Goulds Pumps AF-MXR Bearings User Manual

Installation, Operation and Maintenance Instructions

Model AF (6”-36”) MXR Bearings

FOREWORD

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 in this 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

AF (6-36) IOM

TABLE OF CONTENTS

Page

SAFETY

GENERAL INFORMATION

INSTALLATION

OPERATION

PREVENTATIVE MAINTENANCE

Section

AF (6-36) IOM

DISASSEMBLY & RE-ASSEMBLY

SPARE PARTS

APPENDIX 1

THIS PAGE

INTENTIONALLY

LEFT BLANK

AF (6-36) IOM

IMPORTANT SAFETY NOTICE

To: Our Valued Customers

User safety is a major focus in the design of our products. Following the precautions outlined in this manual will minimize your risk of injury.

ITT Goulds pumps will provide safe, trouble-free service when properly installed, maintained, and operated.

Safe installation, operation, and maintenance of ITT Goulds Pumps equipment are an essential end user responsibility. This Pump Safety Manual identifies specific safety risks that must be considered at all times during product life. Understanding and adhering to these safety warnings is mandatory to ensure personnel, property, and/or the environment will not be harmed. Adherence to these warnings alone, however, is not sufficient — it is anticipated that the end user will also comply with industry and corporate safety standards. Identifying and eliminating unsafe installation, operating and maintenance practices is the responsibility of all individuals involved in the installation, operation, and maintenance of industrial equipment.

Please take the time to review and understand the safe installation, operation, and maintenance guidelines outlined in this Pump Safety Manual and the Instruction, Operation, and Maintenance (IOM) manual. Current manuals are available at your nearest Goulds Pumps sales representative.

www.gouldspumps.com/literature_ioms.html or by contacting

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

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

www.gouldspumps.com.

S-1

SAFETY WARNINGS

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

WARNING

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

WARNING

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

WARNING

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

WARNING

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

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

S-2

SAFETY

DEFINITIONS

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

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

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Example: Pump shall never be operated without coupling guard installed correctly.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Example: Throttling flow from the suction side may cause cavitation and pump damage.

ELECTRICAL HAZARD



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

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

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

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

Example:

parts, resulting in a spark and heat generation.

 Improper impeller adjustment could cause contact between the rotating and stationary

S-3

GENERAL PRECAUTIONS

WARNING

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

General Precautions

WARNING

NEVER use heat to disassemble pump due to risk of explosion from tapped liquid.

NEVER APPLY HEAT TO REMOVE IMPELLER. It may explode due to trapped liquid.

WARNING

NEVER operate pump without coupling guard correctly installed.





NEVER operate pump without safety devices installed.

 



NEVER run pump below recommended minimum flow when dry, or without prime.

ALWAYS lock out power to the driver before performing pump maintenance.

NEVER operate pump with discharge valve closed.

NEVER operate pump with suction valve closed.

DO NOT change service application without approval of an authorized ITT Goulds Pumps representative.

Safety Apparel:

 Insulated work gloves when handling hot bearings or using bearing heater  Heavy work gloves when handling parts with sharp edges, especially

impellers

 Safety glasses (with side shields) for eye protection  Steel-toed shoes for foot protection when handling parts, heavy tools, etc.  Other personal protective equipment to protect against hazardous/toxic fluids

Receiving:

Assembled pumping units and their components are heavy. Failure to properly lift and support equipment can result in serious physical injury and/or equipment damage. Lift equipment only at specifically identified lifting points or as instructed in the current IOM. Current manuals are available at

www.gouldspumps.com/literature_ioms.html or from your local ITT Goulds

Pumps sales representative. Note: Lifting devices (eyebolts, slings, spreaders, etc.) must be rated, selected, and used for the entire load being lifted.

Alignment:

WARNING

Shaft alignment procedures must be followed to prevent catastrophic failure of



drive components or unintended contact of rotating parts. Follow coupling manufacturer’s coupling installation and operation procedures.

S-4

WARNING

CAUTION

General Precautions

Before beginning any alignment procedure, make sure driver power is locked out.



Failure to lock out driver power will result in serious physical injury.

Piping:

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



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

WARNING

CAUTION

WARNING

Flanged Connections:

Use only fasteners of the proper size and material.

Replace all corroded fasteners.

Ensure all fasteners are properly tightened and there are no missing fasteners.

Startup and Operation:

When installing in a potentially explosive environment, please ensure that the



motor is properly certified.

Operating pump in reverse rotation may result in contact of metal parts, heat



generation, and breach of containment.

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



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



unexpected heat generation and equipment damage.

If using a cartridge mechanical seal, the centering clips must be installed and set screws loosened prior to setting impeller clearance. Failure to do so could result



in sparks, heat generation, and mechanical seal damage.

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



and must be constructed from a non-sparking material.

Never operate a pump without coupling guard properly installed. Personal injury will occur if pump is run without coupling guard.

Make sure to properly lubricate the bearings. Failure to do so may result in excess



heat generation, sparks, and / or premature failure.

The mechanical seal used in an ATEX classified environment must be properly certified. Prior to start up, ensure all points of potential leakage of process fluid to



the work environment are closed.

Never operate the pump without liquid supplied to mechanical seal. Running a mechanical seal dry, even for a few seconds, can cause seal damage and must be



avoided. Physical injury can occur if mechanical seal fails.

Never attempt to replace packing until the driver is properly locked out and the coupling spacer is removed.

WARNING

Dynamic seals are not allowed in an ATEX classified environment.



DO NOT operate pump below minimum rated flows or with suction and/or discharge valve closed. These conditions may create an explosive hazard due to



vaporization of pumpage and can quickly lead to pump failure and physical injury.

S-5

WARNING

CAUTION

WARNING

CAUTION

General Precautions

Ensure pump is isolated from system and pressure is relieved before disassembling pump, removing plugs, opening vent or drain valves, or disconnecting piping.

Shutdown, Disassembly, and Reassembly:

Pump components can be heavy. Proper methods of lifting must be employed to avoid physical injury and/or equipment damage. Steel toed shoes must be worn at all times.

The pump may handle hazardous and/or toxic fluids. Observe proper decontamination procedures. Proper personal protective equipment should be worn. Precautions must be taken to prevent physical injury. Pumpage must be handled and disposed of in conformance with applicable environmental regulations.

Operator must be aware of pumpage and safety precautions to prevent physical injury.

Lock out driver power to prevent accidental startup and physical injury.

Allow all system and pump components to cool before handling them to prevent physical injury.

If pump is a Model NM3171, NM3196, 3198, 3298, V3298, SP3298, 4150, 4550, or 3107, there may be a risk of static electric discharge from plastic parts that are not properly grounded. If pumped fluid is non-conductive, pump should be



drained and flushed with a conductive fluid under conditions that will not allow for a spark to be released to the atmosphere.

Never apply heat to remove an impeller. The use of heat may cause an explosion due to trapped fluid, resulting in severe physical injury and property damage.

Wear heavy work gloves when handling impellers as sharp edges may cause physical injury.

Wear insulated gloves when using a bearing heater. Bearings will get hot and can cause physical injury.

S-6

ATEX CONSIDERATIONS and INTENDED USE

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

1. Monitoring the pump frame and liquid end temperature.

2. Maintaining proper bearing lubrication.

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

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

All pumping unit (pump, seal, coupling, motor and pump accessories) certified for use in an ATEX classified environment, are identified by an ATEX tag secured to the pump or the baseplate on which it is mounted. A typical tag would look like this:

www.gouldspumps.com/literature_ioms.html or from your local ITT Goulds

The CE and the Ex designate the ATEX compliance. The code directly below these symbols reads as follows:

II = Group 2 2 = Category 2 G/D = Gas and Dust present T4 = Temperature class, can be T1 to T6 (see Table 1)

Table 1

Max permissible

surface temperature

Code

T1 842 (450) 700 (372)

T2 572 (300) 530 (277)

T3 392 (200) 350 (177)

T4 275 (135) 235 (113)

T5 212 (100) Option not available

T6 185 (85) Option not available

F (oC)

The code classification marked on the equipment must be in accordance with the specified area where the equipment will be installed. If it is not, do not operate the equipment and contact your ITT Goulds Pumps sales representative before proceeding.

Max permissible

liquid temperature

F (oC)

S-7

PARTS

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

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

S-8

GENERAL INFORMATION

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

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

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

INSTALLATION AND OPERATION CHECKLIST ........................................ 14

PUMP DESCRIPTION

The AF pump generates flow by the thrust or lift action of rotating axial vanes of the impeller. Axial flow pumps generate high flow rates and low head which are ideal for re-circulation, evaporator, and generator cooling systems. The AF has an elbow that directs the flow through the suction and out the discharge end of the pump. It can be used in the top or end suction configuration depending on the customer’s needs. Refer to original factory documentation for the arrangement of your pump. The model AF is based on (6) power ends and (12) hydraulic pump sizes. The first (3) power ends have ball bearings, the others have taper and spherical roller bearings. Groupings are as follows:

Power Inboard Outboard Pump End

Bearing Bearing Size

1MXR Ball (2) Ang. Contact 6”, 8”, 10” 2MXR Ball (2) Ang. Contact 12”, 14” 3MXR Ball (2) Ang. Contact 16”, 18” 4MXR Sphrcl Roller Taper Roller 20”, 24” 5MXR Sphrcl Roller Taper Roller 700mm, 30” 6MXR Sphrcl Roller Taper Roller 36”

Elbow – The elbow is cast with 150# flat face suction and discharge flanges, it comes with an opening in the rear for a back-pullout. The back-pullout consists of the bearing housing, shaft, and impeller. The elbow has cast feet for mounting to a sub-base or it can be mounted directly in the piping. It also comes with an optional elbow liner.

Elbow or Casing Liner (Optional) – An optional liner provides erosion and corrosion protection for longer elbow or casing life. It may also come with a serrated inside diameter for pumping stringy material.

Back-Pullout - The back-pullout is based on the (6) power ends listed previously. It consists of a bearing housing, bearings, stuffing box cover, locknuts,

lockwashers, labyrinth oil seals, shaft, shaft sleeve (w/packing), oil slinger (20” ~36”), impeller, keys, shaft washer, and a front and back foot.

Stuffing Box Cover – The cast stuffing box cover is used to close the rear of the elbow and provide a mounting surface for a mechanical seal or stuffing box and gland. Inside it has a machined flat face with a (3) or (4) bolt pattern to accept a stuffing box or standard cartridge mechanical seal. When used with a mechanical seal it has a cast in 5 deg. taper bore opening to assist in ejecting particles from the seal area. The cover comes with adjusting ears that allow for centering on the shaft and also to center the impeller in the elbow.

Mechanical Seal Adapter (Optional) – An optional adapter is used when the mechanical seal requires a restrictor bushing. The restrictor bushing is supplied with the mechanical seal.

Optional Packed Stuffing Box / Sleeve – The stuffing box is

cast and is separate from the elbow and stuffing box cover. It comes with a replaceable wear sleeve that is keyed to the shaft. Included are 5 rings of packing and a lantern ring to seal the shaft area. Two flush ports provide packing lubrication. A gland is used for packing adjustment. The stuffing box can also be modified to accept a mechanical seal if required.

Casing – A sacrificial wear casing is provided on the 700mm and 36” sizes. Adjusting lugs are used to center the casing relative to the impeller. The casing has 150# flanges for mounting to the elbow and comes with an optional liner.

Impeller - The impeller is cast with (4) fixed vanes. It is machined with internal steps for easy assembly onto the shaft. It comes configured for 0 or +5 degree, clockwise or counterclockwise rotation, and top or end suction. The impeller is held in place with a shaft washer and bolts. The 700mm and 36” impellers come with cover plates and o-rings, to seal them from the pumpage.

AF (6-36) IOM 11

The seal prevents corrosion and allows for easy impeller replacement. The impeller is dynamically balanced (double plane) per ISO 1940 to a quality grade G-16.

Shaft – The shaft is cantilevered into the pump elbow to eliminate the need for internal bearings. It is designed to have small deflections, high critical speeds, and corrosion resistance. The shafts are stepped for easy assembly with the impeller.

Bearings - The inboard radial bearing absorbs radial loads and aligns the pump shaft. It is either a ball or spherical roller bearing, depending on pump size. The outboard thrust bearing absorbs 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 option is available on 12” and larger sizes. A coiled tube mounted inside the bearing housing circulates water to cool the oil bath. It is attached to the bottom of the

bearing housing by a removable bottom plate and gasket. It is generally used when process temperatures cause excessive heat build up in the bearing housing and or bearings.

Configurations and Drives – Most AF pumps are Vbelt driven to allow for varying speeds. V-belts can be configured for side by side, overhead, under-slung, or vertical operation. The pumps can also be configured with gear reducers and or jack shafts for direct connect operation.

Maximum Sphere Size – The maximum solid size that the AF can pass depends on the pump size. The following are the maximum sphere sizes for each pump:

Pump Sphere Pump Sphere Size

Size Size Size

6” 1.5” 18” 4.5” 8” 2.0” 20” 5.0” 10” 2.5” 24” 6.0” 12” 3.0” 700mm 6.0” 14” 3.5” 30” 7.5” 16” 4.0” 36” 9.0”

NAMEPLATE INFORMATION

Every Goulds 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 (Example 20”X20”-20”, 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.

Fig. 1

12 AF (6-36) IOM

RECEIVING THE PUMP

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

STORAGE REQUIREMENTS

Short Term: (Less than 6 months) Goulds normal packaging 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) Goulds long-term packaging via crating. Preservative treatment of bearings and machined surfaces is required. Rotate the shaft several times every 3 months. Refer to driver manufacturers instruction manual for their long-term storage procedures. Store in a covered dry location.

Note: Long term storage treatment can be purchased with initial pump order.

UNCRATING/DE-SKIDDING

Care should be taken when uncrating or de-skidding pumps. If shipment is not delivered in good 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 sheets as well as the instruction book for the pump is included in the shipment - DO NOT DISCARD.

HANDLING

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 does not come in contact with 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 (Figs. 2 and 3 show examples of proper lifting techniques).

WARNING

FIG. 3

FIG. 2

AF (6-36) IOM 13

INSTALLATION AND OPERATION CHECKLIST

Model AF

COMPLETE INITIAL DESCRIPTION PAGE NO.

Manual read and understood 1~69 Level foundation 15 Level subbase 15 ~ 19 Check motor rotation ---CW ---CCW 29 Component rough alignment complete 21 ~ 28 V-belt tension and alignment per drive mfgr. 21 Coupling alignment per cplg mfgr. 23 Piping installed and alignment rechecked 21,22,36 Mech. seal adjusted per mfgr. Mfgrs Mnl Seal flush connected 33,34 Impeller alignment and clearance set Inch/Side 26 ~ 28 Pump shaft-free turnin Bearing types and lubrication 12,32,39 V-belt or coupling guards installed 60,61 Motor electrical connections Mfgrs Mnl

14 AF (6-36) IOM

INSTALLATION

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

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

SUB-BASE INSTALLATIONS ...................................................................... 16

PIPE HUNG INSTALLATIONS ..................................................................... 19

CONNECTION OF PIPING ............................................................................ 20

DRIVE ALIGNMENT PROCEDURES ........................................................... 21

IMPELLER ALIGNMENT .............................................................................. 28

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

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

All equipment being installed must be properly grounded to prevent unexpected static electric discharge. If not, a static electric discharge may occur when the pump is drained and disassembled for maintenance purposes.

LOCATION/FOUNDATION

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 shall 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.

The most commonly used foundation bolts are the sleeve-type (Fig 4) and J type (Fig. 5).

BASEPLATE

BOLT

SHIMS

DAM

SLEEVE

Fig. 4

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.

AF (6-36) IOM 15

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 INSTALLATIONS

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. 6). The coupling should not be reconnected until all realignment operations have been completed. A recommended coupling alignment procedure is included in the following sections.

SHIMS OR WEDGES

Fig. 6

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. 7).

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.

BASEPLATE

J-BOLT

SHIMS

DAM

Fig. 5

SHIMS OR WEDGES

Fig. 7

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” - ¼” 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. 8)

16 AF (6-36) IOM

BASEPLATE

BOLT

GROUT

DAM

FOUNDATION

Fig. 8

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. 9)

BASEPLATE

BOLT

SPRING POCKETS

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 when the system is cold. The jam nut keeps the stop nut from turning during normal operation when the sub-base 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.

Fig. 10

DAM

9. Allow grout to set at least 48 hours.

10. Tighten foundation bolts.

GROUT

FOUNDATION

Fig. 9

SPRING MOUNTED BASE

Fig. 10 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.

The following is a brief description of the spring pocket components and their function (see Fig. 11). 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

Fig. 11

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:

AF (6-36) IOM 17

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”) should exist between the flange of the vertical pipe and the pump elbow with the gasket in place (Fig. 12).

FLANGE BOLTS

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

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 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 installation drawing may indicate the approximate number of turns required for each

WARNING

Do not tighten bolts.

1/16”

Fig. 12

spring location, 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” 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”, turn the adjusting screws a uniform amount to close the gap. For a gap of 1/32” or less, omit this step.

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.

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 being 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 sub-base deck through the proper oil level line will show the correct level at the highest end of the bearing housing. A horizontal 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

Spring Size Wire Size Spring Rate Adjusting Screw Size Load Change per Full Turn

1 .812” 1140 #/in. 1-1/2”-6 UNC 190 # 2 .750” 760 #/in. 1-1/2”-6 UNC 127 # 3 .532” 560 #/in. 1-1/2”-6 UNC 93 # 4 1.00” 1000 #/in. 2”-4-1/2 UNC 222 # 5 .375” 133 #/in. ¾”-10 UNC 13 #

Table 1

18 AF (6-36) IOM

screw holders un-grouted. 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 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 sub-base will affect the pump alignment,

4. and the weight of the components is more likely to cause distortion when the pump is connected to the rigid pipe system.

5. If a spring is replaced while the system is hot, the stop nut should not be set until the system is cold.

6. The springs must be allowed to push the base back to its cold position.

An optional grease filled spring pocket is shown in figure

13. 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.

PIPE HUNG INSTALLATIONS

PIPE SUPPORT DESIGN REQUIREMENTS

1. Piping supports must meet Hydraulic Institute, ASME/ANSI, DIN requirements, in conjunction with standard construction practices.

2. Piping shall be stiff enough to prevent unwanted pump vibrations.

3. Thermal expansion of the piping must be accounted for by the piping/system designer.

4. Refer to the installation/dimensional drawing for pump weights

5. Refer to pump flange load drawing for allowable loads

6. Follow the power transmission manufacturer’s recommendations for angular limits and thermal movement of the pump relative to pump driver.

NOTE: Future access to the pump impeller and shaft will require removal of a section of the horizontal pipe. The piping shall have a spool piece for this purpose (See Fig. 14).

Fig. 13

Upper

Spool Piece

Lower Flange

Flange

Fig. 14

INSTALLATION OF THE PUMP IN THE PIPING

1. Connect the elbow upper flange to the vertical pipe run and tighten the flange bolts.

2. Check the impeller clearance in the elbow/casing to be sure it is well centered using the criteria that the minimum gap at the vane O.D. is at least ½ the maximum gap. See the impeller check sheet on pg. 28 of this IOM.

AF (6-36) IOM 19

3. Connect the horizontal pipe or spool piece to the elbow lower flange and tighten the flange bolts.

4. Check pump for level. Pump should be less than 1/2 degree (0.1”/ft) from horizontal so bearings are not starved of oil (see Fig.15). Be sure thermal expansion does not cause this angle to be exceeded.

Must be less than 1/2 degree

Exaggerated for effect

Fig. 15

5. With the underslung arrangement install the motor after the pump is connected to the piping. Be sure motor shaft is parallel to the pump shaft in the horizontal and vertical plane (see Fig.16).

Fig. 16

6. If pump unit is direct drive utilizing a drive shaft, refer to the drive shaft manufacturer’s installation manual for mounting instructions.

NOTE: PIPE FLANGES 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 will cause excessive strain on the pump.

CONNECTION OF PIPING

GENERAL

Never draw piping into place by forcing at the flanged connections of the pump. This may impose dangerous strains on the unit and cause misalignment between pump and driver. Pipe strain will adversely effect the operation of the pump resulting in physical injury and damage to the equipment.

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.

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

WARNING

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.

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.

20 AF (6-36) IOM

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