Goulds Pumps AF-LM-LMR User Manual

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Pump Safety Tips

Safety Apparel:

• Insulated work gloves when handling hot bearings

or using a bearing heater

• Heavy work gloves when handling parts with sharp

edges, especially impellers

• Safety glasses (with side shields) for eye protection,

especially in machine shop areas

• Steel-toed shoes for foot protection when handling

parts, heavy tools, etc.

• Other personal protective equipment to protect

against hazard/toxic fluids

Coupling Guards:

• Never operate a pump without a V-belt guard

properly installed

Flanged Connections:

• Never force piping to make a connection with a

pump

• Use only fasteners of the proper size and material

• Ensure there are no missing fasteners

• Beware of corroded or loose fasteners

Operation:

• Do not operate below minimum rated flow, or with

discharge valves closed

• Do not open vent or drain valves, or remove plugs

while system is pressurized

Maintenance Safety:

• Always lockout power

• Ensure pump is isolated from system and pressure

is relieved before disassembling pump, removing plugs, or disconnecting piping

• Use proper lifting and supporting equipment to

prevent serious injury

• Observe proper decontamination procedures

• Know and follow company safety regulations

• Never apply heat to remove impeller

• Observe all cautions and warnings highlighted in

pump instruction manual

Safety Definitions

These pumps have been designed for saf e and reliable operation when properly used and maintained in accordance with instructions contained in this manual. A pum p is a pressure containing device with rotating parts that can be hazardous. Operators and maintenance personnel must realize this and follow safety meas ures. Goulds pumps shall not be liable for physical injury, damage or delays caused by a failure to observe the instructions in this manual. The following symbols are used to denote special attention:

Electrical Hazard. Particular care must be taken when electrical power source to the equipment is energized.

Warning. O perating procedure, prac tice etc which, if not c orrect ly followed, could result in personal injury or loss of life

Caution. Operating procedure, practice etc which if not followed could result in dam age or destruction of equipment

ATEX. If equipment is to be installed in a potentially explosive atmosphere and these procedures are not followed, personal injury or equipment damage from an explosion may

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FOREWORD

When pumping unit is installed in a potentially explosive atmosphere, the instructions after the Ex symbol

please contact a Goulds representative before proceeding.

This manual provides instructions for the Installation, operation, and maintenance of the Goulds Axial Flow (AF) pump model. This manual covers the standard product. For special options, supplemental instructions are supplied. This manual must be read and understood before installation and start-up.

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

Goulds shall not be liable for physical injury, damage or delays caused by a failure to observe the instructions for Installation, Operation, and Maintenance contained i n thi s manual.

Warranty is valid only when genuine Goulds 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 Goulds Pumps, Inc.

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

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

THIS MANUAL EXPLAINS

 Proper Installation  Start-up Procedures  Operation Procedures  Routine Maintenance  Pump Overhaul  Trouble shooting  Order Spare or Repair Parts

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,

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General Precautions

potentially explosive environment.

Never apply heat to remove impeller. It may explode due to trapped liquid

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

Never operate pump without coupling guard correctly installed

Never operate pump beyond the rated conditions to which the pump was sold

Never start pump without proper prime, or proper liquid level in self priming pumps

Never run pump below recommended minimum flow or when dry

Always lock out power to the driver before performing pump maintenance

Never operate pump without safety devices installed

Never operate pump with discharge valve closed

Never operate pump with suction valve closed

Do not change conditions of service without approval of an authorized Goulds representative

Explosion Prevention

In order to reduce the possibility of accidental explosions in atmospheres containing explosive gasses and/or dust, the instructions under the ATEX symbol must be closely followed. ATEX certification is a directive enforced in Europe for non-electrical and electrical equipment installed in Europe. ATEX requirements are not restricted to Europe, and are useful guidelines for equipment installed in any

Special ATEX considera ti ons

All installation and operation instructions in this manual must be strictly adhered to. In addition, care must be taken 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. maintining proper bearing lubrication

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

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ATEX Identification

Temperature in Celsius

For a pumping unit (pump, seal, coupling, motor and pump accessories) to be certified for use in an ATEX classified environment, the proper ATEX identification must be present. The ATEX tag will be secured to the pump or the baseplate on which it is mounted. A typical tag will look like this:

II 2 G/D X 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

X ------------ Temperature class, can be T1 to T6 (see following table)

Maximum Process Temperature to achieve desired T rating

T Rating per EN 1127-1 Maximum Surface

450 410

300 260 200 165 135 100 100 65

Maximum Process

The code classification marked on the equipment should be in accordance with the specified area where the

equipment will be installed. If it is not, please contact your ITT/Goulds representative before proceeding.

85 50

Intended Use

The ATEX conformance is only applicable when the pump unit is operated within its intended use. All instructions

within this manual must be followed at all times. Operating, installing or maintaining the pump unit in any way that is

not covered in this manual 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. If there is any question regarding the

intended use of the equipment please contact an ITT/Goulds representative before proceeding.

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SAFETY

GENERAL INFORMATION

INSTALLATION

OPERATION

PREVENTATIVE MAINTENANCE

DISASSEMBLY & RE-ASSEMBLY

Section

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SPARE PARTS

APPENDIX 1

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SAFETY

! ! !

DEFINITIONS ................................................................................................... 9

GENERAL PRECAUTIONS.............................................................................. 9

DEFINITIONS

Axial flow pumps are pressure-containing devices with rotating parts that can be hazardous. It has been designed for safe and reliable operation when properly used and maintained in accordance with instructions contained in this manual. It is not to be operated at speeds, working pressures, discharge pressures, or temperatures higher than, nor used with liquids other than stated in the original order acknowledgement, without written permission of ITT Industries, Gould’s Pumps, Inc. Operators and maintenance personnel must realize this and follow safety measures. ITT Industries, Gould’s Pumps, Inc. shall not be liable for physical injury, damage or delays caused by a failure to observe the instructions in this manual.

Throughout this manual, the words Warning, Caution, and Note are used to indicate procedures or situations which require special operator attention:

WARNING

Warning is used to indicate the presence of a hazard which can cause severe personal injury, death or substantial property damage if the warning is ignored.

CAUTION

Caution is used to indica te the presence of a hazard which will or can cause minor personal injury or property damage if the warning is ignored.

NOTE: Operating procedure, condition, etc. that is essential to observe.

EXAMPLES

WARNING

Pump shall never be operated without V-belt or coupling guard installed correctly.

CAUTION

Obstructions to flow or pipe fowling may cause cavitation and pump damage.

NOTE: Proper alignment is essential for long pump life.

GENERAL PRECAUTIONS

WARNING

Personal injury will result if procedures outli n ed in this manual are not followed.

• Never apply heat to remove the impeller. It may

explode due to trapped liquid.

• Never use heat to disassemble pump due to risk of

explosion from trapped liquid.

• Never operate pump without V-belt or coupling

guard correctly installed.

• Never operate pump beyond the rated conditions

to which the pump was sold.

• Never start pump without proper prime (sufficient

liquid in pump casing).

• Never run the pump < 75% or > 115% of the Best

Efficiency Point (B.E.P.), AF pumps are unstable in these regions.

• Always lock out power to the driver before

performing maintenance.

• Never operate pump without safety devices

installed.

• Never operate pump with suction valve closed.

• Never operate pump with discharge valve closed.

• Do not change conditions of service without

approval of an authorized Gould’s representative

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GENERAL INFORMATION

GENERAL .................................................................................................... 11

PUMP DESCRIPTION .................................................................................. 11

NAME PLATE INFORMATION .................................................................... 12

RECEIVING THE PUMP .............................................................................. 13

INSTALLATION AND OPERATION CHECKLIST ........................................ 13

GENERAL

This instruction manual is intended to assist those involved with the installation, operation and maintenance of Gould’s pumps. It is recommended that this manual be thoroughly reviewed prior to installing or performing any work on the pump or motor.

The design, material and workmanship incorporated into the construction of Gould’s pumps makes them capable of giving long, trouble-free service. The life and satisfactory service of any mechanical unit, however, are enhanced and extended by periodic inspection and careful maintenance. Keep this

instruction manual handy for reference. Further information can be obtained by contacting Gould’s Pumps, Ashland Operations, East Centre St., Ashland, PA 17921 or your local representative.

Gould’s Pumps will not be liable for any damages or delay caused by failure to comply with the provisions of this instruction manual. This pump is not to be operated at speeds, working pressures, discharge pressures, or temperatures, nor used on liquids other than stated in the original order acknowledgment without written permission of Gould’s Pumps.

PUMP DESCRIPTION

The AF pump generates flow by the thrust or lift action of the rotating axial vanes of the impeller. It provides high flow rates and low heads which are ideal for re-circulation, evaporator, and generator cooling systems. The AF utilizes an elbow to direct the flow through the suction and out the discharge end of the pump. The pump accommodates top or end suction configurations using either the LMR or LM bearing arrangement. The LMR is for top suction and the LM is for end suction. Arrangements are as follows:

Power Inboard Outboard End Bearing Bearing

LMR Spherical roller Spherical thrust/spacer/Spherical roller LM Spherical roller Spherical roller/spacer/Spherical thrust

Elbow – AF elbows are fabricated with 150# flat face suction and discharge flanges. They come with fabricated feet for mounting to a sub-base or without feet to be mounted directly in the piping. The elbows have a built in stuffing box and a rear flange for mounting the power end to the elbow. There are also adjusting lugs for aligning the shaft to the stuffing box.

Casing – The AF comes with a casing or spool piece to simplify impeller installation and alignment. The casing bolts to the elbow and shrouds the impeller. It has a gasket or o-ring seal between it and the elbow. Adjusting lugs on the elbow center the casing relative to the impeller.

Power End - The power end is made up of the bearing housing, bearings, locknuts, lock washers, labyrinth oil seals, shaft, shaft sleeve (w/packing), oil slinger, keys, shaft, and shaft washer.

Stuffing Box – The stuffing box is integral with the elbow and provides a mounting surface for a mechanical seal or cylindrical bore with flush ports and gland face for packing. The standard packed box includes (5) rings of packing and (2) lantern rings to seal the shaft area. (2) flush ports are provided for lubrication. The innermost flush port is used with process flow and the outermost port for water flush. A special alternate packing arrangement is available that includes a throat bushing and additional ring of packing near the gland (see the attached addendum). A gland is used for packing adjustment.

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Shaft Sleeve – If packing is specified, a replaceable wear sleeve is provided with the power end. The sleeve is keyed to prevent rotation. The stuffing box can also be modified to accept a mechanical seal if required.

Impeller - The impeller is cast with (4) fixed vanes at 0 or +5 degrees, CW or CCW rotation, and top or end suction. The impeller bore is stepped for easy assembly to the shaft. It is held in place with a key, shaft washer, and bolts. It has a cover plate and o-rings to prevent corrosion and allow for easy impeller replacement. The impeller is dynamically balanced (two plane) per ISO 1940 to a quality grade G-16.

Shaft – The shaft is cantilevered into the elbow to eliminate the need for internal bearings. It is sized for minimal deflection, high critical speed, and extreme corrosion resistance. The shafts are stepped for easy assembly with the impeller. The shaft comes with a replaceable sleeve when used with stuffing boxes.

Bearings - The inboard radial bearing absorbs shaft radial loads and aligns the pump shaft. It is a spherical roller bearing. The outboard thrust bearing absorbs impeller thrust loads and comes as either back-to-back angular contacts or a single taper roller bearing, depending on pump size. Lubrication is by flood oil or grease, depending on customer requirements.

Oil-Cooling (Optional ) – An oil-cooling coil is available on all sizes, it is installed in the bottom of the bearing housing and circulates water to cool the oil bath. Generally, it is used when process temperatures cause excessive heat build up in the bearing housing and/or bearings.

Configurations and Drives – The 42”, 1200mm, 54”, 60”, and 66”pumps are usually gear driven and come on a subbase as standard. They can also be pipe mounted with a drive shaft to a motor on a separate subbase.

NAMEPLATE INFORMATION

Every Gould’s pump has a nameplate that provides information about the pump, including hydraulic characteristics. The nameplate for the AF is located on the bearing housing. Note the format of the pump size: Discharge X Suction - Impeller Diameter in inches or

millimeters (Example 42” X 42”-42” or 1200mm X 1200mm-1200mm, see Fig. 1). When ordering spare parts you will need to identify pump model, size, serial number, and the item number of required parts. Information can be found in this manual.

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COMPLETE

INITIAL

DESCRIPTION

PAGE NO.

Manual read and understood

1~54

Level foundation

Level subbase

Check motor rotation ---CW _____ ---CCW _____

Component rough alignment complete

21~26

V-belt tension and alignment per drive mfgr.

21,22

Coupling alignment per cplg mfgr.

Piping installed and alignment rechecked

19, 20

Mech. seal adjusted per mfgr.

Mfgrs Mnl

Seal flush lines connected

Impeller alignment and clearance set ______ Inch/Side

Pump shaft-free turning

Bearing lubrication

30, 38

V-belt or coupling guards installed

9, 22,30

Motor electrical connections

Mfgrs Man’l

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) Gould’s normal packaging is via a skid. It is designed to protect the pump during shipping only. Upon receipt, store in a covered and dry location.

Long Term: (More than 6 months) Gould’s longterm packaging via crating. Preservative treatment of bearings and machined surfaces is required. Rotate the shaft several times every 3 months. Refer to drive manufacturer's instruction manual for their long-term storage procedures. Store in a covered dry location

Note: Long-term storage treatment can be purchased with initial p u mp order.

UNCRATING/DE-SKIDDING

Care should be taken when uncrating or de-skidding pumps. If shipment is not delivered in proper order, and in accordance with the bill of lading, note the damage or shortage on both the receipt and freight bill. Make any claims to the transportation company promptly. Instruction books and sheets are included in the shipment - DO NOT DISCARD.

LIFTING THE PUMP/SUB-BASE

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. Lift assembled unit by the lifting holes found in the sub-base. If the motor, sheaves, and guard are in place, be sure that the lifting cable or chain clears these components. If necessary remove the guard or use a spreader bar to prevent damage. In case the motor ships separate use the eyebolts or lifting lugs found on the motor to hoist it into place on the sub-base.

INSTALLATION AND OPERATION CHECKLIST

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Equipment that will operate in a potentially accordance with the following instructions.

All equipment being installed must be

maintenance purposes.

INSTALLATION

PREPARATION FOR INSTALLATION ........................................................ 15

LOCATION/FOUNDATION .......................................................................... 15

SUB-BASE LEVELING ................................................................................ 16

CONNECTION OF PIPI NG .......................................................................... 19

PIPE HUNG INSTALLATION ....................................................................... 21

DRIVE ALIGNMENT PROCEDURES .......................................................... 22

IMPELLER ALIGNMENT ............................................................................. 27

ROTATION CHECK ..................................................................................... 29

PREPARATION FOR INSTALLATION

AF units are usually shipped completely assembled. Check all bolts and nuts on the entire unit and make sure they are securely tightened. If necessary, install and adjust drive components per manufacturer’s recommendations

explosive environment must be installed in

properly grounded to prevent unexpected static electric discharge. If not, a static electric discharge may occur when the pump is drained and disassembled for

AF pump shall be located in a clean, dry area free from flooding. The area should provide adequate space for operation, maintenance, inspection and repair, considering complete disassembly and handling of equipment. The pump should have a supply of clean liquid for packing or mechanical seal lubrication. The pump should be positioned to provide the most efficient pipeline system.

The AF pumps covered by these instructions may be designed to hang in the piping system, furnished with spring loaded sub-base bolts, or have a sub-base designed to be anchor bolted and grouted to the foundation.

The foundation must be substantial enough to absorb any vibration and form a permanent, rigid support for the pumping unit to the degree that there shall not be any adverse movement or settling over a long period of time.

Foundations for anchor bolted and grouted sub-bases are typically concrete with anchor bolts cast in to secure the pump.

LOCATION/FOUNDATION

The most commonly used foundation bolts are the sleeve-type (Fig 2 and J type Fig. 3)

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SHIMS OR WEDGES

Both designs permit movement for final bolt adjustment. Anchor bolts should be located in the concrete by a template dimensioned from the pump installation drawing. The top of the sleeve-type bolt should be temporarily sealed with waste material to prevent concrete from entering during the concrete pouring operation. Foundation bolts are located according to the bolt hole dimensions shown on the installation drawing. Bolt size is based on hole size, they should be 1/8” to ¼” under the sub-base hole size. For information on spring mounted sub-bases, see the following section under spring mounted bases.

SUB-BASE LEVELING

GROUTED BASE

When the unit is received with the pump and driver mounted to the sub-base, it should be placed on the foundation and the coupling halves or V-belts disconnected (Fig. 4). The coupling should not be reconnected until all realignment operations have been completed. A recommended coupling alignment procedure is included in the following sections.

Fig. 4

Fig. 5

1. The sub-base should be supported on rectangular metal blocks or on metal wedges having a slight taper. There should be support blocks or wedges on both sides of each foundation bolt. A gap of about 3/4" to 1-1/2' should be allowed between the sub-base and the foundation for grouting (Fig. 5).

2. Adjust the metal supports or wedges until the shafts of the pump and driver and sub-base are level. Check the coupling faces, as well as the suction and discharge flanges of the pump, for horizontal and vertical position by means of a level. Check also for any internal rubbing in the pump. Correct, if necessary, by adjusting the supports or wedges under the sub-base as required. In most cases, factory alignment will be regained by shimming under the sub-base alone. Provisions must be made to support the discharge piping independently from the pump to prevent excessive loads and maintain pump-driver alignment.

3. The sub-base should be level to within .125 in. (3 mm) over the length of the base and .0875 in. (1.5 mm) over the width of the base. Bases anchored with conventional foundation bolts use shims on both sides of the anchor bolts to level the base. The bolts which secure the pump sub-base to the foundation should be 1/8” – 1/4” less in diameter than the holes in the sub-base (hole size is shown on the certified installation drawing).

4. Clean outside areas of sub-base that will contact grout. Do not use oil-based cleaners because grout will not bond to it. Refer to grout manufacturer's instructions.

5. Build a dam around foundation and thoroughly wet the foundation (Fig. 6).

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Fig. 10

SPRING POCKETS

Fig. 8

BOLT

BASEPLATE

GROU

DAM

GROUT

FOUNDATION

Fig. 6

BOLT

BASEPLATE

DAM

GROUT

FOUNDATION

Fig. 7

SPRING MOUNTED BASE

Fig. 8 shows a V-belt driven AF pump on a spring mounted sub-base. Sub-bases supported by spring pockets assure that the pump remains level, regardless of vertical movement due to thermal pipe expansion during operation.

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

7. Allow grout to set.

8. Fill remainder of sub-base with grout. Remove air as before (Fig. 7)

9. Allow grout to set at least 48 hours.

10. Tighten foundation bolts.

Fig. 8

The following is a brief description of the spring pocket components and their function (see Fig. 9). The adjusting screw is used to compress or relax the spring. Turning the screw causes the adjusting screw nut assembly to move vertically and change the amount of force the spring exerts against the spring retainer, which is fastened to the sub-base. The stop nut is to limit the vertical up motion of the sub-base in case part of the load is removed from the pump unit

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Fig. 9

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1/16”

FLANGE BOLTS

BLOCKS

Spring Size

Wire Size

Spring Rate

Adjusting Screw Size

Load Change per Full Turn

.812”

1140 #/in.

1-1/2”-6 UNC

190 #

.750”

760 #/in.

1-1/2”-6 UNC

127 #

.532”

560 #/in.

1-1/2”-6 UNC

93 #

1.00”

1000 #/in.

2”-4-1/2 UNC

222 #

.375”

133 #/in.

¾”-10 UNC

13 #

Table 1

when the system is cold. The jam nut keeps the stop nut from turning during normal operation when the subbase has been pushed down from the thermal expansion. The adjusting screw holder is a bearing surface for the end of the adjusting screw and serves to hold the end of the screw in a fixed location. The adjusting screw was lubricated at the factory but should be re-lubricated with heavy protective grease during the pump installation. The springs and other parts should be coated with an agent to protect the surface from corrosion, and a heavy lubricant should be applied to the adjusting screw holder pocket.

The following steps are used to set the springs and level the sub-base:

1. Place blocks under the sub-base, near each spring holder, and position the sub-base level on the blocks. A small gap (approx. 1/16" or 1.6 mm) should exist between the flange of the vertical pipe and the pump elbow with the gasket in place (Fig. 10).

allow the required horizontal motion without having the adjusting screw nut assembly hit the walls of the spring holder. Make sure there is sufficient clearance between the adjusting screw holder and the bottom of the sub-base for vertical thermal expansion, this clearance is usually shown on the pump installation drawing.

NOTE: Each spring carries a share of the unit load but generally do not carry equal loads. Each holder has a small "window” to check the spring coil spacing, which is an indication of the relative load on the spring. The ins tallation drawing may indicate the approximate number of turns required for each spring loca tion, especially if the unit uses more than (4) springs. If necessary refer to table 1 for spring rate information.

4. Turn the adjusting screws until the bottom of the sub-base just clears each block. Next adjust each screw evenly until the pump flange and gasket are less than 1/32” (0.8 mm) away from the pipe flange. Careful adjustment is necessary to keep the pump level and obtain better weight distribution on the springs. After the springs have been loaded and adjusted, the base should be off the support blocks and level.

5. Check the alignment of the impeller and the pump elbow. If necessary, correct the alignment by adjusting the springs or by using shims.

NOTE: If the flange gap is over 1/32” (0.8 mm), turn the adjusting screws a uniform amount to close the gap. For a gap of 1/32” (0.8 mm) or less, omit this step.

Fig. 10

2. Install several flange bolts to help maintain alignment of the flanges.

6. Tighten the vertical pipe flange bolts, recheck the alignment and connect the horizontal pipe flange to the elbow. The pump unit should be level and there should not be any rubbing of the impeller in the elbow when the shaft is turned by hand.

WARNING

Do not tighten bolts.

3. Position the adjusting screw holders, while the adjusting screw end is seated in the hole, in the direction of the horizontal thermal expansion. This will

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Never draw piping into place by

damage to the equipment.

7. Run each stop nut down to make light contact with the spring retainer. Lock in place by turning the jam nut down tight against the stop nut.

8. Inspect each spring holder to check the gap between the coils of the spring. There must be enough total gap to accommodate the downward thermal expansion of the system without having them compressed solid.

NOTE: Pumps with oil lubrication should be checked for oil level while thermal expansion is taking place. It may be necessary to add oil to the bearing housing to provide the proper oil level to the higher bearing. A line parallel with the subbase deck through the pr o p er oil level line will show the correct level at the highest end of the bearing housing. A hori zontal line back from that point will establish the proper level mark on the sight gauge.

The system should be operated at normal temperature before the adjusting screw holders are grouted in place. Some customers operate their units with the adjusting screw holders ungrouted. If it becomes necessary to remove a spring assembly from a spring pocket, for safety the following steps should be strictly adhered to:

1. Make sure the spring is relaxed. If the spring

cannot be relaxed with the adjusting screw, the safest method is to pry off the Plexiglas cover and cut the coils using a torch.

2. Remove the bolts or cap screws, which fasten

the spring retainer to the holder and lift out the entire assembly.

3. When the pump is connected to the system and a spring is removed, there should be support under the sub-base near the spring location until the spring has been replaced and adjusted. Distortion of the subbase will affect the pump alignment, and the weight of the components is more likely to cause distortion when the pump is connected to the rigid pipe system.

4. If a spring is replaced while the system is hot, the stop nut should not be set until the system is cold. The springs must be allowed to push the base back to its cold position. An optional grease filled spring pocket is shown in figure 11. The difference between the standard pocket and the grease filled pocket is the addition of a grease fitting and grease seal. Adjustment and setting of the grease filled pocket are identical.

Fig. 11

GENERAL

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

Guidelines for piping are given in the “Hydraulic Institutes Standards” available from: Hydraulic Institute, 30200 Detroit Road, Cleveland OH 441451967 and must be reviewed prior to pump installation.

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CONNECTION OF PIPI NG

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

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

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

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

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

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

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

SUCTION AND DISCHARGE P IPING

WARNING

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

1. Use of elbows close to the pump suction flange should be avoided. There should be a minimum of 2 pipe diameters of straight pipe between the elbow and suction inlet. Where used, elbows should be long radius.

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

3. To prevent suction cavitation, horizontal reducers should be eccentric with the sloping side down and concentric for vertical applications.

5. Pump must never be throttled on suction side.

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

Suction lift conditions

1. Suction pipe must be free from air pockets.

2. Suction piping must slope upwards to pump.

3. All joints must be airtight.

Suction head/Flooded suction conditions

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

2. Keep suction pipe free from air pockets.

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

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

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

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

Discharge piping

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

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

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

Final Piping Check

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

2. Check alignment, per the impeller alignment procedure outlined on pg. 28 to determine absence of pipe strain. If pipe strain exists, correct the piping.

20 AF (42-66) IOM

Page 21

Foundation

Pipe

Shaft

Level Sub-base

be Parallel

level .005”/ft

PIPE HUNG INSTALLATION

LOCATION OF UNIT

The pump should be located in a clean, dry area free from flooding. The area should provide adequate space for maintenance and repair, considering complete disassembly and handling of equipment. The unit should be positioned to provide the most efficient pipeline system.

PIPING

Short, direct suction and discharge pipelines having a minimum of elbows and fittings will result in the least amount of pipe friction. Excessive friction losses will result in insufficient capacity and cavitation. Future access to the pump impeller and shaft will require removal of a section of discharge pipe (spool piece).

NOTE: The horizontal pipe flange must be parallel with the pump flange before the bolts are tightened. If the flanges are not parallel, forcing them parallel by tightening the bolts may put excessive strain on the pump.

INSTALLATION OF PUMP IN PIPELINE

1. Connect the pump top flange to the vertical pipe and tighten flange bolts. Level pump within .005” (0.42 mm)/Meter.

2. Check the impeller clearance in the casing so that it is reasonably well centered using the criteria that the minimum gap at the vane.

3. O.D. is at least 50% of the maximum gap (see the impeller alignment worksheet, pg. 28 for instructions)

4. Connect the casing flange to the spool piece and tighten the flange bolts.

INSTALLATION OF THE DRIVER

Install the driver (motor and reduction gear on a separate sub-base) as indicated on the installation drawing for the pump. The universal joint drive shaft requires the gear and pump shafts be parallel within 1 degree but off-set as indicated on the drawing. The optimal universal joint life is obtained with off-set shaft angles of 1 to 3 degrees.

Level the driver base relative to the pump, in accordance with the proceeding paragraph using leveling wedges adjacent to the anchor bolts. Partially tighten the anchor bolt nuts and check the shaft alignment between the motor and reduction gear. If the alignment is reasonably satisfactory, grout the base in place.

After the grout has hardened, tighten the anchor bolt nuts. Check and correct the motor shaft alignment. We recommend the actual shaft misalignment for the flexible couplings be considerably less than the maximum allowed by the coupling manufacturer for long coupling life and reduced vibration levels.

CONNECTION TO PUMP DRI VER

The pipe hung pump is connected to the driver via a drive shaft and universal joints at each end. Follow the drive shaft installation instructions and the angle limits per the pump installation drawing. An extendable guard is provided for the drive shaft and should be used any time the pump driver is rotating.

AF (42-66) IOM 21

Motor

Extendable Guard

Reduction Gear

Flanges must

Drive

Shaft Offset +/- 1 to 3 deg.

Vertical

Spool Piece

Flanges must

Pump must be

Horizontal Pipe

Fig. 11A

Page 22

injury.

Fig. 12

DRIVE ALIGNMENT PROCEDURES

Alignment procedures must be followed to prevent unintended contact of rotating parts.

Follow coupling manufacturer’s installation and operation procedures.

WARNING

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

Lock out driver power to prevent electric shock, accidental start-up and physical

The AF pump comes with two drive variations, V-belt and gear driven. Accurate alignment of both systems is essential to long pump life and reduced pump problems.

The points at which alignment are checked and adjusted are:

• Initial Alignment is done prior to operation when the pump and the driver are at ambient temperature.

• Final Ali g n ment is done after operation when the pump and driver are at operating temperature.

Alignment is achieved by adding or removing shims from under the feet of the driver and gearbox and shifting equipment horizontally by adjusting bolts as needed.

NOTE: Proper alignment is the responsibility of the installer and user of the unit.

Trouble free operation can be accomplished by following these procedures.

Initial Alignment (Cold Alignment)

• Before Grouting Sub-base - To ensure alignment can be attained. After Grouting Sub-base - To ensure no changes have occurred during the mounting process.

• After Spring Setting – To ensure no changes have occurred during the leveling process.

After Connecting Piping - To ensure pipe strains have not altered alignment. If changes have occurred, alter piping to remove pipe strains on pump flanges.

• Final Ali g n ment (Hot Alignment)

• After First Run - To obtain correct alignment

when both pump and driver are at operating

22 AF (42-66) IOM

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.

V-BELT DRIVE (SHEAVES)

Well designed and properly installed V-belt drives are capable of running for years. AF pumps come in several different belt drive configurations i.e. side by side, overhead, underslung or “Z” mount. Installation and alignment procedures are similar for all configurations. Remove the guard or guards by referring to the assembly/disassembly instructions. There are a few items that should be checked during installation and alignment. Sheave Alignment - Alignment must be maintained for full power transmission, minimum vibration, and long drive life. A dial indicator can be used to check runout on the periphery and face of each sheave. A straight edge can be used to check parallel and angular alignment of the pump and drive sheaves, see Fig. 12.

Belt Installation - When installing new belts, shorten center distance between sheaves so that belts can be placed on the sheave without the use of force. Never 'roll' or "Pry" the belts into place, as this could damage the belt cords.

Page 23

1. Check Belt Fit - Regardless of the belt section used, the belt should never be allowed to bottom in the groove. This will cause the belts to lose their wedging action and slippage can occur. Sheaves or belts that permit such a condition to occur should be changed.

2. Maintain Proper Belt Tension - Proper tension is essential for long belt life. Improper tension could cause belt fatigue and/or hot bearings.

3. Impeller Alignment after Belt Tensioning – If the impeller was aligned prior to belt tensioning a check should be made to determine that it is still centered. An off center impeller may rub and cause unnecessary pump damage. Belt Tension will usually cause impeller misalignment opposite the motor. Be sure to align or re-align in accordance with the Impeller Alignment section page 26.

The general method of tensioning belts is given below, and should satisfy most drive requirements. General Method: STEP 1. Reduce the center distance so that the belts may be placed over the sheaves and in the grooves without forcing them over the sides of the grooves. Arrange the belts so that both belt spans have a proximately the same sag between the sheaves. Apply tension to the belts by increasing the center distance until the belts are snug, see Fig. 13.

Fig. 13

WARNING

Do not operate the pump without the proper drive guard in place. Failure to observe this warning could result in perso n al injury to operating personnel

STEP 2. Operate the drive a few minutes to seat the belts in the sheave grooves. Observe the operation of the drive under its highest load condition (usually starting). A Slight bowing of the slack side of the drive indicates proper tension. If the slack side remains taut during the peak load, the drive is too tight. Excessive bowing or slippage indicates insufficient tension. If the belts squeal as the motor begins operation or at some subsequent peak load, they are

not tight enough to deliver the torque demanded by the drive machine. The drive should be stopped and the belts tightened.

STEP 3. Check the tension on a new drive frequently during the first day by observing the slack side span. After a few days of operation the belts will seat themselves in the sheave grooves and it may become necessary to readjust so that the drive again shows a slight bow in the slack side. Other methods of determining proper belt tension can be obtained from the drive manufacturer.

5. Use Belt Guards - Belt guards protect personnel from danger and the drive from contamination. Inspect periodically to assure that belts do not rub against guard.

6. Keep Belts Clean - Dirt and grease reduce belt life. An occasional wiping with a dry cloth to remove any build-up of a foreign material can extend the life of the belt. Should oil or grease splatter onto the belts, clean with soap and water.

Belt dressing affects performance only temporarily and is never recommended. Maintaining a clean drive is a better practice. If any questions arise pertaining to the drive limitations, consult the manufacturer.

GEAR DRIVE (COUPLINGS)

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

Remove the guard or guards by referring to the assembly/disassembly instructions. Disconnect motor/gearbox and the pump/gearbox coupling halves before proceeding with the alignment. First, align the pump/gearbox coupling then the motor/gearbox coupling. Check both coupling connections for parallel and angular alignment by either the Dial Indicator or Straight-Edge Method outlined below. Good alignment is achieved when the dial indicator readings, for both parallel and angular misalignment, are .003" (.076mm) Total Indicated Reading (T.I.R.) or less when the pump and driver are at operating temperature (Final Alignment). Fig. 14 describes what to look for.

AF (42-66) IOM 23

Page 24

Fig. 14

1. Mount two dial indicators off one half of the coupling (X) so they contact the other coupling half (Y) (Fig. 15).

Fig. 15

2. Check setting of indicators by rotating coupling half (X) to ensure indicators stay in contact with coupling half (Y) but do not bottom out. Adjust indicators accordingly.

MEASUREMENT

3. To ensure accuracy of indicator readings, always rotate both coupling halves together so indicators contact the same point on coupling half (Y). This will eliminate any measurement problems due to runout on coupling half (Y).

4. Take indicator measurements with hold-down bolts tightened. Loosen hold down bolts prior to making alignment corrections.

5. Take care not to damage indicators when moving driver during alignment corrections.

Keep this instruction manual handy for reference. Further information can be obtained by contacting Goulds Pumps, 240 Fall St., Seneca Falls, New York 13148 or your local representative.

ALIGNMENT PROCEDURE On gear driven AF pumps angular and parallel

misalignment are corrected in the vertical direction by means of shims under the motor or gearbox mounting feet, and in the horizontal direction by adjusting bolts that slide the motor or gearbox in the proper direction.

After each adjustment, it is necessary to recheck the alignment of the coupling halves. Adjustment in one direction may disturb adjustments already made in another direction. It should not be necessary to adjust the pump in any way.

ANGULAR ALIGNMENT

Couplings are in angular alignment when indicator “A“ (Angular Indicator), Fig 15, does not vary by more than .003” (.076mm) as measured at four points on the coupling periphery 90° apart at operating temperature. Outlined below are two acceptable methods to achieve the desired alignment.

METHOD 1 - Dial Indicator Method

For steps 1 through 5 refer to Fig. 16 on the following page.

1. Zero indicator “A” at position 1 of coupling half (Y). Mark this position on both flanges.

2. Rotate both flanges 180° to position 3. Observe needle and record reading.

3. Negative Reading - The coupling halves are further apart at position 3 than position 1.

Positive Reading - The coupling halves are closer at position 3 than position 1.

24 AF (42-66) IOM

Page 25

Directions for viewing coupling

View from front end of pump

Fig. 16

4. Correct any misalignment by shimming the under the motor or gearbox feet to attain the proper alignment.

When using positions 2 and 4 in steps 1-3, correct any misalignment by sliding the motor back and forth to attain the proper alignment.

5. Repeat steps 1-4 substituting position 2 for position 1 and position 4 for position 3. Use the same marks made on the coupling from position 1 and be sure to turn the coupling halves together.

METHOD 2 - Feeler Gauge Method For the following steps refer to Fig. 16.

1. Insert a feeler gauge at position 1 at the periphery of the couplings. Mark this position on both flanges.

2. Record the largest gauge size that fits snugly between the two flanges.

3. Rotate both flanges to position 3 - 180°.

4. Insert a feeler gauge at the periphery of the couplings at position 3

5. Record the largest gauge size that fits snugly between the two flanges.

6. Calculate the difference between the readings at positions 1 and 3. The difference should not be greater than .003" (.076mm).

7. Correct any misalignment by shimming under the motor or gearbox feet to attain the proper alignment.

When using positions 2 and 4 in steps 1 - 6, correct any misalignment by sliding the motor or gearbox back and forth to attain the proper alignment.

8. Repeat steps 1-6 substituting positions 2 and 4 for position 1 and 3 respectively. Use the same marks made on the coupling from position 1 and be sure to turn the coupling halves together.

Parallel Alignment

The unit is in parallel alignment when indicator “P” (Parallel Indicator) does not vary by more than .003” (.076mm) as measured at four points on the coupling periphery 90' apart at operating temperature. There are two methods outlined below that are acceptable to achieve the desired alignment.

NOTE: Equal amounts of shims must be added to or removed from eac h d river foot. Otherwise the vertical angular alignment will be affected.

METHOD I - Dial Indicator Method

For the following steps, refer to Fig. 16.

1. Zero the indicator “P” at position 1 of coupling half (Y). Mark this position on both flanges.

2. Rotate both flanges 180° to position 3. Observe needle and record reading.

3. Negative Reading - Coupling half (Y) is shifted toward position 1.

If the value is greater than .003” (.076mm), correct the misalignment by evenly (at equal amounts on both sides) shimming the motor higher. When using positions 2 and 4 in steps 1 - 2, correct any misalignment by sliding the motor evenly toward position 2.

Positive Reading - Coupling half (Y) is shifted toward position 3.

If the value is greater than .003" (.076mm), correct the misalignment by evenly (at equal amounts on both sides) shimming the motor or gearbox lower. When using positions 2 and 4 in steps 1 - 2, correct any misalignment by sliding the motor or gearbox evenly toward position 4.

4. Repeat steps 1-3 until indicator “P” reads .003" (.076mm) or less.

AF (42-66) IOM 25

Page 26

5. Once the ideal alignment is reached, repeat steps 1-4 substituting position 2 for position 1 and position 4 for position 3.

METHOD 2 - Straight-Edge Method

For the following steps refer to Fig. 16.

1. Place a straight edge across the two coupling flanges at position 1 and mark the spot on both flanges.

2. Adjust the motor or gearbox so that the straightedge rests evenly on both flanges (within .003" .076mm).

3. Rotate both flanges 90° to positions 2 and repeat steps one and two.

4. The unit will be in parallel alignment when the straight edge rests evenly (within .003” .076mm) on the coupling periphery at both positions along the periphery.

NOTE: Care must be taken to h ave the straight edge parallel to the axis of the shafts

Complete Alignment

A unit is in complete alignment when both indicators “A” (angular) and “P” (parallel) do not vary by more than .003” (.076 mm) as measured at four points 90° apart.

Vertical Correction (Top-to-Bottom)

1. Zero indicators “A” and “P” at top dead center (12 o'clock) of coupling half (Y).

2. Rotate indicator to bottom dead center (6 o'clock). Observe the needles and record the readings.

3. Make corrections as outlined previously.

Horizontal Correction (Side-to-Side)

1. Zero indicators “A” and “P” on the left side of coupling half (Y), 90° from top dead center (9 o'clock).

2. Rotate indicators through, top dead center to the right side, 180° from the start (3 o'clock), Observe the needle, measure and record the reading.

3. Make corrections as outlined previously.

4. Recheck both vertical and horizontal readings to ensure adjustment of one did not disturb the other. Correct as necessary.

Factors that may disturb alignment

The unit should be checked periodically for alignment. If the unit does not stay in line after being properly installed, the following are possible causes:

1. Settling or spring of the foundation.

2. Wear of bearings.

3. Pipe strains distorting or shifting the machine.

4. Shifting of the sub-base due to heat created from an adjacent heat source.

5. Shifting of the building structure due to variable loading or other causes.

6. Loose nuts or bolts on the pump or driver assembly.

NOTE: With experience, the installer will understand the interaction between angular and parallel and will make corrections appropriately.

26 AF (42-66) IOM

Page 27

Improper impeller adjustment could cause

generation.

The impeller clearance setting procedure

heat generation and equipment damage.

IMPELLER ALIGNMENT

GENERAL

contact between the rotating and stationary parts, resulting in a spark and heat

must be followed. Improperly setting the clearance or not following any of the proper procedures can result in sparks, unexpected

The AF impeller has been aligned at the factory but should be checked prior to pump operation. The impeller requires several thousandths of and inch of clearance to prevent rubbing due to the action of hydraulic forces when the pump is operating. Many corrosion-resistant alloys will gall and build up if rubbing occurs, therefore, pumps using these alloys need to be free from any rubbing.

Turn the shaft by hand, if the impeller rubs the inside of the casing it must be realigned. The following steps are used to align the impeller.

Note: Impeller rubbing is often caused by pipe strain or belt tension. Pipe strain must be eliminated prior to impeller alignment. The impeller should aligned after proper belt tensioning.

Clearance measurement - The alignment worksheet on page 27 is used to align the impeller of the AF pump. The measurement procedure is as follows:

Make sure the cap screws fastening the casing to the elbow are tight, so an accurate measurement of the impeller clearances can be made prior to adjustment.

Mark each blade 1, 2, 3 and 4 and then align the impeller blades as shown on the impeller alignment worksheet (approx. 2, 4, 8, and 10 o’clock)

Rotate the shaft and measure the gap between each blade and the casing at all four clock positions indicated on the worksheet. The value of interest is the largest value of feeler gage thickness that will slide easily the whole length of the vane tip.

Add the measurements for all positions together and divide by the number of measurements. This will give the average measurement.

Divide the average measurement by 2. This will give the minimum clearance.

If any blade has a clearance in any position smaller than the calculated minimum clearance the prop is not sufficiently centered and should be adjusted.

Impeller Alignment

1. Loosen the bolts that attach the casing to the elbow.

2. Use the adjusting bolts attached to the elbow to adjust the impeller clearance. The adjusting bolts are used to raise and lower the casing and shift the casing left to right relative to the impeller.

3. Move the casing relative to the impeller until the impeller is centered. At this point it is recommended that the Impeller Alignment Worksheet (on the following page) be filled out and filed with the pump maintenance records for future reference.

4. Tighten the bolts between the casing and the elbow and re-check the clearance to be sure the adjustments have centered the impeller. If the impeller is centered the casing may be taper pinned to the elbow to maintain alignment.

AF (42-66) IOM 27

Page 28

(1.16 mm )

(0.58 mm )

28 AF (42-66) IOM

Page 29

When installing in a potentially explosive properly certified.

ROTATION CHECK

Before the V-belts or couplings are installed, the motor should be wired and the direction of rotation checked. A rotation arrow is located on the bearing housing (134C).

Serious damage could occur if the pump is run the wrong direction.

environment, ensure that the motor is

AF (42-66) IOM 29

Page 30

THIS PAGE

INTENTIONALLY

LEFT BLANK

30 AF (42-66) IOM

Page 31

When installing in a potentially explosive properly certified.

The coupling guard used in an ATEX from a non-sparking material.

OPERATION

PREPARATION FOR OPERATION ............................................................. 31

STARTING THE PUMP ............................................................................... 35

OPERATION ................................................................................................ 36

SHUTDOWN ................................................................................................ 37

FINAL ALIGNMENT .................................................................................... 38

PREPARATION FOR OPERATION

CHECKING ROTATIO N

environment, ensure that the motor is

Damage occurs from:

1. Increased vibration levels-affects bearings, stuffing box or seal chamber and mechanical seal

2. Increased radial loads Stresses on shaft and bearings

3. Heat build up-Vaporization causing rotating parts to score or seize

4. Cavitation-Damage to internal surfaces of pump

CAUTION

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

WARNING

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

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

A check must be made to be sure motor rotation coincides with the pump rotation direction. Depending on your pump arrangement (V-belt or gear-drive) use one of the following methods to check motor rotation.

Direct Connect

1. Lock out power to the driver.

2. Remove the pump coupling guard.

3. Make sure the coupling halves are securely fastened to shafts.

4. Unlock driver power.

5. Make sure everyone is clear. Jog the driver just long enough to determine direction of rotation of the output shaft of the gearbox. Rotation must correspond to an arrow on bearing housing.

6. Lock out power to driver.

7. Replace the pump coupling guard.

classified environment must be constructed

V-BELT

1. Lock out power to the driver.

2. Remove the V-belt guard.

3. Make sure the sheaves are securely fastened to shafts.

AF (42-66) IOM 31

Page 32

Bearings must be lubricated properly in sparks and premature failure.

AXIAL FLOW PUMP

APPROX. OIL VOLUME

Pump Size

Quarts

Liters

42” / 1200mm / 54”

70.5

60” / 66”

Table 2

4. Unlock driver power.

5. Make sure everyone is clear. Jog the driver just long enough to determine direction of rotation. Rotation must correspond to an arrow on bearing housing.

6. Lock out power to driver.

7. Replace the V-belt guard.

CHECK IMPELLER CLEA RANCE

Check impeller clearance before installing the pump. The impeller mus t not rub when the shaft is turned by hand, therefore it is recommended that the Impeller Alignment Worksheet (shown on pg. 27) is filled out and filed with the pump m aintenance records f or future reference.

CHECK FOR FREE TURNING

Before the pump is started, rotate the pump by hand to be sure it turns freely, and does not rub or bind.

BEARINGS

The bearing assembly uses spherical roller bearings to carry the radial load, and a spherical roller thrust bearing to carry the axial thrust load from the impeller. The bearing housing has a horizontal split along the centerline for ease of assembly and inspection.

Approximate values only. Always fill using sight glass to verify level. Oil level should be at t he center of the sight glass. See comments in this sec tion.

LUBRICATION

The bearing uses oil bath lubrication. Oil lubricated bearing assemblies are shipped without oil. Oil must be added to the bearing housing before starting. Remove the bearing housing breather (113A) and add oil until oil level is at the center of the sight glass. If the unit has an external oil lube system, fill the bearing housing and the reservoir to satisfy the system requirements. Replace the breather. Table 2.shows the oil volume required.

order to prevent excess heat generation,

Run the pump for 1 minute to fill the oil galleys and in and around each bearing. Check the sight glass and add oil accordingly. Monitor the oil level indicator for the first 24 hours of operation and maintain fill level.

OIL TYPE

Use an industrial quality lubrication oil such as Mobil DTE series, Exxon Teresstic, or similar of ISO VG68. ISO VG46 may be used in ambient temperatures below 40F.

In any case the operating temperature viscosity must be a minimum of 150SSU.

An oil with a higher viscosity than required will increase the bearing operating temperature because of the extra viscous drag, but never to the point where the viscosity becomes lower than required from the increased heat generation. It is therefore better for the bearings to have an oil that is too heavy rather than too light.

Change the oil after the first 200 hours of operation. For normal operating conditions, change the oil at least four (4) times a year. If the bearing assembly is exposed to dirty or moist conditions, the oil should be changed more often.

OIL LEVEL CONTROL

If the level of oil in the bearing housing (134C) is too high, excessive heat may be generated due to churning. If the level is too low, excessive heat may be generated due to inadequate lubrication. A liquid level switch connected to the oil sump can be used to warn of a dangerous oil level condition.

Observe the oil level requirements shown on the assembly drawing furnished with the pump. If excessive heat is experienced within these levels, consult the factory. Be sure that the shaft centerline is horizontal through the bearing housing

NORMAL BEARING TEMPERATURE

The running temperature for a bearing assembly depends on many factors such as speed, bearing loads, lubrication, ambient air temperatures, and condition of bearings. Temperatures higher than the human hand can tolerate are very satisfactory for good bearing operation and should not cause any alarm.

For a given speed and loading, the bearing housing temperature will stabilize at some temperature, usually

32 AF (42-66) IOM

Page 33

PACKING RINGS

CORRECT

INCORRECT

below 200°F., which will be the normal temperature for temperature, without any change in speed or loading can mean a lubrication difficulty or the approach of bearing failure.

INSTALLING A BEARING

Long bearing life is dependent on careful handling of the bearing when it is out of the housing and during the installation procedure. Dirt and rough handling are prime enemies of precision bearings. Bearings should be pressed, not “hammered” into place. If heat is used to facilitate the installation, a hot oil bath is the best method.

THRUST BEARING ORIENTATION

Fig. 20 at the end of this section shows the axial thrust bearing (112C) in the outboard location. This is used for top suction pumps. End suction pumps have the flow and axial thrust in the opposite direction. Therefore, the complete thrust bearing assembly is reoriented in the opposite direction. This does not change the basic disassembly procedure, other than the sequence of installing the thrust bearing assembly components on the shaft. The illustration shows the thrust bearing (112C) mounted on a sleeve (196). For the other bearing orientation, the bearing is mounted on an extension of the spacer (443), eliminating the separate sleeve.

SHAFT SEALING

A packed stuffing box or mechanical seal is used to seal the AF pump shaft. Both methods are described below.

PACKED STUFFING BOX

The original equipment packing is a suitable grade for the service intended. To pack the standard stuffing box use the following procedure: For the special (6) ring packing arrangement see the appendix 1.

1. Stuffing box and shaft sleeve must be clean and

free of grit.

2. Form packing over shaft or mandrel of same

diameter. Carefully cut to packing length. Discard rings cut too short.

3. Pre-form each ring by coiling 1 -1 /2 turns.

the installation.

4. To install packing rings, do not pull straight. Expand the coil as a coil spring, see Fig 17 for the correct and incorrect method of installing packing.

Fig. 17

Expand the first coil as shown and insert into stuffing box. Tamp packing to stuffing box shoulder firmly with the gland. Note, where the cut is positioned.

5. Install the first lantern ring into the stuffing box.

6. Install the second and third coil as required by

7. Install the second lantern ring into stuffing box,

8. Install the third and fourth coil as required by

9. After packing and lantern rings are properly

10. Turn lubricant supply on, start pump, and adjust

11. Periodic maintenance is absolutely required for all

Packed stuffing boxes are not allowed in an ATEX classified environment.

Failure to property locate the lantern ring with the flush port will result in insufficient packing lubrication.

sectional drawing, staggering the cut 90° to 120°.

carefully noting its proper position on the sectional drawing.

sectional drawing, staggering the cut 90° to 120°.

installed, insert gland into stuffing box. Tighten gland nuts finger tight only. The shaft should turn freely.

the gland as described in Section III-E Stuffing Box Adjustment.

packed pumps. Normal shaft run-out should be under .005” to avoid pounding of stuffing box packing. With excessive shaft run-out, shaft straightening or replacement is necessary.

AF (42-66) IOM 33

Page 34

The mechanical seal used in an ATEX certified.

The mechanical seal must always be properly heat generation and seal failure.

GLAND ADJUSTMENT

Adjust the stuffing box if packing is used. When the pump is first started, there should be considerable leakage by the gland to cool the packing. Gradually tighten the gland nuts on flat at a time while observing the leakage and stuffing box temperature. Packing requires time to “run-in” and extra coolant (leakage) while it is being “run-in”. If the leakage is reduced too quickly, the packing will overheat and may be destroyed. The shaft sleeve may also be damaged.

LEAKAGE

Normal leakage for a properly adjusted box, depending on shaft size and speed, varies from a few drops a second to a small trickle out of the gland.

MECHANICAL SEAL

classified environment must be properly

through the seal gland. Clear, grit-free liquid is necessary. Goulds Pumps strongly recommends the stocking of replacement sealing elements.

WARNING

Do not make shaft adjustments on mechanical seal installations without consulting seal instructions and the pump assembly drawing. Damage to the mechanical seal may result.

Dynamic seals are not allowed in an ATEX classified environment.

flushed. Failure to do so will result in excess

Most mechanical seals are installed and adjusted at the factory. A common seal type used on the AF pump is the cartridge type. Cartridge seals are preset at the seal manufacturer’s facility and require no field settings. Due to size and design, some installed mechanical seals are supplied with holding clips. These clips keep the sealing faces apart to avoid damage during transport. The clips must be removed before the shaft is to be rotated. Pumps with retained seal faces will be specifically marked and instructions from the seal manufacturer for clip removal will be provided.

If the seal has been installed in the pump at the Goulds factory, these clips have already been removed. For other types of mechanical seals, refer to the seal manufacturer’s instructions for installation and setting.

Mechanical seals have a stationary and a rotating sealing face. Commonly, these sealing rings are of carbon and ceramic material, brittle in nature, and easily damaged. As the sealing rings seat with the operation of the pump, a compatible wear pattern develops between the mating surfaces.

To disassemble the mechanical seal after the wear pattern is established would necessitate the replacement of the rotating element and stationary sealing elements. Do not replace only one component.

To insure the life and sealing characteristics of the mechanical seal, lubricating liquid must be circulated

34 AF (42-66) IOM

Page 35

When starting pump, immediately observe

STARTING THE PUMP

PRIMING PUMP

Pumps that are not self-priming must be fully primed at all times during operation.

Start up Precautions

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 system has been adequately cleaned and flushed.

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 manufacturers instructions for assistance.

5. Pumpage tempartatures in excess of 200°F will require warmup of pump prior to operation. Circulate a small amount of pumpage throught the pump until the casing temperature is within 100°F of the pumpage temperature and evenly heated.

pressure gauges. If discharge pressure is not quickly attained, stop driver, re-prime and

attempt to restart

6. Never start the pump until it has been properly primed. Check the pump impeller for submergence. The pump must be full of liquid with specified submergence head above the impeller. Do not run the pump dry, as this might damage pump and seal components.

7. Lubricating liquid must be flowing to the stuffing box before pump is started.

FLUSH FLOWS

Packing or mechanical seals are used to seal the rotating shaft. Generally, a clear liquid such as water is used to lubricate and cool the sealing elements. The lubricating liquid pressure must be 10 -15 psi higher than the pressure inside the elbow to prevent pumpage from entering the sealing elements. The lubricating liquid must be clean and free of grit. Shaft scoring, packing destruction, and mechanical seal face damage will result from contaminated lubricant.

The stuffing box may be on the suction or the discharge side of the impeller, depending on the direction of flow through the elbow ordered by the customer. If the pressure inside the elbow is unknown, it should be measured with a pressure gauge when the pump is operating. The standard stuffing box is furnished with (2) N.P.T. holes for piping the lubricating liquid. The lubricating liquid is piped into one of them. Some users simply plug the other hole. For additional cooling of the sealing elements, an outlet pipe with a valve can be installed to allow more liquid to flow through the stuffing box.

For special (6) row packing arrangement see appendix 1 at the end of this manual for flush pressures and flow rates.

(Mechanical seals have no leakage and usually require a lubricant flow through the stuffing box for cooling). The lubricating flow should be regulated by the valve in the outlet pipe rather than by throttling the flow in the supply pipe.

DRIVER

Start driver.

CAUTION

Immediately observe pressure gauges. If discharge pressure is not quickly attained-stop driver, check submergence level and attempt to restart

SET DESIRED FLOW

If your system is equipped with a variable frequency drive (VFD) or a variable speed V-belt drive, you may at this point want to set your speed for the desired flow.

CAUTION

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

AF (42-66) IOM 35

Page 36

Service temperature in an ATEX classified ATEX identification section.

Do not operate pump below

pump failure and physical injury.

Observe pump for vibration levels,

shut down and resolve.

recirculation.

Always vary capacity with regulating

curves received with order.

OPERATION

GENERAL CONSIDERATIONS

environment is limited by the table in the

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

Reference Hydraulic Institute for NPSH and pipe friction values needed to evaluate suction piping.

Most axial flow pumps are in evaporator circulation service and since the evaporator performance and the amount of product depends on the rate of liquid circulation, care should be taken to maintain these pumps in good operating condition.

bearing temperature and excessive noise. If normal levels are exceeded,

Always operate the pump at or near the rated conditions to prevent damage resulting form cavitation or

valve in the discharge line. NEVER throttle flow from the suction side.

Pump must never be throttled on suction side.

NPSHa must always exceed NPSHr as shown on Goulds performane

When production drops off, it is usually due to lower circulation rate. An approximation of this rate can be made by several methods:

• Temperature drop across the heat exchanger.

• Visual inspection of flow in evaporator body.

• Testing the circulating pump.

Items (1) and (2) above are covered by the evaporator manufacturer.

While field conditions preclude absolute accuracy, a check of pump performance will give reasonably close results. This can be done by installing a mercury manometer at pipe taps located at least-one pipe diameter away from the suction and discharge flanges of the pump. If-gauges are used, the pressure differential times 2.31 divided by the specific gravity of the slurry indicates the TDH against which the pump is actually operating. If a manometer is used, then inches of mercury times 1.0455 divided by specific gravity equals TDH, providing water is in both legs of the manometer and connecting lines. Check the pump speed and determine flow rate (gpm) from the pump curve. This curve will also give efficiency from which the hp requirement can be determined. A double check is to take motor ammeter readings, convert to hp, figure 90% drive efficiency, and use it against the pump curve to get GPM. This is only an approximate check, as the hp curve on some applications is rather flat, but is probably within 7-1/2%. It is important to take and record these readings when the equipment is new, so that later readings can be judged on a relative basis.

OPERATING AT REDUCED CAPACITY

WARNING

DO NOT operate pump below minimum rated flows or with a discharge valve closed. This condition may create an explosive hazard due to vaporization of pumpage and can quickly lead to pump failure and physic al injury.

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

36 AF (42-66) IOM

Page 37

Listed below are some causes for circulation loss. Keep in mind that operation at reduced capacities can cause damage to the pump.

1. Increase in TDH against which pump operates could be caused by:

a) Heat exchanger tubes partially plugged. b) Too many heat exchanger tubes blanked off. c) Improperly sized or partially plugged strainer.

2. Viscosity of slurry higher than it should be.

3. Pump speed low. V-belt drive may be slipping and operating pump below design speed.

4. Pump throttled on suction side. This could be caused by: a) rubber lining pulling away from the suction pipe

and partially collapsing, b) large solids dropping into the suction, or c) by an improperly sized or-plugged strainer in

the suction pipe.

5. Pump partially plugged by large solid jammed between two impeller blades. This will also cause rough operation with excessive vibration.

6. Incorrect pump rotation. When changing motors for any reason or after any electrical system changes or modifications, always check motors for correct direction of rotation.

7. Worn pump impeller and/or casing. On a new pump, clearance between tip of impeller blade and casing is carefully determined. As this clearance increases, pump performance decreases.

It is not practical to predict performance at any given clearance without running a test at this clearance. On small pumps, this effect is magnified as the percentage of impeller blade area lost from wear and corrosion is higher.

Other pump conditions and possible causes are: HIGH HP DEMAND

1. Increased head or viscosity

2. Pump speed too high

3. Specific-gravity of slurry higher-than normal

4. Packing gland pulled up too tight

5. Impeller rubbing in casing

NOISY OR ROUGH OPERATION

1. Throttled suction or plugging

2. Impeller rubbing in casing

DAMAGE OCCURS FROM:

1. Increased vibration levels - Affects bearings, stuffing box seal chamber, and mechanical seals.

2. Heat build up - Vaporization causing rotating parts to score or seize.

3. Cavitation - Damage to internal surfaces of pump.

4. Loose impeller

5. Broken impeller blade

6. Bearings not properly lubricated

7. Bent shaft

8. Impeller out of balance.

Operating under freezing conditions

Exposure to freezing conditions, while pump is idle, could cause liquid to freeze and damage the pump. Liquid inside pump should be drained.

AF (42-66) IOM 37

Page 38

SHUTDOWN

1. Turn off power to pump motor.

2. In case of necessary maintenance or pump inspection, lock driver to prevent accidental rotation.

FINAL ALIGNMENT

1. Run the pump under ac tual conditions for a sufficient length of time to bring the pump and driver up to operating temperature.

WARNING

When handling hazardous and/or toxic fluids, skin and eye protection are required. If pump is being drained, precautio n s must be taken to prevent physical injury. Pumpage must be handled and disposed of in conformance with applicable environmental regul ation.

2. Check alignment per alignment procedure outlined earlier.

38 AF (42-66) IOM

Page 39

The preventive maintenance section must

classification for the equipment.

Inspection intervals should be shortened

classified as potentially explosive.

applicable environment regulations.

PREVENTATIVE MAINTENANCE

GENERAL COMMENTS .............................................................................. 39

MAINTENANCE SCHEDULE ...................................................................... 39

MAINTENANCE OF BEARINGS ................................................................. 40

MAINTENANCE OF SHAFT SEALS ........................................................... 41

PUMP TROUBLE SHOOTING ................................................................ 43-44

GENERAL COMMENTS

A routine maintenance progr am can extend the life of your pump. Well

maintained equipment w ill last longer and require fewer repairs. You should ke ep maintenance records, this will help pinpoint cause s of problems.

Condition Monitoring

For additional safety precautions, and where noted in this manual, condition monitoring devices should be used.

This includes, but is not limited to:

• Pressure gauges

• Flow meters

• Level indicators

• Motor load readings

For assistance in selecting the proper instrumentation and its use, please contact your ITT/Goulds representative.

• Temperature detectors

• Bearing monitors

• Leak detectors

• PumpSmart control system

MAINTENANCE SCHEDULE

be adhered to in order to keep the applicable ATEX classification of the equipment. Failure to follow these procedures will void the ATEX

ROUTINE MAINTENANCE

• Bearing lubrication

• Seal monitoring

• Vibration analysis

• Discharge pressure

• Temperature monitoring

appropriately if the pumpage is abrasive and/or corrosive, or if the environment is

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

AF (42-66) IOM 39

Page 40

and pump seizure.

Throughout this section on bearing

APPROX. OIL VOLUME

Pump Size

Quarts

Litres

42” / 1200mm / 54”

70.5

60” / 66”

Bearings must be lubricated properly in order and premature failure.

ROUTINE INSPECTIONS

• Check for unusual noise, vibration and bearing

temperatures.

• Inspect pump and piping for leaks

• Check seal chamber/stuffing box leakage

• Packing: Excessive leakage requires adjustment

or possible packing replacement. Refer to page 35 for packing gland adjustment.

• Mechanical Seal: Should be no leakage.

3 MONTH INSPECTIONS

• Check foundation and hold down bolts for

tightness.

• If pump has been idle, check packing. Replace if

necessary.

• If any rubbing noise has been noticed, re-align the

impeller.

• Oil should be changed at least every 3 months

(2000 hrs) or more often if there are any adverse atmospheric conditions that might contaminate or break down the oil, or if it is cloudy or contaminated as seen through the sight glass.

ANNUAL INSPECTIONS

• Check pump capacity, pressure and power. If

pump performance does not satisfy your process requirements, and process requirements have not changed, pump should be disassembled, inspected, and worn parts should be replaced, otherwise, a system inspection should be done.

Operation of the unit without proper lubrication will cause bearing failure,

lubrication, different pumpage temperatures are listed. If the equipment is ATEX certified and the listed temperature exceeds the applicable value shown in the table under ATEX identification, then that temperature is not valid. Should this situation occur, please consult with your ITT/Goulds representative.

OIL LUBRICATED BEARINGS

Remove the bearing housing breather (113A) and add oil until oil level is at the center of the sight glass. If the unit has an external oil lube system, fill the bearing housing and the reservoir to satisfy the system requirements. Replace the breather. Table 3. shows the oil volume required.

MAINTENANCE OF BEARINGS

AXIAL FLOW PUMP

Approximate values only. Always fill using sight glass to verify l evel. Oil level should be at the cent er of the sight glass. See comments in this section.

Table 3

to prevent excess heat generation, sparks

40 AF (42-66) IOM

Page 41

OIL TYPE

A good SAE#30 or #40 is usually satisfactory. Consult a reputable supplier for acceptable substitutes for the oils mentioned. The viscosity of the oil should be 150 SSU at the operating temperature to prevent accelerated bearing wear 150° F is the maximum temperature at which a typical 30 wt. oil will supply the required viscosity.

For the best results, the minimum oil viscosity should be maintained as follows:

Operating temp. below 150 °F - SAE 30 Operating temp. 150 - 160 °F - SAE 40 Operating temp. 160 - 180 °F - SAE 50

OIL LEVEL CONTROL

If the level of oil in the bearing housing (134C) is too high, excessive heat may be generated due to

churning. If the level is too low, excessive heat may be generated due to inadequate lubrication. A liquid level switch connected to the oil sump can be used to warn of a dangerous oil level condition.

NORMAL BEARING TEMPERATURE

For a given speed and loading, the bearing housing temperature will stabilize at some temperature, usually below 200°F., which will be the normal temperature for the installation. Higher temperatures than this normal temperature, without any change in speed or loading can mean a lubrication difficulty or the approach of bearing failure..

MAINTENANCE OF SHAFT SEALS

MECHANICAL SEAL

When mechanical seals are furnished, a manufacturer’s reference drawing is supplied with the data package. This drawing should be kept for future use when performing maintenance and adjusting the seal. The seal drawing will also specify required flush liquid attachment points. The seal and all flush piping must be checked and installed as needed prior to starting the pump.

AF (42-66) IOM 41

The life of a mechanical seal depends on various factors such as cleanliness of the liquid handled and its lubricating properties. Due to the diversity of operating conditions it is, however, not possible to give definite indications as to its life.

WARNING

Never operate the pum p without liquid supplied to the 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 the mechanical seal fails.

Page 42

Fig. 19

PACKING RINGS

CORRECT

INCORRECT

PACKED STUFFING BOX

If the axial flow pump has a standard stuffing box to seal the rotating shaft the packing rings were installed at the factory, but at some point during the life of the pump they must be replaced. The following steps are used to replace the standard packing:

1. Drain the system or isolate the pumpage from the

pump before replacing the packing.

2. Remove the nuts from the gland studs that hold the

gland in place.

3. Use a packing puller remove the first (2) rows of

packing from the box.

4. Use threaded rods or a packing puller to remove

the lantern ring from the box.

5. Use a packing puller remove the second (2) rings

of packing from the box.

6. Use threaded rods or a packing puller to remove

the second lantern ring from the box.

7. Use a packing puller remove the final ring of

packing from the bottom of the box

8. Clean the stuffing box of any grit or build-up. Clean

the shaft sleeve prior to replacing the packing. If the sleeve is damaged now is the time to replace it.

9. Install the packing and lantern ring in the reverse

order of removal, 1 rings of packing, lantern ring, 2 rings of packing, lantern ring, 2 rings of packing, and the gland. Firmly seat each ring. Stagger joints in each ring 90°. Make sure middle of lantern ring lines up with flush tap in the stuffing box.

10. Die formed packing rings are used when re-

packing a box. Care must be used during their installation. To install packing, twist the ring sideways just enough to get it around the shaft. Do not attempt to pull rings straight out, see Fig. 18.

11. Insert the lantern ring with tapped extractor holes facing outward from the box, be sure it is aligned with the flush ports in the stuffing box, see Fig. 19.

12. Install the gland nuts finger tight. Then with the lubricating supply on and the pump running, gradually tighten the gland nuts one flat at a time, while observing the leakage and stuffing box temperature. Pac king requires time to run-in. Allow a minimum of ½ hour between adjustments. If the leakage is reduced quickly, the packing will overheat and may be destroyed. The shaft sleeve may also become damaged. T he norm al leakage for a properly adjusted stuffing box, depending on the shaf t size and speed, varies from a f ew drops per second to a small trickle out of the gland.

LABYRINTH SEALS

Labyrinth seals are found on the inboard and outboard end caps of the bearing housing to prevent contaminants from entering the bearing housing.

On some older models lip seals were used. These were assisted by cast slingers that fling contaminant fluids away prior to reaching the lip seals. Lip seals do not require any preventative maintenance but should be replaced during any rebuild operations. They can be cleaned occasionally from the outside by removing the slingers.

42 AF (42-66) IOM

Fig. 18

Page 43

Pump Troubleshooting

Impeller clogged with foreign material

Back flush pump or manually clean impeller

Excess air entrapped in liquid

Install vent in piping or eliminate air source

Suction and/or discharge valve closed or clogged

Open valves to remove partially blocked condition

Pump not producing rated flow

Speed (rpm) too low

New drive or gear box to obtain higher pump speed

Instruments give erroneous readings

Check and calibrate instruments, replace if necessary

is accelerated

Analyze pumpage and correct or change pump wet end materials to harder composition

Packing gland improperly adjusted

Tighten gland nuts

Excessive leakage

125% of BEP

Packing has short life

Pump not assembled correctly

Compare pump assembly to instruction manual

CONNECTION OF SEALING LIQUID

If stuffing box pressure is above atmospheric pressure and the pumpage is clean, normal gland leakage of 4060 drops per minute is usually sufficient to lubricate and cool packing and sealing liquid is not required.

NOTE: Otherwise an external flush should be used to lubricate and cool pa cking.

An external sealing liquid is required when:

1. Abrasive particles in the pumpage could score the shaft sleeve.

2. Stuffing box pressure is below atmospheric pressure due to pump running when suction source is under vacuum. Under these

PROBLEM PROBABLE CAUSE REMEDY

Pump not primed or prime lost, liquid level does not completely fill elbow Fill system piping completely so the impeller is submerged Suction inlet clogged Remove obstructions from pump inlet

NOTE: Most pack ing requires lubrication. Failure to lubricate packing may shorten the life of the packing and pump.

conditions, packing will not be cooled and lubricated and air will be drawn into the pump. If an outside source of clean compatible liquid is required,

The pressure should be 15-20 psi (1.1-1.4 kg/cm pressure. The piping should be connected to the stuffing box flush port inlet.

3. Under extreme temperature and pressure a pipe should also be connected to the flush port outlet.

) above suction

No liquid delivered or intermittent flow

Air leak in suction line Test suction piping for leaks Speed (rpm) too low New drive or gear box to obtain higher pump speed

Insufficient suction head Fill system piping so the liquid level is above the pump impeller centerline Pump not primed or prime lost, pump does not completely fill elbow Fill system piping completely so the impeller is submerged

or head

Incorrect impeller or impeller diameter Check vane angles and/ or impeller clearances System head too high Check system curve calculations, reduce system resistance

Pump assembled incorrectly Compare pump assembly to instruction manual Insufficient NPSH available Increase liquid level or lower pump

Wear of internal wetted parts

Pump assembled incorrectly Compare pump assembly to instruction manual Higher solids concentration than specifi ed

from stuffing box Worn mechanical seal parts Replace worn parts Overheating mechanical seal Check lubrication and cooling lines Shaft sleeve scored Re-machine or replace as required

Pump run off design point

Packing gland not properly adjusted Replace packing and readjust gland as specified in the operating manual Packing not properly installed Check packing manufacturer's instructions.

Suction and /or discharge valve closed or clogged Open valves to remove shut-off condition Wrong direction of rotation Suction piping incorrect Replace or modify suction piping

Insufficient NPSH available Increase liquid level or lower pump

Impeller partly clogged Back flush pump or manually clean impeller

Suction piping incorrect Replace or modify suction piping Excessive air entrapped in liquid Install vent in piping or eliminate air source

Incorrect rotation Check motor wiring

Worn or broken impeller, bent vanes Inspect and replace if necessary

Chemicals in liquid other than specified

Stuffing box improperly packed Check packing and re-pack box

Shaft/shaft sleeve worn Replace shaft or shaft sleeve if necessary

Change rotation to concur with direction indicated by the arrow on the bearing housing

Analyze pumpage and correct or change pump wet end materials to suit pumpage composition

Check head and flow, AF’s should normally be run between 75% and

AF (42-66) IOM 43

Table 3

Page 44

Pump Troubleshooting (Cont’d)

Inadequate lubricant cooling

Check pumpage temperature and add oil cooling system if necessary

a regular basis

Check pump and drive component vibration levels, rebalance coupling if Impeller out of balance

Check pump vibrations, if necessary rebalance impeller

125% of BEP

Viscosity higher than specified

Analyze pumpage and compare to specified viscosity

Imbalance

Impeller out of balance

Check impeller balance

operation, maintenance manual

necessary

Impeller clearances too tight

Check impeller clearances adjust if necessary

125% of BEP

High rate of mechanical seal failure

125% of BEP

Check pump and drive component vibration levels, rebalance coupling if Sub-base not installed correctly

Compare pump sub-base installation to instruction manual

power

Stuffing box packing too tight

Readjust packing. Replace if worn

Rotating parts binding, internal clearances too tight

Check internal wearing parts for proper clearances

PROBLEM PROBABLE CAUSE REMEDY

Lubricant level Be sure the oil level is at center line of sight glass

Improper lubricant Check lubricant for suitability Not lubricated enough Increase frequency of grease lubrication Broken or bent impeller vanes Check impeller dimensions and vane layout Excessive shaft misalignment Check shaft run-out and consult factory

Bearings run hot and or fail on

Coupling out of balance Suction pressure too high Check liquid levels and static suction pressure

Bearing incorrectly installed Check bearing orientation to sectional drawing

Pump run off design point

Pump and/or driver not secured to sub-base Check fasteners, if loose check alignment and re-tighten Specific gravity higher than specified Analyze pumpage and compare to specified gravity

Broken or bent impeller or shaft Replace as required Pump foundation not rigid or sub-base not completely secured Tighten hold down bolts on sub-base Check foundation rigidity

Improper coupling lubrication

Coupling out of balance Pump operating speed too close to system’s natural frequency Change speed to be +/- 20% of the pumps natural frequency

Pump is noisy or vibrates at higher than normal levels

Pump run off design point

W or n bearings Replace Suction or discharge piping not anchored or properly supported Anchor per Hydraulic Institute Strandards Manual recommendation Suction and/or discharge valve closed or clogged Open valves to remove partially blocked condition Excessive shaft misalignment Check shaft run-out and consult factory

Insufficient NPSH available Increase liquid level or lower pump Excessive shaft misalignment Check shaft run-out and consult factory

Impeller out of balance Check pump vibrations, if necessary rebalance impeller Overheating of seal faces Check flush flow with mfgr’s recommendation, increase if necessary

Pump run off design point Shaft/shaft sleeve worn Replace shaft or shaft sleeve if necessary Coupling out of balance

Axial thrust or radial load higher than bearing rating Calculate bearing life for make and model bearing Improper coupling lubrication

Excessive shaft deflection Check shaft diameter, sag and deflection, consult factory

Lubricant contamination Inspect oil or grease for contaminants Piping not properly anchored Check to see if excessive pipe strain is being transferred to pump flanges

Pump assembled incorrectly Compare pump assembly to instruction manual Partly clogged impeller causing

Motor not secure Check motor fasteners

Bearing incorrectly installed Check bearing orientation to sectional drawing

Impeller partly clogged Back flush pump or manually clean impeller

Pump assembled incorrectly Compare pump assembly to instruction manual

Excessive shaft deflection Check shaft diameter, sag and deflection, consult factory

Pump assembled incorrectly Compare pump assembly to instruction manual Pump is cavitating, insufficient NPSH available System problem, increase liquid level or lower pump

Suction pressure too high Check liquid levels and static suction pressure Bearing installed incorrectly Check bearing orientation to sectional drawing

Excessive shaft deflection Check shaft diameter, sag and deflection, consult factory Lack of seal flush to seal faces Check shaft diameter, sag and deflection, consult factory

Incorrect seal installation Check seal materials vs. pumpage to determine compatibility Pump is run dry Fill system piping completely so the impeller is submerged

Check coupling lubrication schedule in manufacturers installation, operation, maintenance manual

necessary

Check head and flow, AF’s should normally be run between 75% and

Back flush pump or manually clean impeller

Check coupling lubrication schedule in manufacturers installation,

Check pump and drive component vibration levels, rebalance coupling if

Check head and flow, AF’s should normally be run between 75% and

necessary

Piping not properly anchored Check to see if excessive pipe strain is being transferred to pump flanges Pump and/or driver not secured to sub-base Check fasteners, if loose check alignment and re-tighten Specific gravity higher than specified Analyze pumpage and compare to specified gravity

Motor requires excessive

Pump run off design point Check measured head and flow to specified head and flow

Bearing failing Replace if necessary

Viscosity higher than specified Analyze pumpage and compare to specified viscosity Pump assembled incorrectly Compare pump assembly to instruction manual

Head higher than rating. Reduced flow Check for fouling in the piping or obstruction in discharge Liquid heavier than expected Check specific gravity and viscosity Incorrect rotation Jog motor and check rotation

44 AF (42-66) IOM AF (42-66) IO

Table 3 (Cont’d)

Page 45

DISASSEMBLY & RE-ASSEMBLY

PUMP DISASSEMBLY & RE-ASSEMBLY .................................................. 45

Disassembly of Pump ....................................................................... 46

Re-Assembly of Pump ....................................................................... 46

LM & LMR POWER END DISASSEMBLY & RE-ASSEMBLY .................... 46

Power E nd Disassembly ................................................................... 46

Power E nd Re-Assembly .................................................................. 47

INSPECTIONS ............................................................................................. 48

Impeller .............................................................................................. 48

Shaft ................................................................................................... 48

Shaft Sleeve ....................................................................................... 48

Bearings ............................................................................................. 48

Oil Seals, O-Rings, Gaskets.............................................................. 48

PUMP DISASSEMBLY & RE-ASSEMBLY

Refer to the pump part list (pg. 50) and sectional drawings (Fig.’s 22, 23) for proper part designation in these instructions. The order of steps for disassembly and assembly of the liquid end and power end is the suggested method. However, any workable sequence to accomplish the desired results may be used.

Pump Disassembly

1. Remove all auxiliary water lines to pump and completely drain pump and pipeline. Remove bolts which fasten pump to suction and discharge piping.

2. If the pump is pipe mounted remove it from the piping and support it on adequate cribbing. If the pump is base mounted the casing (100) and power end may be removed while the elbow (315A) remains attached to the base.

3. Support the casing (100) by the lifting eye on top. Loosen and remove all of the bolts and nuts that secure the casing to the elbow (315A). With the casing supported, swing it away from the impeller (101) until it clears and set it down on a hard surface. Be careful not to damage the mating gasket or o-ring surfaces.

4. Disconnect coupling halves and remove any intermediate shafting. Support the impeller (101) with a chain around top vane. Remove the impeller end cap (9988). Remove the screws (370C) that secure the impeller (101) and shaft washer (9985) to the shaft (122). Tapped holes in the hub of the impeller on the discharge side are provided for pulling the impeller

from the shaft. If no holes are provided, strapping or chains around the impeller vanes will provide a means of pulling the impeller from the shaft. Always use the shaft center for the center point of a puller. Be sure to retain the impeller key (178).

NOTE: If chains are used for pulling, place blocking between chain and impeller vanes.

5. Support bearing housing (134) and impeller end of shaft (122). Remove hex head bolts (370G) that secure bearing housing (134) to suction elbow (315A).

6. If packing is used, disassemble the gland (107), packing (106), and lantern rings (105) from stuffing box. If mechanical seal (383) was used, please see the mechanical seal IOM for proper removal of seal.

7. With the power end properly supported. Carefully pull it from suction elbow (315A).

8. The shaft sleeve (126) can be removed by loosening set screw and sliding the sleeve from shaft (122). Be sure to retain the sleeve key (128D).

AF (42-66) IOM 45

Page 46

PUMP RE-ASSEMBLY

1. Be sure shaft (122) and sleeve (126) are clean and free of all burrs. Slide shaft sleeve (126) over shaft (122), making sure that O-rings are in place as indicated on assembly drawing. Secure sleeve with set screw (222C) and key (128D).

2. Provide adequate support for bearing housing (134) and shaft (122). Carefully slide shaft through stuffing box of suction elbow. Bolt bearing housing to suction elbow (315A).

3. Install shaft O-rings (496C & 496D) on shaft (122). Place the shaft key (178) in the keyway. Lubricate the O-rings as required.

4. Carefully install impeller (101) on shaft (122). With shaft washer (9985) in place, install (4) cap screws (370C) to secure the impeller to the shaft. Install impeller end cap (9988) with o-ring (496B) as required.

5. Bolt casing (100) to elbow (315A) with (6) bolts evenly spaced around bolt circle. Leave bolts loose enough to shift casing for alignment with impeller. The actual adjustment of casing is accomplished by turning the (3) adjusting screws (370B) against casing flange.

6. The procedure for setting impeller clearance is described in the ALIGNMENT section of these instructions. When acceptable alignment has been achieved, secure the initial (6) bolts, then install the remaining bolts and tighten.

7. Before connecting the coupling halves, check direction of motor rotation. Manually turn pump shaft to insure no rubbing. Be sure the pump and gear box shafts are in alignment according to the previously discussed alignment procedure.

8. Connect coupling halves and any intermediate shafting.

9. Assemble discharge piping to casing.

10. If packing is used, assemble gland, packing, lantern rings and sleeve into stuffing box. Do not compress too tightly until after start-up. The packing will need to be "run-in" and adjusted for proper flow of lubricating water. If a mechanical seal is used, please see the mechanical seal IOM for proper installation of seal.

11. Connect seal water and cooling lines to pump. Fill the oil lubrication system. Be sure bearing housing oil is level with the center of the sight glass.

LM & LMR POWER END DISASSEMBLY & ASSEMBLY

Power End Disassembly (See Fig.’s 20, 21)

WARNING

Lockout driver power to prevent accidental startup.

1. Lockout power supply to motor.

2. Close suction and discharge valve.

WARNING

The pump may handle hazardo u s and/or toxic fluids. Skin and eye protection may be required. Precautions must be taken to prevent injury or environmental damage.

1. Remove piping from pump.

2. Remove coupling guard and coupling (direct connect) or belt guard and belts (belt drive).

3. Drain oil from bearing housing, disconnect oil circulation system, and remove pump from sub-base.

4. Wash down pump with appropriate cleaner.

5. Disassemble Pump per instructions per that section. Discharge piping and impeller (101) will be

disassembled. The power end with the shaft (122) will be removed from the elbow (315A).

6. Remove cap screws (370H) fastening thrust bearing retainer (109) to bearing housing (134). Carefully pull retainer over shaft. Top suction pumps have thrust bearing (112C) at the outboard location and the thrust bearing stationary race and (6) small springs (9890) may be jarred free. Do not damage oil seal (332).

7. Be sure overhung portion of shaft is supported.

8. Remove cap screws (370F) fastening radial bearing retainer (119B) to bearing housing (134). Carefully pull retainer away from bearing housing without damaging lip seal (333).

46 AF (42-66) IOM

Page 47

9. Disassemble bearing halves by removing bolts and knocking out taper pins. Carefully lift top half. The shaft (122) with bearings can be lif ted fr om bottom half of housing

10. Remove thrust end locknut (136) and lockwasher (382). a. For top suction pumps (Fig.20), the thrust bearing (112C), thrust bearing sleeve (196) and thrust bearing spacer (237) can be pulled from shaft (122). Press or pull radial bearing (112) from shaft by applying force on inner race bearing. b. For end suction pumps (Fig.21), press the entire thrust bearing stack off by pushing against stationary race of thrust bearing (112C).

11. Loosen set screws and pull oil wheel (248) off shaft.

12. Push inboard radial bearing (168C) off shaft toward coupling end by applying force on bearing inner race with a press.

POW ER END RE-ASSEMBLY

1. Be sure shaft is clean and free from all burrs.

2. Heat inboard radial bearing (168C) in a 200 deg. F oil bath or by induction heater. Slide bearing on shaft (122), butting against shaft shoulder. Position oil wheel (248) on shaft (122) and secure with set screws.

3. Heat thrust end bearings (112) & (112C) and sleeve (if used), in 200 deg. F oil bath. If thrust bearing rotating race mounts on spacer (443), install race on collar and heat collar with bearing mounted in oil bath.

a) For top suction pumps (Fig. 20), slide bearing (112), spacer (237), and sleeve into position, tight against each other and against shaft shoulder. After sleeve has cooled, install thrust bearing (112C).

4. When the thrust bearing is in the outboard position the stationary race will usually fit over the lock nut and washer. This saves the trouble of trying to keep the race in position because it can be set aside until retainer (109) is installed.

a) For end suction pumps (Fig.21), slide spacer (443) with mounted thrust bearing (112C), including stationary race, into position against shaft shoulder. If a spacer drive key is used, be sure it is installed. Install bearing (112) against collar.

5. Secure bearings with lockwasher (382) and locknut (136). Retighten locknut while components are cooling to keep them tight together.

6. Install (6) thrust bearings springs (9890) in thrust bearing retainer (109) or bearing housing (134) halves. Use thick grease in each hole to help hold springs until assembly.

7. Lower shaft (122) into bottom half of bearing housing (134). Be careful not to damage bearings or machined fits.

8. If springs (9890) are located in the housing, keep the shaft about 3/8" outboard of normal position so springs are not compressed.

9. Lower top half of housing into position, align with taper pins, and secure together with bolts.

10. Install thrust bearing retainer. Do not damage lip seal.

11. Slide thrust bearing retainer (109) and gasket (360R) onto shaft to contact bearing housing (134). Do not damage lip seal (332). Fasten retainer to bearing housing with cap screws.

AF (42-66) IOM 47

Page 48

INSPECTIONS

IMPELLER

1. Inspect impeller vanes for damage (101). Check the vane O.D. for erosion. Check the vane surfaces, replace if grooved, worn, or eroded deeper than 3/16 in. (5.0 mm.) Excessive impeller wear may cause a reduction in performance.

2. Inspect the leading and trailing edges of the vanes for pitting, erosion or corrosion damage replace if grooved, or worn deeper than 3/16 in. (5.0 mm.)

3. Inspect the root (vane attach point at hub) of each vane for cracks. Impeller vane failure can cause unbalance in the rotating assembly that will lead to catastrophic failure of the pump.

4. Inspect the keyway and stepped bores for signs of pitting, wear or corrosion damage.

5. Check the O-ring groove and bolt holes for signs of pitting or corrosion.

SHAFT

1. Check the shaft (122) for straightness, wear,

corrosion, and radial run-out. Maximum run-out for non-contact portions of the shaft is .002 in. (.05 mm) max.

2. Bearing seats and seal areas must be smooth and

free of scratches and grooves. Shaft hole threads must be in good condition. Replace if necessary.

SHAFT SLEEVE

1. The shaft sleeve (126) should be replaced if badly grooved or worn. Localized wear or grooving greater than 3/32 in. (2.4 mm) deep is cause for replacement, see Fig. 50.

BEARINGS

The bearings (112, 112C, and 168C) should be inspected for contamination and damage. The condition of the bearing will provide useful information on operating conditions in the bearing housing. Lubrication condition and residue should be noted. Bearing damage should be investigated to determine the cause. If cause is not normal wear, it should be corrected before the pump is returned to service.

DO NOT RE-USE BEARINGS.

OIL SEALS, O-RINGS, GASKETS

Although the oil seals (332, 333), O-rings (351A, 351B, 496A, 496B, 496C) and gaskets (360R, 360X,) may seem OK during inspection and examination, DO NOT RE-USE SEALS when rebuilding the pump. Replace them while pump is disassembled.

48 AF (42-66) IOM

Page 49

SPARE PARTS

When ordering spare parts, always state Goulds Serial No., and indicate part name and item number from relevant sectional drawing. It is imperative for service reliability to have a sufficient stock of readily available spares.

RECOMMENDED SPARE PARTS

Suggested Spare Parts

• Elbow and or Casing (100, 315A)

• Impeller (101)

• Gaskets (360R, 360X)

• O-Rings (351A, 351B, 496B, 496C, 496D)

• Shaft (122)

• Inboard Radial Bearing (168C)

• Outboard Thrust Bearings (112, 112C)

• Bearing Lockwasher (382)

• Bearing Locknut (136)

• Outboard Oil Seal (332)

• Inboard Oil Seal (333)

• Shaft Sleeve (126) (Optional)

• Sleeve O-rings (496A) (Optional)

• Stuffing Box Bushing (473) (Optional)

• Lantern Ring (105) (Optional)

• Stuffing Box Packing (106) (Optional)

• Packing Gland (107) (Optional)

HOW TO ORDER PARTS

When ordering parts c a ll

1-800-446-8537

or your local Goulds Representative

EMERGENCY SERVICE

Emergency parts service is available

24 hours a day, 365 days/year

Call 1-800-446-8537

AF (42-66) IOM 49

Page 50

Item

Part Description

Item

Part Description

101

PROPELLER

355

HEX NUT, GLAND

105

LANTERN RING

357D

NUT, ELBOW TO CASING

106

PACKING, PACKED BOX

358U

PIPE PLUG [½-14 NPT]

107

GLAND

358V

PIPE PLUG [1”-11.5 NPT]

109

RETAINER, THRUST BEARING

360X

GASKET, BRG., OUTBOARD

113A

BREATHER

370B

CAP SCREW

119B

RETAINER, RADIAL BEARING

370C

SCREW, SHAFT WASHER

122

SHAFT

370D

SCREW, ELBOW TO CASING

126

SHAFT SLEEVE

370E

CAP SCREW-ALIGNMENT

134

BEARING HOUSING ASSEMBLY

370G

HEX HD CAP SCREW, BEARING FRAME

Part of 134 assy

SCREW,HHC 1"-8 X 4-1/2"LG

370H

HEX HD CAP SCREW, THRUST RETAINER Part of 134 assy

NUT,HEX 1"- 8 HVY

370I

NUT, HEX, BEARING FRAME TO ELBOW

136

LOCKNUT, THRUST BEARING

400

KEY, COUPLING

168C

BEARING, RADIAL, INBOARD

408N

PIPE PLUG [3/8-18 NPT]

178

PROPELLER KEY

415

JAM NUT

196

SLEEVE, THRUST BEARING

415A

JAM NUT

222

SET SCREW, OIL WHEEL

443

SPACER, THRUST BEARING

237

SPACER, THRUST BEARING

496B

O-RING, PROPELLER CAP

248

OIL WHEEL

496C

O-RING, SHAFT

315A

ELBOW

972G

MALE CONNECTOR

319

SIGHT WINDOW

972H

FEMALE CONNECTOR

319A

SIGHT WINDOW

984A

COOLING COIL

333

OIL SEAL, OUTBOARD

9985

SHAFT WASHER/PROPELLER LOCKPLATE

351A

CASING O-RING

9988

PROPELLER END COVER

351B

CASING O-RING

AF PARTS LIST–42-54 inch Pumps

100 CASING 353 STUD, GLAND

112 BEARING, RADIAL, OUTBOARD 360R GASKET, BRG., INBOARD 112C BEARING, THRUST 370A SCREW, PROPELLER END COVER

128D SLEEVE KEY 370F HEX HD CAP SCREW, RADIAL BEARING

RETAINER

TO ELBOW

TO BEARING FRAME

Part of 134 assy PIN,TAPER #10 X 3-1/2" (PLN) 382 LOCKWASHER, THRUST BEARING

222C SET SCREW, SLEEVE KEY 496A O-RING, SHAFT SLEEVE

332 OIL SEAL, INBOARD 9890 SPRINGS, THRUST BRG

50 AF (42-66) IOM

Page 51

42–54 (End Suction) AF with LM Bearings

42–54 (Top Suction) AF with LMR Bearings

Fig. 20

Fig. 21

AF (42-66) IOM 51

Page 52

42–54 AF with LMR Be a rings / Mechanical

Fig. 22

Seal / and Casing Gasket seal

52 AF (42-66) IOM

Page 53

42–54 AF with LM Bearings / Special Packing

Fig. 23

Arrangement / Dual Casing O-ring seal

AF (42-66) IOM 53

Page 54

Item

Part Description

Item

Part Description

100

CASING

357D

HEX NUT, ELBOW TO CASING

105

LANTERN RING

358V

PIPE PLUG [1"-11.5 NPT] (NOT SHOWNl

106

PACKING, PACKED BOX

360R

GASKET, BRG., INBOARD

107

GLAND

360X

GASKET, BRG., OUTBOARD

109

RETAINER, THRUST BEARING

370A

STUD, PROPELLER END COVER

112

BEARING, RADIAL, OUTBOARD

370B

CAP SCREW - SUCTION ALIGNMENT

113A

BREATHER

370D

STUD, ELBOW TO CASING

119B

RETAINER, RADIAL BEARING

370E

CAP SCREW-ALIGNMENT

122

SHAFT

370F

CAP SCREW, RADIAL BEARING RETAINER

126

SHAFT, SLEEVE

370G

CAP SCREW, BEARING FRAME TO ELBOW

128D

SLEEVE KEY

370H

CAP SCREW, THRUST RETAINER TOBEARING

AME TO ELBOW

136

LOCKNUT, THRUST BEARING

382

LOCKNUT CLIP

168C

BEARING, RADIAL INBOARD

383

MECHANICAL SEAL

178

PROPELLER KEY

400

KEY, COUPLING

196

SLEEVE, THRUST BEARING

408A

PIPE PLUG [ 1"-11.5 NPTJ

248

OIL WHEEL

415A

JAM NUT - ALIGNMENT

315A

ELBOW

443

SPACER, BEARING

319

SIGHT WINDOW

467A

HEX BUSHING - BREATHER

319A

SIGHT WINDOW

473

THROAT BUSHING

332

OIL SEAL, OUTBOARD

494

FRAME COOLER ASSEMBLY

351A

CASING 0-RING

496B

O-RING. PROPELLER END COVER

351B

CASING 0-RING

496C

O-RING, SHAFT TO PROPELLER

353

STUD, GLAND

9890

SPRINGS, THRUST BEARING

355

HEX NUT, GLAND

9985

SHAFT WASHER / PROPELLER LOCKPLATE

9988

PROPELLER END COVER

AF PARTS LIST–60-66 inch

Top Suction Pumps

101 PROPELLER 358U PIPE PLUG [1/2-14 NPT] (NOT SHOWN)

112C BEARING, THRUST 370C CAP SCREW, SHAFT WASHER

FRAME

134 BEARING FRAME ASSEMBLY 370I HEX NUT, BEARING FR

222 SET SCREW, OIL WHEEL 408H PLUG - PROPELLER CAP

222C SET SCREW, SLEEVE KEY 415 JAM NUT - SUCTION ALIGNMENT

333 0 I L SEAL, INBOARD 496A O-RING, SHAFT SLEEVE

54 AF (42-66) IOM

Page 55

60–66 (Top Suction) AF with LMR Bearings

Fig. 24

AF (42-66) IOM 55

Page 56

60–66 AF with LMR Be a rings / Mechanical

Fig. 25

Seal / and Casing Gasket seal

56 AF (42-66) IOM

Page 57

Item

Part Description

Item

Part Description

100

CASING

357D

HEX NUT, ELBOW TO CASING

105

LANTERN RING

358V

PIPE PLUG [1"-11.5 NPT] (NOT SHOWNl

106

PACKING, PACKED BOX

360R

GASKET, BRG., INBOARD

107

GLAND

360X

GASKET, BRG., OUTBOARD

109

RETAINER, THRUST BEARING

370A

STUD, PROPELLER END COVER

112

BEARING, RADIAL, OUTBOARD

370B

CAP SCREW - SUCTION ALIGNMENT

113A

BREATHER

370D

STUD, ELBOW TO CASING

119B

RETAINER, RADIAL BEARING

370E

CAP SCREW-ALIGNMENT

122

SHAFT

370F

CAP SCREW, RADIAL BEARING RETAINER

126

SHAFT, SLEEVE

370G

CAP SCREW, BEARING FRAME TO ELBOW

128D

SLEEVE KEY

370H

CAP SCREW, THRUST RETAINER TOBEARING HEX NUT, BEARING FRAME TO ELBOW

136

LOCKNUT, THRUST BEARING

382

LOCKNUT CLIP

168C

BEARING, RADIAL INBOARD

383

MECHANICAL SEAL

178

PROPELLER KEY

400

KEY, COUPLING

196

SLEEVE, THRUST BEARING

408A

PIPE PLUG [ 1"-11.5 NPTJ

248

OIL WHEEL

415A

JAM NUT - ALIGNMENT

315A

ELBOW

443

SPACER, BEARING

319

SIGHT WINDOW

467A

HEX BUSHING - BREATHER

319A

SIGHT WINDOW

473

THROAT BUSHING

332

OIL SEAL, OUTBOARD

494

FRAME COOLER ASSEMBLY

351A

CASING 0-RING

496B

O-RING,. PROPELLER END COVER

351B

CASING 0-RING

496C

O-RING, SHAFT TO PROPELLER

353

STUD, GLAND

9890

SPRINGS, THRUST BEARING

355

HEX NUT, GLAND

9985

SHAFT WASHER / PROPELLER LOCKPLATE

9988

PROPELLER END COVER

AF PARTS LIST–60-66 inch

End Suction Pumps

101 PROPELLER 358U PIPE PLUG [1/2-14 NPT] (NOT SHOWN)

112C BEARING, THRUST 370C CAP SCREW, SHAFT WASHER

FRAME

134 BEARING FRAME ASSEMBLY 370I

222 SET SCREW, OIL WHEEL 408H PLUG - PROPELLER CAP

222C SET SCREW, SLEEVE KEY 415 JAM NUT - SUCTION ALIGNMENT

333 0 I L SEAL, INBOARD 496A O-RING, SHAFT SLEEVE

AF (42-66) IOM 57

Page 58

60–66 (End Suction) AF with LM Bearings

Fig. 26

58 AF (42-66) IOM

Page 59

60–66 AF with LM Bearings / Special Packing

Fig. 27

Arrangement / Dual Casing O-ring seal

AF (42-66) IOM 59

Page 60

THIS PAGE

INTENTIONALLY

LEFT BLANK

60 AF (42-66) IOM

Page 61

Fig. 24

Sleeve dia. Flush flow

Inlet

Outlet

APPENDIX 1

SPECIAL PACKING ARRANGEMENT

(High pressure, dual flush packing)

The following information covers the installation, operation and maintenance of the high pressure, dual flush packing arrangement. This arrangement was developed for high pressure, to minimize product dilution, and to minimize external packing leakage.

DESCRIPTION

The arrangement consists of (6) rings of packing (106), (2) lantern rings (105), and (1) restrictor bushing arranged as follows: 3P, 1L, 2P, 1L, 1P, 1RB from the gland face to the bottom of the stuffing box, See fig. 24 below.

The flush flow depends on the application, the more heat generated the higher the flows must be to effectively remove the heat. The table below can be used as a starting point for initial setting: The table below represents the flow required with one flush line, for a dual flush arrangement the flow can be divided up equally.

(inches) (gpm)

2 .05 3 .15 4 .30 6 1.3 8 2.5 10 5.0 12 8.0

The stuffing box is furnished with (2) inlet and (2) outlet ports for piping of the flush liquid. The inlets are chosen based on shaft rotation direction so the flush flow travels the longer route to the outlet ports (see fig

25). The outlet ports may be plugged, but for improved cooling of the sealing elements, outlet pipes are installed to allow more flow through the stuffing box. With this setup flush flows are regulated by a valve on the outlet line rather than by throttling the flow on the inlet li ne

The inner lantern ring uses product flush to minimize product dilution. This flush should be filtered to reduce particle size and minimize sleeve / packing wear.

The outer lantern ring is supplied with water and is used as with any other packing arrangement to lubricate and cool the packing as the shaft rotates and generates heat.

The flush pressures should be 10% higher than the pressure inside the pump. For end suction pumps this will also include pump discharge pressure. Product flush pressure to the inner lantern ring may be slightly less than the water flush pressure to ensure flow toward the inside of the pump.

AF (42-66) IOM 61

Page 62

PACKING RINGS

CORRECT

INCORRECT

INSTALLATION

1. Be sure the stuffing box and shaft sleeve (126) must be clean and free of grit.

2. A Teflon restrictor bushing is used in the bottom of the box and is installed similar to packing (see Fig. 26). With the restrictor bushing wrapped around the shaft, push it squarely into the stuffing box until it bottoms out. Be sure the ends have not separated and that it sits square in the bottom of the box. Note, where the cut is positioned.

3. Form packing over a mandrel of same shaft diameter and carefully cut packing to length. Discard rings cut too short.

4. Pre-form each ring by coiling 1 -1 /2 turns.

5. To install packing rings, do not pull straight. Expand the coil as a coil spring, see Fig 26 for the correct and incorrect method of installing packing.

Fig. 26

6. Expand the first coil as shown and insert into stuffing box. Tamp the packing up against the restrictor bushing shoulder firmly with a nylon bar or wood rod. Note, where the cut is positioned.

7. Assemble the first lantern ring around the shaft and push it squarely into the stuffing box until it bottoms out against the first ring of packing. Failure to property locate the lantern ring with respect to the flush ports will result in insufficient packing lubrication. Packing and shaft sleeve damage may result.

8. Install the second and third coil as required by the sectional drawing, staggering the cuts 90° to 120°.

9. Assemble the second lantern ring around the shaft and push it squarely into the stuffing box until it bottoms out on the third ring of packing. Failure to property locate the lantern ring with respect to the flush ports will result in insufficient packing lubrication. Packing and shaft sleeve damage may result.

10. Install the third, fourth and fifth packing ring as required by the sectional drawing, staggering the cuts 90° to 120°.

11. After all packing and lantern rings have been properly installed, insert gland into stuffing box. Tighten gland nuts finger tight only. The shaft should turn freely.

12. Turn lubricant supply on, start pump, and adjust the gland as described in the operation section that follows.

13. Periodic maintenance is absolutely required for all packed pumps. Normal shaft run-out should be under .005” to avoid pounding of stuffing box packing. With excessive shaft run-out, shaft straightening or replacement is necessary.

GLAND ADJUSTMENT

LEAKAGE

Normal leakage for a properly adjusted box, depending on shaft size and speed, varies from a few drops a second to a small trickle out of the gland.

62 AF (42-66) IOM

Page 63

THIS PAGE

INTENTIONALLY

LEFT BLANK

Page 64

HOW TO ORDER

EMERGENCY SERVICE

Form No. IAF (42-66) 04/14

When ordering parts call

1-800-446-8537

or your local Goulds Representative

Emergency parts service is available

24 hours/day, 365 days/year . . .

Call 1-800-446-8537

Visit our website at w w w .gouldspumps.com

2014 Goulds Pumps, Incorporated

a subsidiary of ITT Corporation

Goulds Pumps AF-LM-LMR User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Explosion Prevention

Special ATEX considera ti ons

ATEX Identification

Intended Use

TABLE OF CONTENTS

PUMP DESCRIPTION

NAMEPLATE INFORMATION

Table 2

Approximate values only. Always fill using sight glass to verify level. Oil level should be at t he center of the sight glass. See comments in this sec tion.

Condition Monitoring

Approximate values only. Always fill using sight glass to verify l evel. Oil level should be at the cent er of the sight glass. See comments in this section.

Table 3

Table 3 (Cont’d)

SHAFT SLEEVE