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3498
User Manual
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Goulds Pumps 3498 User Manual

Installation, Operation and Maintenance Instructions
Model 3498
4 3498 IOM 12/04
FOREWORD
This manual provides instructions for the Installation, Operation, and Maintenance of the Goulds Pumps Model 3498, a double suction, horizontally split case 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 maintenance.
ITT Industries - 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.
NOTE: When pumping unit is installed in a potentially explosive atmosphere, the instructions after 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 of the equipment is to be modified, please contact a Goulds representative before proceeding.
Warranty is valid only when genuine ITT Industries - 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 Industries - Goulds Pumps.
Supervision by an authorized ITT Industries - Goulds Pumps representative is recommended to assure proper installation.
Additional manuals can be obtained by contacting your local ITT Industries - Goulds Pumps representative or by calling 1-(800)-446-8537.
THIS MANUAL EXPLAINS
Proper Installation
n
Start-up Procedures
n
Operation Procedures
n
Routine Maintenance
n
Pump Overhaul
n
Troubleshooting
n
Ordering Spare or Repair Parts
n
3498 IOM 12/04 5
6 3498 IOM 12/04
TABLE OF CONTENTS
PAGE
9 SAFETY
13 GENERAL INFORMATION
15 INSTALLATION
29 OPERATION
35 PREVENTIVE MAINTENANCE
SECTION
1
2
3
4
5
43 DISASSEMBLY & REASSEMBLY
47 APPENDICES
47 I - Instructions for Ordering Parts
49 II - Tools
51 III - Useful Formulas
53 IV - Field Test Report
6
7
3498 IOM 12/04 7
8 3498 IOM 12/04
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 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.
WARNING
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
WARNING 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 shar p ed ges, 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 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
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
CAUTION
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
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
WARNING
WARNING
WARNING
WARNING
CAUTION
CAUTION
WARNING
CAUTION
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
o
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
o
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
12 3498 IOM 12/04
GENERAL INFORMATION
PUMP DESCRIPTION ...........................13
NAMEPLATE INFORMATION .....................14
PUMP DESCRIPTION
This product line consists of 64 sizes of double suction, horizontally split case pumps from size 12x16-28 through size 66x70-60.
Casing - The casing is close-grained Cast Iron or Ductile Iron, and is of axially-split double-volute design with suction and discharge flanges and mounting feet cast integral with the lower half casing. Tapped and plugged holes are provided for priming, vent, drain and gauge connections. Upper half casing is removable without disturbing suction or discharge piping. Flanges are of (125/125#) (125/250#) (250/250#) ASA Standard. Suction and Discharge are on a common centerline in both the horizontal and vertical planes.
Impeller - The impeller is of the enclosed double-suction type made of (bronze) (cast iron) (316 stainless steel) and statically and hydraulically balanced. The impeller is keyed to the shaft and positioned axially by the shaft sleeves. Hub has sufficient metal thickness to allow machining for installation of impeller rings.
Shaft - The shaft is made of (AISI 4140, 316 stainless steel, 17-4 ph) and of ample size to operate under load with a minimum of deflection.
Bearings - The bearings are grease lubricated or oil lubricated. The inboard or coupling end bearing is either a single or double row anti-friction bearing. The outboard bearing is a double row anti-friction bearing which is retained by bearing locknut and lockwasher.
Bearing Housings - The bearing housings are bolted and doweled to the end of the lower half casing and will assure positive alignment of the rotating element. The housings provide a fit for the inboard bearing that allows freedom for thermal expansion while the outboard bearing is clamped in place to take all thrust loads and keep the rotating element in its proper axial location.
Baseplate - The baseplate is sufficiently rigid to support the pump and driver and is steel with a drip pan beneath the pump end. The drip pan contains a tapped drain connection.
Coupling - Coupling is an all metal type.
The coupling used in an ATEX classified environ-
!
ment must be properly certified.
Coupling Guard - The coupling guard shall be all metal.
2
Shaft Sleeves - The shaft sleeves are made of (bronze) (420 hardened stainless steel) [packing only] (316 stainless steel)(cast iron) and will protect the shaft from wear and from contact with the pumped liquid. An O-ring is furnished under sleeve to prevent leakage.
Stuffing Box - The stuffing box consists of at least six (6) rings of die formed, graphite, acrylic yarn packing and a split type gland to permit removal and access to packing. Ample space is provided for repacking the stuffing box. Arrangement provides for field or factory conversion to mechanical seals without machine work.
Casing Rings - The casing rings are made of (bronze) (cast iron) (316 stainless steel) and are installed with an anti­rotation device.
3498 IOM 12/04 13
The coupling guard used in an ATEX classified
!
environment must be constructed from a non­sparking material.
Rotation - Pump has a clockwise or counterclockwise
rotation when viewed from its driven end.
NAMEPLATE INFORMATION
Every pump has a Goulds Pumps nameplate that provides information about the pump. The nameplate is located on the pump casing.
Special tags which provide additional information (mechanical seal data, etc.) and special tagging required by customers are located on the pump casing or on the bearing frame.
The standard nameplate (Fig. 1) provides information about the pump size, type, serial number, rated head, capacity, speed, impeller diameter, model number, and maximum field hydrostatic test pressure.
The Identification No. is a number which the end user of the pump requests to be put on the nameplate to identify the pump in his operation.
The year indicates the year in which the pump was built.
Rating and hydrostatic test pressure are expressed in English units. Note the format of pump size: Discharge x Suction - Nominal Impeller Diameter in inches, for example, 24x24-26.
The frame plate provides information concerning the bearings and their lubrication. The inboard and outboard bearing numbers refer to the bearing manufacturer’s numbers.
When ordering spare parts you will need to identify pump model, size, serial number, and the catalog number of required parts. Pump information can be taken from the Goulds Pumps nameplate. Catalog numbers can be found in this manual.
Fig. 1
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.
14 3498 IOM 12/04
INSTALLATION
RECEIVING THE PUMP .........................15
LIFTING THE PUMP ...........................15
STORAGE REQUIREMENTS ......................17
LOCATION .................................20
FOUNDATION ...............................20
SETTING THE BASEPLATE (BEFORE PIPING) ...........21
ALIGNMENT PROCEDURE .......................22
DOWELING.................................23
SUCTION AND DISCHARGE PIPING .................24
STUFFING BOX LUBRICATION ....................26
RECEIVING THE PUMP
3
Check pump for shortages and damage immediately upon arrival. Prompt reporting to the carrier’s agent with notations made on the freight bill, will expedite satisfactory adjustment by the carrier.
Horizontal pumps and drivers are normally shipped from the factory mounted on a baseplate and painted with primer and one finish coat. Couplings may either be completely assembled or have the coupling hubs mounted on the shafts and the connecting members removed. When the connecting members are removed, they will be packaged in a separate container and shipped with the pump or attached to the baseplate.
LIFTING THE PUMP
The following instructions are for the safe lifting of your pump.
The unit should be unloaded and handled by lifting equally at four or more points on the baseplate. The lugs on the upper half casing are designed for lifting the upper half casing only.
HORIZONTAL
Bare Pump
1. Using a nylon sling, chain, or wire rope, hitch around both bearing housings. (See Fig. 2)
Shafts are in alignment when unit is shipped; however, due to shipping, the pumps may arrive misaligned and, therefore, alignment must be established during installation. Goulds Pumps has determined that proper and correct alignment can only be made by accepted erection practices. Refer to the following paragraphs on “Foundation,” “Baseplate Setting,” “Grouting Procedure,” “Alignment Procedure,” and “Doweling.”
Fig. 2
3498 IOM 12/04 15
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