Goulds Pumps 3910 User Manual

Installation, Operation and Maintenance

Model 3910 11th Edition (ISO 13709)

FOREWORD

This manual provides instructions for the Installation, Operation, and Maintenance of the Goulds Model 3910 Vertical Bearing Frame In-line Process Pump designed to meet the requirements of

the 11th Edition (ISO 13709) of API* Standard 610. 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.

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

ITT - Goulds Pumps shall not be liable for physical injury, damage or delays caused by a failure to observe the instructions for installation, operation, and maintenance contained in this manual.

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

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

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

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

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

THIS MANUAL EXPLAINS

* American Petroleum Institute

1220 L Street, Northwest

Washington, D.C. 20005

3910-11th IOM 5/08

Proper Installation

Start-up Procedures

Operation Procedures

Routine Maintenance

Pump Overhaul

Troubleshooting

Ordering Spare or Repair Parts

5

TABLE OF CONTENTS

PAGE		SECTION
9	SAFETY		1
13	GENERAL INFORMATION		2
17	INSTALLATION		3
21	OPERATION		4
27	PREVENTIVE MAINTENANCE		5
31	DISASSEMBLY & REASSEMBLY		6
61	SPARE PARTS	7
63	APPENDICES		8
I - 63	Installation & Disassembly Instructions for Goulds ANSI B15.1 Coupling Guards

A - 63 (Casing Mount Motor Support Only) - All Power Ends Except those with

Optional Air Cooling Package

B - 67 (Casing Mount Motor Support Only) - Power Ends with Optional Air Cooling

Package

II - 71 Dial Indicator (Rim-and-Face) Alignment Procedure

III -75 Removal and Installation of Back Pull-Out Assembly Using Goulds Back Pull-Out

Removal Device

3910-11th IOM 5/08

7

8	3910-11th IOM 5/08

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 www.gouldspumps.com/literature_ioms.html or by contacting your nearest Goulds Pumps sales representative.

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

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

S-1

SAFETY WARNINGS

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

WARNING

A pump is a pressure vessel with rotating parts that can be hazardous. Any pressure vessel can explode, rupture, or discharge its contents if sufficiently over pressurized causing death, personal injury, property damage, and/or damage to the environment. All necessary measures must be taken to ensure over pressurization does not occur.

WARNING

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

WARNING

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

WARNING

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

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

S-2

SAFETY

DEFINITIONS

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

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

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Example: Pump shall never be operated without coupling guard installed correctly.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Example: Throttling flow from the suction side may cause cavitation and pump damage.

ELECTRICAL HAZARD

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

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

When installed in potentially explosive atmospheres, the instructions that follow the Ex symbol must be

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

Example: Improper impeller adjustment could cause contact between the rotating and stationary parts, resulting in a spark and heat generation.

S-3

GENERAL PRECAUTIONS

WARNING

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

		General Precautions
WARNING		NEVER APPLY HEAT TO REMOVE IMPELLER. It may explode due to
		trapped liquid.
WARNING		NEVER use heat to disassemble pump due to risk of explosion from tapped liquid.
WARNING		NEVER operate pump without coupling guard correctly installed.
WARNING		NEVER run pump below recommended minimum flow when dry, or without
		prime.
WARNING		ALWAYS lock out power to the driver before performing pump maintenance.
WARNING		NEVER operate pump without safety devices installed.
WARNING		NEVER operate pump with discharge valve closed.
WARNING		NEVER operate pump with suction valve closed.
WARNING		DO NOT change service application without approval of an authorized ITT
		Goulds Pumps representative.
		Safety Apparel:
		Insulated work gloves when handling hot bearings or using bearing heater
		Heavy work gloves when handling parts with sharp edges, especially
WARNING		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
WARNING		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

		General Precautions
WARNING		Before beginning any alignment procedure, make sure driver power is locked out.
		Failure to lock out driver power will result in serious physical injury.
		Piping:
CAUTION		Never draw piping into place by forcing at the flanged connections of the pump.
		This may impose dangerous strains on the unit and cause misalignment between
		pump and driver. Pipe strain will adversely effect the operation of the pump
		resulting in physical injury and damage to the equipment.
WARNING		Flanged Connections:
		Use only fasteners of the proper size and material.
WARNING		Replace all corroded fasteners.
WARNING		Ensure all fasteners are properly tightened and there are no missing fasteners.
WARNING		Startup and Operation:
		When installing in a potentially explosive environment, please ensure that the
		motor is properly certified.
WARNING		Operating pump in reverse rotation may result in contact of metal parts, heat
		generation, and breach of containment.
WARNING		Lock out driver power to prevent accidental start-up and physical injury.
WARNING		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.
WARNING		If using a cartridge mechanical seal, the centering clips must be installed and set
		screws loosened prior to setting impeller clearance. Failure to do so could result
		in sparks, heat generation, and mechanical seal damage.
WARNING		The coupling used in an ATEX classified environment must be properly certified
		and must be constructed from a non-sparking material.
WARNING		Never operate a pump without coupling guard properly installed. Personal injury
		will occur if pump is run without coupling guard.
WARNING		Make sure to properly lubricate the bearings. Failure to do so may result in excess
		heat generation, sparks, and / or premature failure.
CAUTION		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.
CAUTION		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.
WARNING		Never attempt to replace packing until the driver is properly locked out and the
		coupling spacer is removed.
WARNING		Dynamic seals are not allowed in an ATEX classified environment.
WARNING		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.

S-5

		General Precautions
WARNING		Ensure pump is isolated from system and pressure is relieved before
		disassembling pump, removing plugs, opening vent or drain valves, or
		disconnecting piping.
		Shutdown, Disassembly, and Reassembly:
WARNING		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
WARNING		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.
WARNING		Operator must be aware of pumpage and safety precautions to prevent physical
		injury.
WARNING		Lock out driver power to prevent accidental startup and physical injury.
CAUTION		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,
CAUTION		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.
WARNING		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.
CAUTION		Wear heavy work gloves when handling impellers as sharp edges may cause
		physical injury.
CAUTION		Wear insulated gloves when using a bearing heater. Bearings will get hot and can
		cause physical injury.

S-6

ATEX CONSIDERATIONS and INTENDED USE

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

1.Monitoring the pump frame and liquid end temperature.

2.Maintaining proper bearing lubrication.

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

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

Current IOMs are available at www.gouldspumps.com/literature_ioms.html or from your local ITT Goulds 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:

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		Max permissible
	surface temperature		liquid temperature
Code	oF (oC)		oF (oC)
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

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.

S-7

PARTS

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

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

S-8

GENERAL INFORMATION

PUMP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
NAMEPLATE INFORMATION . . . . . . . . . . . . . . . . . . . . . 14
RECEIVING THE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 15
Storage Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15	2

PUMP DESCRIPTION

The Model 3910 is a vertical bearing frame in-line centrifugal pump that meets the requirements of API

Standard 610 11th Edition (ISO 13709).

The model is based on 5 power ends and 27 hydraulic pump sizes.

Casing - The casing is a vertical in-line mounted design. The gasket is fully confined. ANSI Class 300 raised face serrated flanges are standard; ANSI Class 300 flat face serrated and ring joint flanges are available.

Impeller - The impeller is fully enclosed and key driven by the shaft. An impeller nut with locking set screw prevents axial movement.

Seal Chamber Cover - The Model 3910 seal chamber cover meets API 682 2nd Edition dimensions for improved performance of mechanical seals.

Power End - Regreasable bearings are standard. The power end is sealed with labyrinth seals. Pure oil mist lubrication is optional. Some modifications are required to convert from grease to oil mist.

Shaft - The standard shaft is machined and ground to comply with API 610 11th Edition (ISO 13709) criteria.

Bearings - The inboard (radial) bearing carries only radial load; it is free to float axially in the frame. The outboard (thrust) bearing is shouldered and locked to the shaft and retained in the bearing frame to enable it to carry radial and thrust loads. All fits are precision machined to industry standards. The inboard bearing is a single row deep groove ball bearing. The outboard bearing is a duplex angular contact bearing, which uses a pair of single row angular contact ball bearings mounted back-to-back.

Motor Support - The fabricated steel motor support is designed to support the driver and to provide ample access to both the seal piping and the coupling.

Direction of Rotation - Counterclockwise (left hand) as viewed from the driver, looking at the pump shaft.

3910-11th IOM 5/08

13

NAMEPLATE INFORMATION

Every pump has a Goulds 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 provides information about the pump’s size, rating, bearings, serial number, hydrostatic test pressure of pressure containment parts, maximum allowable working pressure at designated temperature and construction / customer’s item number. Rating and

hydrostatic test pressure are expressed in English units. Fig. 1A Note the format of pump size: Discharge x Suction -

Nominal Impeller Diameter in inches, for example, 2x3-13 (Fig. 1A).

The standard nameplate is also available in a version which expresses the rating and hydrostatic test pressure in metric units (Fig. 1B).

When ordering spare parts you will need to identify pump model, size, serial number, and the item number of required parts. Pump information can be taken from the Goulds nameplate. Item numbers can be found in this manual.

If applicable, your pump unit may have the ATEX tag affixed to the pump and/or baseplate (Fig. 2). See the Safety section for a description of the symbols and codes.

Fig. 1B

Fig. 2

14	3910-11th IOM 5/08

RECEIVING THE PUMP

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

STORAGE REQUIREMENTS

Short Term (Less than 6 months) Goulds normal packaging procedure is designed to protect the pump during shipping. Upon receipt, store in a covered and dry location.

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

NOTE: Long term storage treatment may be

purchased with initial pump order.

HANDLING

! WARNING

Pump and components are heavy. Failure to properly lift and support equipment could result in serious physical injury, or damage to pumps.

Use care when moving pumps. Lifting equipment must be able to adequately support the entire assembly. Hoist bare pump using suitable hooks through the holes in the frame mounted support or suitable slings through the large openings in the casing mounted support (Fig. 3).

2

Fig. 4

Or with hooks through the holes in the frame mounted support or with slings through the large openings in the casing mounted support.

Fig. 3

Units with drivers mounted are moved with slings under the pump casing and driver (Figs. 4 and 5).

Fig. 5

! WARNING

Units with drivers mounted can be top heavy. Driver weight could cause the assembled unit to overturn and

could result in serious physical injury, or damage to pumps.

3910-11th IOM 5/08

15

16	3910-11th IOM 5/08

INSTALLATION

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SITE/FOUNDATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ALIGNMENT AND ALIGNMENT CRITERIA . . . . . . . . . . . . . 18
General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . 18
Alignment Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ALIGNMENT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 18
PIPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Suction Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Discharge Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20	3
Bypass Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Auxiliary Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Final Piping Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Equipment that will operate in a potentially explosive environment must be installed in accordance with the following instructions.

GENERAL

Procedures for installation described within this section are general in nature. It is assumed that the installer has a basic knowledge of acceptable methods. More detailed procedures are described in various publications,

including API Recommended Practice 686/ PIP (Process Industry Practices) REIE 686, “Recommended Practices for Machinery Installation and Installation Design.”

SITE/FOUNDATION

A pump should be located near the supply of liquid and have adequate space for operation, maintenance, and inspection. Be sure to allow for crane or hoist service.

Model 3910 in-line pumps are designed to be mounted directly in the piping. The pump casing has a flat base which may be mounted on a concrete foundation which has been poured on a solid footing.

Fig. 6

The foundation must be able to absorb any vibration and to form a permanent, rigid support for the pumping unit

(Fig. 6). Goulds recommends this mounting method.

Optional casing supports, which provide additional stability, are also available (Fig. 7).

Fig. 7

If it is intended that the piping support the pumping unit, piping supports should be properly designed to accommodate the weight of the pumping unit.

All equipment being installed must be properly grounded to prevent unexpected static electric discharge.

3910-11th IOM 5/08

17

ALIGNMENT AND ALIGNMENT CRITERIA

Alignment procedures must be followed to prevent unintended contact of rotating parts. Follow coupling manufacturer's installation and operation procedures.

GENERAL CONSIDERATIONS

! WARNING

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

To remove coupling guard, refer to coupling guard installation and disassembly instructions in Appendix I.

The times at which alignment is checked and adjusted are:

Initial Alignment (Cold Alignment) is done prior to operation when the pump and the driver are at ambient temperatures.

Final Alignment (Hot Alignment) is done after operation when the pump and driver are at operating temperatures.

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

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

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

NOTE: Proper alignment is the responsibility of the

installer and user of the unit.

Accurate alignment of the equipment must be attained. Trouble-free operation can be accomplished by achieving alignment within the levels specified in the following section.

Three common alignment methods are utilized:

•Reverse Dial Indicator method is most common.

•Laser method is similar to reverse dial indicator method, but uses a laser to obtain the necessary measurements.

•Dial Indicator (rim-and-face) method.

Follow alignment equipment manufacturer's procedures when utilizing reverse dial indicator or laser methods. A detailed procedure for alignment using the dial indicator (rim-and-face) method is included as Appendix II.

ALIGNMENT CRITERIA

Good alignment is attained when readings as specified in this section have been achieved with pump and driver at operating temperatures (final alignment).

Table 2 shows maximum allowable Total Indicator Reading (T.I.R.) for parallel and angular misalignment.

Table 2

Maximum Allowable

Parallel and Angular Misalignment

Maximum Allowable Misalignment

	Group Parallel		Angular
		0.05 mm	0.03 degrees
	All		[0.125 mm/cm (.0005 in. /in.)
		(.002 in.)
			of coupling face diameter]

ALIGNMENT TROUBLESHOOTING

	Problem	Probable Cause	Remedy
	Cannot obtain horizontal (Side-to-Side)		Loosen motor support hold down bolts and
		Driver flange bolt bound	slide motor support and driver until hori-
	alignment, angular or parallel
			zontal alignment is achieved.

18	3910-11th IOM 5/08

PIPING

Guidelines for piping are given in the “Hydraulic Institute Standards,” available from:

Hydraulic Institute

9 Sylvan Way

Parsippany, NJ 07054

and in API RP 686, and must be reviewed prior to pump installation.

! WARNING

Never draw piping into place by forcing at the flanged connections of the pump. This may impose dangerous strains on the unit and cause misalignment between

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

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

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

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

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

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

5.All piping must be supported independently of, and line up naturally with, the pump flanges. Table 2 shows piping flange alignment criteria.

Table 4

Piping Flange Alignment

	Type	Criteria
	Axial	Flange gasket thickness ± 0.8 mm (.03 in.).
	Parallel	0.001 mm/mm (.001 in./in.) of flange diameter
		to a maximum of 0.8 mm (.03 in.).
	Concentric	Flange bolts should easily install by hand.

In no case should loads on the pump flanges exceed the limits stated in API Standard 610, 11th Edition (ISO 13709).

6.Bottom of casing should be supported by a solid foundation or casing feet should be used.

SUCTION PIPING

CAUTION

NPSHA must always exceed NPSHR as shown on Goulds performance curves received with order. (Reference Hydraulic Institute for NPSH and pipe friction values needed to evaluate suction piping).

Properly designed and installed suction piping is a necessity for	3
trouble-free pump operation. Suction piping should be flushed
BEFORE connection to the pump.

1.Use of elbows close to the pump suction flange should be avoided. There should be a minimum of two (2) pipe diameters of straight pipe [five (5) pipe diameters is preferred] between the elbow and suction inlet. Where used, elbows should be long radius.

2.Use suction pipe one (1) or two (2) sizes larger than the pump suction, with a reducer at the suction flange. Suction piping should never be of smaller diameter than the pump suction.

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

CAUTION

Pump must never be throttled on suction side.

4.A suction screen should be installed prior to initial start-up and when suction system has been opened for work. The screen should be of the cone type with a net area equal to at least three (3) times the cross sectional area of the suction pipe. The mesh of the screen should be sized to prevent particles larger than 1.6 mm (1/16 in.) from entering the pump and should be installed in a spool piece to allow removal for cleaning. The screen should remain in the system until periodic inspection shows system is clean.

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

Suction Lift Conditions

1.Suction pipe must be free from air pockets.

2.Suction piping must slope upwards to pump.

3.All joints must be air tight.

4.A means of priming the pump must be provided.

3910-11th IOM 5/08

19

Suction Head/Flooded Suction Conditions

1.An isolation valve should be installed in the suction line at least two (2) pipe diameters from the pump suction to permit closing of the line for pump inspection and maintenance.

2.Keep suction pipe free from air pockets.

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

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

5.The size of entrance from supply should be one (1) or two (2) sizes larger than the suction pipe.

6.The suction pipe must be adequately submerged below the liquid surface to prevent vortices and air entrainment at the supply.

DISCHARGE PIPING

Properly designed and installed discharge piping is a necessity for trouble-free pump operation. Discharge piping should be flushed BEFORE connection to the pump.

1.Isolation and check valves should be installed in discharge line. Locate the check valve between isolation valve and pump; this will permit inspection of the check valve. The isolation valve is required for priming, regulation of flow, and for inspection and maintenance of pump. The check valve prevents pump or seal damage due to reverse flow through the pump when the driver is turned off.

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

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

BYPASS PIPING

Systems that require operation at reduced flows for prolonged periods should be provided with a bypass line connected from the discharge side (before any valves) to the source of suction.

A minimum flow orifice can be sized and installed in bypass line to preclude bypassing excessive flows. Consult nearest sales office or factory for assistance in sizing orifice.

An automatic recirculation control valve and/or solenoid operated valve should be considered if a constant bypass (i.e. orifice) is not possible.

AUXILIARY PIPING

The mechanical seal must have an appropriate seal flush system. Failure to do so will result in excess heat generation and seal failure.

Cooling systems such as those for bearing lubrication, mechanical seal systems, etc., where provided, must be operating properly to prevent excess heat generation, sparks, and premature failure.

Sealing systems that are not self purging or self venting, such as plan 23, require manual venting prior to operation. Failure to do so will result in excess heat generation and seal failure.

Auxiliary piping may be required for seal chamber cover cooling, mechanical seal flush or other special features supplied with the pump. Consult pump data sheet for specific auxiliary piping recommendations.

If seal chamber cover cooling is required, follow guidelines listed below.

1.Flows of 4 l/min. (1 GPM) will generally satisfy cooling requirements.

2.Cooling water pressure should not exceed 7.0 kg/cm2 (100 psig).

FINAL PIPING CHECK

After connecting the piping to pump:

The Preventive Maintenance section must be adhered to in order to keep the applicable ATEX classification of the equipment. Failure to follow these procedures will void the ATEX classification for the equipment.

Check alignment, per alignment criteria outlined previously, to determine if pipe strain has affected alignment. If pipe strain exists, correct piping.

20	3910-11th IOM 5/08

OPERATION

PREPARATION FOR START-UP . . . . . . . . . . . . . . . . . . . . 21
Checking Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Coupling Pump and Driver . . . . . . . . . . . . . . . . . . . . . . . . 21
Lubricating Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Shaft Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Priming Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
Start-up Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . .	23
STARTING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . 24
Operational Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Operating at Reduced Capacity . . . . . . . . . . . . . . . . . . . . .	25
Operating Under Freezing Conditions . . . . . . . . . . . . . . . . . .	25	4
SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FINAL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . .	25

PREPARATION FOR START-UP

When installation in a potentially explosive environment, ensure that the motor is properly certified.

CHECKING ROTATION

CAUTION

Serious damage may result if pump is run in the

wrong rotation.

1. Lock out power to driver.

! WARNING

Lock out driver power to prevent accidental start-up

and physical injury.

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

! WARNING

Do NOT jog a coupled pump.

NOTE: Pump is shipped with coupling spacer

removed.

3.Unlock driver power.

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

5. Lock out power to driver.

COUPLING PUMP AND DRIVER

! WARNING

Lock out driver power to prevent accidental rotation

and physical injury.

The coupling used in an ATEX classified environment must be properly certified.

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

The coupling guard used in an ATEX classified environment must be constructed from a nonsparking material.

2.Install coupling guard. Refer to coupling guard installation instructions in Appendix I.

! WARNING

Never operate a pump without coupling guard properly installed. Refer to Appendix I for coupling guard

installation instructions. Personal injury will occur if pump is run without coupling guard.

3910-11th IOM 5/08

21

LUBRICATING BEARINGS

Bearings musts be lubricated properly in order to prevent excess heat generation, sparks and premature failure.

Grease Lubrication

Greased lubricated ball bearings are standard on the Model 3910 units.

The bearings are greased at the factory.

See Preventive Maintenance section for lubrication recommendations.

Pure Oil Mist Lubrication

Pure oil mist is an optional feature for the Model 3910. Follow oil mist generator manufacturer’s instructions. The inlet and outlet connections are located on the side of the bearing frame.

See Preventive Maintenance section for lubrication recommendations and connection locations.

! WARNING

Operation of the unit without proper lubrication will

cause bearing failure and pump seizure.

SHAFT SEALING WITH

MECHANICAL SEAL

The mechanical seal used in an ATEX classified environment must be properly certified.

Pumps may be shipped with or without mechanical seal installed. Cartridge type mechanical seals are commonly used for this model. Cartridge seals are preset at the seal manufacturer’s facility and require no field settings.

Cartridge seals installed by the user require disengagement of the holding clips prior to operation, allowing the seal to slide into place. If the seal has been installed in the pump by Goulds, these clips have already been disengaged. For other types of mechanical seals, refer to the seal manufacturer’s instructions for installation and setting.

Connection of Sealing Liquid

The mechanical seal must have an appropriate seal flush system. Failure to do so will result in excess heat generation and seal failure.

Cooling systems such as those for bearing lubrication, mechanical seal systems, etc., where provided, must be operating properly to prevent excess heat generation, sparks, and premature failure.

Sealing systems that are not self purging or self venting, such as plan 23, require manual venting prior to operation. Failure to do so will result in excess heat generation and seal failure.

For satisfactory operation, there must be a liquid film between seal faces to lubricate them. Refer to seal manufacturer’s drawing for location of taps. Some methods which may be used to flush/cool the seal are:

•Product Flushing - In this arrangement, the pumpage is piped from the casing (and cooled in an external heat exchanger when required) then injected into seal chamber.

•External Flush - A clean, cool compatible liquid is injected from an outside source directly into seal

chamber. Flushing liquid must be at a pressure 0.35-1.05 kg/cm2 (5-15 psi) greater than seal chamber pressure. Injection rate should be 2-8 l/min. (12-2 GPM).

•Other methods may be used which make use of multiple gland connections and/or seal chamber connections. Refer to documentation supplied with the pump, mechanical seal reference drawing, and piping diagrams.

PRIMING PUMP

Pumpsoperation.must be fully primed at all times during

Never start the pump until it has been properly primed. Several different methods of priming can be used, depending upon type of installation and service involved.

Suction Supply Above Pump

1. Slowly open the suction valve (Fig. 8).

Fig. 8

2.Open air vents on the suction and discharge piping, casing, seal chamber, and seal piping, if provided, until all air is vented and only liquid flows out.

3.Close the vents.

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Suction Supply Below Pump

A foot valve and outside source of liquid may be used to prime the pump. Outside source of liquid can come from a priming pump pressurized discharge line, or other supply (Fig. 9 and 10).

Fig. 9

Fig. 10

1.Close discharge valve and open air vents in suction and discharge piping, casing, seal chamber, and seal piping, if provided.

2.Open valve in outside supply line until all air is vented and only liquid flows out.

! WARNING

When handling hazardous and/or toxic fluids, proper personal protective equipment is required. If pump is being drained, precautions must be taken to prevent physical injury. Pumpage must be handled and disposed of in conformance with applicable regulations.

3. Close the vents and then the outside supply line.

Other Methods of Priming Pump

• Priming by ejector.

• Priming by automatic priming pump.

4

START-UP PRECAUTIONS

CAUTION

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

CAUTION

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

1.All equipment and personal safety related devices and controls must be installed and operating properly.

2.To prevent premature pump failure at initial start-up due to dirt or debris in the pipe system, ensure the pump can be run continuously at full speed and flow for 2 to 3 hours.

3.Variable speed drivers should be brought to rated speed as quickly as possible.

4.Variable speed drivers should not be adjusted or checked for speed governor or overspeed trip settings while coupled to the pump at initial start-up. If settings have not been verified, uncouple the unit and refer to driver manufacturer’s instructions for assistance.

3910-11th IOM 5/08

23

5.Running a new or rebuilt pump at slow speeds may not provide enough flow to adequately flush and cool the wear ring and seal chamber cover bushing.

6.Pumpage temperatures in excess of 93° C (200° F) will require warm-up of pump prior to operation. Circulate a small amount of pumpage through the pump until the

casing temperature is within 56° C (100° F) of the pumpage temperature and evenly heated.

NOTE: Warm-up rate should not exceed 1.4° C

(2.5° F) per minute.

STARTING PUMP

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

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

3.Start driver.

CAUTION

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

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

!CAUTION

Observe pump for vibration levels, bearing temperature, and excessive noise. If normal levels are exceeded, shut down and resolve.

OPERATION

GENERAL CONSIDERATIONS

CAUTION

Always vary capacity with regulating valve in the discharge

line. NEVER throttle flow from the suction side.

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

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

OPERATIONAL CHECKS

CAUTION

The following are minimum operational checks for the pump only. Consult driver and auxiliary equipment manufacturers’ literature for additional information.

1.On grease lubricated units, remove grease relief plugs to verify that grease is present. Replace plugs.

2.On pure oil mist lubricated units, remove viewing port plugs and assure oil mist is flowing properly. Replace plugs.

3.Check bearing temperatures using a pyrometer or other accurate temperature measuring device. Monitor bearing temperature frequently during initial operation to determine if a bearing problem exists as well as to establish normal bearing operating temperature.

4.On units equipped with auxiliary piping, assure that proper flows have been established and that equipment is operating properly.

5.Establish baseline vibration readings to determine normal running conditions. If it is determined that the unit is running rough, consult factory.

6.Monitor all gauges to ensure pump is running at or near rating and that suction screen (when used) is not clogged.

OPERATING AT REDUCED CAPACITY

! WARNING

Do NOT operate pump below minimum rated flows or with 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.

24	3910-11th IOM 5/08