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Goulds Pumps
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3610
User Manual
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Table of contents
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Goulds Pumps 3610 User Manual

Table of Contents
Introduction and Safety .......................................................................................................... 4
Introduction ............................................................................................................................. 4
Safety ...................................................................................................................................... 4
Safety terminology and symbols ........................................................................................... 5
Environmental safety ............................................................................................................ 5
User safety ........................................................................................................................... 6
Ex-approved products .......................................................................................................... 8
Monitoring equipment ........................................................................................................... 8
Product warranty ..................................................................................................................... 9
Transportation and Storage ................................................................................................. 10
Inspect the delivery ............................................................................................................... 10
Transportation guidelines ...................................................................................................... 10
Storage guidelines ................................................................................................................ 12
Table of Contents
Product Description .............................................................................................................. 13
General description ............................................................................................................... 13
Nameplate information .......................................................................................................... 14
Installation ............................................................................................................................. 17
Preinstallation ....................................................................................................................... 17
Baseplate-mounting procedures ........................................................................................... 18
Install the pump, driver, and coupling .................................................................................... 20
Pump-to-driver alignment ...................................................................................................... 20
Grout the baseplate .............................................................................................................. 25
Piping checklists ................................................................................................................... 26
Installation, Operation, and Maintenance Manual 1
Table of Contents
Commissioning, Startup, Operation, and Shutdown ......................................................... 31
Preparation for startup .......................................................................................................... 31
Remove the coupling guard .................................................................................................. 32
Check the rotation ................................................................................................................. 32
Couple the pump and driver .................................................................................................. 32
Bearing lubrication ................................................................................................................ 38
Lubricating-oil requirements ............................................................................................... 39
Shaft sealing with a mechanical seal .................................................................................... 41
Connection of sealing liquid for mechanical seals ................................................................. 42
Pump priming ........................................................................................................................ 42
Prime the pump with the suction supply above the pump ..................................................... 42
Prime the pump with an outside supply ................................................................................. 43
Prime the pump with a separate hand or manually controlled priming pump ........................ 44
Prime the pump by bypassing the discharge check valve ..................................................... 44
Prime the pump with an ejector ............................................................................................. 45
Prime with an automatic primer pump ................................................................................... 46
Start the pump ...................................................................................................................... 47
Pump operation precautions ................................................................................................. 48
Shut down the pump ............................................................................................................. 49
Make the final alignment of the pump and driver ................................................................... 49
Doweling the pump casing .................................................................................................... 49
Maintenance ........................................................................................................................... 52
Maintenance schedule .......................................................................................................... 52
Bearing maintenance ............................................................................................................ 53
Mechanical-seal maintenance .............................................................................................. 53
Disassembly ......................................................................................................................... 54
Preassembly inspections ...................................................................................................... 66
Reassembly .......................................................................................................................... 73
2 Installation, Operation, and Maintenance Manual
Table of Contents
Troubleshooting .................................................................................................................... 87
Operation troubleshooting ..................................................................................................... 87
Alignment troubleshooting .................................................................................................... 88
Parts Listings and Cross-Sectionals ................................................................................... 89
Parts list ................................................................................................................................ 89
Cross-sectional diagrams ..................................................................................................... 90
Parts list ................................................................................................................................ 91
Cross-sectional diagrams ..................................................................................................... 92
Other Relevant Documentation or Manuals ........................................................................ 93
Local ITT Contacts ................................................................................................................ 94
Regional offices .................................................................................................................... 94
Installation, Operation, and Maintenance Manual 3

Introduction and Safety

Introduction and Safety

Introduction

Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the unit.
Requesting other information
Special versions can be supplied with supplementary instruction leaflets. See the sales contract for any modifications or special version characteristics. For instructions, situations, or events that are not considered in this manual or in the sales documents, please contact the nearest ITT representative.
Always specify the exact product type and identification code when requesting technical information or spare parts.

Safety

WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is over­pressurized. Take all necessary measures to avoid over-pressurization.
• Operating, installing, or maintaining the unit in any way that is not covered in this manual could cause death, serious personal injury, or damage to the equipment. This includes any modification to the equipment or use of parts not provided by ITT. If there is a question regarding the intended use of the equipment, please contact an ITT representative before proceeding.
• This manual clearly identifies accepted methods for disassembling units. These methods must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in their removal unless explicitly stated in this manual.
• If the pump/motor is damaged or leaking, do not operate as it may cause an electric shock, fire, explosion, liberation of toxic fumes, physical harm, or environmental damage. Correct/repair the problem prior to putting back in service.
• Do not change the service application without the approval of an authorized ITT representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result in physical injury, damage, or delays.
4 Installation, Operation, and Maintenance Manual

Safety terminology and symbols

About safety messages
It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product. They are published to help prevent these hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
Hazard levels
Hazard level Indication
DANGER: result in death or serious injury
Introduction and Safety
A hazardous situation which, if not avoided, will
Hazard categories
WARNING: result in death or serious injury
CAUTION: result in minor or moderate injury
NOTICE:
A hazardous situation which, if not avoided, could
A hazardous situation which, if not avoided, could
• A potential situation which, if not avoided, could result in undesirable conditions
• A practice not related to personal injury
Hazard categories can either fall under hazard levels or let specific symbols replace the ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary hazard levels and may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard
The Ex symbol
The Ex symbol indicates safety regulations for Ex-approved products when used in atmospheres that are potentially explosive or flammable.

Environmental safety

The work area
Always keep the station clean to avoid and/or discover emissions.
Installation, Operation, and Maintenance Manual 5
Introduction and Safety
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable environmental regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
WARNING:
Do NOT send the product to the ITT manufacturer if it has been contaminated by any nuclear radiation. Inform ITT so that accurate actions can take place.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Recycling guidelines
Always follow local laws and regulations regarding recycling.

User safety

General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment within the work area:
• Helmet
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
Electrical connections
Electrical connections must be made by certified electricians in compliance with all internation­al, national, state, and local regulations. For more information about requirements, see sections dealing specifically with electrical connections.
Precautions before work
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information about safety devices in other chapters of this manual.
Observe these safety precautions before you work with the product or are in connection with the product:
6 Installation, Operation, and Maintenance Manual
• Provide a suitable barrier around the work area, for example, a guard rail.
• Make sure that all safety guards are in place and secure.
• Make sure that you have a clear path of retreat.
• Make sure that the product cannot roll or fall over and injure people or damage property.
• Make sure that the lifting equipment is in good condition.
• Use a lifting harness, a safety line, and a breathing device as required.
• Allow all system and pump components to cool before you handle them.
• Make sure that the product has been thoroughly cleaned.
• Disconnect and lock out power before you service the pump.
• Check the explosion risk before you weld or use electric hand tools.
Precautions during work
Observe these safety precautions when you work with the product or are in connection with the product:
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product can cause personal injury and damage to property, and may void the warranty.
• Never work alone.
• Always wear protective clothing and hand protection.
• Stay clear of suspended loads.
• Always lift the product by its lifting device.
• Beware of the risk of a sudden start if the product is used with an automatic level control.
• Beware of the starting jerk, which can be powerful.
• Rinse the components in water after you disassemble the pump.
• Do not exceed the maximum working pressure of the pump.
• Do not open any vent or drain valve or remove any plugs while the system is pressurized.
• Never operate a pump without a properly installed coupling guard.
Introduction and Safety
Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump, remove plugs, or disconnect piping.
Hazardous liquids
The product is designed for use in liquids that can be hazardous to your health. Observe these rules when you work with the product:
• Make sure that all personnel who work with biologically hazardous liquids are vaccinated against diseases to which they may be exposed.
• Observe strict personal cleanliness.
• A small amount of liquid will be present in certain areas like the seal chamber.
Wash the skin and eyes
1. Follow these procedures for chemicals or hazardous fluids that have come into contact with your eyes or your skin:
Condition Action
Chemicals or hazardous fluids in eyes
Chemicals or hazardous fluids on skin
Installation, Operation, and Maintenance Manual 7
1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
Introduction and Safety

Ex-approved products

Follow these special handling instructions if you have an Ex-approved unit.
Personnel requirements
These are the personnel requirements for Ex-approved products in potentially explosive atmospheres:
• All work on the product must be carried out by certified electricians and ITT-authorized mechanics. Special rules apply to installations in explosive atmospheres.
• All users must know about the risks of electric current and the chemical and physical characteristics of the gas, the vapor, or both present in hazardous areas.
• Any maintenance for Ex-approved products must conform to international and national standards (for example, IEC/EN 60079-17).
ITT disclaims all responsibility for work done by untrained and unauthorized personnel.
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in potentially explosive atmospheres:
• Only use the product in accordance with the approved motor data.
• The Ex-approved product must never run dry during normal operation. Dry running during service and inspection is only permitted outside the classified area.
• Before you start work on the product, make sure that the product and the control panel are isolated from the power supply and the control circuit, so they cannot be energized.
• Do not open the product while it is energized or in an explosive gas atmosphere.
• Make sure that thermal contacts are connected to a protection circuit according to the approval classification of the product, and that they are in use.
• Intrinsically safe circuits are normally required for the automatic level-control system by the level regulator if mounted in zone 0.
• The yield stress of fasteners must be in accordance with the approval drawing and the product specification.
• Do not modify the equipment without approval from an authorized ITT representative.
• Only use parts that are provided by an authorized ITT representative.
Description of ATEX
The ATEX directives are a specification enforced in Europe for electrical and non-electrical equipment installed in Europe. ATEX deals with the control of potentially explosive atmos­pheres and the standards of equipment and protective systems used within these atmos­pheres. The relevance of the ATEX requirements is not limited to Europe. You can apply these guidelines to equipment installed in any potentially explosive atmosphere.
Guidelines for compliance
Compliance is fulfilled only when you operate the unit within its intended use. Do not change the conditions of the service without the approval of an ITT representative. When you install or maintain explosion proof products, always comply with the directive and applicable standards (for example, IEC/EN 60079–14).

Monitoring equipment

For additional safety, use condition-monitoring devices. Condition-monitoring devices include but are not limited to these devices:
• Pressure gauges
• Flow meters
• Level indicators
• Motor load readings
8 Installation, Operation, and Maintenance Manual
• Temperature detectors
• Bearing monitors
• Leak detectors
• PumpSmart control system

Product warranty

Coverage
ITT undertakes to remedy faults in products from ITT under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an ITT representative within the warranty period.
• The product is used only under the conditions described in this manual.
• The monitoring equipment incorporated in the product is correctly connected and in use.
• All service and repair work is done by ITT-authorized personnel.
• Genuine ITT parts are used.
• Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved products.
Limitations
The warranty does not cover faults caused by these situations:
• Deficient maintenance
• Improper installation
• Modifications or changes to the product and installation made without consulting ITT
• Incorrectly executed repair work
• Normal wear and tear
ITT assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
Introduction and Safety
Warranty claim
ITT products are high-quality products with expected reliable operation and long life. However, should the need arise for a warranty claim, then contact your ITT representative.
Installation, Operation, and Maintenance Manual 9

Transportation and Storage

Transportation and Storage

Inspect the delivery

Inspect the package

1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order. If the product has been picked up at a distributor, make a claim directly to the distributor.

Inspect the unit

1. Remove packing materials from the product. Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps. For your personal safety, be careful when you handle nails and straps.
4. Contact your sales representative if anything is out of order.

Transportation guidelines

Pump handling and lifting

Precautions for moving the pump
Use care when moving pumps. Consult with a lifting and rigging specialist before lifting or moving the pump to avoid possible damage to the pump or injury to personnel.
WARNING:
Make sure that the unit cannot roll or fall over and injure people or damage property.
NOTICE:
Use a forklift truck with sufficient capacity to move the pallet with the pump unit on top.
Precautions for lifting the pump
WARNING:
Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear steel­toed shoes at all times.
NOTICE:
• Make sure that the lifting equipment supports the entire assembly and is only used by authorized personnel.
• Do not attach sling ropes to shaft ends.
Lifting the pump
Hoist a bare pump using suitable slings under the bearing housing saddle on each end.
Figure 1: Example of the proper lifting method for a bare pump
10 Installation, Operation, and Maintenance Manual
Transportation and Storage
Figure 2: Example of the proper lifting method for a bare pump
Baseplate-mounted units have lifting points for use with proper lifting devices.
Figure 3: Example of the proper lifting method for baseplate-mounted units without a driver
Installation, Operation, and Maintenance Manual 11
Transportation and Storage
Figure 4: Example of the proper lifting method for baseplate-mounted units with a driver

Storage guidelines

Long-term storage

If the unit is stored for more than 6 months, these requirements apply:
• Store in a covered and dry location.
• Store the unit free from heat, dirt, and vibrations.
• Rotate the shaft by hand several times at least every three months.
Treat bearing and machined surfaces so that they are well preserved. Refer to the drive unit and coupling manufacturers for their long-term storage procedures.
For questions about possible long-term storage treatment services, please contact your local ITT sales representative.
12 Installation, Operation, and Maintenance Manual

Product Description

General description

Product description
The Model 3610 is a horizontal centrifugal pump that meets the requirements of API 610 8th through 11th Editions (ISO 13709 1st and 2nd Editions) and has these characteristics:
• Safety, Reliability, and Versatility
• Axially-Split
• Single-stage
• Between the bearings
Product Description
Casing
The flanges are ASME Class 300 raised-face serrated with a 125-250 RMS finish. Other flanges are also available:
• ASME Class 300 ring joint
• ASME Class 600 raised-face serrated
• ASME Class 600 ring joint
Impeller
The impeller is fully closed and key driven.
Seal chamber
The seal chamber meets API 682 2nd Edition dimensions for improved performance of mechanical seals. Customer-selected cartridge mechanical seals are standard.
Power end
The power end has these characteristics:
• Carbon steel bearing housings are standard.
• The oil level is viewed through a sight glass.
• Constant-level oilers and labyrinth seals are standard.
Installation, Operation, and Maintenance Manual 13
Product Description
Bearings
Shaft
• No machining is required in order to convert the standard ring oil lube to either purge or pure mist. Pure mist applications require minor bearing housing modifications.
• Pressure lubrication is required with hydrodynamic thrust bearings.
Bearing type Characteristics
Inboard (radial)
Outboard (thrust)
• Consists of a single-row deep-groove ball bearing (standard)
• Carries only radial load
• Optional sleeve bearings
• Consists of a pair of single-row angular contact ball bearings mounted back-to-back (standard)
• Shouldered and locked to the shaft
• Retained in the bearing frame to enable the bearing to carry both radial and thrust loads
• Optional hydrodynamic thrust bearing for use with sleeve type journal bearings
The heavy duty shaft has these characteristics:
• Designed for cartridge mechanical seals
• Minimal shaft deflection at the seal faces (0.002 in. [0.051 mm]) when run in the worst­case condition (typically minimum flow)
• Critical speed at least 20% above design operating speed
Direction of rotation
The shaft rotates clockwise or counterclockwise when viewed from the power end.

Nameplate information

Important information for ordering
Every pump has a nameplate that provides information about the pump. The nameplate is located on the pump casing.
When you order spare parts, identify this pump information:
• Model
• Size
• Serial number
• Item numbers of the required parts
Refer to the nameplate on the pump casing for most of the information. See Parts List for item numbers.
Nameplate on the pump casing using English units
14 Installation, Operation, and Maintenance Manual
Product Description
Nameplate field Explanation
MODEL Pump model SIZE Size of the pump FLOW Rated pump flow, in gallons per minute HEAD Rated pump head, in feet RPM Rated pump speed, in revolutions per minute HYDRO PRESS Hydrostatic pressure at 100°F, in pounds per square inch MAX. DES. WORKING Maximum working pressure at temperature °F, in pounds per square inch
PRESS S/N Serial number of the pump CONT./ITEM NO. Customer contract or item number IMP. DIA. Rated impeller diameter MAX. DIA. Maximum impeller diameter STD. DIM. Standard ANSI dimensional code MAT'L Material of construction
Nameplate on the pump casing using metric units
Nameplate field Explanation
MODEL Pump model SIZE Size of the pump FLOW Rated pump flow, in gallons per minute HEAD Rated pump head, in feet RPM Rated pump speed, in revolutions per minute HYDRO PRESS Hydrostatic pressure at 38°C, in pounds per square inch MAX. DES. WORKING Maximum working pressure at temperature °C, in pounds per square inch
PRESS S/N Serial number of the pump CONT./ITEM NO. Customer contract or item number IMP. DIA. Rated impeller diameter MAX. DIA. Maximum impeller diameter STD. DIM. Standard ANSI dimensional code MAT'L Material of construction
Installation, Operation, and Maintenance Manual 15
Product Description
ATEX nameplate
Nameplate field Explanation
II Group 2 2 Category 2 G/D Pump can be used when gas and dust are present T4 Temperature class
NOTICE:
Make sure that the code classifications on the pump are compatible with the specific environment in which you plan to install the equipment. If they are not compatible, do not operate the equipment and contact your ITT representative before you proceed.
16 Installation, Operation, and Maintenance Manual

Installation

Preinstallation

Precautions
WARNING:
• When installing in a potentially explosive environment, make sure that the motor is properly certified.
• You must earth (ground) all electrical equipment. This applies to the pump equipment, the driver, and any monitoring equipment. Test the earth (ground) lead to verify that it is connected correctly.
• Electrical Connections must be made by certified electricians in compliance with all international, national, state, and local rules.
NOTICE:
Supervision by an authorized ITT representative is recommended to ensure proper installation. Failure to do so may result in equipment damage or decreased performance.

Pump location guidelines

WARNING:
Assembled units and their components are heavy. Failure to properly lift and support this equipment can result in serious physical injury and/or equipment damage. Lift equipment only at the specifically identified lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated, selected, and used for the entire load being lifted.
Installation
Guideline Explanation/comment
Make sure that the space around the pump is This facilitates ventilation, inspection, maintenance, sufficient. and service.
If you require lifting equipment such as a hoist or This makes it easier to properly use the lifting tackle, make sure that there is enough space above equipment and safely remove and relocate the the pump. components to a safe location.
Protect the unit from weather and water damage This is applicable if nothing else is specified. due to rain, flooding, and freezing temperatures.
Do not install and operate the equipment in closed Acceptable devices: systems unless the system is constructed with properly-sized safety devices and control devices.
Take into consideration the occurrence of unwanted The best pump location for noise and vibration noise and vibration. absorption is on a concrete floor with subsoil

Foundation requirements

Requirements
• The foundation must be able to absorb any type of vibration and form a permanent, rigid support for the unit.
• The location and size of the foundation bolt holes must match those shown on the assembly drawing provided with the pump data package.
• The foundation must weigh between two and three times the weight of the pump.
• Provide a flat, substantial concrete foundation in order to prevent strain and distortion when you tighten the foundation bolts.
• Pressure relief valves
• Compression tanks
• Pressure controls
• Temperature controls
• Flow controls If the system does not include these devices, consult the engineer or architect in charge before you operate the pump.
underneath.
Installation, Operation, and Maintenance Manual 17
Installation
Sleeve-type bolts
J-type bolts
• Sleeve-type and J-type foundation bolts are most commonly used. Both designs allow movement for the final bolt adjustment.
1. Baseplate
2. Shims or wedges
3. Foundation
4. Sleeve
5. Dam
6. Bolt
1. Baseplate
2. Shims or wedges
3. Foundation
4. Dam
5. Bolt

Baseplate-mounting procedures

Prepare the baseplate for mounting

This procedure assumes you have a basic knowledge of baseplate and foundation design and installation methods. Follow industry-standard procedures, such as API RP 686/ PIP REIE 686, or this procedure before you grout the baseplate.
1. Make sure that all baseplate surfaces that will contact grout are free from contamination such as rust, oil, and grime.
2. Thoroughly clean all baseplate surfaces that will come in contact with grout. Make sure to use a cleaner that will not leave residue.
NOTICE:
You may need to sandblast the surfaces of a baseplate that come in contact with grout, and then coat those surfaces with a primer that is grout-compatible. Make sure to remove all equipment before sandblasting.
18 Installation, Operation, and Maintenance Manual
3. Make sure that all machined surfaces are free from burrs, rust, paint, or any other type of contamination. If necessary, use a honing stone to remove burrs.

Prepare the foundation for mounting

1. Chip the top of the foundation to a minimum of 1.0 in. (25.0 mm) in order to remove porous or low-strength concrete. If you use a pneumatic hammer, make sure that it does not contaminate the surface with oil or other moisture.
NOTICE:
Do not chip the foundation using heavy tools such as jackhammers. This can damage the structural integrity of the foundation.
2. Remove water or debris from the foundation bolt holes or sleeves.
3. If the baseplate uses sleeve-type bolts, then fill the sleeves with a non-binding, moldable material. Seal the sleeves in order to prevent the grout from entering.
4. Coat the exposed portion of the anchor bolts with a non-bonding compound such as paste wax in order to prevent the grout from adhering to the anchor bolts. Do not use oils or liquid wax.
5. If recommended by the grout manufacturer, coat the foundation surface with a compatible primer.
Installation

Install and level the baseplate

NOTICE:Illustrations are for reference only and may not depict the particular pump model.
Figure 5: Jackscrew locations, side view
Figure 6: Jackscrew locations, top view
1. Lower the baseplate carefully onto the foundation bolts. The baseplate will rest on top of the foundation on the jackscrews provided on the baseplate.
Installation, Operation, and Maintenance Manual 19
Installation
2. Adjust the leveling jackscrews, located adjacent to the foundation bolt holes, until the baseplate rests 1 to 2 in. (25 to 50 mm) above the foundation in order to allow for adequate grouting. This provides even support for the baseplate after grouting.
3. Level the baseplate to within 0.002 in./ft. (0.167 mm/m) of the length or width of the baseplate by adjusting the jackscrews.
• The maximum total variation from one end or side of the baseplate to the other is
0.015 in. (0.38 mm).
• Use the equipment mounting surfaces in order to establish the level.
4. Use a non-bonding (anti-seize) compound such as paste wax to coat the portions of the jackscrews that will contact the grout. This facilitates removal of the screws after grouting.
NOTICE:
Do not use oils or liquid wax.
5. Thread the nuts onto the foundation bolts and hand-tighten.

Install the pump, driver, and coupling

1. Mount and fasten the pump on the baseplate. Use applicable bolts.
2. Mount the driver on the baseplate. Use applicable bolts and hand tighten.
3. Install the coupling. See the installation instructions from the coupling manufacturer.

Pump-to-driver alignment

Precautions
WARNING:
• Follow shaft alignment procedures in order to prevent catastrophic failure of drive components or unintended contact of rotating parts. Follow the coupling installation and operation procedures from the coupling manufacturer.
• Always disconnect and lock out power to the driver before you perform any installation or maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical injury.
NOTICE:
Proper alignment is the responsibility of the installer and the user of the unit. Check the alignment of frame-mounted units before you operate the unit. Failure to do so can result in equipment damage or decreased performance.
Alignment methods
Three common alignment methods are used:
• Dial indicator
• Reverse dial indicator
• Laser
Follow the instructions from the equipment manufacturer when you use the reverse dial indicator or laser methods. Detailed instructions for using the dial indicator method are contained in this chapter.
20 Installation, Operation, and Maintenance Manual

Alignment checks

When to perform alignment checks
You must perform alignment checks under these circumstances:
• The process temperature changes.
• The piping changes.
• The pump has been serviced.
Types of alignment checks
Type of check When it is used
Initial alignment (cold alignment) Prior to operation when the pump and the driver are at ambient check temperature.
Final alignment (hot alignment) After operation when the pump and the driver are at operating check temperature.
Initial alignment (cold alignment) checks
When Why
Before you grout the baseplate This ensures that alignment can be accomplished. After you grout the baseplate This ensures that no changes have occurred during the grouting
After you connect the piping This ensures that pipe strains have not altered the alignment.
Installation
process.
Final alignment (hot alignment) checks
When Why
After the first run This ensures correct alignment when both the pump and the driver
Periodically This follows the plant operating procedures.
are at operating temperature.

Permitted indicator values for alignment checks

NOTICE:
The specified permitted reading values are valid only at operating temperature. For cold settings, other values are permitted. You must use the correct tolerances. Failure to do so can result in misalignment and reduced pump reliability.
IMPORTANT
• For electric motors, the motor shaft initial (cold) parallel vertical alignment setting should be 0.002 to 0.004 in. (0.05 to 0.10 mm) lower than the pump shaft.
• For other drivers such as turbines and engines, follow the driver manufacturer's recommendations.
When dial indicators are used to check the final alignment, the pump and drive unit are correctly aligned when these conditions are true:
• The total indicator runout is a maximum of 0.002 in. (0.05 mm) at operating temperature.
• The tolerance of the indicator is 0.0005 in./in. (0.0127 mm/mm) of indicator separation at operating temperature.

Alignment measurement guidelines

Guideline Explanation
Rotate the pump coupling half and the driver This prevents incorrect measurement. coupling half together so that the indicator rods have contact with the same points on the driver coupling half.
Move or shim only the driver in order to make This prevents strain on the piping installations. adjustments.
Installation, Operation, and Maintenance Manual 21
Installation
Guideline Explanation
Make sure that the hold-down bolts for the driver This keeps the driver stationary since movement feet are tight when you take indicator measure- causes incorrect measurement. ments.
Make sure that the hold-down bolts for the driver This makes it possible to move the driver when you feet are loose before you make alignment correc- make alignment corrections. tions.
Check the alignment again after any mechanical This corrects any misalignments that an adjustment adjustments. may have caused.

Attach the dial indicators for alignment

You must have two dial indicators in order to complete this procedure.
1. Attach two dial indicators on the pump coupling half (X): a) Attach one indicator (P) so that the indicator rod comes into contact with the perimeter
of the driver coupling half (Y). This indicator is used to measure parallel misalignment.
b) Attach the other indicator (A) so that the indicator rod comes into contact with the inner
end of the driver coupling half. This indicator is used to measure angular misalignment.
2. Rotate the pump coupling half (X) in order to check that the indicators are in contact with the driver coupling half (Y) but do not bottom out.
3. Adjust the indicators if necessary.

Perform angular alignment for a vertical correction

1. Set the angular alignment indicator to zero at the top-center position (12 o’clock) of the driver coupling half (Y).
2. Rotate the indicator to the bottom-center position (6 o’clock).
3. Record the indicator reading.
When the reading value is... Then...
Negative The coupling halves are farther apart at the
Positive The coupling halves are closer at the bottom than
bottom than at the top. Perform one of these steps:
• Add shims in order to raise the feet of the driver at the shaft end.
• Remove shims in order to lower the feet of the driver at the other end.
at the top. Perform one of these steps:
• Remove shims in order to lower the feet of the driver at the shaft end.
• Add shims in order to raise the feet of the driver at the other end.
22 Installation, Operation, and Maintenance Manual
1. Shims
Figure 7: Example of incorrect vertical alignment (side view)
4. Repeat the previous steps until the permitted reading value is achieved.

Perform angular alignment for a horizontal correction

1. Set the angular alignment indicator (A) to zero on left side of the driver coupling half (Y), 90° from the top-center position (9 o’clock).
2. Rotate the indicator through the top-center position to the right side, 180° from the start position (3 o’clock).
3. Record the indicator reading.
When the reading value is... Then...
Negative The coupling halves are farther apart on the right side than
the left. Perform one of these steps:
• Slide the shaft end of the driver to the left.
• Slide the opposite end to the right.
Positive The coupling halves are closer together on the right side
than the left. Perform one of these steps:
• Slide the shaft end of the driver to the right.
• Slide the opposite end to the left.
Installation
Figure 8: Example of incorrect horizontal alignment (top view)
4. Repeat the previous steps until the permitted reading value is achieved.

Perform parallel alignment for a vertical correction

Refer to the alignment table in "Permitted indicator values for alignment checks" (see Table of Contents for location of table) for the proper cold alignment value based on the motor temperature rise and the pump operating temperature.
Before you start this procedure, make sure that the dial indicators are correctly set up. A unit is in parallel alignment when the parallel indicator (P) does not vary by more than
0.002 in. (0.05 mm) as measured at four points 90° apart at the operating temperature.
1. Set the parallel alignment indicator (P) to zero at the top-center position (12 o’clock) of the driver coupling half (Y).
2. Rotate the indicator to the bottom-center position (6 o’clock).
3. Record the indicator reading.
Installation, Operation, and Maintenance Manual 23
Installation
When the reading value is... Then...
Negative The pump coupling half (X) is lower than the
driver coupling half (Y). Remove shims of a thickness equal to half of the indicator reading value under each driver foot.
Positive The pump coupling half (X) is higher than the
driver coupling half (Y). Add shims of a thickness equal to half of the indicator reading value to each driver foot.
NOTICE:
1. Shims
Figure 9: Example of incorrect vertical alignment (side view)
4. Repeat the previous steps until the permitted reading value is achieved.

Perform parallel alignment for a horizontal correction

A unit is in parallel alignment when the parallel indicator (P) does not vary by more than
0.002 in. (0.05 mm) as measured at four points 90° apart at the operating temperature.
1. Set the parallel alignment indicator (P) to zero on the left side of the driver coupling half (Y), 90° from the top-center position (9 o’clock).
2. Rotate the indicator through the top-center position to the right side, 180° from the start position (3 o’clock).
3. Record the indicator reading.
When the reading value is... Then...
Negative The driver coupling half (Y) is to the left of the
Positive The driver coupling half (Y) is to the right of the
4. Slide the driver carefully in the appropriate direction.
NOTICE:Make sure to slide the driver evenly. Failure to do so can negatively affect horizontal angular correction.
pump coupling half (X).
pump coupling half (X).
Figure 10: Example of incorrect horizontal alignment (top view)
24 Installation, Operation, and Maintenance Manual
5. Repeat the previous steps until the permitted reading value is achieved.

Perform complete alignment for a vertical correction

A unit is in complete alignment when both the angular indicator (A) and the parallel indicator (P) do not vary by more than 0.002 in. (0.05 mm) as measured at four points 90° apart.
1. Set the angular and parallel dial indicators to zero at the top-center position (12 o’clock) of the driver coupling half (Y).
2. Rotate the indicators to the bottom-center position (6 o’clock).
3. Record the indicator readings.
4. Make corrections according to the separate instructions for angular and parallel alignment until you obtain the permitted reading values.

Perform complete alignment for a horizontal correction

A unit is in complete alignment when both the angular indicator (A) and the parallel indicator (P) do not vary by more than 0.002 in. (0.05 mm) as measured at four points 90° apart.
1. Set the angular and parallel dial indicators to zero at the left side of the driver coupling half (Y), 90° from the top-center position (9 o’clock).
2. Rotate the indicators through the top-center position to the right side, 180° from the start position (3 o’clock).
3. Record the indicator readings.
4. Make corrections according to the separate instructions for angular and parallel alignment until you obtain the permitted reading values.
Installation

Grout the baseplate

Required equipment:
• Cleaners: Do not use an oil-based cleaner because the grout will not bond to it. See the instructions provided by the grout manufacturer.
• Grout: Non-shrink grout is recommended.
NOTICE:
It is assumed that the installer who grouts the baseplate has knowledge of acceptable methods. More detailed procedures are described in various publications, including API Standard 610, latest edition, Appendix L; API RP 686, Chapter 5; and other industry standards.
1. Clean all the areas of the baseplate that will come into contact with the grout.
2. Build a dam around the foundation.
3. Thoroughly wet the foundation that will come into contact with the grout.
4. Pour grout through the grout hole into the baseplate up to the level of the dam. When you pour the grout, remove air bubbles from it by using one of these methods:
• Puddle with a vibrator.
• Pump the grout into place.
Installation, Operation, and Maintenance Manual 25
Installation
5. Allow the grout to set.
1. Baseplate
2. Shims or wedges
3. Grout
4. Foundation
5. Sleeve
6. Dam
7. Bolt
6. Fill the remainder of the baseplate with grout, and allow the grout to set for at least 48 hours.
1. Baseplate
2. Grout
3. Foundation
4. Dam
5. Bolt
7. Remove the leveling jackscrews after the grout hardens in order to remove any stress points.
8. Tighten the foundation bolts.
9. Recheck the alignment.

Piping checklists

General piping checklist

Precautions
CAUTION:
• Never draw piping into place by using force at the flanged connections of the pump. This can impose dangerous strains on the unit and cause misalignment between the pump and driver. Pipe strain adversely affects the operation of the pump, which results in physical injury and damage to the equipment.
• Vary the capacity with the regulating valve in the discharge line. Never throttle the flow from the suction side. This action can result in decreased performance, unexpected heat generation, and equipment damage.
26 Installation, Operation, and Maintenance Manual
Piping guidelines
Checklist
Installation
CAUTION:
Flange loads from the piping system, including those from the thermal expansion of the piping, must not exceed the limits of the pump. Casing deformation can result in contact with rotating parts, which can result in excess heat generation, sparks, and premature failure.
Guidelines for piping are given in the Hydraulic Institute Standards available from the Hydraulic Institute at 9 Sylvan Way, Parsippany, NJ 07054-3802. You must review this document before you install the pump.
Check Explanation/comment Checked
Check that all piping is supported This helps to prevent: independently of, and lined up naturally with, the pump flange.
See Alignment criteria for pump • Wear on the pump bearings, seal, and shafting flanges.
Check that only necessary fittings This helps to minimize friction losses. are used.
Do not connect the piping to the — pump until:
• The grout for the baseplate or sub-base becomes hard.
• The hold-down bolts for the pump are tightened.
Make sure that all the piping joints This prevents air from entering the piping system or and fittings are airtight. leaks that occur during operation.
If the pump handles corrosive fluids, make sure that the piping allows you to flush out the liquid before you remove the pump.
If the pump handles liquids at elevated temperatures, make sure that the expansion loops and joints are properly installed.
• Strain on the pump
• Misalignment between the pump and the drive unit
Alignment criteria for pump flanges
Type Criteria
Axial The flange gasket thickness is ±0.03 in. (0.8 mm). Parallel Align the flange to be within 0.001 in./in. to 0.03 in./
Concentric You can easily install the flange bolts by hand.
Fastening
WARNING:
• Only use fasteners of the proper size and material.
• Replace all corroded fasteners.
• Make sure that all fasteners are properly tightened and that there are no missing fasteners.

Suction-piping checklist

Performance curve reference
CAUTION:
Vary the capacity with the regulating valve in the discharge line. Never throttle the flow from the suction side. This action can result in decreased performance, unexpected heat generation, and equipment damage.
in. (0.025 mm/mm to 0.8 mm/mm) of the flange diameter.
Installation, Operation, and Maintenance Manual 27
Installation
Net positive suction head available (NPSHA) must always exceed NPSH required (NPSHR) as shown on the published performance curve of the pump.
Suction-piping checks
Check Explanation/comment Checked
Check that elbows in general do not have sharp bends.
Check that the suction piping is The suction piping must never one or two sizes larger than the have a smaller diameter than the suction inlet of the pump. suction inlet of the pump.
Install an eccentric reducer be­tween the pump inlet and the suction piping.
Check that the eccentric reducer at the suction flange of the pump has the following properties:
• Sloping side down
• Horizontal side at the top
When suction strainers or suction Suction strainers help to prevent bells are used, check that they are clogging. at least three times the area of the suction piping.
If more than one pump operates This recommendation helps you to from the same liquid source, achieve a higher pump perfor­check that separate suction-piping mance. lines are used for each pump.
If necessary, make sure that the — suction piping includes a drain valve and that it is correctly in­stalled.
Liquid source below the pump
Check Explanation/comment Checked
Make sure that the suction piping This helps to prevent the occur­is free from air pockets. rence of air and cavitation in the
Check that the suction piping — slopes upwards from the liquid source to the pump inlet.
If the pump is not self-priming, Use a foot valve with a diameter check that a device for priming the that is at least equivalent to the pump is installed. diameter of the suction piping.
Liquid source above the pump
Check Explanation/comment Checked
Check that an isolation valve is This permits you to close the line installed in the suction piping at a during pump inspection and main­distance of at least two times the tenance. pipe diameter from the suction inlet.
Make sure that the suction piping This helps to prevent the occur­is free from air pockets. rence of air and cavitation in the
Check that the piping is level or — slopes downward from the liquid source.
Make sure that no part of the — suction piping extends below the suction flange of the pump.
pump inlet.
Do not use the isolation valve to throttle the pump. Throttling can cause these problems:
• Loss of priming
• Excessive temperatures
• Damage to the pump
• Voiding the warranty
pump inlet.
28 Installation, Operation, and Maintenance Manual
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