Goulds Pumps VIC Installation, Operation And Maintenance Instructions

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INSTRUCTION MANUAL

IOMGWVICR01-EN

MODEL VIC

VERTICAL INDUSTRIAL TURBINE CAN PUMPS

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

Foreword

This manual provides instructions for the Installation, Operation, and Maintenance of the Goulds Water Technology Vertical Industrial Turbine Type Can Pumps. This manual covers a standard product. For special options, supplemental instructions are available. This manual must be read and understood before

installation and start-up.

This instruction manual covers several different pump models. Most assembly, disassembly, and inspection procedures are the same for all the pumps. However, where there are differences, these differences will be noted within the manual. The design, materials, and workmanship incorporated in the construction of the Goulds Water Technology VIC 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.

The information contained in this book is intended to assist operating personnel by providing information on the characteristics of the purchased equipment. It does not relieve the user of their responsibility of using accepted engineering practices in the installation, operation, and maintenance of this equipment.

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

Warranty is valid only when genuine Goulds Water Technology pumps parts are used.

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

For information or questions not covered in this manual, contact Goulds Water Technology at (806) 743-5700.

THIS MANUAL EXPLAINS :

• Proper Installation • Pump Overhaul

• Start-up Procedures • Trouble Shooting

• Operation Procedures • Ordering Spare or Repair Parts

• Routine Maintenance

Owner’s Information

Pump Model Number:

Pump Serial Number:

Motor Model Number:

Motor Serial Number:

Dealer:

Dealer Telephone:

Purchase Date:

Installation Date:

Table of Contents

SUBJECT PAGE

SECTION 1 – Safety ................................................................................................................................................... 4

SECTION 2 – General Information ............................................................................................................................. 4

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

Receiving and Checking ............................................................................................................................................4

Materials and Equipment Required ...........................................................................................................................5

Storage ...................................................................................................................................................................... 5

General Description .................................................................................................................................................. 6

SECTION 3 – Installation ........................................................................................................................................... 9

Foundation / Piping ...................................................................................................................................................9

Pump Installation .................................................................................................................................................... 10

Installing the Bowl Assembly ................................................................................................................................... 10

Installing the Column .............................................................................................................................................. 11

Installing the Discharge Head .................................................................................................................................. 12

Installing the Stufﬁng Box........................................................................................................................................12

Installing the Mechanical Seal .................................................................................................................................. 13

Installing the Driver ................................................................................................................................................ 14

Installing the Thrust Pot ..........................................................................................................................................14

SECTION 4 – Pump Start Up and Operation ............................................................................................................ 20

SECTION 5 – Maintenance ...................................................................................................................................... 21

Preventive Maintenance Schedule ............................................................................................................................ 21

Packing Adjustment and Replacement ...................................................................................................................... 21

Thrust Pot Lubrication and Maintenance ................................................................................................................. 22

Seasonal Shutdown .................................................................................................................................................. 22

Recommended Lubricants .......................................................................................................................................23

Troubleshooting ......................................................................................................................................................24

SECTION 6 – Disassembly and Reassembly ..............................................................................................................26

Disassembly ............................................................................................................................................................. 26

Inspection and Reassemble ......................................................................................................................................27

SECTION 7 – Repair Parts ........................................................................................................................................29

Limited Warranty ......................................................................................................................................................30

Safety Instructions – SECTION 1

DANGER

WARNING

CAUTION

WARNING

Hazardous voltage can shock, burn or cause death.

WARNING

CAUTION

WARNING

CAUTION

TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MAJOR PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN THE MANUAL AND ON THE PUMP.

This is a SAFETY ALERT SYMBOL. When you see this symbol on the pump or in the manual, look for one of the following signal words and be alert to the potential for personal injury or property damage.

Warns of hazards that WILL cause serious personal injury, death or major property damage.

Warns of hazards that CAN cause serious personal injury, death or major property damage.

Warns of hazards that CAN cause personal injury or property damage.

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

NOTICE: INDICATES SPECIAL INSTRUCTIONS WHICH ARE VERY IMPORTANT AND MUST BE FOLLOWED.

THIS MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION AND OPERATION OF THIS UNIT. THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS PRIOR TO PERFORMING ANY WORK ON THIS PUMP.

MAINTAIN ALL SAFETY DECALS.

Install, ground and wire according to local and National Electrical Code Requirements.

Install an all leg disconnect switch near the pump.

Disconnect and lockout electrical power before installing or servicing the pump.

Electrical supply must match motor’s nameplate speciﬁcations. Incorrect voltage can cause ﬁre, damage motor and void the warranty.

Single phase pump motors are equipped with an automatic thermal protector, which opens the motor’s electrical circuit when an overload condition exists. This can cause the pump to start unexpectedly.

General Precautions

Personal injuries will result if procedures outlined in this manual are not followed

can cause ﬁre, damage to motor and voids warranty.

Safety Apparel:

• Insulated work gloves when handling hot sand collar.

• Heavy work gloves when handling parts with sharp

Electric supply MUST match pump’s nameplate speciﬁcations. Incorrect voltage

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 ﬂuid.

Maintenance Safety:

• Always lock out power prior to any procedure.

• Ensure pump is isolated from system and the pressure is relieved before disassembling the pump, removing plugs, or disconnecting the piping.

• Use proper lifting and supporting equipment to prevent serious injury or death.

• Observe all decontamination procedures.

General Information – SECTION 2

INTRODUCTION

NOTE: The information in this manual intends to be

used as a guide only. If you are in doubt, consult your Goulds Water Technology representative for speciﬁc information about your pump.

The design, material, and workmanship incorporated in the construction of Goulds Water Technology VIC 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 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.

Rotating components of the pump assembly must be covered with a suitable

rigid guard to prevent injury to personnel.

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

Study thoroughly Sections 1 through 6 and carefully follow the instructions for installing and operating. Section 5 contains answers to troubleshooting and maintenance questions. Keep this instruction manual handy for reference.

Goulds Water Technology will not be

liable for any damages or delay caused by failure to comply with the provisions of this instruction manual.

RECEIVING AND CHECKING

The pump should be carefully supported prior to unloading from the carrier. Handle all components carefully. Inspection for damage of the shipping crate should be made prior to unpacking the pump. After unpacking, visually inspect the pump and check the following:

1. Contents of the pump assembly against the

packing list.

2. All components against damage.

3. All shafting for damage, should the crate be broken or show careless handling. All shafting must be checked for straightness.

Any shortages or damages should be immediately called to the attention of the local freight agent of the carrier by which the shipment arrived and proper notation made on the bill. This will prevent any controversy when a claim is

made and facilitate prompt and satisfactory adjustment.

MATERIALS AND EQUIPMENT REQUIRED

The material and equipment necessary for installation of the pump will vary with the size of the pump and the type of installation.

The following list of standard tools and supplies is offered only as a guide.

BULK MATERIAL

• Anti-Galling lubricant

(such as Dow Corning “MOLYKOTE”)

• Thread Compound

• Lubrication Oil

• Turbine Oil

• Grease

RIGGING EQUIPMENT

• Mobile power hoist, traveling crane or derrick.

• Drag line and blocks.

• Lifting Bail for Threaded Column.

• Elevator clamps, if unit is unassembled.

• Clevises – for use with eyebolts.

• Timbers – size, length and quantity to support long

pump parts on the ﬂoor.

• I-Beams or timbers to support pump over

installation.

HAND TOOLS

• Pipe wrenches

• Feeler gauges

• Machinist Level

• Set of mechanics tools including: ﬁles, wire brush,

pliers, wire cutters and pocket knife.

• Clean rags

• Dial indicator to assist in motor and pump

alignment.

OPTIONAL TOOLS TO FACILITATE PUMP ASSEMBLY AND DISASSEMBLY

• Taperlock driver to assist in bowl assembly and

disassembly for pumps with taper lock impellers only.

STORAGE

Goulds Water Technology carefully preserves and protects its products for shipment. However, the effective life of the preservatives applied at the factory can vary from 3 to 18 months depending on the severity of the environment in which the equipment is stored. This section provides procedures for preparation prior to storage and maintenance during storage of Goulds Water Technology pumps. These procedures are necessary

to protect the precision parts of the pumps. Speciﬁc procedures for storing motors, gear-drivers, and engines, should be obtained from the equipment manufacturer. This section is intended to be of general assistance to users of Goulds Water Technology VIC pumps. It shall not modify, amend and/or otherwise alter the scope of Goulds Water Technology VIC pumps warranty responsibilities to the purchaser in any way whatsoever.

Storage Preparation

Goulds Water Technology VIC pumps require proper preparation for storage and, regular maintenance during storage. The pump shall be considered in storage when it has been delivered to the job site and is awaiting installation.

Preferably, the storage area shall be paved, well drained and free from ﬂooding, and be indoors whenever possible.

Weatherproof coverings used for outdoor storage shall be ﬂame resistant type sheeting or tarpaulins. They shall be placed so as to provide good drainage and air circulation and shall be tied down to protect from wind damage.

Storage area shall be maintained in a clean condition at all times.

Pumps and/or component parts shall be placed on skids, pallets, or shoring to permit good air circulation.

Pumps and/or component parts shall be sorted so as to permit ready access for inspection and/or maintenance without excessive handling.

Pumps and/or component parts stacked during storage shall be arranged so that the racks, containers, or crates bear full weight without distortion of pumps or parts. Identiﬁcation markings must be readily visible. Any cover removed for internal access shall be replaced immediately.

Pump and bowl assembly shafting shall be rotated counter clockwise, as a minimum, once a month. Shaft shall not be left in the same previous position, nor in the extreme raised or lowered lateral position. Shaft should rotate freely.

NOTE: For further information on these procedures

contact your Goulds Water Technology representative.

Recommended Storage Procedures

Controlled storage facilities should be maintained at an even temperature 10º F (6º C) or more above the dew point with relative humidity less than 50% and little or no dust. (If these requirements can not be met the pump is to be considered in uncontrolled storage.)

For uncontrolled storage periods of 6 months or less, the pump is to be inspected periodically to insure that all preservatives are intact.

All pipe threads and ﬂanged pipe covers are to be sealed with tape.

The pump must not be stored closer than six inches (15 cm) from the ground.

Uncontrolled Long Term Storage Preparations

When applicable to the pump, storage periods over six months require the preceding storage procedure and storage preparation plus the following:

Inspect the lube oil and seal ﬂush piping and either ﬁll the piping with rust preventative oil, or re-coat the piping periodically to prevent corrosion.

Place 10 pounds (4.5 kg) of moisture absorbing desiccant or 5 pounds (2.3 kg) of vapor phase inhibitor crystals near the center of the pump. If the pump is assembled, place an additional one pound (0.5 kg) in the discharge nozzle securely fastened to the discharge elbow.

Install a moisture indicator near the perimeter of the pump. Cover the pump with 6 mil (0.15 mm) minimum thickness black polyethylene or equal and seal it with tape. Provide a small ventilation hole approximately ½ inch (12 mm) diameter.

Discharge Head

The discharge head is either a cast iron head or a fabricated head. Ports are provided for connecting the pressure gauge, stufﬁng box or mechanical seal bypass return and lubricator connections. The driver support portion of the discharge head is designed with large windows for easy stufﬁng box or mechanical seal adjustment. The windows are covered with coupling guards for safe operation.

Column

Threaded or ﬂanged column construction provides positive shaft and bearing alignment and ease of assembly and disassembly. The line-shaft is supported within the column by using bearing retainers in the column assembly. The retainers are usually integrally fabricated in the column pipes. Bearings are spaced to provide vibration free operation below the shaft ﬁrst critical speed in order to insure long bearing life and reduced shaft wear.

Provide a roof or shed shelter to protect from direct exposure to the elements.

GENERAL DESCRIPTION

The model VIC pump is a vertical industrial turbine type pump installed in a can (barrel), and is designed to meet wide ranges of service with maximum dependability. See Figure 1 or Figure 2 for some typical VIC pump.

Drivers

When mechanical seals are required, the most common type of drivers supplied are solid vertical shaft motors with adjustable spacer type couplings. When packed stufﬁng boxes are used with open line shaft pumps, hollow shaft motors or right angle gear drives, are often used with a separate head shaft through the driver and connected to the pump by a threaded coupling.

Bowl Assembly

The bowls are generally of ﬂanged construction for accurate alignment and ease of assembly and disassembly. Impellers may be either open or enclosed depending on the design requirements. They are fastened to the pump shaft by taperlocks. For temperatures over 140°F (60°C) and in the larger size bowls (over 18”), impellers are keyed to the shaft. A special ﬁrst stage low NPSH impeller may be provided in certain application.

Thrust Pot

A thrust pot is utilized when the driver is not designed to carry the pump thrust.

DISCHARGE HEAD ASSEMBLY

ITEM DESCRIPTION

600 DISCHARGE HEAD 610 COUPLING ASSEMBLY 617 SEAL HOUSING BEARING 616 SEAL HOUSING 779 SEAL HOUSING GASKET 620 MECHANICAL SEAL

COLUMN ASSEMBLY

642 COLUMN PIPE 645 COLUMN BOLTING 646 LINESHAFT 649 LINESHAFT COUPLING 652 BEARING RETAINER 656 LINESHAFT BEARING 643 CLEAN-OUT PIPE (OPTIONAL) 601 BARREL

BOWL ASSEMBLY

660 PUMP SHAFT 670 INTERMEDIATE BOWL 672 INTER. BOWL BEARING 673 IMPELLER 677 TAPERLOCK 680 WEAR RING (OPTIONAL) 760 HEX BOLT 692 SAND COLLAR 688 SUCTION BOWL/BELL 690 SUCTION BEARING 747 PLUG

Figure 1 VIC Pump with Solid Shaft Motor, Fabricated

T-Head, Mechanical Seal and Flanged Column

DISCHARGE HEAD ASSEMBLY

ITEM DESCRIPTION

600 DISCHARGE HEAD 604 ADJUSTING NUT 730 GIB KEY 608 HEAD SHAFT 616 STUFFING BOX 617 STUFFING BOX BEARING 618 SPLIT GLAND 620 PACKING 622 SLINGER 757 GLAND ADJUSTING SCREW 779 STUFFING BOX GASKET

COLUMN ASSEMBLY

642 COLUMN PIPE (FLG) 645 COLUMN BOLTING 646 LINESHAFT 652 BEARING RETAINER 656 LINESHAFT BEARING 649 LINESHAFT COUPLING 601 BARREL

BOWL ASSEMBLY

660 BOWL SHAFT 670 INTERMEDIATE BOWL 672 INTER. BOWL BEARING 673 IMPELLER 677 TAPERLOCK 680 WEAR RING (OPTIONAL) 760 HEX BOLT 692 SAND COLLAR 688 SUCTION BOWL/BELL 690 SUCTION BEARING 747 PLUG

Figure 2 VIC Pump with Cast L-Head, VHS Motor,

Packed stufng Box and anged

column

Installation – SECTION 3

When pumping unit is installed in a potentially explosive environment, the instruction after

the 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 equipment is to be modiﬁed, please contact a Goulds Water Technology representative before proceeding.

FOUNDATION AND PIPING

SUB BASE (SOLE PLATE) OR BARREL FLANGE INSPECTION

Sub base and sole plate are terms in common use to describe a general class of solid steel plates mounted in grout (or bolted to steel structures) at the pumpfoundation interface.

1. Remove the sub base from the pump discharge head

or barrel ﬂange, when shipped assembled.

2. Completely clean the underside of the sub base. It is

sometimes necessary to coat the underside of the sub base with an epoxy primer. (This is available as an option.)

3. Remove the rust preventative solution from the

machined topside with an appropriate solution.

SITE WITH CONCRETE FOUNDATION

1. A pump should have adequate space for operation,

maintenance, and inspection.

2. Sub base mounted pumps are normally grouted

on a concrete foundation, which has been poured on a solid footing. The foundation must be able to absorb any vibration and to form a permanent, rigid support for the pumping unit.

3. The foundation must be of adequate strength to

support the complete weight of the pump, plus the weight of the liquid passing through it. A typical installation will have bolts with a pipe sleeve 2 ½ times the bolt diameter embedded in the concrete.

Bolts should be sized and located in accordance with the dimensions given on the Certiﬁed Pump Outline Drawing, if provided. The pipe sleeve allows movement for the ﬁnal positioning of the foundation bolts to conform to the holes in the sub base ﬂange. See Figure 3.

All equipment being installed must be properly grounded to prevent unexpected static electrical

discharge. If not, a static electric discharge may occur when the pump is drained and disassembled for maintenance purpose.

4. Remove water and/or debris from anchor bolt holes/

sleeves prior to grouting. If the sleeve type bolts are being used, ﬁll the sleeves with packing or rags to prevent grout from entering.

5. Carefully lower the sub base onto the foundation

bolts. Hand tighten the nuts.

6. Leveling the sub base may be done by several

methods. Two common methods are:

A. Using leveling wedges. This is shown in Figure 4. B. Leveling nuts on the anchor bolts.

Regardless of the method, a machinist level must be used for leveling.

NOTE: When using a machinist level, it is important

that the surface being leveled is free of all contaminants, such as dust, to ensure an accurate reading.

7. Level the sub base in two directions at 90º on the

machined surface. The levelness tolerance is 0.005 inches per foot for commercial, and 0.001 inches per foot for API.

FOUNDATION

DAM

GROUT

CENTERLINE ANCHOR BOLT

SUB BASE

LEVELING WEDGES

BOLT

SHIMS

DAM

Figure 3

SUB BASE

FOUNDATION

SLEEVE

FLOOR SLEEVE (OPTIONAL)

Figure 4

SUB BASE OR BARREL FLANGE GROUTING

1. Inspect foundation for dust, dirt, oil, chips, water,

etc. and remove any contaminants. Do not use oilbased cleaners as grout will not bond to it. Refer to grout manufacturer’s instructions.

2. Build dam around foundation (See Figure 4).

Thoroughly wet foundation.

3. Pour grout between sub base or barrel ﬂange and

WARNING

CAUTION

concrete foundation, 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.

4. Allow grout to set at least 48 hours.

5. Tighten foundation bolts.

SITE WITH STRUCTURAL STEEL FOUNDATION

When the pump is mounted directly on a structural steel frame, pumps shall be located directly over, or as near as possible to, the main building members, beams or walls. The barrel, discharge head mounting ﬂange or sub base, shall be bolted to the support to avoid distortion, prevent vibration and retain proper alignment.

PUMP INSTALLATION

When pumping unit is installed in a potentially

explosive environment, the instruction after the

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 equipment is to be modiﬁed, please contact a Goulds Water Technology representative before proceeding.

Pumps of 20 feet (6 m) or less in length are usually shipped assembled, with the exception of the driver, mechanical seal with tubing and coupling assembly, spacer or non spacer type. When provided, refer to the Certiﬁed Pump Outline for the applicable base plate plan for the location of anchor bolt holes.

INSTALLING A PARTIALLY ASSEMBLED PUMP

PIPING

Guidelines for piping are given in the “Hydraulic Institute Standards”, available from: Hydraulic Institute, 9 Sylvan Way, Parsippany, NJ 07054-3802 and must be reviewed prior to pump installation.

Never draw piping into place by forcing

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

1. All piping must be supported independently, and

line up naturally with the pump ﬂange so that undue pipe strain is not imposed on the pump.

2. DO NOT connect piping to pump until grout has

hardened and pump hold-down bolts have been tightened.

3. It is suggested that expansion loops or joints, if used,

be properly installed in the discharge line. When handling liquids at elevated temperatures expansion joints are used, so linear expansion of piping will not draw pumps out of alignment.

4. Carefully clean all pipe parts, valves and ﬁttings, and

piping branches prior to assembly.

5. Isolation and check valves should be installed in

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

6. Increasers, if used, should be placed between pump

and check valves.

7. Cushioning devices should be used to protect the

pump from surges and water hammer if quickclosing valves are installed in the system.

1. If a base plate was supplied, install as described in Foundation/Piping Section (page 9).

2. Clean the mounting surface of the plate and clean bottom surface of discharge head mounting ﬂange.

3. Check that all fasteners on the pump are tight, as it is recognized that transportation and handling may result in bolt relaxation.

4. Install the barrel (can) to discharge head O-ring (743).

5. Sling through discharge head holes or thread two eyebolts through bolt holes in mounting ﬂange and hoist unit into position over foundation.

NOTE: Eyebolts or sling should be rated to handle

in excess of the pump weight (see Outline Drawing).

6. Lower the unit and carefully guide it so that unit does not strike the side of the base plate. Continue to lower unit until the discharge head ﬂange engages and rests ﬁrmly on the plate, then secure with capscrews provided.

7. When a lineshaft is shipped separately check shaft for straightness; average total run out should not exceed 0.005” T.I.R. (0.127mm) for 10 feet (3 m). Shaft must be within tolerance prior to installation.

8. Refer to remainder of this manual for complete assembly, startup, maintenance, disassembly and recommended lubricants for the pump.

INSTALLING THE BOWL ASSEMBLY

Do not work under a heavy suspended

object unless there is positive support and safe guards, which will protect personnel, should a hoist or sling fail.

Do not attempt to lift bowl assembly by the pump shaft. This can result in

damaging the pump shaft.

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