Goulds Pumps 3420 User Manual

Installation, Operation and Maintenance Instructions

Model 3420

2 3420 IOM 8/09

FOREWORD

This manual provides instructions for the Installation, Operation, and Maintenance of the Goulds Model 3420/25 Single Stage Double Suction Pump*. This manual covers the standard product plus common options that are available. For special options, supplemental instructions are supplied. 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.

ITT - Goulds Pumps 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.

When pumping unit is installed in a potentially explosive atmosphere, the instructions after the 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 a Goulds representative before proceeding.

Warranty is valid only when genuine ITT - Goulds Pumps parts are used.

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

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

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

* The 3420 is an all English dimension unit and the 3425 is a hard metric design.

A symbol must be

THIS MANUAL EXPLAINS

Proper Installation

Start-up Procedures

Operation Procedures

Routine Maintenance

Pump Overhaul

Trouble Shooting

Ordering Spare or Repair Parts

3420 IOM 8/09 3

4 3420 IOM 8/09

TABLE OF CONTENTS

PAGE SECTION

7 SAFETY

11 GENERAL INFORMATION

15 INSTALLATION

25 OPERATION

37 PREVENTIVE MAINTENANCE

43 DISASSEMBLY & REASSEMBLY

77 SPARE AND REPAIR PARTS

99 APPENDIX

3420 IOM 8/09 5

Industrial Process Pump Safety Manual

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.

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

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

www.gouldspumps.com.

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

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 hazardous. Any pressure vessel can explode, rupture, or discharge its contents if sufficiently over pressurized causing death, 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 avoided, 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 follow 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.

General Precautions

WARNING

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

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

WARNING

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 before performing pump maintenance.



NEVER operate pump without safety devices installed.

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, especially impellers  Safety glasses (with side shields) for eye protection  Steel-toed shoes for foot protection when handling parts, 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

WARNING

equipment only at specifically identified lifting points or as instructed in the current IOM.

Current manuals are available at 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.

www.gouldspumps.com/literature_ioms.html or

S-4

WARNING

General Precautions

Alignment:

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.

WARNING

CAUTION

WARNING

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 flanged connections of the 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.

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.

WARNING

CAUTION

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.



S-5

CAUTION

WARNING

General Precautions

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

CAUTION

WARNING

CAUTION

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.

Ensure pump is isolated from system and pressure is relieved before disassembling pump, removing plugs, opening 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 representative 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 ................................11

NAMEPLATE INFORMATION ...........................13

RECEIVING THE PUMP ...............................14

PUMP DESCRIPTION

The model is based on 8 bearing configurations and 15 hydraulic sizes. Groupings are as follows:

Group Description Sizes

(modified)

—

LDS

XXL

Ball radial and duplex ball thrust bearings. Flood oil lube with constant level oiler optional grease lube. Bearing housings bolt to the casing. Goulds non-metallic labyrinth seals.

Ball radial and duplex ball thrust bearings. Ring oil lube with constant level oiler optional grease lube. Bearing housing secured with tongue and groove fits and a bearing cap with studs and nuts. Goulds metallic labyrinth seals.

Same as M group except the shaft is longer to accommodate a wider pump.

Ball radial and duplex ball thrust bearings. Ring oil lube with constant level oiler, optional grease lube. Bearing housing secured with tongue and groove fits and a bearing cap with studs and nuts. Goulds metallic labyrinth seals.

Double row roller bearings, both thrust and radial. Ring oil lube with constant level oiler, optional grease lube. Bearing housing secured with tongue and groove fits and a bearing cap with studs and nuts. Goulds metallic labyrinth seals.

12 x 14-15

16 x 18-17H

18 x 20-20

16 x 18-30 18 x 20-30 20 x 24-24 20 x 24-30

20 x 24-28

18 x 20-24

24 x 30-32

30 x 30-31 30 x 30-38

30 x 36-42

20x30-42

36x42-52

The model 3420 is a horizontal between bearings, enclosed impeller double suction centrifugal pump.

Casing - The casing is horizontally split. The upper and lower halves are held together with studs and nuts and/or capscrews. Flanged suction and discharge connections are located in the lower half of the casing and conform to ANSI

16.1/16.5 class 125/150. The casing is supported by integrally cast feet. Separate bearing housings are attached directly to machined fits in each end of the casing with capscrews or machined fits secured with bearing caps and studs and nuts. All sizes have dual volute casings to reduce radial loads on the shaft. The casings are standard with two jacking screws, two lifting lugs for the upper half, two tapered dowel pins for alignment, and a .030 or .016 in. (.75 or .41 mm) non-asbestos parting gasket. The upper half is

3420 IOM 8/09 7

provided with a vent connection, a priming connection, and one or two stuffing box seal ring connections. The lower half is provided with two drain connections, suction and discharge gauge connections, and stuffing box overflow connections.

Impeller - The impeller is an enclosed, double suction design providing axial hydraulic balance. All exterior surfaces are fully machined. The impeller receives a one or two plane spin balance as standard. The impeller is keyed to the shaft and held in place using shaft sleeves and sleeve nuts.

Wear Rings - Casing and impeller wear rings are supplied as standard to maintain proper running clearances and to minimize leakage between the suction and discharge chambers in the casing. Each casing ring is held in place with

a machined hook lock. The impeller rings are held in place using axial set screws.

Shaft - The shaft is a heavy duty design that minimizes deflection and vibration. The shaft deflection is a maximum of .002 in (.051 mm) at the stuffing box face under the worst operating conditions. The shaft is completely dry with O-ring seals between the impeller and shaft sleeves and the shaft sleeves and the sleeve nuts. The standard shaft is AISI 4340 steel with an option for 316 stainless steel.

Shaft Sleeves - Shaft sleeves are standard on all pumps. They are keyed to the shaft at the impeller and held in place using sleeve nuts. The sleeve nuts tighten against rotation and are secured in place with set screws.

Stuffing Box - Non-asbestos packing is standard. The stuffing box contains a Teflon™ split lantern ring and renewable stuffing box throat bushings. Tapped openings are provided for water sealing from either the pump casing or an outside source. Bypass piping is optional. Two-piece machined split glands are standard on all packed pumps.

Mechanical Seals - Mechanical seals can be supplied as a non-standard option. Most seal designs fit in the standard stuffing box. Goulds does not have its own design gland, so the gland must be supplied by the seal manufacturer.

Bearings - There are many different bearing configurations that are offered on the 3420. Specific configurations are dependent on pump size and group and purchased setup. Grease lubricated ball, grease lubricated roller, flood oil lubricated ball, ring oil lubricated ball, and ring oil lubricated roller bearings are used on various sizes. Oil lubrication is standard with grease optional. The bearing housings are sealed with machined labyrinth seals or lip seals.

Baseplates - Fabricated steel bases are standard with a drip collection chamber and a tapped drain connection. The base is designed to be grouted and has grout and vent holes. Soleplates for the pump only or motor only are offered as an option.

8 3420 IOM 8/09

NAMEPLATE INFORMATION

Every pump has two or three Goulds nameplates that provide information about the pump. The tags are located on the upper half and lower half of the casing.

Description Fig. No. Example

Pump Casing Tag - provides information

about the pump’s hydraulic characteristics. Note the format of the pump size: Discharge x Suction - Nominal maximum Impeller Diameter in inches. (Example: 2x3-8)

(Figs.1&2).

Fig. 1

English

When ordering parts, you will need to identify the pump model, size, serial number, and the item number of the required parts. Information can be taken from the pump casing tags. Item numbers can be found later on in this manual.

Bearing Frame Tag - provides

information on the lubrication system used (Fig. 3).

ATEX Tag - If applicable, your pump unit may have the following ATEX tag affixed to the pump and/or baseplate. See the Safety section for a description of the symbols and codes (Fig. 4).

Fig. 2

Metric

Fig. 3

Fig. 4

3420 IOM 8/09 9

RECEIVING THE PUMP

Inspect the pump as soon as it is received. Carefully check that everything is in good order. Make notes of damaged or missing items on the receipt and freight bill. File any claims with the transportation company as soon as possible.

Storage Requirements

Short Term: (Less than 6 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 three months. Refer to driver and coupling manufacturers for their long term storage procedures. Store in a covered dry location.

Note: Long term storage treatment can be purchased with the initial pump order.

HANDLING

! WARNING

Pump and components are heavy. Failure to properly lift and support the equipment could result in serious physical injury, or damage to the pump(s). Steel-toed shoes must be worn at all times.

Fig. 3A

Use care when moving pumps. Lifting equipment must be able to adequately support the entire assembly. Hoist a bare pump or a pump and soleplate unit using a suitable sling, under the two bearing housings (Fig. 3A). Baseplate mounted units without motors are moved by supporting the pump with a sling under the two bearing housings and a sling under the motor end of the baseplate (Fig. 3B). Baseplate mounted units with motors are moved with slings attached to the baseplate lifting lugs. The use of a spreader bar is required so that the pump is not damaged (Fig 3C).

Fig. 3B

Fig. 3C

10 3420 IOM 8/09

INSTALLATION

SITE/FOUNDATION................................15

BASEPLATE INSTALLATION PROCEDURE .................16

LEVEL BASEPLATE ...............................16

ALIGNMENT AND ALIGNMENT PROCEDURE ...............18

Alignment Check ................................18

Alignment Criteria ...............................18

SetUp......................................19

Measurement ..................................19

Angular Alignment ...............................19

Parallel Alignment ...............................20

Complete Alignment ..............................20

Alignment Trouble Shooting ..........................21

GROUT BASEPLATE ...............................21

Alignment Check ................................21

PIPING........................................21

General .....................................21

Suction Piping .................................22

Discharge Piping ................................22

Final Piping Check ...............................23

FOUNDATION

The foundation must be substantial enough to absorb vibration. (Hydraulic Institute Standards recommends the foundation weigh at least five [5] times the weight of the pump unit.) It must form a permanent and rigid support for the baseplate. This is important in maintaining the alignment of a flexibly coupled unit.

Foundation bolts of the proper size should be embedded in the concrete to a depth of eight (8) to twelve (12) inches and locked with either a hook around a reinforcing bar or alternatively, a nut and washer at the bottom. The bolts should have a sleeve around them at least six (6) times the bolt diameter in length and at least two (2) bolt sizes larger in I.D. If a nut and washer are used for locking, the washer should have an O.D. two (2) sizes larger than the sleeve. Foundation bolts should be sized .125" less than the anchor bolt holes in the base.

The foundation should be poured to within .75" - 1.5" of the finished height. (See Fig. 4) Freshly poured foundations should be allowed to cure for several days before the unit is set in place and grouted.

Fig. 4

3420 IOM 08/09 15

BASEPLATE INSTALLATION PROCEDURE

Industry standard procedures and/or the following procedure should be followed prior to grouting the baseplate. The procedure assumes the installer has a basic knowledge of baseplate and foundation design and installation methods.

BASEPLATE PREPARATION

1. Inspect all surfaces of the baseplate that will contact the grout for contamination (rust, oil, grime, etc.)

2. Thoroughly clean all surfaces of the baseplate that will contact the grout with a cleaner that will not leave any residue.

NOTE: It may be necessary to sandblast the contact surfaces and coat with a primer compatible with the grout. If sandblasting is necessary, remove all the equipment prior to sandblasting.

LEVEL BASEPLATE

1. Place two 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.

3. Inspect all machined surfaces for burrs, rust, paint, or any other type of contamination. If necessary, use a honing stone to remove any burrs.

FOUNDATION PREPARATION

1. Chip the top of the foundation .50-1.0 in. (13-25 mm) to remove porous or low strength concrete. If using a pneumatic hammer, assure that it is not contaminating the surface with oil, moisture, etc.

2. Remove water and/or debris from the foundation bolt holes/sleeves. If sleeve type bolts are being used, fill the sleeves with stuffing material and seal to prevent grout from entering.

3. Coat the exposed portion of the anchor bolts with a non-bonding compound to prevent grout from adhering to the anchor bolts.

4. If recommended by the grout manufacturer, coat the foundation surface with a compatible primer.

2. Remove water and/or debris from anchor bolt holes/sleeves prior to grouting. If sleeve type bolts are being used, fill the sleeves with rags to prevent grout from entering.

Fig. 6

16 3420 IOM 08/09

3. Carefully lower the baseplate onto the foundation bolts.

4. Level the baseplate to within .125 in. (3.2 mm) over the length of the baseplate and to within .088 in. (1.5 mm) over the width of the baseplate by adjusting the wedges. If the baseplate has vertical leveling screws, use the screws to level the base.

5. Hand tighten the foundation bolts.

Fig. 7

3420 IOM 08/09 17

ALIGNMENT AND ALIGNMENT PROCEDURE

Alignment procedures must be followed to prevent

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

! WARNING

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

To remove guard, refer to coupling guard assembly/ disassembly instructions.

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.

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 procedures.

NOTE: Alignment check must be made if process temperature changes, piping changes and or pump service is performed.

ALIGNMENT CRITERIA

Good alignment is achieved when the 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).

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 shows recommended preliminary (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.)

NOTE: Proper alignment is the responsibility of the installer and user 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 have

•

occurred during grouting process.

After Connecting Piping - To ensure pipe strains have

•

not altered alignment. If changes have occurred, alter piping to remove pipe strains on pump flanges.

Table 1

Cold Setting of Parallel

Vertical Alignment

Pumpage Temperature Set Driver Shaft

ambient N/A

100°F 200°F 300°F

.000" - .002" HIGH

.002” - .004” HIGH

.004” - .006” HIGH

18 3420 IOM 08/09

SET UP

1. Mount two dial indicators on the pump coupling half (X) so they contact the other coupling half (Y) (Figs. 8 & 9).

Fig. 8

Fig. 10

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. 9

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.

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.

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 points 90° apart (Fig. 10).

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).

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

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.

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.

3420 IOM 08/09 19

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 vertical 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.

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.

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.

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.

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 (3 o‘clock). Observe needle and record reading.

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

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

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.

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.

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

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ALIGNMENT TROUBLESHOOTING

Problem Probable Cause Remedy

Driver feet bolt bound.

Cannot obtain horizontal (Side-to-Side)

alignment, angular or parallel

Cannot obtain vertical (Top-to-Bottom)

alignment, angular or parallel

Baseplate not leveled properly, probably

Baseplate not leveled properly,

probably bowed.

GROUT BASEPLATE

1. Clean areas of baseplate that will contact grout. Do not use oil-based cleaners because grout will not bond to it. Refer to grout manufacturers instructions.

2. Build dam around foundation. Thoroughly wet foundation (Fig. 11).

3. Pour grout through grout hole in baseplate, up to level of dam. Remove air bubbles from grout as it is poured by puddling, using a vibrator, or pumping the grout into place. Non-shrink grout is recommended.

twisted.

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 add ing or removing shims at the center of the baseplate.

4. Allow grout to set.

5. Fill remainder of baseplate with grout. Remove air as before (Fig. 12).

Flange loads from the piping system, including

those from thermal expansion of the piping, must not exceed the limits of the pump. Casing deformation can result in contact with rotating parts and result in excess heat generation, sparks and premature failure.

Fig. 11

Fig. 12

6. Allow grout to set at least 48 hours.

7. Tighten foundation bolts.

ALIGNMENT CHECK

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

PIPING

GENERAL

Guidelines for piping are given in the “Hydraulic Institute Standards” available from: Hydraulic Institute, 30200 Detroit Road, Cleveland, OH 44145-1967 and must be reviewed prior to pump installation.

3420 IOM 08/09 21

! WARNING

Never draw piping into place by forcing at the flanged connections of the 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.

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

2. Piping runs should be as short as possible to minimize friction losses.

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

4. It is suggested that expansion loops or joints be properly installed in suction and/or discharge lines when handling liquids at elevated temperatures, so linear expansion of piping will not draw pump out of alignment.

! WARNING

All expansion joints should be properly supported, anchored, and restrained. Failure to do so may result in serious physical injury if the expansion joint fails.

5. The piping should be arranged to allow pump flushing prior to removal of the unit on services handling corrosive liquids.

6. Carefully clean all pipe parts, valves and fittings, and pump branches prior to assembly.

straight pipe between the elbow and the pump suction flange.

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

4. Reducers, if used, should be eccentric, at the pump suction flange, with sloping side down.

5. Pump must never be throttled on suction side.

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

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

Suction Lift Conditions

1. Suction pipe must be free from air pockets.

2. Suction piping must slope upwards to pump.

3. All joints must be air tight.

4. 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 the suction line at least two pipe diameters from the suction to permit closing of the line for pump inspection and maintenance.

2. Keep suction pipe free from air pockets.

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

SUCTION PIPING

! WARNING

NPSHAmust always exceed NPSHRas shown on Goulds performance curves received with order. Reference Hydraulic Institute for NPSH and pipe friction values needed to evaluate 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 two pipe diameters of straight pipe between the elbow and suction inlet. Where used, elbows should be long radius.

2. If an elbow must be used at the suction flange, it must be in the vertical position only. If an elbow must be used in other than a vertical position, it is permissable only by providing a minimum of two diameters of

4. No portion of the piping should extend below pump suction flange.

5. The size of entrance from supply should be one or two sizes larger than the suction pipe.

6. The suction pipe must be adequately submerged 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 the check valve between isolation valve and pump, this will permit inspection of the check valve. The isolation valve is required for priming, regulation of flow, and for inspection and maintenance of pump. The check valve prevents pump or seal damage due to reverse flow through the pump when the driver is turned off.

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

22 3420 IOM 08/09

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

FINAL PIPING CHECK

After connecting the piping to pump:

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

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

3420 IOM 08/09 23

24 3420 IOM 08/09

OPERATION

PREPARATION FOR START-UP ..........................25

Check Rotation ...................................25

Couple Pump and Driver ..............................25

Lubricating Bearings ................................26

Shaft Sealing ....................................27

Priming Pump ...................................29

STARTING PUMP ...................................31

OPERATION ......................................31

General Considerations...............................31

Operating at Reduced Capacity ..........................31

Operating Under Freezing Conditions .......................32

SHUTDOWN ......................................32

FINAL ALIGNMENT .................................32

PREPARATION FOR START-UP

When installing in a potentially explosive

environment, ensure that the motor is properly certified.

4. Make sure everyone is clear. Jog driver just long enough to determine the direction of rotation. The rotation must correspond to the arrow on the pump casing.

CHECK ROTATION

1. Lock out power to the driver.

! WARNING

Lock out driver power to prevent accidental start-up and physical injury.

All equipment being installed must be properly

grounded to prevent unexpected static electric discharge.

2. Make sure the coupling hubs are securely fastened to the shafts.

! WARNING

Do not jog a coupled pump.

Serious injury may result if pump is run in the wrong direction.

CAUTION

5. Lock out the power to the driver.

COUPLE PUMP & DRIVER

! WARNING

Lock out driver power to prevent accidental rotation and physical injury.

1. Install and lubricate the coupling per the manufacturer’s instructions.

The coupling used in an ATEX classified

environment must be properly certified.

NOTE: Pump is shipped with the coupling hubs disconnected.

3. Unlock driver power.

3420 IOM 8/09 25

2. Install the coupling guard (Fig. 13). Refer to the Coupling Guard Installation and Disassembly Section (Appendix I).

The coupling guard used in an ATEX classified

environment must be constructed from a non-sparking material.

! WARNING

Never operate a pump without the coupling guard installed. Personal injury will occur if the pump is run without the coupling guard.

Leakage of process liquid may result in creating an

explosive atmosphere. Ensure the materials of the pump casing, impeller, shaft, sleeves, gaskets and seals are compatible with the process liquid.

A build up of gases within the pump, sealing system

and or process piping system may result in an explosive environment within the pump or process piping system. Ensure process piping system, pump and sealing system are properly vented prior to operation.

LUBRICATING BEARINGS

Bearings must be lubricated properly in order to

prevent excess heat generation, sparks and premature failure.

Cooling systems such as those for bearing

lubrication, mechanical seal systems, etc, where provided, must be operating properly to prevent excess heat generation, sparks and premature failure.

Rotate shaft by hand to ensure it rotates smoothly

and there is no rubbing which could lead to excess heat generation and or sparks.

Ensure that pump and systems are free of foreign

objects before operating and that objects cannot enter the pump during operation. Foreign objects in the pumpage or piping system can cause blockage of flow which can result in excess heat generation, sparks and premature failure.

Fig. 13

Pumps are shipped without oil.

Oil Lubrication: Oil lubricated pumps are not lubricated at the factory. Constant level oilers are supplied with oil lubricated pumps. The oiler can be found in the box of fittings that accompanied the pump during shipment. The oiler was adjusted to maintain the proper oil level before leaving the factory. The adjustment should be checked in case the setting was disturbed during shipment. See Figure

14. The correct dimensions for A and B are given in Table

2. Fill the bearing housing with oil using the oil bottle. Continue to refill the oil bottle until oil stops draining from the oiler into the housing. See Table 4 for recommended oil.

CAUTION

Instructions

1. Remove adjustment assembly from oiler.

2. Adjust bars to dim. "A".

3. Lock in position.

4. Replace adjust. assem. in oiler

Do not insulate bearing housings as this can result

in excess heat generation, sparks and premature failure.

Check for magnetism on the pump shaft and

degauss the shaft if there is any detectable magnetism. Magnetism will attract ferritic objects to the impeller, seal and bearings which can result in excess heat generation, sparks and premature failure.

Pure/Purge Oil Mist: For pure oil mist, connect the oil mist system according to the manufacturer's recommendations. For purge oil mist, connect the oil mist system per the manufacturers instructions. Fill the pump with oil as detailed for oil lubrication above. In both cases, refer to the pump dimensional drawing for the location of the oil mist connections to the bearing housings. See Table 2 for oil bottle settings and Table 4 for recommended oil.

Fig. 14

26 3420 IOM 8/09

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Goulds Pumps 3420 User Manual

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User Manual