Goulds Pumps IC User Manual

Goulds Pumps

Installation, Operation, and Maintenance Manual

Model IC, ICI, ICH, ICIH

Table of Contents

Introduction and Safety...................................................................................................................................................4

Introduction.......................................................................................................................................................................4

Requesting other information......................................................................................................................................4

Safety...................................................................................................................................................................................4

Safety terminology and symbols..................................................................................................................................5

Environmental safety.....................................................................................................................................................6

User safety.......................................................................................................................................................................6

Ex-approved products...................................................................................................................................................7

Product warranty...............................................................................................................................................................8

Transportation and Storage............................................................................................................................................9

Inspect the delivery...........................................................................................................................................................9

Inspect the package........................................................................................................................................................9

Inspect the unit...............................................................................................................................................................9

Transportation guidelines.................................................................................................................................................9

Pump handling and lifting............................................................................................................................................9

Storage guidelines............................................................................................................................................................10

Long-term storage.......................................................................................................................................................10

Table of Contents

Product Description........................................................................................................................................................11

General description.........................................................................................................................................................11

Nameplate information..................................................................................................................................................12

Installation.........................................................................................................................................................................14

Preinstallation...................................................................................................................................................................14

Pump location guidelines............................................................................................................................................14

Foundation requirements............................................................................................................................................15

Baseplate-mounting procedures....................................................................................................................................15

Prepare the baseplate for mounting..........................................................................................................................15

Prepare the foundation for mounting.......................................................................................................................16

Install the baseplate using shims or wedges.............................................................................................................16

Install the baseplate using jackscrews.......................................................................................................................17

Install the baseplate using spring mounting.............................................................................................................18

Install the baseplate using stilt mounting.................................................................................................................19

Baseplate-leveling worksheet......................................................................................................................................21

Install the pump, driver, and coupling.........................................................................................................................22

Pump-to-driver alignment..............................................................................................................................................22

Alignment checks.........................................................................................................................................................22

Permitted indicator values for alignment checks....................................................................................................23

Alignment measurement guidelines..........................................................................................................................23

Attach the dial indicators for alignment...................................................................................................................24

Pump-to-driver alignment instructions....................................................................................................................24

Grout the baseplate.........................................................................................................................................................27

Piping checklists..............................................................................................................................................................28

General piping checklist..............................................................................................................................................28

Permitted nozzle loads and torques at the pump nozzles.....................................................................................30

Suction-piping checklist..............................................................................................................................................32

Discharge piping checklist..........................................................................................................................................34

Bypass-piping considerations.....................................................................................................................................35

Auxiliary-piping checklist............................................................................................................................................36

Final piping checklist...................................................................................................................................................36

Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual 1

Table of Contents

Commissioning, Startup, Operation, and Shutdown............................................................................................37

Preparation for startup...................................................................................................................................................37

Remove the coupling guard...........................................................................................................................................37

Check the rotation...........................................................................................................................................................39

Couple the pump and driver..........................................................................................................................................40

Install the coupling guard...........................................................................................................................................40

Bearing lubrication..........................................................................................................................................................42

Lubricating oil requirements......................................................................................................................................42

Lubricate the bearings with oil...................................................................................................................................43

Lubricating-grease requirements...............................................................................................................................44

Shaft-sealing options.......................................................................................................................................................44

Mechanical seal options..............................................................................................................................................45

Connection of sealing liquid for mechanical seals..................................................................................................45

Packed stuffing box option.........................................................................................................................................45

Connection of sealing liquid for a packed stuffing box.........................................................................................45

Pump priming..................................................................................................................................................................46

Prime the pump with the suction supply above the pump...................................................................................46

Prime the pump with the suction supply below the pump...................................................................................46

Other methods of priming the pump.......................................................................................................................48

Start the pump.................................................................................................................................................................48

Limits of operation......................................................................................................................................................48

Pump operation precautions.........................................................................................................................................49

Shut down the pump......................................................................................................................................................50

Make the final alignment of the pump and driver......................................................................................................50

Maintenance......................................................................................................................................................................51

Maintenance schedule.....................................................................................................................................................51

Bearing maintenance.......................................................................................................................................................52

Lubricating oil requirements......................................................................................................................................52

Change the oil...............................................................................................................................................................53

Lubricating-grease requirements...............................................................................................................................53

Regrease the grease-lubricated bearings...................................................................................................................53

Shaft seal maintenance...................................................................................................................................................53

Mechanical-seal maintenance.....................................................................................................................................53

Packed stuffing-box maintenance..............................................................................................................................54

Disassembly......................................................................................................................................................................55

Disassembly precautions.............................................................................................................................................55

Tools required...............................................................................................................................................................55

Drain the pump............................................................................................................................................................55

Remove the coupling...................................................................................................................................................56

Remove the back pull-out assembly..........................................................................................................................56

Remove the coupling hub...........................................................................................................................................57

Remove the impeller....................................................................................................................................................57

Remove the seal-chamber cover ...............................................................................................................................59

Remove the stuffing-box cover .................................................................................................................................60

Disassemble the power end........................................................................................................................................60

Pre-assembly inspections...............................................................................................................................................62

Replacement guidelines...............................................................................................................................................62

Shaft and sleeve replacement guidelines...................................................................................................................66

Bearing-frame inspection............................................................................................................................................66

Seal chamber and stuffing box cover inspection.....................................................................................................67

Bearings inspection......................................................................................................................................................68

Reassembly.......................................................................................................................................................................68

Assemble the rotating element and bearing frame.................................................................................................68

Shaft sealing..................................................................................................................................................................71

Install the impeller.......................................................................................................................................................73

2 Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual

Table of Contents

Install the back pull-out assembly ............................................................................................................................74

Post-assembly checks...................................................................................................................................................75

Assembly references....................................................................................................................................................75

Troubleshooting...............................................................................................................................................................79

Operation troubleshooting............................................................................................................................................79

Alignment troubleshooting............................................................................................................................................80

Assembly troubleshooting.............................................................................................................................................80

Parts Listings and Cross-Sectional Drawings.........................................................................................................82

Parts list.............................................................................................................................................................................82

Other Relevant Documentation or Manuals...........................................................................................................84

For additional documentation.......................................................................................................................................84

Local ITT Contacts.........................................................................................................................................................85

Regional offices................................................................................................................................................................85

Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual 3

Introduction and Safety

Introduction

Purpose of this manual

The purpose of this manual is to provide necessary information for:

• Installation

• Operation

• Maintenance

CAUTION:

Read this manual carefully before installing and using the product. Improper use of the product can cause

personal injury and damage to property, and may void the warranty.

NOTICE:

Save this manual for future reference, and keep it readily available at the location of the unit.

Requesting other information

Special versions can be supplied with supplementary instruction leaflets. See the sales contract for any

modifications or special version characteristics. For instructions, situations, or events that are not

considered in this manual or in the sales documents, please contact the nearest ITT representative.

Always specify the exact product type and identification code when requesting technical information or

spare parts.

Safety

WARNING:

• The operator must be aware of safety precautions to prevent physical injury.

• Any pressure-containing device can explode, rupture, or discharge its contents if it is over-pressurized. Take all necessary measures to avoid over-pressurization.

• Operating, installing, or maintaining the unit in any way that is not covered in this manual could cause death, serious personal injury, or damage to the equipment. This includes any modification to the equipment or use of parts not provided by ITT. If there is a question regarding the intended use of the equipment, please contact an ITT representative before proceeding.

• This manual clearly identify accepted methods for disassembling units. These methods must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in their removal.

• Do not change the service application without the approval of an authorized ITT representative.

CAUTION:

You must observe the instructions contained in this manual. Failure to do so could result in physical injury, damage, or delays.

4 Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual

Safety terminology and symbols

About safety messages

It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product. They are published to help prevent these hazards:

• Personal accidents and health problems

• Damage to the product

• Product malfunction

Hazard levels

Hazard level Indication

DANGER:

WARNING:

Introduction and Safety

A hazardous situation which, if not avoided, will result in death or serious injury

A hazardous situation which, if not avoided, could result in death or serious injury

Hazard categories

A hazardous situation which, if not avoided, could

CAUTION:

NOTICE:

Hazard categories can either fall under hazard levels or let specific symbols replace the ordinary hazard level symbols.

Electrical hazards are indicated by the following specific symbol:

Electrical Hazard:

These are examples of other categories that can occur. They fall under the ordinary hazard levels and may use complementing symbols:

• Crush hazard

• Cutting hazard

• Arc flash hazard

result in minor or moderate injury

• A potential situation which, if not avoided, could result in undesirable conditions

• A practice not related to personal injury

The Ex symbol

The Ex symbol indicates safety regulations for Ex-approved products when used in atmospheres that are potentially explosive or flammable.

Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual 5

Introduction and Safety

Environmental safety

The work area

Always keep the station clean to avoid and/or discover emissions.

Waste and emissions regulations

Observe these safety regulations regarding waste and emissions:

• Appropriately dispose of all waste.

• Handle and dispose of the processed liquid in compliance with applicable environmental regulations.

• Clean up all spills in accordance with safety and environmental procedures.

• Report all environmental emissions to the appropriate authorities.

Electrical installation

For electrical installation recycling requirements, consult your local electric utility.

Recycling guidelines

Always follow local laws and regulations regarding recycling.

User safety

General safety rules

These safety rules apply:

• Always keep the work area clean.

• Pay attention to the risks presented by gas and vapors in the work area.

• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards.

• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.

Safety equipment

Electrical connections

Wash the skin and eyes

Use safety equipment according to the company regulations. Use this safety equipment within the work area:

• Helmet

• Safety goggles, preferably with side shields

• Protective shoes

• Protective gloves

• Gas mask

• Hearing protection

• First-aid kit

• Safety devices

NOTICE:

Never operate a unit unless safety devices are installed. Also see specific information about safety devices in other chapters of this manual.

Electrical connections must be made by certified electricians in compliance with all international, national, state, and local regulations. For more information about requirements, see sections dealing specifically with electrical connections.

Do the following if chemicals or hazardous fluids have come into contact with your eyes or your skin:

6 Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual

Introduction and Safety

If you need to wash your...

Eyes

Skin

Then...

1. Hold your eyelids apart forcibly with your fingers.

2. Rinse the eyes with eyewash or running water for at least 15 minutes.

3. Seek medical attention.

1. Remove contaminated clothing.

2. Wash the skin with soap and water for at least one minute.

3. Seek medical attention, if required.

Ex-approved products

Follow these special handling instructions if you have an Ex-approved unit.

Personnel requirements

These are the personnel requirements for Ex-approved products in potentially explosive atmospheres:

• All work on the product must be carried out by certified electricians and ITT-authorized mechanics. Special rules apply to installations in explosive atmospheres.

• All users must know about the risks of electric current and the chemical and physical characteristics of the gas, the vapor, or both present in hazardous areas.

• Any maintenance for Ex-approved products must conform to international and national standards (for example, IEC/EN 60079-17).

ITT disclaims all responsibility for work done by untrained and unauthorized personnel.

Product and product handling requirements

These are the product and product handling requirements for Ex-approved products in potentially explosive atmospheres:

• Only use the product in accordance with the approved motor data.

• The Ex-approved product must never run dry during normal operation. Dry running during service and inspection is only permitted outside the classified area.

• Before you start work on the product, make sure that the product and the control panel are isolated from the power supply and the control circuit, so they cannot be energized.

• Do not open the product while it is energized or in an explosive gas atmosphere.

• Make sure that thermal contacts are connected to a protection circuit according to the approval classification of the product, and that they are in use.

• Intrinsically safe circuits are normally required for the automatic level-control system by the level regulator if mounted in zone 0.

• The yield stress of fasteners must be in accordance with the approval drawing and the product specification.

• Do not modify the equipment without approval from an authorized ITT representative.

• Only use parts that are provided by an authorized ITT representative.

Description of ATEX

The ATEX directives are a specification enforced in Europe for electrical and non-electrical equipment installed in Europe. ATEX deals with the control of potentially explosive atmospheres and the standards of equipment and protective systems used within these atmospheres. The relevance of the ATEX requirements is not limited to Europe. You can apply these guidelines to equipment installed in any potentially explosive atmosphere.

Guidelines for compliance

Compliance is fulfilled only when you operate the unit within its intended use. Do not change the conditions of the service without the approval of an ITT representative. When you install or maintain explosion proof products, always comply with the directive and applicable standards (for example, IEC/ EN 60079–14).

Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual 7

Introduction and Safety

Product warranty

Coverage

ITT undertakes to remedy faults in products from ITT under these conditions:

• The faults are due to defects in design, materials, or workmanship.

• The faults are reported to an ITT representative within the warranty period.

• The product is used only under the conditions described in this manual.

• The monitoring equipment incorporated in the product is correctly connected and in use.

• All service and repair work is done by ITT-authorized personnel.

• Genuine ITT parts are used.

• Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved products.

Limitations

The warranty does not cover faults caused by these situations:

• Deficient maintenance

• Improper installation

• Modifications or changes to the product and installation made without consulting ITT

• Incorrectly executed repair work

• Normal wear and tear

ITT assumes no liability for these situations:

• Bodily injuries

• Material damages

• Economic losses

Warranty claim

ITT products are high-quality products with expected reliable operation and long life. However, should the need arise for a warranty claim, then contact your ITT representative.

8 Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual

Transportation and Storage

Inspect the delivery

Inspect the package

1. Inspect the package for damaged or missing items upon delivery.

2. Note any damaged or missing items on the receipt and freight bill.

3. File a claim with the shipping company if anything is out of order.

If the product has been picked up at a distributor, make a claim directly to the distributor.

Inspect the unit

1. Remove packing materials from the product.

Dispose of all packing materials in accordance with local regulations.

2. Inspect the product to determine if any parts have been damaged or are missing.

3. If applicable, unfasten the product by removing any screws, bolts, or straps.

For your personal safety, be careful when you handle nails and straps.

4. Contact your sales representative if anything is out of order.

Transportation and Storage

Transportation guidelines

Pump handling and lifting

Precautions for moving the pump

Use care when moving pumps.

WARNING:

Make sure that the pump cannot roll or fall over and injure people or damage property.

NOTICE:

Use a forklift truck with sufficient capacity to move the pallet with the pump unit on top.

Keep the pump unit in the same position in which it was shipped from the factory.

Close the suction and discharge ends of the pump with plugs for transport and storage.

Precautions for lifting the pump

WARNING:

Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear steel-toed shoes at all times.

NOTICE:

• Make sure that the lifting equipment supports the entire assembly and is only used by authorized personnel.

• Do not attach sling ropes to shaft ends.

Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual 9

Transportation and Storage

Lifting the pump

Hoist the pump using a suitable sling under solid points such as the casing, flanges, or frame.

Storage guidelines

Long-term storage

If the pump is stored for more than 6 months, these requirements apply:

• Store in a covered and dry location.

• Store the unit free from heat, dirt, and vibrations.

• Rotate the shaft by hand several times at least every three months.

Treat bearing and machined surfaces so that they are well preserved. Refer to the drive unit and coupling manufacturers for their long-term storage procedures.

For questions about possible long-term storage treatment services, please contact your local ITT sales representative.

10 Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual

Product Description

General description

The model IC is a single-stage volute casing pump. Hydraulic design and dimensions comply with ISO 2858/ EN 22858. The technical design complies with ISO 5199/EN 25199. The model ICI additionally has an inducer. Models ICH and ICIH additionally have cooling or heating of the casing cover and/or the volute casing.

Product Description

Casing

Impeller

Seal chamber

Power end

Frame adapter

• Heavy-duty, top centerline discharge

• Integral cast feet

• Back pullout design

• Standard 3/8 in. NPT casing drain

• Optional renewable wear ring

The impeller is fully enclosed and key driven by the shaft. Standard back vanes or balance holes reduce axial thrust and seal chamber pressures.

• Wide choice of sealing arrangements for maximum sealing flexibility

• Patented “cyclone” seal chamber for improved lubrication, heat removal, and solids handling

• Confined casing gasket

• Large capacity oil sump reduces oil temperature for extended bearing life.

• Heavy-duty cast iron frame gives rigid support to the shaft and bearings for longer service.

• Magnetic drain plug maintains a clean oil environment for extended bearing life.

• Standard double lip seals at the pump and coupling end maintain a seal tight, clean operating environment.

• O-ring seal between the frame and adapter for optimized alignment and sealing.

• Provides safe and accurate alignment for the liquid end to the bearing frame.

• Large access windows make installation and maintenance of seal and auxiliary support systems trouble-free.

Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual 11

Product Description

Bearings

Heavy-duty ball bearings provide L10 bearing life in excess of 17,500 hours.

The size of the bearing bracket is shown in the data sheet and/or order confirmation.

Bearing bracket Bearing type

24 6307 - C3 3307A - C3 32 6309 - C3 3309A - C3 42 6311 - C3 3311A - C3 48 6313 - C3 3313A - C3

Shaft

Rigid shaft designed for less than 0.05 mm shaft deflection. Standard 400 series stainless steel shaft (1.4021) provides reliable power transmission and corrosion resistance at both the pump and coupling ends.

Intended applications

• ISO chemical process

• Industrial process

Nameplate information

Pump side Drive side

Pump nameplate

Nameplate field Explanation

Type* Type of pump

S/N* Serial number

Q Rated pump flow, in cubic meters per hour

P Rated pump power, in kilowatts

H Rated pump head, in meters

n Rated pump speed, in min

all w C

Maximum permitted casing-operation-pressure

-1

(Highest discharge pressure at the rated operating temperature to which the pump casing can be used)

max op

Maximum permitted operating temperature of pumped liquid

Item No Customer-related order number

Imp Ø Outer diameter of the impeller

MATL Material of construction

*All details of design and materials are defined with this information. You must specify these details when you order spare parts.

12 Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual

ATEX nameplate

Product Description

The conformity with the EC directive 94/9/EG "Appliances and Protection Systems for designated use in areas endangered to explosion" is declared by the issue of the EC Declaration of Conformity and the attachment of the ATEX label on the bearing bracket of the pump. The ATEX label is also attached to the pump nameplate.

Nameplate field Explanation

CE Marking of compliance with the EC directive 94/9/

Ex Specific marking for explosion protection

II Appliance group

2G Category (2) and explosive atmosphere due to gases,

vapors, or mist (G)

c ignition protection in use: constructual safety (c)

T1-T. Classification of the theoretically available range of

the temperature classes

Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual 13

Installation

Preinstallation

Precautions

WARNING:

• When installing in a potentially explosive environment, make sure that the motor is properly certified.

• You must earth (ground) all electrical equipment. This applies to the pump equipment, the driver, and any monitoring equipment. Test the earth (ground) lead to verify that it is connected correctly.

NOTICE: Supervision by an authorized ITT representative is recommended to ensure proper installation. Failure to do so may result in equipment damage or decreased performance.

Pump location guidelines

WARNING:

Assembled units and their components are heavy. Failure to properly lift and support this equipment can result in serious physical injury and/or equipment damage. Lift equipment only at the specifically identified lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated, selected, and used for the entire load being lifted.

Guideline Explanation/comment

Keep the pump as close to the liquid source as practically possible.

Make sure that the space around the pump is sufficient.

If you require lifting equipment such as a hoist or tackle, make sure that there is enough space above the pump.

Protect the unit from weather and water damage due to rain, flooding, and freezing temperatures.

Do not install and operate the equipment in closed systems unless the system is constructed with properly-sized safety devices and control devices.

Take into consideration the occurrence of unwanted noise and vibration.

This minimizes the friction loss and keeps the suction piping as short as possible.

This facilitates ventilation, inspection, maintenance, and service.

This makes it easier to properly use the lifting equipment and safely remove and relocate the components to a safe location.

This is applicable if nothing else is specified.

Acceptable devices:

• Pressure relief valves

• Compression tanks

• Pressure controls

• Temperature controls

• Flow controls If the system does not include these devices, consult

the engineer or architect in charge before you operate the pump.

The best pump location for noise and vibration absorption is on a concrete floor with subsoil underneath.

If the pump location is overhead, undertake special precautions to reduce possible noise transmission.

14 Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual

Consider a consultation with a noise specialist.

Foundation requirements

Requirements

• The foundation must be able to absorb any type of vibration and form a permanent, rigid support for the pump unit.

• The location and size of the foundation bolt holes must match those shown on the assembly drawing provided with the pump data package.

• The foundation must weigh between two and three times the weight of the pump.

• Provide a flat, substantial concrete foundation in order to prevent strain and distortion when you tighten the foundation bolts.

• Sleeve-type and J-type foundation bolts are most commonly used. Both designs allow movement for the final bolt adjustment.

• The concrete foundation must have sufficient firmness according to DIN 1045 or equal standard.

Sleeve-type bolts

Installation

1. Baseplate

2. Shims or wedges

3. Foundation

4. Sleeve

5. Dam

6. Bolt

J-type bolts

1. Baseplate

2. Shims or wedges

3. Foundation

4. Dam

5. Bolt

Baseplate-mounting procedures

Prepare the baseplate for mounting

1. Remove all the attached equipment from the baseplate.

2. Clean the underside of the baseplate completely.

Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual 15

3. If applicable, coat the underside of the baseplate with an epoxy primer.

Use an epoxy primer only if you used an epoxy-based grout.

4. Remove the rust-proofing coat from the machined mounting pads using an appropriate solvent.

5. Remove water and debris from the foundation-bolt holes.

Installation

Prepare the foundation for mounting

1. Chip the top of the foundation to a minimum of 1.0 in. (25.0 mm) in order to remove porous or lowstrength concrete.

If you use a pneumatic hammer, make sure that it does not contaminate the surface with oil or other moisture.

NOTICE: Do not chip the foundation using heavy tools such as jackhammers. This can damage the structural integrity of the foundation.

2. Remove water or debris from the foundation bolt holes or sleeves.

3. If the baseplate uses sleeve-type bolts, then fill the sleeves with a non-binding, moldable material. Seal the sleeves in order to prevent the grout from entering.

4. Coat the exposed portion of the anchor bolts with a non-bonding compound such as paste wax in order to prevent the grout from adhering to the anchor bolts.

Do not use oils or liquid wax.

5. If recommended by the grout manufacturer, coat the foundation surface with a compatible primer.

Install the baseplate using shims or wedges

Required tools:

• Two sets of shims or wedges for each foundation bolt

• Two machinist's levels

• Baseplate-leveling worksheet

This procedure is applicable to cast iron and fabricated steel baseplates.

1. If you use sleeve-type bolts, fill the bolt sleeves with packing material or rags to prevent grout from entering the bolt holes.

2. Put the sets of wedges or shims on each side of each foundation bolt.

The sets of wedges should have a height of between 0.75 in. (19 mm) and 1.50 in. (38 mm).

1. Shims or wedges

Figure 1: Top view

1. Shims or wedges

Figure 2: Side view

3. Lower the baseplate carefully onto the foundation bolts.

4. Put the machinist's levels across the mounting pads of the driver and the mounting pads of the pump.

16 Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual

NOTICE: Remove all dirt from the mounting pads in order to make sure that you achieve the

correct leveling. Failure to do so can result in equipment damage or decreased performance.

5. Level the baseplate both lengthwise and across by adding or removing shims or moving the wedges.

These are the leveling tolerances:

• A maximum difference of 0.125 in. (3.2 mm) lengthwise

• A maximum difference of 0.059 in. (1.5 mm) across

You can use the baseplate-leveling worksheet when you take the readings.

6. Hand-tighten the nuts for the foundation.

Install the baseplate using jackscrews

Tools required:

• Anti-seize compound

• Jackscrews

• Bar stock

• Two machinist's levels

• Baseplate-leveling worksheet

This procedure is applicable to the feature-fabricated steel baseplate and the advantage base baseplate.

1. Apply an anti-seize compound on the jackscrews.

The compound makes it easier to remove the screws after you grout.

2. Lower the baseplate carefully onto the foundation bolts and perform these steps:

a) Cut the plates from the bar stock and chamfer the edges of the plates in order to reduce stress

concentrations. b) Put the plates between the jackscrews and the foundation surface. c) Use the four jackscrews in the corners in order to raise the baseplate above the foundation.

Make sure that the distance between the baseplate and the foundation surface is between 0.75 in.

(19 mm) and 1.50 in. (38 mm). d) Make sure that the center jackscrews do not touch the foundation surface yet.

Installation

1. Jackscrew

2. Baseplate

3. Foundation

4. Plate

3. Level the driver mounting pads:

NOTICE: Remove all dirt from the mounting pads in order to make sure that you achieve the correct leveling. Failure to do so can result in equipment damage or decreased performance.

a) Put one machinist's level lengthwise on one of the two pads.

Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual 17

b) Put the other machinist's level across the ends of the two pads. c) Level the pads by adjusting the four jackscrews in the corners.

Installation

Make sure that the machinist's level readings are as close to zero as possible, both lengthwise and

across.

Use the baseplate-leveling worksheet when you take the readings.

1. Machinist's levels

2. Driver's mounting pads

3. Foundation bolts

4. Jackscrews

5. Grout hole

6. Pump's mounting pads

4. Turn the center jackscrews down so that they rest on their plates on the foundation surface.

5. Level the pump mounting pads:

NOTICE: Remove all dirt from the mounting pads in order to make sure that you achieve the correct leveling. Failure to do so can result in equipment damage or decreased performance.

a) Put one machinist's level lengthwise on one of the two pads. b) Put the other level across the center of the two pads. c) Level the pads by adjusting the four jackscrews in the corners.

Make sure that the machinist's level readings are as close to zero as possible, both lengthwise and

across.

1. Driver's mounting pads

2. Machinist's levels

3. Foundation bolts

4. Jackscrews

5. Grout hole

6. Pump's mounting pads

6. Hand-tighten the nuts for the foundation bolts.

7. Check that the driver's mounting pads are level and adjust the jackscrews and the foundation bolts if necessary.

The correct level measurement is a maximum of 0.002 in./ft (0.0167 mm/m).

Install the baseplate using spring mounting

NOTICE: The spring-mounted baseplate is designed only to support piping loads from thermal expansion. You must support the suction and discharge piping individually. Failure to do so may result in equipment damage.

The foundation pads are not provided with the baseplate. Make sure that the foundation pads are 316

18 Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual

stainless-steel plates, which have a 16-20 micro-inch surface finish.

Before you start this procedure, make sure that the foundation pads are correctly installed on the foundation/floor (see the manufacturer's instructions).

1. Put the baseplate on a support above the foundation/floor.

Make sure that there is enough space between the baseplate and the foundation/floor in order to install the spring assemblies.

2. Install the lower part of the spring assembly:

a) Screw the lower jam nut onto the spring stud. b) Screw the lower adjusting nut onto the spring-stud, on top of the jam nut. c) Set the lower adjusting nut to the correct height.

The correct height depends on the required distance between the foundation/floor and the baseplate.

d) Put a washer, a follower, a spring, and one more follower onto the lower adjusting nut.

3. Install the spring assembly on the baseplate:

a) Insert the spring assembly into the baseplate's anchorage hole from below. b) Put a follower, a spring, another follower, and a washer onto the spring stud. c) Fasten the spring assembly with the upper adjusting nut by hand.

4. Thread the upper jam nut onto the spring stud by hand.

5. Repeat steps 2 through 4 for all the spring assemblies.

6. Lower the baseplate so that the spring assemblies fit into the foundation pads.

7. Level the baseplate and make the final height adjustments:

a) Loosen the upper jam nuts and adjusting nuts. b) Adjust the height and level the baseplate by moving the lower adjusting nuts. c) When the baseplate is level, tighten the top adjusting nuts so that the top springs are not loose in

their followers.

8. Fasten the lower and upper jam nuts on each spring assembly.

Installation

Install the baseplate using stilt mounting

1. Upper jam nut

2. Follower

3. Washer

4. Foundation pads

5. Spring

6. Upper adjusting nut

7. Spring stud

Figure 3: Example of an installed spring assembly

NOTICE: The stilt-mounted baseplate is not designed to support static piping loads. Make sure to individually support the suction and discharge piping. Failure to do so may result in equipment damage.

Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual 19

Installation

1. Put the baseplate on a support above the foundation/floor.

Make sure that there is enough space between the baseplate and the foundation/floor to install the stilts.

2. Install the lower part of the stilt assembly:

a) Screw the lower jam nut and adjusting nut onto the stilt. b) Set the lower adjusting nut to the correct height.

The correct height depends on the required distance between the foundation/floor and the baseplate.

c) Put a washer onto the lower adjusting- nut.

3. Install the stilt assembly on the baseplate:

a) Insert the stilt assembly into the baseplate's anchorage hole from below. b) Put a washer onto the stilt. c) Fasten the stilt assembly with the upper adjusting nut by hand.

4. Screw the upper jam nut onto the stilt by hand.

5. Repeat steps 2 through 4 for all the stilt assemblies.

6. Lower the baseplate so that the stilts fit into the foundation cups.

7. Level the baseplate and make the final height adjustments:

a) Loosen the upper jam nuts and adjusting nuts. b) Adjust the height and level the baseplate by moving the lower adjusting nuts. c) When the baseplate is level, tighten the top adjusting nuts.

8. Fasten the lower and upper jam nuts on each stilt.

1. Mounting plate

2. Mounting nut

3. Stilt bolt

4. Foundation cups

5. Washer

6. Upper adjustment nut

7. Mounting washer

8. Mounting bolt

Figure 4: Example of an installed stilt assembly

20 Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual

Baseplate-leveling worksheet

1)____________________

2)____________________

3)____________________

4)____________________

5)____________________

6)____________________

7)____________________

8)____________________

9)____________________

10)___________________

11)___________________

12)___________________

13)___________________

14)___________________

15)___________________

16)___________________

17)___________________

18)___________________

Level measurements

Installation

Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual 21

Installation

Install the pump, driver, and coupling

1. Mount and fasten the pump on the baseplate. Use applicable bolts.

2. Mount the driver on the baseplate. Use applicable bolts and hand tighten.

3. Install the coupling.

See the installation instructions from the coupling manufacturer.

Pump-to-driver alignment

Precautions

WARNING:

• Follow shaft alignment procedures in order to prevent catastrophic failure of drive components or unintended contact of rotating parts. Follow the coupling installation and operation procedures from the coupling manufacturer.

• Always disconnect and lock out power to the driver before you perform any installation or maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical injury.

NOTICE: Proper alignment is the responsibility of the installer and the user of the unit. Check the alignment of frame-mounted units before you operate the unit. Failure to do so can result in equipment damage or decreased performance.

Alignment checks

When to perform alignment checks

You must perform alignment checks under these circumstances:

• The process temperature changes.

• The piping changes.

• The pump has been serviced.

Types of alignment checks

Type of check When it is used

Initial alignment (cold alignment) check

Final alignment (hot alignment) check

Initial alignment (cold alignment) checks

When Why

Before you grout the baseplate This ensures that alignment can be accomplished.

After you grout the baseplate This ensures that no changes have occurred during the grouting

After you connect the piping This ensures that pipe strains have not altered the alignment.

Prior to operation when the pump and the driver are at ambient temperature.

After operation when the pump and the driver are at operating temperature.

process.

If changes have occurred, you must alter the piping to remove pipe strains on the pump flanges.

Final alignment (hot alignment) checks

When Why

After the first run This ensures correct alignment when both the pump and the driver

are at operating temperature.

22 Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual

When Why

Periodically This follows the plant operating procedures.

Permitted indicator values for alignment checks

NOTICE: The specified permitted reading values are valid only at operating temperature. For cold settings, other values are permitted. You must use the correct tolerances. Failure to do so can result in misalignment and reduced pump reliability.

IMPORTANT

• For electric motors, the motor shaft initial (cold) parallel vertical alignment setting should be 0.002 to

0.004 in. (0.05 to 0.10 mm) lower than the pump shaft.

• For other drivers such as turbines and engines, follow the driver manufacturer's recommendations.

When dial indicators are used to check the final alignment, the pump and drive unit are correctly aligned when these conditions are true:

• The total indicator runout is a maximum of 0.002 in. (0.05 mm) at operating temperature.

• The tolerance of the indicator is 0.0005 in./in. (0.0127 mm/mm) of indicator separation at operating temperature.

Cold settings for parallel vertical alignment

Introduction

This section shows the recommended preliminary (cold) settings for electric motor-driven pumps based on different temperatures of pumped fluid. Consult driver manufacturers for recommended cold settings for other types of drivers such as steam turbines and engines.

Installation

NOTICE: For electric motors, the motor shaft setting should be 0.002–0.004 in (0.05–0.1 mm) lower than the pump shaft. For other drivers, follow the driver manufacturer's recommendations.

Recommended settings

Pumpage temperature Recommended setting

50°F (10°C) 0.002 in. (0.05 mm), low

150°F (65°C) 0.001 in. (0.03 mm), high

250°F (120°C) 0.005 in. (0.12 mm), high

350°F (175°C) 0.009 in. (0.23 mm), high

450°F (218°C) 0.013 in. (0.33 mm), high

550°F (228°C) 0.017 in. (0.43 mm), high

650°F (343°C) 0.021 in. (0.53 mm), high

700°F (371°C) 0.023 in. (0.58 mm), high

Alignment measurement guidelines

Guideline Explanation

Rotate the pump coupling half and the driver coupling half together so that the indicator rods have contact with the same points on the driver coupling half.

Move or shim only the driver in order to make adjustments. This prevents strain on the piping

Make sure that the hold-down bolts for the driver feet are tight when you take indicator measurements.

This prevents incorrect measurement.

installations.

This keeps the driver stationary since movement causes incorrect measurement.

Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual 23

Installation

Guideline Explanation

Make sure that the hold-down bolts for the driver feet are loose before you make alignment corrections.

Check the alignment again after any mechanical adjustments. This corrects any misalignments that an

Attach the dial indicators for alignment

You must have two dial indicators in order to complete this procedure.

1. Attach two dial indicators on the pump coupling half (X):

a) Attach one indicator (P) so that the indicator rod comes into contact with the perimeter of the

driver coupling half (Y).

This indicator is used to measure parallel misalignment.

b) Attach the other indicator (A) so that the indicator rod comes into contact with the inner end of

the driver coupling half.

This indicator is used to measure angular misalignment.

This makes it possible to move the driver when you make alignment corrections.

adjustment may have caused.

2. Rotate the pump coupling half (X) in order to check that the indicators are in contact with the driver coupling half (Y) but do not bottom out.

3. Adjust the indicators if necessary.

Pump-to-driver alignment instructions

Perform angular alignment for a vertical correction

1. Set the angular alignment indicator to zero at the top-center position (12 o’clock) of the driver coupling half (Y).

2. Rotate the indicator to the bottom-center position (6 o’clock).

3. Record the indicator reading.

When the reading value is...

Negative The coupling halves are farther apart at the bottom than at the top. Perform one of

Positive The coupling halves are closer at the bottom than at the top. Perform one of these

Then...

these steps:

• Add shims in order to raise the feet of the driver at the shaft end.

• Remove shims in order to lower the feet of the driver at the other end.

steps:

• Remove shims in order to lower the feet of the driver at the shaft end.

• Add shims in order to raise the feet of the driver at the other end.

24 Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual

Shims

Figure 5: Side view of an incorrect vertical alignment

Y X

4. Repeat the previous steps until the permitted reading value is achieved.

Perform angular alignment for a horizontal correction

1. Set the angular alignment indicator (A) to zero on left side of the driver coupling half (Y), 90° from the top-center position (9 o’clock).

2. Rotate the indicator through the top-center position to the right side, 180° from the start position (3 o’clock).

3. Record the indicator reading.

When the reading value is... Then...

Negative The coupling halves are farther apart on the right side than

the left. Perform one of these steps:

• Slide the shaft end of the driver to the left.

• Slide the opposite end to the right.

Positive The coupling halves are closer together on the right side

than the left. Perform one of these steps:

• Slide the shaft end of the driver to the right.

• Slide the opposite end to the left.

Installation

Figure 6: Top view of an incorrect horizontal alignment

4. Repeat the previous steps until the permitted reading value is achieved.

Perform parallel alignment for a vertical correction

Before you start this procedure, make sure that the dial indicators are correctly set up.

A unit is in parallel alignment when the parallel indicator (P) does not vary by more than 0.002 in. (0.05 mm) as measured at four points 90° apart at the operating temperature.

1. Set the parallel alignment indicator to zero at the top-center position (12 o’clock) of the driver coupling half.

2. Rotate the indicator to the bottom-center position (6 o’clock).

3. Record the indicator reading.

Model IC, ICI, ICH, ICIH Installation, Operation, and Maintenance Manual 25

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