
the product:
6 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual
• Provide a suitable barrier around the work area, for example, a guard rail.
• Make sure that all safety guards are in place and secure.
• Make sure that you have a clear path of retreat.
• Make sure that the product cannot roll or fall over and injure people or damage property.
• Make sure that the lifting equipment is in good condition.
• Use a lifting harness, a safety line, and a breathing device as required.
• Allow all system and pump components to cool before you handle them.
• Make sure that the product has been thoroughly cleaned.
• Disconnect and lock out power before you service the pump.
• Check the explosion risk before you weld or use electric hand tools.
Precautions during work
Observe these safety precautions when you work with the product or are in connection with the
product:
• Never work alone.
• Always wear protective clothing and hand protection.
• Stay clear of suspended loads.
• Always lift the product by its lifting device.
• Beware of the risk of a sudden start if the product is used with an automatic level control.
• Beware of the starting jerk, which can be powerful.
• Rinse the components in water after you disassemble the pump.
• Do not exceed the maximum working pressure of the pump.
• Do not open any vent or drain valve or remove any plugs while the system is pressurized.
• Never operate a pump without a properly installed coupling guard.
Introduction and Safety
Make sure that the pump is isolated from the system and that pressure is relieved before
you disassemble the pump, remove plugs, or disconnect piping.
Hazardous liquids
The product is designed for use in liquids that can be hazardous to your health. Observe these
rules when you work with the product:
• Make sure that all personnel who work with biologically hazardous liquids are vaccinated
against diseases to which they may be exposed.
• Observe strict personal cleanliness.
Wash the skin and eyes
1. Follow these procedures for chemicals or hazardous fluids that have come into contact with
your eyes or your skin:
Condition Action
Chemicals or hazardous
fluids in eyes
Chemicals or hazardous
fluids on skin
1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least
15 minutes.
3. Seek medical attention.
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
Ex-approved products
Follow these special handling instructions if you have an Ex-approved unit.
Model 3196 i-FRAME Installation, Operation, and Maintenance Manual 7
Introduction and Safety
Personnel requirements
These are the personnel requirements for Ex-approved products in potentially explosive
atmospheres:
• All work on the product must be carried out by certified electricians and ITT-authorized
mechanics. Special rules apply to installations in explosive atmospheres.
• All users must know about the risks of electric current and the chemical and physical
characteristics of the gas, the vapor, or both present in hazardous areas.
• Any maintenance for Ex-approved products must conform to international and national
standards (for example, IEC/EN 60079-17).
ITT disclaims all responsibility for work done by untrained and unauthorized personnel.
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in
potentially explosive atmospheres:
• Only use the product in accordance with the approved motor data.
• The Ex-approved product must never run dry during normal operation. Dry running during
service and inspection is only permitted outside the classified area.
• Before you start work on the product, make sure that the product and the control panel are
isolated from the power supply and the control circuit, so they cannot be energized.
• Do not open the product while it is energized or in an explosive gas atmosphere.
• Make sure that thermal contacts are connected to a protection circuit according to the
approval classification of the product, and that they are in use.
• Intrinsically safe circuits are normally required for the automatic level-control system by the
level regulator if mounted in zone 0.
• The yield stress of fasteners must be in accordance with the approval drawing and the
product specification.
• Do not modify the equipment without approval from an authorized ITT representative.
• Only use parts that are provided by an authorized ITT representative.
Product approval standards
Regular standards
All standard products are approved according to CSA standards in Canada and UL standards
in USA. The drive unit degree of protection follows IP68. See the nameplate for maximum
submersion, according to standard IEC 60529.
All electrical ratings and performance of the motors comply with IEC 600341.
Explosion-proofing standards
All explosion-proof products for use in explosive atmospheres are designed in compliance with
one or more of the following approvals:
• EN, ATEX Directive 94/9/EC
• FM According to NEC
• Class 1 Div 1 Groups “C”, and “D”
• Class 2 Div 1 Groups “E”, “F”, and “G”
• Class 3 Div 1 Hazardous Locations
ATEX/IECEx:
• Group: IIC
• Category: Ex ia
• Temperature Class: T4 (for ambients up to 100ºC)
• ATEX Marking: Ex II 1 G
8 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual
CSA certification
Introduction and Safety
Intrinsically safe for:
• Class I, Div. 1, Groups A, B, C, D
• Class II, Div. 1, Groups E, F, G
• Class III
• Certified to Canadian and US requirements
Product warranty
Coverage
ITT undertakes to remedy faults in products from ITT under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an ITT representative within the warranty period.
• The product is used only under the conditions described in this manual.
• The monitoring equipment incorporated in the product is correctly connected and in use.
• All service and repair work is done by ITT-authorized personnel.
• Genuine ITT parts are used.
• Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved
products.
Limitations
The warranty does not cover faults caused by these situations:
• Deficient maintenance
• Improper installation
• Modifications or changes to the product and installation made without consulting ITT
• Incorrectly executed repair work
• Normal wear and tear
ITT assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
Warranty claim
ITT products are high-quality products with expected reliable operation and long life. However,
should the need arise for a warranty claim, then contact your ITT representative.
Model 3196 i-FRAME Installation, Operation, and Maintenance Manual 9
Transportation and Storage
Transportation and Storage
Inspect the delivery
Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
If the product has been picked up at a distributor, make a claim directly to the distributor.
Inspect the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
4. Contact your sales representative if anything is out of order.
Transportation guidelines
Pump handling
WARNING:
NOTICE:Use a forklift truck or an overhead crane with sufficient capacity to move the pallet
with the pump unit on top. Failure to do so can result in equipment damage.
Lifting methods
WARNING:
Table 1: Methods
Pump type Lifting method
A bare pump without lifting han- Use a suitable sling attached properly to solid points like the casing,
dles the flanges, or the frames.
A bare pump with lifting handles Lift the pump by the handles.
A base-mounted pump Use slings under the pump casing and the drive unit, or under the base
Mounted on top of a Polyshield See separate information regarding the Polyshield ANSI Combo.
ANSI Combo
• Make sure that the unit cannot roll or fall over and injure people or damage property.
• These pumps might use carbon or ceramic silicon carbide components. Do not drop the pump or
subject it to shock loads as this can damage the internal ceramic components.
• Assembled units and their components are heavy. Failure to properly lift and support this equipment
can result in serious physical injury and/or equipment damage. Lift equipment only at the specifically
identified lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated,
selected, and used for the entire load being lifted.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear
steel-toed shoes at all times.
• Do not attach sling ropes to shaft ends.
rails.
10 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual
Examples
Transportation and Storage
Figure 1: Example of a proper lifting method
NOTICE:Do not use this lifting method to lift a Polyshield ANSI Combo with the pump and
motor mounted. Doing so may result in equipment damage.
Figure 2: Example of a proper lifting method
NOTICE:Do not use this lifting method to lift a Polyshield ANSI Combo with the pump and
motor mounted. Doing so may result in equipment damage.
Figure 3: Example of a proper lifting method
NOTICE:When lifting a unit that does not have a way to secure the strap on the suction flange,
you must secure the strap around the frame adapter. Failure to do so may result in equipment
damage.
Model 3196 i-FRAME Installation, Operation, and Maintenance Manual 11
Transportation and Storage
Figure 4: Example of a proper lifting method with a strap secured around the frame adapter
Storage guidelines
Pump storage requirements
Storage requirements depend on the amount of time that you store the unit. The normal
packaging is designed only to protect the unit during shipping.
Length of time in storage Storage requirements
Upon receipt/short-term (less than six months)
Long-term (more than six months)
• Store in a covered and dry location.
• Store the unit free from dirt and vibrations.
• Store in a covered and dry location.
• Store the unit free from heat, dirt, and vibrations.
• Rotate the shaft by hand several times at least
every three months.
Frostproofing
NOTICE:
Risk of damage to the mechanical seal or shaft sleeve on units supplied with cartridge
mechanical seals. Make sure to install and tighten the centering clips and loosen the set
screws in the seal locking ring.
Treat bearing and machined surfaces so that they are well preserved. Refer to drive unit and
coupling manufacturers for their long-term storage procedures.
You can purchase long-term storage treatment with the initial unit order or you can purchase it
and apply it after the units are already in the field. Contact your local ITT sales representative.
Table 2: Situations when the pump is or is not frostproof
Situation Condition
Operating The pump is frostproof.
Immersed in a liquid The pump is frostproof.
Lifted out of a liquid into a temperature below The impeller might freeze.
freezing
12 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual
Product Description
General description 3196
The 3196 is a horizontal overhung, open impeller, centrifugal pump. This pump is ANSI B73.1
compliant.
The model is based on 5 power ends and 29 hydraulic sizes.
Product Description
Figure 5: 3196 pump
This table shows the number of hydraulic sizes available for each drive-unit size group.
Drive-unit size group Number of hydraulic sizes
STi 5
MTi 15
LTi 15
XLT-i 5
i-17 4
Model 3196 i-FRAME Installation, Operation, and Maintenance Manual 13
Product Description
Part description 3196
Impeller
Cover
Figure 6: 3196 part description
Table 3: Casing
This table describes the pump casing parts.
Part Description
Discharge Top-centerline
Casing ventilation Self venting
Gasket Fully confined
Mounting method Integral foot support for maximum resistance to misalignment due to piping loads.
Standard flange ANSI flat-faced serrated flange
Optional flanges One of the following flanges can be used:
• ANSI class 150 raised-face serrated flange
• ANSI class 300 flat-face serrated flange
• ANSI class 300 raised-face serrated flange
The impeller is
• fully open
• screwed onto the shaft
The threads are sealed from the pumped liquid by a Teflon O-ring for the 3196.
Standard seal
• The 3196 is available with a stuffing-box cover designed for a packing and a BigBore or a
TaperBore PLUS seal chamber.
Optional seal
14 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual
Product Description
• a dynamic seal is available which uses a repeller to pump liquid out of the stuffing box
while the pump operates. A static seal prevents leakage when the pump is shut down.
Table 4: Power end
This table describes the main parts of the power end.
Part Description
Frame adapter The ductile iron frame adapter has
• a machined rabbet fitted to the seal chamber/ stuffing box cover
• a precision dowel pin fitted to the bearing frame.
Power end
Shaft The shaft is available with or without a sleeve.
Bearings The inboard bearing
• Flood-oil lubrication is standard.
• No machining is required to convert from oil to grease or oil-mist lubrication.
Regreasable bearings and oil-mist lubrication are optional.
• The oil level is checked through a sight glass.
• The power end is sealed with labyrinth seals.
• The power end is made in the following sizes:
• STi
• MTi
• LTi
• XLT-i
• i-17
• carries only radial loads.
• is free to float axially in the frame.
• is a single-row deep-groove ball bearing
The outboard bearing
• is shouldered and locked to the shaft and housing to enable it to carry radial
and thrust loads.
• is a double-row angular-contact bearing, except for the LTi which uses a pair
of single-row angular-contact ball bearings mounted back-to-back.
General description i-ALERT™ Condition Monitor
Description
The i-ALERT Condition Monitor is a compact, battery-operated monitoring device that
continuously measures the vibration and temperature of the pump power end. The condition
monitor uses blinking red LEDs to alert the pump operator when the pump exceeds pre-set
vibration and temperature limits. This allows the pump operator to make changes to the
process or the pump before a catastrophic failure occurs. The condition monitor is also
equipped with a single green LED to indicate when it is operational and has sufficient battery
life.
Software License Agreement
BY USING THE i-Alert™ CONDITION MONITOR, YOU AGREE TO BE BOUND BY THE
TERMS AND CONDITIONS OF THE FOLLOWING LICENSE AGREEMENT. PLEASE READ
THIS AGREEMENT CAREFULLY.
ITT Corporation and its subsidiaries, affiliates, either directly, or through its authorized
sublicensees ("ITT") grants you a limited, non-exclusive license to use the software embedded
in this device ("Software") in binary executable form in the normal operation of the i-Alert™
condition monitor for monitoring the condition of an ITT Goulds pump models. Title, ownership
rights, and intellectual property rights in and to the Software remain in ITT or its third-party
providers. You agree that this license agreement does not need to be signed for it to take
effect.
You acknowledge that this Software is the property of ITT and is protected under United States
of America copyright laws and international copyright treaties. You further acknowledge that
the structure, organization, and code of the Software are valuable trade secrets of ITT and/or
its third-party providers and that the Software in source code form remains a valuable trade
Model 3196 i-FRAME Installation, Operation, and Maintenance Manual 15
Product Description
secret of ITT. You agree not to decompile, disassemble, modify, reverse assemble, reverse
engineer, or reduce to human readable form the Software or any part thereof or create any
derivative works based on the Software. You agree not to export or re-export the Software to
any country in violation of the export control laws of the United States of America.
Alarm mode
The condition monitor enters alarm mode when either vibration or temperature limits are
exceeded over two consecutive readings within a ten minute period. Alarm mode is indicated
with two red flashing LEDs within two second intervals.
Temperature and vibration limits
Variable Limit
Temperature 195°F (91°C)
Vibration 100% increase over the baseline level
Battery life
The i-ALERT Condition Monitor battery is not replaceable. You must replace the entire unit
once the battery runs out of power.
The battery life is not covered as part of the standard five-year pump warranty.
This table shows the average condition monitor battery life under normal and alarm-mode operating
conditions.
Condition monitor operational state Battery life
Normal operating and environmental conditions Three to five years
Alarm mode One year
Nameplate information
Important information for ordering
Every pump has nameplates that provide information about the pump. The nameplates are
located on the casing and the bearing frame.
When you order spare parts, identify this pump information:
• Model
• Size
• Serial number
• Item numbers of the required parts
Refer to the nameplate on the pump casing for most of the information. See Parts List for item
numbers.
Nameplate types
Nameplate Description
Pump casing Provides information about the hydraulic characteristics of the pump.
Bearing frame Provides information about the lubrication system used.
ATEX If applicable, your pump unit might have an ATEX nameplate affixed to the pump, the
IECEx If applicable, your pump unit might have the following IECEx nameplate affixed to the
The formula for the pump size is: Discharge x Suction - Nominal Maximum Impeller
Diameter in inches.
(Example: 2x3-8)
baseplate, or the discharge head. The nameplate provides information about the
ATEX specifications of this pump.
pump and/or baseplate. The nameplate provides information about the IECEx
specifications of this pump.
16 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual
Nameplate on the pump casing using English units
Table 5: Explanation of nameplate on the pump casing
Nameplate field Explanation
IMPLR. DIA. Impeller diameter, in inches
MAX. DIA. Maximum impeller diameter, in inches
GPM Rated pump flow, in gallons per minute
FT HD Rated pump head, in feet
RPM Rated pump speed, revolutions per minute
MOD. Pump model
SIZE Size of the pump
STD. NO. ANSI standard designation
MAT L. CONST. Material of which the pump is constructed
SER. NO. Serial number of the pump
MAX DSGN PSI Maximum pressure at 100ºF according to the pump design
@ 100F
Product Description
Nameplate on the pump casing using metric units
Table 6: Explanation of the nameplate on the pump casing
Nameplate field Explanation
IMPLR. DIA. Impeller diameter
MAX. DIA. Maximum impeller diameter
M3/HR Rated pump flow, in cubic meters per hour
M HD Rated pump head, in meters
RPM Rated pump speed, in revolutions per minute
MOD. Pump model
SIZE Size of the pump
STD. NO. ANSI standard designation
MAT L. CONST Material of which the pump is constructed
SER. NO. Serial number of the pump
MAX. DSGN KG/CM3@ Kilograms per cubic centimeter at 20°C
20°C
Model 3196 i-FRAME Installation, Operation, and Maintenance Manual 17
Product Description
Nameplate on the bearing frame
Table 7: Explanation of the nameplate on the bearing frame
Nameplate field Explanation
MOD. Pump model
SIZE Size of the pump
SER. NO. Serial number of the pump
LUBE Lubricant, oil or grease
ATEX nameplate
Nameplate field Explanation
II Group 2
2 Category 2
G/D Pump can be used when gas and dust are present
T4 Temperature class
NOTICE:Make sure that the code classifications on the pump are compatible with the specific
environment in which you plan to install the equipment. If they are not compatible, do not
operate the equipment and contact your ITT representative before you proceed.
18 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual
Installation
Preinstallation
Precautions
WARNING:
• When installing in a potentially explosive environment, make sure that the motor is properly certified.
• You must earth (ground) all electrical equipment. This applies to the pump equipment, the driver, and
any monitoring equipment. Test the earth (ground) lead to verify that it is connected correctly.
NOTICE:Supervision by an authorized ITT representative is recommended to ensure proper
installation. Failure to do so may result in equipment damage or decreased performance.
Pump location guidelines
WARNING:
Assembled units and their components are heavy. Failure to properly lift and support this equipment can
result in serious physical injury and/or equipment damage. Lift equipment only at the specifically identified
lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated, selected, and used for
the entire load being lifted.
Installation
Guideline Explanation/comment
Keep the pump as close to the liquid source as This minimizes the friction loss and keeps the
practically possible. suction piping as short as possible.
Make sure that the space around the pump is This facilitates ventilation, inspection, maintesufficient. nance, and service.
If you require lifting equipment such as a hoist This makes it easier to properly use the lifting
or tackle, make sure that there is enough equipment and safely remove and relocate the
space above the pump. components to a safe location.
Protect the unit from weather and water dam- This is applicable if nothing else is specified.
age due to rain, flooding, and freezing temperatures.
Do not install and operate the equipment in Acceptable devices:
closed systems unless the system is constructed with properly-sized safety devices and
control devices.
Take into consideration the occurrence of The best pump location for noise and vibration
unwanted noise and vibration. absorption is on a concrete floor with subsoil
If the pump location is overhead, undertake Consider a consultation with a noise specialist.
special precautions to reduce possible noise
transmission.
• Pressure relief valves
• Compression tanks
• Pressure controls
• Temperature controls
• Flow controls
If the system does not include these devices,
consult the engineer or architect in charge
before you operate the pump.
underneath.
Foundation requirements
Requirements
• The foundation must be able to absorb any type of vibration and form a permanent, rigid
support for the unit.
• The location and size of the foundation bolt holes must match those shown on the
assembly drawing provided with the pump data package.
Model 3196 i-FRAME Installation, Operation, and Maintenance Manual 19
Installation
Sleeve-type bolts
• The foundation must weigh between two and three times the weight of the pump.
• Provide a flat, substantial concrete foundation in order to prevent strain and distortion
when you tighten the foundation bolts.
• Sleeve-type and J-type foundation bolts are most commonly used. Both designs allow
movement for the final bolt adjustment.
1. Baseplate
2. Shims or wedges
3. Foundation
4. Sleeve
5. Dam
6. Bolt
J-type bolts
1. Baseplate
2. Shims or wedges
3. Foundation
4. Dam
5. Bolt
Baseplate-mounting procedures
Prepare the baseplate for mounting
1. Remove all the attached equipment from the baseplate.
2. Clean the underside of the baseplate completely.
3. If applicable, coat the underside of the baseplate with an epoxy primer.
Use an epoxy primer only if you used an epoxy-based grout.
4. Remove the rust-proofing coat from the machined mounting pads using an appropriate
solvent.
5. Remove water and debris from the foundation-bolt holes.
Install the baseplate using shims or wedges
Required tools:
• Two sets of shims or wedges for each foundation bolt
20 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual
Installation
• Two machinist's levels
• Baseplate-leveling worksheet
This procedure is applicable to cast iron and fabricated steel baseplates.
1. If you use sleeve-type bolts, fill the bolt sleeves with packing material or rags to prevent
grout from entering the bolt holes.
2. Put the sets of wedges or shims on each side of each foundation bolt.
The sets of wedges should have a height of between 0.75 in. (19 mm) and 1.50 in. (38
mm).
1. Shims or wedges
Figure 7: Top view
1. Shims or wedges
Figure 8: Side view
3. Lower the baseplate carefully onto the foundation bolts.
4. Put the machinist's levels across the mounting pads of the driver and the mounting pads of
the pump.
NOTICE:Remove all dirt from the mounting pads in order to make sure that you achieve the
correct leveling. Failure to do so can result in equipment damage or decreased
performance.
5. Level the baseplate both lengthwise and across by adding or removing shims or moving the
wedges.
These are the leveling tolerances:
• A maximum difference of 0.125 in. (3.2 mm) lengthwise
• A maximum difference of 0.059 in. (1.5 mm) across
You can use the baseplate-leveling worksheet when you take the readings.
6. Hand-tighten the nuts for the foundation.
Install the baseplate using jackscrews
Tools required:
• Anti-seize compound
• Jackscrews
• Bar stock
Model 3196 i-FRAME Installation, Operation, and Maintenance Manual 21
Installation
• Two machinist's levels
• Baseplate-leveling worksheet
This procedure is applicable to the feature-fabricated steel baseplate and the advantage base
baseplate.
1. Apply an anti-seize compound on the jackscrews.
The compound makes it easier to remove the screws after you grout.
2. Lower the baseplate carefully onto the foundation bolts and perform these steps:
a) Cut the plates from the bar stock and chamfer the edges of the plates in order to reduce
stress concentrations.
b) Put the plates between the jackscrews and the foundation surface.
c) Use the four jackscrews in the corners in order to raise the baseplate above the
foundation.
Make sure that the distance between the baseplate and the foundation surface is
between 0.75 in. (19 mm) and 1.50 in. (38 mm).
d) Make sure that the center jackscrews do not touch the foundation surface yet.
1. Jackscrew
2. Baseplate
3. Foundation
4. Plate
3. Level the driver mounting pads:
NOTICE:Remove all dirt from the mounting pads in order to make sure that you achieve the
correct leveling. Failure to do so can result in equipment damage or decreased
performance.
a) Put one machinist's level lengthwise on one of the two pads.
b) Put the other machinist's level across the ends of the two pads.
22 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual
Installation
c) Level the pads by adjusting the four jackscrews in the corners.
Make sure that the machinist's level readings are as close to zero as possible, both
lengthwise and across.
Use the baseplate-leveling worksheet when you take the readings.
1. Machinist's levels
2. Driver's mounting pads
3. Foundation bolts
4. Jackscrews
5. Grout hole
6. Pump's mounting pads
4. Turn the center jackscrews down so that they rest on their plates on the foundation surface.
5. Level the pump mounting pads:
NOTICE:Remove all dirt from the mounting pads in order to make sure that you achieve the
correct leveling. Failure to do so can result in equipment damage or decreased
performance.
a) Put one machinist's level lengthwise on one of the two pads.
b) Put the other level across the center of the two pads.
c) Level the pads by adjusting the four jackscrews in the corners.
Make sure that the machinist's level readings are as close to zero as possible, both
lengthwise and across.
1. Driver's mounting pads
2. Machinist's levels
3. Foundation bolts
4. Jackscrews
5. Grout hole
6. Pump's mounting pads
6. Hand-tighten the nuts for the foundation bolts.
7. Check that the driver's mounting pads are level and adjust the jackscrews and the
foundation bolts if necessary.
The correct level measurement is a maximum of 0.002 in./ft (0.0167 mm/m).
Model 3196 i-FRAME Installation, Operation, and Maintenance Manual 23
Installation
Install the baseplate using spring mounting
NOTICE:The spring-mounted baseplate is designed only to support piping loads from thermal
expansion. You must support the suction and discharge piping individually. Failure to do so
may result in equipment damage.
The foundation pads are not provided with the baseplate. Make sure that the foundation pads
are 316 stainless-steel plates, which have a 16-20 micro-inch surface finish.
Before you start this procedure, make sure that the foundation pads are correctly installed on
the foundation/floor (see the manufacturer's instructions).
1. Put the baseplate on a support above the foundation/floor.
Make sure that there is enough space between the baseplate and the foundation/floor in
order to install the spring assemblies.
2. Install the lower part of the spring assembly:
a) Screw the lower jam nut onto the spring stud.
b) Screw the lower adjusting nut onto the spring-stud, on top of the jam nut.
c) Set the lower adjusting nut to the correct height.
The correct height depends on the required distance between the foundation/floor and
the baseplate.
d) Put a washer, a follower, a spring, and one more follower onto the lower adjusting nut.
3. Install the spring assembly on the baseplate:
a) Insert the spring assembly into the baseplate's anchorage hole from below.
b) Put a follower, a spring, another follower, and a washer onto the spring stud.
c) Fasten the spring assembly with the upper adjusting nut by hand.
4. Thread the upper jam nut onto the spring stud by hand.
5. Repeat steps 2 through 4 for all the spring assemblies.
6. Lower the baseplate so that the spring assemblies fit into the foundation pads.
7. Level the baseplate and make the final height adjustments:
a) Loosen the upper jam nuts and adjusting nuts.
b) Adjust the height and level the baseplate by moving the lower adjusting nuts.
c) When the baseplate is level, tighten the top adjusting nuts so that the top springs are
not loose in their followers.
8. Fasten the lower and upper jam nuts on each spring assembly.
24 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual
1. Upper jam nut
2. Follower
3. Washer
4. Foundation pads
5. Spring
6. Upper adjusting nut
7. Spring stud
Figure 9: Example of an installed spring assembly
Installation
Install the baseplate using stilt mounting
NOTICE:The stilt-mounted baseplate is not designed to support static piping loads. Make sure
to individually support the suction and discharge piping. Failure to do so may result in
equipment damage.
1. Put the baseplate on a support above the foundation/floor.
Make sure that there is enough space between the baseplate and the foundation/floor to
install the stilts.
2. Install the lower part of the stilt assembly:
a) Screw the lower jam nut and adjusting nut onto the stilt.
b) Set the lower adjusting nut to the correct height.
The correct height depends on the required distance between the foundation/floor and
the baseplate.
c) Put a washer onto the lower adjusting- nut.
3. Install the stilt assembly on the baseplate:
a) Insert the stilt assembly into the baseplate's anchorage hole from below.
b) Put a washer onto the stilt.
c) Fasten the stilt assembly with the upper adjusting nut by hand.
4. Screw the upper jam nut onto the stilt by hand.
5. Repeat steps 2 through 4 for all the stilt assemblies.
6. Lower the baseplate so that the stilts fit into the foundation cups.
7. Level the baseplate and make the final height adjustments:
a) Loosen the upper jam nuts and adjusting nuts.
b) Adjust the height and level the baseplate by moving the lower adjusting nuts.
c) When the baseplate is level, tighten the top adjusting nuts.
8. Fasten the lower and upper jam nuts on each stilt.
Model 3196 i-FRAME Installation, Operation, and Maintenance Manual 25
Installation
1. Mounting plate
2. Mounting nut
3. Stilt bolt
4. Foundation cups
5. Washer
6. Upper adjustment nut
7. Mounting washer
8. Mounting bolt
Figure 10: Example of an installed stilt assembly
26 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual
Baseplate-leveling worksheet
Installation
Model 3196 i-FRAME Installation, Operation, and Maintenance Manual 27
Installation
Install the pump, driver, and coupling
1. Mount and fasten the pump on the baseplate. Use applicable bolts.
2. Mount the driver on the baseplate. Use applicable bolts and hand tighten.
3. Install the coupling.
See the installation instructions from the coupling manufacturer.
Pump-to-driver alignment
Precautions
WARNING:
• Follow shaft alignment procedures in order to prevent catastrophic failure of drive components or
unintended contact of rotating parts. Follow the coupling installation and operation procedures from
the coupling manufacturer.
• Always disconnect and lock out power to the driver before you perform any installation or
maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical
injury.
NOTICE:Proper alignment is the responsibility of the installer and the user of the unit. Check
the alignment of frame-mounted units before you operate the unit. Failure to do so can result in
equipment damage or decreased performance.
Alignment checks
When to perform alignment checks
You must perform alignment checks under these circumstances:
• The process temperature changes.
• The piping changes.
• The pump has been serviced.
Types of alignment checks
Type of check When it is used
Initial alignment (cold align- Prior to operation when the pump and the driver are at ambient
ment) check temperature.
Final alignment (hot align- After operation when the pump and the driver are at operating
ment) check temperature.
Initial alignment (cold alignment) checks
When Why
Before you grout the base- This ensures that alignment can be accomplished.
plate
After you grout the baseplate This ensures that no changes have occurred during the
After you connect the piping This ensures that pipe strains have not altered the alignment.
grouting process.
If changes have occurred, you must alter the piping to remove
pipe strains on the pump flanges.
Final alignment (hot alignment) checks
When Why
After the first run This ensures correct alignment when both the pump and the
driver are at operating temperature.
Periodically This follows the plant operating procedures.
28 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual
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