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
3
TABLE OF CONTENTS
Page
9
11
15
31
37
SAFETY
GENERAL INFORMATION
INSTALLATION
OPERATION
PREVENTATIVE MAINTENANCE
Section
1
2
3
4
5
45
67
69
AF (6-36) IOM
DISASSEMBLY & RE-ASSEMBLY
SPARE PARTS
APPENDIX 1
6
7
8
7
THIS PAGE
INTENTIONALLY
LEFT BLANK
8
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
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
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
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
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
CAUTION
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
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
WARNING
WARNING
WARNING
WARNING
CAUTION
CAUTION
WARNING
CAUTION
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
o
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
o
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.
2
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
2
FIG. 3
FIG. 2
AF (6-36) IOM 13
g
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
32
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.
3
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
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
3
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.
3
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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