Goulds Pumps 3500XD User Manual

Installation, Operation and Maintenance Instructions

Model 3500XD Medium Consistency Pump System

TABLE OF CONTENTS

PAGE

9 PUMP DESCRIPTION

13 INSTALLATION

19 PREPARATION FOR START-UP

21 OPERATION AND CONTROLS

29 MAINTENANCE

SECTION

3500XD IOM 8/07 7

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

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 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

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

Introduction Statements

These pumps have been designed for safe and reliable operation when properly used and maintained in accordance with instructions contained in this manual. A pump is a pressure containing device with rotating parts that can be hazardous. Operators and maintenance personnel must realize this and follow safety measures. Goulds Pumps shall not be liable for physical injury, damage or delays caused by a failure to observe the instructions in this manual.

Throughout this manual the words WARNING, CAUTION and NOTICE are used to indicate procedures or situations which require special operator attention.

DANGER

Operating procedure, practice, etc., which, if not correctly followed, will result in serious personal injury or death.

WARNING

Operating procedure, practice, etc., which, if not correctly followed, could result in serious personal injury or death.

CAUTION

Operating procedure, practice, etc., which, if not correctly followed, could result in minor or moderate injury.

NOTICE

Operating procedure, practice, etc., which, if not correctly followed, could result in damage to equipment and/or property.

Do not twist the baseplate during grouting. This introduces misalignment and can result in rapid bearing or shaft failure.

Follow proper alignment procedures outlined in this manual to prevent mis-alignment that can lead to high vibration levels, bearing failure, mechanical seal failure or shaft failure.

3500XD IOM 8/07 5

8 3500XD IOM 8/07

PUMP DESCRIPTION

RECEIVING THE PUMP ...............................9

INTRODUCTION...................................10

DESIGN CONCEPT .................................10

CONSTRUCTION DETAILS ............................11

RECEIVING THE PUMP

! WARNING

Only trained personnel should do lifting. Pumps and motors often have integral lifting eyes or eye bolts. These are intended for use in lifting the individual pieces of equipment only. Failure to properly lift equipment could result in serious physical injury or damage to equipment.

! WARNING

Keep hands and feet from under the unit during these steps. If slings slip and the unit tips over, severe personal injury or death may result.

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 3 months. Refer to driver and coupling manufacturers for their long term storage procedures. Store in a covered dry location.

Use care when moving pumps. Lifting equipment must be able to adequately support the entire assembly. Hoist bare pump using a suitable sling, under the suction flange and bearing frame. Base- plate mounted units are moved with slings under the pump casing and driver. Refer to Figs. 1-3 for examples of proper lifting techniques.

! WARNING

Refer to the Installation section of this manual for

detailed instructions for lifting a Polyshield Combo with installed equipment. Never lift a

Polyshield mounted using the procedure shown in Fig. 2 and Fig. 3.

ANSI Combo with pump and motor

ANSI

Fig. 1

NOTE: Long term storage treatment can be purchased with the initial pump order or can be applied to pumps already in the field that were not treated at the factory. This service can be supplied by contacting your local Goulds sales representative.

Fig. 2

HANDLING

! WARNING

Pump and components are heavy. Failure to properly lift and support equipment could result in serious physical injury or damage to pumps. Steel toed shoes must be worn at all times.

3500XD IOM 8/07 9

Fig. 3

INTRODUCTION

The Goulds Model 3500XD heavy duty stock pump is a centrifugal pump designed to handle paper stock up to approximately 16% O.D. consistency. The pump design

DESIGN CONCEPT

There are two major obstacles in pumping paper stock at consistencies above 8% with a centrifugal pump: the formation of a fiber network that will not readily flow, and high air content which can cause air binding of a standard centrifugal pump.

The Model 3500XD pump is normally attached to a suction vessel or “standpipe,” and a constant level is maintained above the suction centerline. An X-Ducer mounted on the end of the pump shaft creates turbulence in the suction

incorporates special features to induce flow into the pump suction and to remove air that is present in stock at higher consistencies.

standpipe (Fig. 4, Zone 1), breaking up the fiber network and separating air from the pulp. The pulp is then induced to flow into the pump suction by the static head in the standpipe and the pumping action of the X-Ducer. The amount of turbulence required (minimum pump speed) as well as the minimum standpipe level is a function of the stock type, quality, consistency and temperature of each specific application.

Fig. 4

10 3500XD IOM 8/07

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