Goulds Pumps 3296M User Manual

FOREWORD

This manual provides instructions for the Installation, Operation, and Maintenance of the Goulds Model 3296 “M Group” Magnetic Drive Process Pump. This manual must be read and understood before installation and start-up.

The design, materials, and workmanship incorporated in the construction of Goulds pumps makes them capable of giving, trouble-free service. The life and satisfactory service of any mechanical unit, however, is enhanced and extended by correct application, proper installation, periodic inspection, condition monitoring and careful maintenance. This instruction manual was prepared to assist operators in understanding the construction and the correct methods of installing, operating, and maintaining these pumps.

Goulds shall not be liable for physical injury, damage or delays caused by a failure to observe the instructions for Installation, Operation, and Maintenance contained in this manual.

Warranty is valid only when genuine Goulds parts are used.

Use of the equipment on a service other than stated in the order could nullify the warranty, unless written approval is obtained in advance from Goulds Pumps, Inc.

Supervision by an authorized Goulds representative is recommended to assure proper installation.

Additional manuals can be obtained by contacting your local Goulds representative or by calling 1-800-446-8537.

THIS MANUAL EXPLAINS

Proper Installation

Start Up Procedures

Operation Procedures

Routine Maintenance

Pump Overhaul

Troubleshooting

Ordering Spare or Repair Parts

3296 M Group 6/05 3

TABLE OF CONTENTS

PAGE SECTION

7 SAFETY

9 GENERAL INFORMATION

11 INSTALLATION

19 OPERATION

23 PREVENTIVE MAINTENANCE

27 DISASSEMBLY & REASSEMBLY

55 SPARE AND REPAIR PARTS

61 APPENDIX

3296 M Group 6/05 5

6 3296 M Group 6/05

IMPORTANT SAFETY NOTICE

To: Our Valued Customers

User safety is a major focus in the design of our products. Following the precautions outlined in this manual will minimize your risk of injury.

ITT Goulds pumps will provide safe, trouble-free service when properly installed, maintained, and operated.

Safe installation, operation, and maintenance of ITT Goulds Pumps equipment are an essential end user responsibility. This Pump Safety Manual identifies specific safety risks that must be considered at all times during product life. Understanding and adhering to these safety warnings is mandatory to ensure personnel, property, and/or the environment will not be harmed. Adherence to these warnings alone, however, is not sufficient — it is anticipated that the end user will also comply with industry and corporate safety standards. Identifying and eliminating unsafe installation, operating and maintenance practices is the responsibility of all individuals involved in the installation, operation, and maintenance of industrial equipment.

Please take the time to review and understand the safe installation, operation, and maintenance guidelines outlined in this Pump Safety Manual and the Instruction, Operation, and Maintenance (IOM) manual. Current manuals are available at your nearest Goulds Pumps sales representative.

www.gouldspumps.com/literature_ioms.html or by contacting

These manuals must be read and understood before installation and star t-up.

For additional information, contact your nearest Goulds Pumps sales representative or visit our Web site at

www.gouldspumps.com.

S-1

SAFETY WARNINGS

Specific to pumping equipment, significant risks bear reinforcement above and beyond normal safety precautions.

WARNING

A pump is a pressure vessel with rotating parts that can be hazard o us. An y press ure vessel can explode, rupture, or discharge its contents if sufficiently ove r press u r i zed causi n g deat h, personal injury, property damage, and/or damage to the environment. All necessary measures must be taken to ensure over pressurization does not occur.

WARNING

Operation of any pumping system with a blocked suction and discharge must be avoided in all cases. Operation, even for a brief period under these conditions, can cause superheating of enclosed pumpage and result in a violent explosion. All necessary measures must be taken by the end user to ensure this condition is avoided.

WARNING

The pump may handle hazardous and/or toxic fluids. Care must be taken to identify the contents of the pump and eliminate the possibility of exposure, particularly if hazardous and/or toxic. Potential hazards include, but are not limited to, high temperature, flammable, acidic, caustic, explosive, and other risks.

WARNING

Pumping equipment Instruction, Operation, and Maintenance manuals clearly identify accepted methods for disassembling pumping units. These methods must be adhered to. Specifically, applying heat to impellers and/or impeller retaining devices to aid in their removal is strictly forbidden. Trapped liquid can rapidly expand and result in a violent explosion and injury.

ITT Goulds Pumps will not accept responsibility for physical injury, damage, or delays caused by a failure to observe the instructions for installation, operation, and maintenance contained in this Pump Safety Manual or the current IOM available at www.gouldspumps.com/literature.

S-2

SAFETY

DEFINITIONS

Throughout this manual the words WARNING, CAUTION, ELECTRICAL, and ATEX are used to indicate where special operator attention is required.

Observe all Cautions and Warnings highlighted in this Pump Safety Manual and the IOM provided with your equipment.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Example:

Pump shall never be operated without coupling guard installed correctly.

CAUTION

Indicates a hazardous situation which, if not avoi ded, could result in minor or moderate injury.

Example: Throttling flow from the suction side may cause cavitation and pump damage.

ELECTRICAL HAZARD



Indicates the possibility of electrical risks if directions are not followed.

Example: Lock out driver power to prevent electric shock, accidental start-up, and physical injury.

 When installed in potentially explosive atmospheres, the instructions that follo w the Ex symbol must be

followed. Personal injury and/or equipment damage may occur if these instructions are not followed. If there is any question regarding these requirements or if the equipment is to be modified, please contact an ITT Goulds Pumps representative before proceeding.

Example: parts, resulting in a spark and heat generation.

 Improper impeller adjustment could cause contact between the rotating and stationary

S-3

GENERAL PRECAUTIONS

WARNING

A pump is a pressure vessel with rotating parts that can be hazardous. Hazardous fluids may be contained by the pump including high temperature, flammable, acidic, caustic, explosive, and other risks. Operators and maintenance personnel must realize this and follow safety measures. Personal injuries will result if procedures outlined in this manual are not followed. ITT Goulds Pumps will not accept responsibility for physical injury, damage or delays caused by a failure to observe the instructions in this manual and the IOM provided with your equipment.

WARNING

General Precautions

NEVER use heat to disassemble pump due to risk of explosion from tapped liquid.

NEVER APPLY HEAT TO REMOVE IMPELLER. It may explode due to trapped liquid.

WARNING

WARNING WARNING

WARNING





NEVER operate pump without safety devices installed.

 



NEVER operate pump without coupling guard correctly installed. NEVER run pump below recommended minimum flow when dry, or without

prime. ALWAYS lock out power to the driver befo re per fo rming pump maintenance.

NEVER operate pump with discharge valve closed. NEVER operate pump with suction valve closed.

DO NOT change service application without approval of an authorized ITT Goulds Pumps representative.

Safety Apparel:

 Insulated work gloves when handling hot bearings or using bearing heater  Heavy work gloves when handling parts with sharp edges, especial l y

impellers

 Safety glasses (with side shields) for eye protection  Steel-toed shoes for foot protection when handli ng pa rts, heavy tools, etc.  Other personal protective equipment to protect against hazardous/toxic fluids

Receiving:

Assembled pumping units and their components are heavy. Failure to properly lift and support equipment can result in serious physical injury and/or equipment damage. Lift equipment only at specifically identified lifting points or as instructed in the current IOM. Current manuals are available at

www.gouldspumps.com/literature_ioms.html or from your local ITT Goulds

Pumps sales representative. Note: Lifting devices (eyebolts, slings, spreaders, etc.) must be rated, selected, and used for the entire load being lifted.

Alignment:

WARNING

Shaft alignment procedures must be followed to prevent catastrophic failure of



drive components or unintended contact of rotating parts. Follow coupling manufacturer’s coupling installation and operation procedures.

S-4

WARNING

CAUTION

General Precautions

Before beginning any alignment procedure, make sure driver power is locked out.



Failure to lock out driver power will result in serious physical injury.

Piping:

Never draw piping into place by forcing at the flan ged con necti on s of t he pump. This may impose dangerous strains on the unit and cause misalignment between



pump and driver. Pipe strain will adversely effect the operation of the pump resulting in physical injury and damage to the equipment.

WARNING

CAUTION

WARNING

Flanged Connections:

Use only fasteners of the proper size and material. Replace all corroded fasteners.

Ensure all fasteners are properly tightened and there are no missing fasteners.

Startup and Operation:

When installing in a potentially explosive environment, please ensure that the



motor is properly certified. Operating pump in reverse rotation may result in contact of metal parts, heat



generation, and breach of containment. Lock out driver power to prevent accidental start-up and physical injury.



The impeller clearance setting procedure must be followed. Improperly setting the clearance or not following any of the proper procedures can result in sparks,



unexpected heat generation and equipment damage. If using a cartridge mechanical seal, the centering clips must be installed and set

screws loosened prior to setting impeller clearance. Failure to do so could result



in sparks, heat generation, and mechanical seal damage. The coupling used in an ATEX classified environment must be properly certified



and must be constructed from a non-sparking material. Never operate a pump without coupling guard properly installed. Personal injury

will occur if pump is run without coupling guard. Make sure to properly lubricate the bearings. Failure to do so may result in excess



heat generation, sparks, and / or premature failure. The mechanical seal used in an ATEX classified environment must be properly

certified. Prior to start up, ensure all points of potential leakage of process fluid to



the work environment are closed. Never operate the pump without liquid supplied to mechanical seal. Running a

mechanical seal dry, even for a few seconds, can cause seal damage and must be



avoided. Physical injury can occur if mechanical seal fails. Never attempt to replace packing until the driver is properly locked out and the

coupling spacer is removed.

WARNING

S-5

Dynamic seals are not allowed in an ATEX classified environment.



DO NOT operate pump below minimum rated flows or with suction and/or discharge valve closed. These conditions may create an explosive hazard due to



vaporization of pumpage and can quickly lead to pump failure and physical injury.

WARNING

CAUTION

WARNING

CAUTION



General Precautions

Ensure pump is isolated from system and pressure is relieved before disassembling pump, removing plu gs, ope ni n g vent or drain valves, or disconnecting piping.

Shutdown, Disassembly, and Reassembly:

Pump components can be heavy. Proper methods of lifting must be employed to avoid physical injury and/or equipment damage. Steel toed shoes must be worn at all times.

The pump may handle hazardous and/or toxic fluids. Observe proper decontamination procedures. Proper personal protective equipment should be worn. Precautions must be taken to prevent physical injury. Pumpage must be handled and disposed of in conformance with applicable environmental regulations.

Operator must be aware of pumpage and safety precautions to prevent physical injury.

Lock out driver power to prevent accidental startup and physical injury. Allow all system and pump components to cool before handling them to prevent

physical injury. If pump is a Model NM3171, NM3196, 3198, 3298, V3298, SP3298, 4150, 4550,

or 3107, there may be a risk of static electric discharge from plastic parts that are not properly grounded. If pumped fluid is non-conductive, pump should be drained and flushed with a conductive fluid under conditions that will not allow for a spark to be released to the atmosphere.

Never apply heat to remove an impeller. The use of heat may cause an explosion due to trapped fluid, resulting in severe physical injury and property damage.

Wear heavy work gloves when handling impellers as sharp edges may cause physical injury.

Wear insulated gloves when using a bearing heater. Bearings will get hot and can cause physical injury.

S-6

ATEX CONSIDERATIONS and INTENDED USE

Special care must be taken in potentially explosive environments to ensure that the equipment is properly maintained. This includes but is not limited to:

1. Monitoring the pump frame and liquid end temperature.

2. Maintaining proper bearing lubrication.

3. Ensuring that the pump is operated in the intended hydraulic range.

The ATEX conformance is only applicable when the pump unit is operated within its intended use. Operating, installing or maintaining the pump unit in any way that is not covered in the Instruction, Operation, and Maintenance manual (IOM) can cause serious personal injury or damage to the equipment. This includes any modification to the equipment or use of parts not provided by ITT Goulds Pumps. If there is any question regarding the intended use of the equipment, please contact an ITT Goulds represe ntative before proceeding. Current IOMs are available at Pumps Sales representative.

All pumping unit (pump, seal, coupling, motor and pump accessories) certified for use in an ATEX classified environment, are identified by an ATEX tag secured to the pump or the baseplate on which it is mounted. A typical tag would look like this:

www.gouldspumps.com/literature_ioms.html or from your local ITT Goulds

The CE and the Ex designate the ATEX compliance. The code directly below these symbols reads as follows:

II = Group 2 2 = Category 2 G/D = Gas and Dust present T4 = Temperature class, can be T1 to T6 (see Table 1)

Table 1

Max permissible

surface temperature

Code

T1 842 (450) 700 (372) T2 572 (300) 530 (277) T3 392 (200) 350 (177) T4 275 (135) 235 (113) T5 212 (100) Option not available T6 185 (85) Option not available

F (oC)

The code classification marked on the equipment must be in accordance with the specified area where the equipment will be installed. If it is not, do not operate the equipment and contact your ITT Goulds Pumps sales representative before proceeding.

Max permissible

liquid temperature

F (oC)

S-7

PARTS

The use of genuine Goulds parts will provide the safest and most reliable operation of your pump. ITT Goulds Pumps ISO certification and quality control procedures ensure the parts are manufactured to the highest quality and safety levels.

Please contact your local Goulds representative for details on genuine Goulds parts.

S-8

GENERAL INFORMATION

PUMP DESCRIPTION .............................9

NAMEPLATE INFORMATION ........................9

RECEIVING THE PUMP ...........................10

Storage Requirements ...........................................10

Handling .....................................................10

PUMP DESCRIPTION

The Model 3296 is a sealless frame-mounted centrifugal pump with an enclosed impeller, that is driven by a synchronous magnetic coupling, and meets dimensional standards of ANSI B73.1.

Magnetic Coupling - is a coaxial synchronous type using rare earth magnets. This concept results in a compact design and allows the impeller to turn at the same speed as the motor, (i.e.) there is no slip between the drive and driven magnets.

Magnets - Two types of rare earth magnets are available. Neodymium Iron (NdFe), which is used when pumpage temperatures are less than 250°F (120°C). For liquid pumpage between 250°F (120°C) and 425°F (220°C) Samarium Cobalt (SmCo) magnets are used.

Containment Shell - isolates the pumped liquid from the atmosphere. Standard material is Hastelloy-C which provides excellent corrosion and erosion resistance.

NAMEPLATE INFORMATION

Sleeve Bearings and Thrust Bearings - Goulds

standard bearing material is Pure Sintered Alpha Grade Silicon Carbide. The sleeve bearings are flexibly mounted using O-rings.

Impeller - Model 3296 utilizes an enclosed impeller, hydraulically balanced and keyed to the shaft.

Bearing Frame - the standard configuration is cast ductile iron with flood oil lubricated ball bearings. Pure oil mist systems are available as an option. For protection and reliability of the bearings and the lubricant, a carbon filled teflon non-contacting labyrinth seal is provided. On the inboard side a lip seal is used to prevent leakage of oil into the magnetic drive assembly.

Casing - is top centerline discharge, self venting type incorporates a fully confined gasket. 150 lb. ANSI serrated raised face flanges are standard. The 3296 has been designed such that there is a metal to metal fit between the casing and frame adapter.

Every pump has 3 Goulds nameplates that provide information on your pump. The tags are located on the casing and bearing frame.

Pump Casing Tag - provides information relative to the pumps characteristics. The format of pump size information is: Discharge x Suction - Nominal Impeller Diameter, (ex.1x1

Bearing Frame Tag - provides information relative to the type of magnets being used.

3296 M Group 6/05 9

-6)

Pump Warning Tag - is permanently fastened to the bearing frame. It contains precautions to be observed during the operation, disassembly, maintenance and reassembly of the pump.

When ordering spare parts you will need to know the pump model, size, serial number, and the item number of the required parts. Information can be taken from the pump casing tag. Item number information can be found in this manual.

RECEIVING THE PUMP

Inspect the pump as soon as it is received. Make notes of damaged or missing items on the receipt and freight bill. File any claims with the transportation company immediately.

STORAGE REQUIREMENTS

Short Term - (Less than 3 months) Goulds normal

packaging procedure is designed to protect the pump during shipping. Upon receipt store in a covered and dry location.

Long Term - (More than 6 months) Preservative treatment of bearings and machined surfaces will be required. Rotate shaft several times every 3 months. Refer to driver and coupling manuals for their long term storage procedures. Store in a dry covered location.

HANDLING

! WARNING

Failure to properly lift and support equipment could result in serious injury or damage to pumps.

Use care when moving pumps. Lifting equipment must be able to adequately support the entire assembly. Hoist bare pumps, using a sling under the suction flange and bearing housing.

the pump and driver.

Baseplate mounted units are moved with slings under

10 3296 M Group 6/05

INSTALLATION

SITE/FOUNDATION..............................11

LEVEL BASEPLATE .............................12

ALIGNMENT AND ALIGNMENT PROCEDURE .............12

Alignment Checks..............................................12

Alignment Criteria .............................................13

SetUp.......................................................13

Measurement..................................................13

Angular Alignment .............................................13

Parallel Alignment .............................................14

Complete Alignment ............................................15

Alignment Troubleshooting ......................................15

GROUT BASEPLATE .............................15

PIPING......................................16

Suction Piping .................................................16

Discharge Piping ...............................................17

Final Piping Check .............................................17

SITE/FOUNDATION

A pump should be located near the supply of liquid and have adequate space for operation, maintenance, and inspection.

Baseplate mounted pumps are normally grouted to a concrete foundation, which has been poured on a solid footing. The foundation must be able to

Fig. 4A

absorb any vibration and to form a permanent, rigid support for the pumping unit.

The location and size of the foundation bolts are shown on the outline assembly drawing, provided with the pump data package.

Foundation bolts commonly used are sleeve type (Fig. 4A) and J type (Fig. 4B). Both designs permit movement for final bolt adjustment.

Fig. 4B

3296 M Group 6/05 11

LEVEL BASEPLATE

1. Place 2 sets of wedges or shims on the foundation, one set on each side of every foundation bolt. The wedges should extend .75 in. (20 mm) to 1.5 in. (40 mm) above the foundation, to allow for adequate grouting. This will provide even support for the baseplate once it is grouted.

2. Remove water and/or debris from anchor bolt holes/sleeves prior to grouting. If the sleeve

Fig. 5A

type bolts are being used, fill the sleeves with rags to prevent grout from entering.

3. Carefully lower baseplate onto foundation bolts.

4. Level baseplate to within .125 in.(3mm) over the length of the base and .062 in. (1.5 mm) over the width of the base by adjusting shims or wedges.

5. Hand tighten bolts.

Fig. 5B

ALIGNMENT AND ALIGNMENT PROCEDURE

! WARNING

Before beginning any alignment procedure make sure driver power is locked out. Failure to lock out driver power can result in serious personal injury.

The points at which alignment is checked and adjusted are:

Initial Alignment is done prior to operation when the pump and the driver are at ambient temperature.

Final Alignment is done after operation when the pump and driver are at operating temperature.

Alignment is achieved by adding or removing shims from under the feet of the driver and shifting equipment horizontally as needed.

NOTE: Proper alignment is the responsibility of the installer of the unit.

Accurate alignment of the equipment must be attained. Trouble-free operation can be accomplished by following these procedures:.

ALIGNMENT CHECKS

Initial Alignment (Cold Alignment)

Before Grouting Baseplate- To ensure alignment can be obtained.

After Grouting Baseplate - To ensure no changes to alignment have occurred during grouting process.

After Connecting Piping -To ensure that pipe strains haven’t altered alignment. If changes have occurred, alter piping to remove pipe strains on pump flanges.

Final Alignment (Hot Alignment)

After First Run -To obtain correct alignment when both pump and driver are at operating temperature. Thereafter, alignment should be checked periodically in accordance with plant operating and maintenance procedures.

12 3296 M Group 6/05

ALIGNMENT CRITERIA

Good alignment is achieved when dial indicator readings as specified in the alignment procedure are .002 in. (.05 mm) Total Indicated Reading (T.I.R.) or less when the pump and driver are at operating temperature (Final Alignment).

MEASUREMENT

1. To ensure accuracy of indicator readings, always rotate both coupling halves together so indicators contact the same point on coupling half Y. This will eliminate any measurement problems due to runout on coupling half Y.

During the installation phase, however, it is necessary to set the parallel alignment in the vertical direction to a different criteria due to differences in expansion rates of the pump and driver. Table 1 below shows recommended cold settings for electric motor driven pumps based on different pumpage temperatures. Driver manufacturers should be consulted for recommended cold settings for other types of drivers (steam turbines, engines, etc.)

Table 1

Cold Settings of Parallel Vertical Alignment

PUMPAGE

TEMPERATURE

50°F (10°C) .002in. (.05mm) LOW

150°F (65°C) .001in. (.03mm) HIGH 250°F (120°C) .005in. (.12mm) HIGH 350°F (175°C) .009in. (.23mm) HIGH 425°F (218°C) .013in. (.33mm) HIGH

SET DRIVER SHAFT

SET UP

1. Mount two dial indicators on one of the coupling halves (X) so they contact the other coupling half (Y) (Fig. 6).

2. Check setting of indicators by rotating coupling half X to ensure indicators stay in contact with coupling half Y but do not bottom out. Adjust indicators accordingly.

2. Take indicator measurements with driver feet hold down bolts tightened. Loosen hold down bolts prior to making alignment corrections.

3. Take care not to damage indicators when moving driver during alignment corrections.

ANGULAR ALIGNMENT

A unit is in angular alignment when indicator A (Angular indicator) does not vary by more that .002 in. (.05 mm) as measured at four locations 90° apart.

Vertical Correction (Top to Bottom)

1. Zero indicator A at top dead center (12 o’clock) of coupling half Y.

2. Rotate indicators to bottom dead center (6 o’clock). Observe needle and record reading.

3. Negative Reading - The coupling halves are further apart at the bottom than at the top. Correct by either raising the driver feet at the shaft end (add shims) or lowering the driver feet at the other end (remove shims) (Fig. 7A).

Positive Reading - The coupling halves are closer at the bottom than at the top. Correct by either lowering the driver feet at the shaft end (remove shims) or raising the driver feet at the other end (add shims).

Fig. 7A

Fig. 6

4. Repeat steps 1-3 until indicator A reads .002 in (.05 mm) or less.

3296 M Group 6/05 13

Horizontal Correction (Side to Side)

1. Zero indicator A on left side of coupling half Y, 90° from top dead center (9 o’clock).

2. Rotate indicators through top dead center to the right side, 180° from the start (3 o’clock). Observe needle and record reading.

3. Negative Reading - The coupling halves are further apart on the right side than the left. Correct by either sliding the shaft end of the driver to the left or the other end to the right.

Positive Reading - The coupling halves are closer together on the right side than the left. Correct by either sliding the shaft end of the driver to the right or the other end to the left (Fig. 7B).

Positive Reading - Coupling half X is higher than coupling half Y. Correct by adding shims of thickness equal to half of the indicator reading from each driver foot (Fig. 8A).

Fig. 8A

NOTE: Equal amounts of shims must be added to or removed from each driver foot. Otherwise the vertical angular alignment will be affected.

4. Repeat steps 1 through 3 until indicator P reads within .002 in. (.05 mm) or less when hot, or per Table 1 when cold.

Fig. 7B

4. Repeat steps 1 through 3 until indicator A reads .002 in. (.05 mm) or less.

5. Re-check both horizontal and vertical readings to ensure adjustment of one did not disturb the other. Correct as necessary.

PARALLELALIGNMENT

A unit is in parallel alignment when indicator P (parallel indicator) does not vary by more than .002 in. (.05 mm) as measured at four points 90° apart at operating temperature. Note the preliminary cold setting criteria, Table 1.

Vertical Correction (Top to Bottom)

1. Zero indicator P at top dead center of coupling (12 o’clock) half Y (Fig. 6).

2. Rotate indicator to bottom dead center (6 o’clock). Observe needle and record reading.

3. Negative Reading - Coupling half X is lower than coupling half Y. Correct by removing shims of thickness equal to half of the indicator reading under each driver foot.

Horizontal Correction (Side to Side)

1. Zero indicator P on the left side of coupling half Y, 90° from top dead center (9 o’clock).

2. Rotate indicators through top dead center to the right side, 180° from the start. Observe needle and record reading (3 o’clock).

3. Negative Reading - Coupling half Y is to the left of coupling half X. Correct by sliding driver evenly in the appropriate direction (Fig. 8B).

Positive Reading - Coupling half Y is to the right of coupling half X. Correct by sliding driver evenly in the appropriate direction.

Fig. 8B

NOTE: Failure to slide motor evenly will affect horizontal angular correction.

14 3296 M Group 6/05

4. Repeat steps 1 through 3 until indicator P reads .002 in. (.05 mm) or less.

5. Re-check both horizontal and vertical readings to ensure adjustment of one did not disturb the other.

Correct as necessary.

COMPLETE ALIGNMENT

A unit is in complete alignment when both indicators A (angular) and P (parallel) do not vary by more than .002 in. (.05 mm) as measured at four points 90° apart.

Vertical Correction (Top to Bottom)

1. Zero indicators A and P at top dead center (12 o’clock) of coupling half Y.

2. Rotate indicator to bottom dead center (6 o’clock). Observe the needles and record the readings.

Alignment Troubleshooting

PROBLEM PROBABLE CAUSE REMEDY

Cannot obtain horizontal (Side-to-Side) alignment, angular or parallel

Cannot obtain vertical (Top to Bottom) alignment, angular or parallel

Driver feet bolt bound

Baseplate not leveled properly, probably twisted.

Baseplate not leveled properly, probably bowed.

3. Make corrections as outlined previously.

Horizontal Correction (Side to Side)

1. Zero indicators A and P on the left side of coupling half Y, 90° from top dead center (9 o’clock).

2. Rotate indicators through top dead center to the right side, 180° from the start (3 o’clock). Observe the needle, measure and record the reading.

3. Make corrections as outlined previously.

4. Recheck both vertical and horizontal readings to ensure adjustment of one did not disturb the other. Correct as necessary.

NOTE: With experience, the installer will understand the interaction between angular and parallel and will make corrections appropriately.

Table 2

Loosen pump hold down bolts and slide pump and driver until horizontal alignment is achieved.

Determine which corner(s) of the baseplate are high or low and remove or add shims at the appropriate corner(s) and realign.

Determine if center of baseplate should be raised or lowered and correct by evenly adding or removing shims at the center of the baseplate.

GROUT BASEPLATE

1. Clean areas of baseplate that will contact grout. Do not use an oil-based cleaner because grout will not bond to it.

2. Build a dam around foundation (Fig. 9A). Thoroughly wet foundation.

3. Pour grout slowly through grout holes in baseplate, until level with the top of the dam. The use of non-shrink epoxy grout is recommended, follow manufacturers recommendations. If cementitious grout is used, remove air by puddling or with a vibrator (Fig. 9A).

Fig. 9A

3296 M Group 6/05 15

4. Allow grout to set.

6. Allow grout to set at least 48 hours.

5. Fill remainder of baseplate with grout. Remove air as before (Fig. 9B).

Fig. 9B

PIPING

Guidelines for piping are given in the “Hydraulic Institute Standards” (Edition 14, Centrifugal pump section) and should be reviewed prior to pump installation.

1. All piping must be supported independently and must line up naturally with the pump flanges.

! WARNING

Never draw piping into place by forcing at the flanged connections of the pump. This will impose dangerous strains on the unit and cause misalignment between pump and driver. Pipe strain can adversely effect the operation of the pump. That could result in serious personal injury and damage to equipment.

2. Piping runs shall be designed to minimize friction losses.

3. DO NOT make final connection of piping to pump until grout has hardened and pump and driver hold-down bolts have been tightened.

7. Tighten foundation bolts.

Alignment Check

Re-check alignment before continuing, using methods previously described.

7. Gasket installation and materials must be suitable for the service.

SUCTION PIPING

Properly installed suction piping is a necessity for trouble free pump operation. Suction piping should be flushed BEFORE connection to the pump.

1. Use of elbows close to the pump suction flange should be avoided. There should be a minimum of 2 pipe diameters of straight pipe between the elbow and suction inlet. Any elbows used should be long radius.

2. Size suction pipe one or two sizes larger than pump suction, with a reducer at suction flange. Suction piping must never be of smaller diameter than the pump suction.

3. Reducers, if used, must be eccentric at pump suction flange with sloping side down.

4. Piping that handles hot liquids requires proper installation of expansion loops/joints so that linear expansion of piping will not cause mis-alignment.

5. Piping should be arranged to allow pump flushing and draining prior to the removal of pump for servicing.

6. System should be thoroughly cleaned prior to installation.

4. Suction strainers, when used, must have a net “free area” of at least three times the suction pipe area.

5. Separate suction lines are recommended when more than one pump is operating from the same source of supply.

16 3296 M Group 6/05

Suction Lift Conditions

1. Suction pipe must continuously slope upward towards pump suction to eliminate air pockets.

2. All joints must be air tight.

FINAL PIPING CHECK

After Connecting Piping to the Pump

1. Rotate shaft several times by hand to be sure that there is no binding and all parts are free.

3. A means of priming the pump must be provided, such as a foot valve.

Suction Head/Flooded Suction Conditions

1. An isolation valve should be installed in suction line to permit closing of the line for pump inspection and maintenance.

2. Piping should be level or slope gradually downward from source of supply.

3. No portion of piping should extend below pump suction flange.

4. The suction pipe shall be submerged sufficiently below the liquid surface to prevent vortices and air entrainment at the supply.

DISCHARGE PIPING

1. Isolation and check valves should be installed in discharge line. Locate check valve between isolation valve and pump which will permit inspection of check valve. An isolation valve is required for isolating, priming, regulation of flow, inspection and maintenance of the pump. A check valve prevents pump damage due to reverse flow when driver is turned off.

2. Check alignment, per the alignment procedure outlined previously to determine absence of pipe strain. If pipe strain exists, correct piping.

2. Increasers, if used, should be placed between pump and check valves.

3. Cushioning devices should be used to protect pump from surges and water hammer, if quick-closing valves are installed in system.

3296 M Group 6/05 17

18 3296 M Group 6/05

OPERATION

PREPARATION FOR START-UP ......................19

Flushing Pump ................................................19

Checking Rotation .............................................19

Couple Pump and Driver ........................................20

Install Coupling Guard ..........................................20

Lubricating Bearings............................................20

Connect Condition Monitoring Devices .............................20

Priming Pump .................................................20

STARTING PUMP ...............................21

OPERATION ..................................21

General Considerations ..........................................21

Operating at Reduced Capacity ...................................21

Operating Under Freezing Conditions ..............................21

SHUTDOWN ..................................22

FINAL ALIGNMENT .............................22

PREPARATION FOR START-UP

FLUSHING PUMP

The 3296 is flushed with Ethylene Glycol Solution at the factory to prevent accidental freezing during shipping or storage at the customers site. Residual amounts will remain in the pump but if this is a problem, the 3296 can be flushed out following the below procedure before pump is installed.

Procedure

1. Remove flush liquid supply.

2. Devise a means of collecting flush liquid as it drains out the suction nozzle or casing drain if supplied.

3. Turn flush supply on and run for 5 minutes to remove Ethylene Glycol residue.

4. When done, raise the coupling end of the pump (suction flange down) to drain remaining flush liquid from pump internals. Or, if pump is equipped with a casing drain plug, remove it to drain remaining liquid.

" NPT plug (408A) and connect clean

! WARNING

Failure to properly lift and support equipment could result in serious injury or damage to pumps.

5. Replace any plugs removed and continue preparation for start up.

CHECKING ROTATION

! CAUTION

Serious damage may result if pump is run in the wrong rotation.

1. Lock out power to driver.

! WARNING

Lock out driver power to prevent accidental start-up that could result in serious personal injury.

2. Make sure coupling spacer is removed and coupling hubs are fastened tightly to the shafts and are not loose.

3296 M Group 6/05 19

NOTE: Pump is shipped with coupling spacer removed.

3. unlock driver power.

4. Make sure everyone is clear. Jog driver just long enough to determine direction of rotation. Rotation must correspond to arrow on bearing frame.

Pure Oil Mist Lubrication - Pure oil mist is an optional feature for the 3296. If your pump is equipped with pure oil mist refer to oil mist generator manufacturer’s instruction book for proper operation.

! WARNING

Operation of the unit without proper lubrication will cause bearing failure, and pump seizure.

5. Lock out power to driver.

COUPLE PUMP AND DRIVER

! WARNING

Lock out driver power to prevent accidental start-up that could result in serious personal injury.

Lubricate coupling per manufacturer’s instructions and install coupling spacer.

INSTALL COUPLING GUARD

Install coupling guard as defined in the appendix.

! WARNING

Never operate a pump without a coupling guard properly installed. Operating pump without a properly installed coupling guard can result in serious personal injury.

LUBRICATING BEARINGS

Flood Oil Lubrication - Pumps are shipped without

oil. Fill bearing frame with oil, through filler connection until oil level reaches center of sight-glass (Fig A). A high quality turbine type oil, with rust and oxidation inhibitors should be used as specified in Table 5.

CONNECT CONDITION MONITORING DEVICES

Always connect thermocouple to control panel and/or temperature switch in driver starter. If unit is also equipped with leak detection and vibration monitoring systems, these must also be connected. (See Appendix for wiring diagrams.)

PRIMING PUMP

Never start pump until properly primed (pump casing and suction piping are full of liquid). Components such as internal sleeve bearings depend on liquid for lubrication and will quickly fail if run dry.

Your particular system conditions will dictate method used to prime pump.

Fig. A

20 3296 M Group 6/05

STARTING PUMP

1. Make sure suction valve and any recirculation or cooling lines are open.

2. Fully close or partially open discharge valve as dictated by system conditions.

3. Start driver.

! CAUTION

Immediately observe pressure gauges. If discharge pressure is not quickly attained - stop driver, reprime and attempt to restart.

4. Slowly open discharge valve until the desired flow is obtained.

OPERATION

GENERAL CONSIDERATIONS

Always vary capacity with valve in discharge line. NEVER throttle flow from suction side.

Driver may overload or magnets de-couple if pumpage specific gravity (density) is greater than originally assumed, or rated flow rate is exceeded.

Always operate the pump at or near the rated conditions to prevent damage resulting from cavitation or recirculation.

! CAUTION

Do not operate above rated temperature range of magnets as this will weaken or ruin the magnets.

Table 3

Temperature Ratings

Magnetic Types

Neodymium Iron

NdFe

Samarium

Cobalt

SmCo

Drive

Designation

A,B,C,D,E,F 250°F (120°C)

AA,BB,CC,DD,

EE,FF

OPERATING AT REDUCED CAPACITY

Rated

Temperature

425°F (220°C)

! CAUTION

Continuous operation against closed discharge valve will cause pump to overheat. Overheating the magnetic drive assembly will weaken or ruin the magnets.

! WARNING

Continuous operation against closed discharge valve may vaporize liquid creating an explosive hazard due to confined vapor under high pressure and temperature.

Table 4

Minimum Allowable Flow

Minimum Flow*

60 Hertz 50 Hertz

Pump

Group

* Based on water with a specific Gravity of 1.0 and

Specific Heat of 1.0

Size

2x3-8 60 32 11 6 3x4-8 - 112.5 40 23

3x4-8G 150 75 30 14

1x2-10 17 8.5 3 1.6 2x3-10 80 44 16 8

3x4-10H - 150 - 28

x3-13 - 41 - 8

2x3-13 - 80 - 15

GPM m

3600 1800 2900 1500

OPERATING UNDER FREEZING CONDITIONS

Exposure to freezing conditions, while pump is idle, could cause liquid to freeze and damage the pump. Liquid inside pump should be drained. Liquid inside cooling coils, if supplied, should also be drained.

! WARNING

Do NOT operate pump below minimum rated flows or with discharge valve closed. These conditions may vaporize liquid creating an explosive hazard due to confined vapor under high pressure and temperature.

3296 M Group 6/05 21

SHUTDOWN

1. Slowly close discharge valve.

2. Shut down and lock out driver to prevent accidental rotation.

FINAL ALIGNMENT

1. Run the unit under actual operating conditions for a sufficient length of time to bring the pump and driver up to operating temperature.

! WARNING

When handling hazardous and/or toxic fluids, skin, eye and respiratory protection are required. If pump is being drained, precautions must be taken to prevent injury or environmental contamination. Pumpage must be handled and disposed of in conformance with applicable environmental regulations.

2. Check and reset alignment per alignment procedure outlined earlier.

3. Reinstall coupling guard per instruction in appendix.

22 3296 M Group 6/05

PREVENTIVE MAINTENANCE

GENERAL COMMENTS ...........................23

MAINTENANCE SCHEDULE ........................23

MAINTENANCE OF BEARINGS ......................24

TROUBLESHOOTING ............................25

GENERAL COMMENTS

A routine maintenance program can extend the life of your pump. Well maintained equipment will last longer and require fewer repairs. You should keep maintenance records, this will help pinpoint potential causes of problems. A sample form is in the appendix that can be copied and used for this purpose.

MAINTENANCE SCHEDULE

Routine Maintenance

Bearing lubrication

Temperature monitoring

Vibration analysis

Discharge pressure

Routine Inspections

Check level and condition of oil through sight glass on bearing frame.

Check for unusual noise, vibration, and bearing temperatures.

Inspect pump and piping for leaks.

3 Month Maintenance

Check foundation hold down bolts of motor and pump for tightness.

Change oil per section V-C.

Check alignment per section III-B.

Yearly Inspections

Check pump capacity, pressure, and power. If the pump performance does not satisfy your process requirements, the pump should be disassembled and inspected. Worn parts should be replaced.

3296 M Group 6/05 23

MAINTENANCE OF BEARINGS

OIL LUBRICATED BEARINGS

Oil level is measured through sight glass. Oil level must not fall below center of site glass. An increase in level may be noted after start up due to oil circulation within the bearing frame. Change Oil after 200 hours for new bearings, thereafter every 4000 operating

Bearing Frame Lubrication Requirement

Pumpage Temp. of

Oil Grades

ISO Grade VG 68 Synthetic VG 68

Approximate SSU

100°F (38°C)

DIN 51517 C 68 Synthetic C68

Kenematic Viscosity at 40°C

(105°F)

(mm

/sec)

Acceptable

less than 325°F (160°C)

Exxon Teresstic EP 68 Chevron GTS Oil 68 Mobil DTE 26 Gulf Harmony 68 Shell Tellus Oil 68 Phillips Mangus Oil 315 Phillips MM SAE 20-20W Phillips HDS SAE 20-20W

hours or 6 months, which ever period is shorter. Change oil every 2000 operating hours under severe operating conditions, such as high temperature services [pumpage temperatures in excess of 325°F (160°C)].

We recommend using Table 5 to help determine your lubricating oil needs.

Table 5

Pumpage Temp. of

325° - 375°F

(160° - 190C°)

with bearing frame cooling

300 Synthetic 300

68 Synthetic 68

Pumpage Temp. of greater than 375°F

(190°C)

with bearing frame cooling

Royal Purple Synfilm 68

NOTE: This is a list of oils that meet the lubrication requirements of this pump. It is not intended to be an endorsement of products listed nor exclude other oils that meet these requirements.

24 3296 M Group 6/05

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