Goulds Pumps XHD User Manual

Installation, Operation, and Maintenance Manual

XHD

Table of Contents

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

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

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

Safety terminology and symbols ........................................................................................... 4

Environmental safety ............................................................................................................ 5

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

Safety regulations for Ex-approved products in potentially explosive atmospheres ............. 7

Product approval standards .................................................................................................... 9

Product warranty ................................................................................................................... 10

Transportation and Storage ................................................................................................. 11

Inspect the delivery ............................................................................................................... 11

Inspect the package ........................................................................................................... 11

Inspect the unit ................................................................................................................... 11

Transportation guidelines ...................................................................................................... 11

Pump handling ................................................................................................................... 11

Lifting methods ................................................................................................................... 11

Storage guidelines ................................................................................................................ 14

Pump storage requirements .................................................................................................. 14

Frostproofing ......................................................................................................................... 14

Table of Contents

Product Description .............................................................................................................. 15

General description ............................................................................................................... 15

General description i-ALERT™ Condition Monitor ................................................................ 17

Nameplate information .......................................................................................................... 18

Installation ............................................................................................................................. 21

Preinstallation ....................................................................................................................... 21

Pump location guidelines .................................................................................................... 21

Foundation requirements ................................................................................................... 21

Baseplate-mounting procedures ........................................................................................... 22

Prepare the baseplate for mounting ................................................................................... 22

Install the baseplate using shims or wedges ...................................................................... 23

Install the baseplate using jackscrews ................................................................................ 24

Direct-coupled baseplate-leveling worksheet ..................................................................... 26

Install pump, driver, and v-belt drive ..................................................................................... 27

Install and align the sheaves .............................................................................................. 27

Install and tension the belt .................................................................................................. 27

Install the pump, driver, and coupling .................................................................................... 28

Pump-to-driver alignment ...................................................................................................... 28

Alignment checks ............................................................................................................... 29

Permitted indicator values for alignment checks ................................................................ 29

Alignment measurement guidelines ................................................................................... 30

Attach the dial indicators for alignment ............................................................................... 30

Pump-to-driver alignment instructions ................................................................................ 30

Grout the baseplate .............................................................................................................. 33

Piping checklists ................................................................................................................... 34

General piping checklist ..................................................................................................... 34

Suction-piping checklist ...................................................................................................... 35

Discharge piping checklist .................................................................................................. 37

Bypass-piping considerations ............................................................................................. 38

Auxiliary-piping checklist .................................................................................................... 39

Final piping checklist .......................................................................................................... 39

XHD Installation, Operation, and Maintenance Manual 1

Table of Contents

Commissioning, Startup, Operation, and Shutdown ......................................................... 40

Preparation for startup .......................................................................................................... 40

Remove the V-belt drive guard ............................................................................................. 41

Remove the coupling guard .................................................................................................. 41

Check the rotation ................................................................................................................. 42

Impeller-clearance check ...................................................................................................... 42

Impeller axial clearances .................................................................................................... 42

Impeller-clearance setting ..................................................................................................... 43

Set impeller to Suction Seal Ring Clearance Dial Indicator Method ............................ 44

Set impeller clearance dial indicator method - XHD ........................................................... 46

Suction seal ring clearance check - XHD only .................................................................... 47

Install the V-belt drive guard ................................................................................................. 47

V-Belt drive operation ........................................................................................................... 48

V belt drive installation checks ............................................................................................ 48

V-belt drive monitoring and protection ................................................................................ 48

Couple the pump and driver .................................................................................................. 49

Install the coupling guard .................................................................................................... 50

Bearing lubrication ................................................................................................................ 52

Lubricate the bearings with oil ............................................................................................ 52

Shaft-sealing options ............................................................................................................ 53

Mechanical seal options ..................................................................................................... 53

Connection of sealing liquid for mechanical seals .............................................................. 53

Packed stuffing box option ................................................................................................. 54

Connection of sealing liquid for a packed stuffing box ........................................................ 54

Seal the shaft with a packed stuffing box ............................................................................ 54

Pump priming ........................................................................................................................ 57

Prime the pump with the suction supply above the pump ................................................... 57

Prime the pump with the suction supply below the pump ................................................... 57

Other methods of priming the pump ................................................................................... 59

Start the pump ...................................................................................................................... 59

Activate the i-ALERT Condition Monitor ................................................................................ 59

i-ALERT™ Condition Monitor routine operation .................................................................... 60

Pump operation precautions ................................................................................................. 61

Shut down the pump ............................................................................................................. 61

Deactivate the i-ALERT™ Condition Monitor ........................................................................ 62

Reset the i-ALERT™ Condition Monitor ................................................................................ 62

Make the final alignment of the pump and driver ................................................................... 62

Maintenance ........................................................................................................................... 63

Maintenance schedule .......................................................................................................... 63

Bearing maintenance ......................................................................................................... 64

Lubricating oil requirements ............................................................................................... 64

Oil volumes ......................................................................................................................... 64

Acceptable oil for lubricating bearings ................................................................................ 64

Lubricating-grease requirements ........................................................................................ 64

Shaft-seal maintenance ...................................................................................................... 66

Disassembly ......................................................................................................................... 68

Disassembly precautions ................................................................................................... 68

Tools required .................................................................................................................... 68

Typical disassembly ........................................................................................................... 69

Complete wet end disconnection - XHD only ...................................................................... 69

Wet end disassembly instructions ...................................................................................... 70

Remove the power end - quick disconnect option for XHD ................................................. 80

Remove the power end- XHD and XHD Value Option ........................................................ 80

Disassemble the power end - XHD, oil lubrication .............................................................. 83

Disassembly of other power end configurations ................................................................. 85

Preassembly inspections ...................................................................................................... 86

2 XHD Installation, Operation, and Maintenance Manual

Table of Contents

Replacement guidelines ..................................................................................................... 86

Power end inspection ......................................................................................................... 86

Reassembly .......................................................................................................................... 87

Assemble the power end- XHD, oil lubrication .................................................................... 87

Assemble the power end to the pedestal ............................................................................ 89

Assembly of other power end configurations ...................................................................... 91

Wet end assembly instructions ........................................................................................... 92

Complete wet end connection - XHD .................................................................................. 92

Wet end assembly instructions ........................................................................................... 93

Assembly references ........................................................................................................ 103

Troubleshooting .................................................................................................................. 111

Operation troubleshooting ................................................................................................... 111

Alignment troubleshooting .................................................................................................. 112

Assembly troubleshooting ................................................................................................... 112

i-ALERT™ Condition Monitor troubleshooting .................................................................... 112

Parts Listings and Cross-Sectionals ................................................................................. 113

Assembly drawings (exploded views) ................................................................................. 113

Certification: CE or CE ATEX ............................................................................................. 120

Certificates of conformance ................................................................................................ 120

Other Relevant Documentation or Manuals ...................................................................... 126

Local ITT Contacts .............................................................................................................. 127

Regional offices .................................................................................................................. 127

XHD 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 overpressurized. 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.

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

• Never operate the pump without safety devices installed.

• Never operate the pump with the discharge valve closed.

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

4 XHD Installation, Operation, and Maintenance Manual

Hazard levels

Introduction and Safety

Hazard level Indication

A hazardous situation which, if not avoided, will

DANGER: result in death or serious injury

Hazard categories

WARNING: result in death or serious injury

CAUTION: result in minor or moderate injury

NOTICE:

A hazardous situation which, if not avoided, could

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

• A practice not related to personal injury

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

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.

WARNING:

Do NOT send the product to the ITT manufacturer if it has been contaminated by any nuclear radiation. Inform ITT so that accurate actions can take place.

Electrical installation

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

XHD Installation, Operation, and Maintenance Manual 5

Introduction and Safety

Recycling guidelines

Always follow local laws and regulations regarding recycling.

User safety

General safety rules

These safety rules apply:

Safety equipment

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

• 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.

• 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

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.

Precautions before work

Observe these safety precautions before you work with the product or are in connection with the product:

• Provide a suitable barrier around the work area, for example, a guard rail.

• Make sure that all safety guards are in place and secure.

• Allow all system and pump components to cool before you handle them.

• Make sure that you have a clear path of retreat.

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

• Make sure that the lifting equipment is in good condition.

• Use a lifting harness, a safety line, and a breathing device as required.

• Make sure that the product is thoroughly clean.

• Make sure that there are no poisonous gases within the work area.

• Make sure that you have quick access to a first-aid kit.

• Disconnect and lock out power before servicing.

• Check the explosion risk before you weld or use electric hand tools.

6 XHD Installation, Operation, and Maintenance Manual

Precautions during work

Observe these safety precautions when you work with the product or are in connection with the product:

• Never work alone.

• Always wear protective clothing and hand protection.

• Stay clear of suspended loads.

• Always lift the product by its lifting device.

• Beware of the risk of a sudden start if the product is used with an automatic level control.

• Beware of the starting jerk, which can be powerful.

• Rinse the components in water after you disassemble the pump.

• Do not exceed the maximum working pressure of the pump.

• Do not open any vent or drain valve or remove any plugs while the system is pressurized. Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump, remove plugs, or disconnect piping.

• Never operate a pump without a properly installed v-belt or

coupling guard.

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

• Never heat the condition monitor to temperatures in excess of 300°F (149°C).

• Never expose the condition monitor to open flames.

• Do not use the condition monitor in atmospheres containing acetic acid.

• Always wear protective gloves. The pump and condition monitor can be hot.

Introduction and Safety

Hazardous liquids

The product is designed for use in liquids that can be hazardous to your health. Observe these rules when you work with the product:

• Make sure that all personnel who work with biologically hazardous liquids are vaccinated against diseases to which they may be exposed.

• Observe strict personal cleanliness.

• A small amount of liquid will be present in certain areas like the seal chamber.

Wash the skin and eyes

1. Follow these procedures for chemicals or hazardous fluids that have come into contact with your eyes or your skin:

Condition Action

Chemicals or hazardous fluids in eyes

Chemicals or hazardous fluids on skin

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 1 minute.

3. Seek medical attention, if necessary.

Safety regulations for Ex-approved products in potentially explosive atmospheres

Description of ATEX

The ATEX directives are a specification enforced in Europe for electrical and non-electrical equipment. 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.

XHD Installation, Operation, and Maintenance Manual 7

Introduction and Safety

Guidelines for compliance

Compliance is only fulfilled when the pump is operated within its intended use, for example within its intended hydraulic range. The conditions of the service must not be changed without approval of an authorized ITT representative. When installing or maintaining explosion-proof pumps, follow these guidelines:

• Always install ATEX-approved equipment in compliance with the directive and applicable standards (IEC/EN 60079–14).

• Do not install explosion proof products in locations that are classified as hazardous in the national electric code, ANSI/NFPA 70–2005.

WARNING:

This manual clearly identifies 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 unless explicitly stated in this manual.

If there are any questions regarding these requirements, the intended use, or if the equipment requires modification, contact an ITT representative before you proceed.

Personnel requirements

ITT disclaims all responsibility for work done by untrained and unauthorized personnel. 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 and/or vapor present in hazardous areas.

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

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 stated on the nameplates.

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

• Never start a pump without the proper priming.

• Before you start working with 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.

• 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.

• Make sure that the equipment is properly maintained:

• Monitor the pump components and the end temperature of the liquid.

• Maintain proper bearing lubrication.

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

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

8 XHD Installation, Operation, and Maintenance Manual

Equipment for monitoring

For additional safety, use condition-monitoring devices. Condition-monitoring devices include but are not limited to these devices:

• Pressure gauges

• Flow meters

• Level indicators

• Motor load readings

• Temperature detectors

• Bearing monitors

• Leak detectors

• PumpSmart control system

Product approval standards

Regular standards

All standard products are approved according to CSA standards in Canada and UL standards in USA. The drive unit degree of protection follows IP68. See the nameplate for maximum submersion, according to standard IEC 60529.

All electrical ratings and performance of the motors comply with IEC 600341.

Introduction and Safety

Explosion-proofing standards

All explosion-proof products for use in explosive atmospheres are designed in compliance with one or more of the following approvals:

• EN, ATEX Directive 94/9/EC

• FM According to NEC

• Class 1 Div 1 Groups “C”, and “D”

• Class 2 Div 1 Groups “E”, “F”, and “G”

• Class 3 Div 1 Hazardous Locations

ATEX/IECEx:

• Group: IIC

• Category: Ex ia

• Temperature Class: T4 (for ambients up to 100ºC)

• ATEX Marking: Ex II 1 G

CSA certification

Intrinsically safe for:

• Class I, Div. 1, Groups A, B, C, D

• Class II, Div. 1, Groups E, F, G

• Class III

• Certified to Canadian and US requirements

XHD Installation, Operation, and Maintenance Manual 9

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

Warranty claim

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

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.

10 XHD 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 guidelines

Transportation and Storage

Precautions

WARNING:

Pump handling

WARNING:

NOTICE:

Use a forklift truck or an overhead crane with sufficient capacity to move the pallet with the pump unit on top. Failure to do so can result in equipment damage.

Lifting methods

WARNING:

• Stay clear of suspended loads.

• Observe accident prevention regulations in force.

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

• These pumps might use carbon or ceramic silicon carbide components. Do not drop the pump or subject it to shock loads as this can damage the internal ceramic components.

• 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.

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

• Do not attach sling ropes to shaft ends.

Table 1: Methods

Pump type Lifting method

A bare pump without lifting Use a suitable sling attached properly to solid points like the casing, the handles flanges, or the frames.

XHD Installation, Operation, and Maintenance Manual 11

Transportation and Storage

Pump type Lifting method

A bare pump with lifting lugs Use a suitable sling attached to the lifting lugs in the casing and bearing

A base-mounted pump Use slings under the pump casing and the drive unit, under the base rails,

Examples

cartridge.

or through lifting lugs, when provided.

Figure 1: Example of bare pump proper lifting method

Figure 2: Example of base mounted pump proper lifting method

12 XHD Installation, Operation, and Maintenance Manual

Transportation and Storage

Figure 3: Example of overhead mounted pump proper lifting method

Figure 4: Example of offset overhead motor mount pump proper lifting method

XHD Installation, Operation, and Maintenance Manual 13

Transportation and Storage

Storage guidelines

Storage location

The product must be stored in a covered and dry location free from heat, dirt, and vibrations.

NOTICE:

• Protect the product against humidity, heat sources, and mechanical damage.

• Do not place heavy weights on the packed product.

Pump storage requirements

Storage requirements depend on the amount of time that you store the unit. The normal packaging is designed only to protect the unit during shipping.

Length of time in storage Storage requirements

Upon receipt/short-term (less than six months)

Long-term (more than six months)

• Store in a covered and dry location.

• Store the unit free from dirt and vibrations.

• 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 drive unit and coupling manufacturers for their long-term storage procedures.

You can purchase long-term storage treatment with the initial unit order or you can purchase it and apply it after the units are already in the field. Contact your local ITT sales representative.

Frostproofing

This table shows to what degree the pump is frostproof:

When the pump is... Then...

Operating The pump is frostproof. Immersed in a liquid The pump is frostproof. Lifted out of a liquid into a temperature below freezing The impeller might freeze. Sitting idle The pump might freeze.

14 XHD Installation, Operation, and Maintenance Manual

Product Description

General description

The XHD is a fully metric, frame-mounted, single stage, end suction extra heavy duty metallined slurry pump.

Pump discharge diameter

The metric size designation represents the pump discharge diameter.

Metric size designation Suction x discharge x Suction x discharge x Power frame size

impeller (mm) impeller (inches)

XHD 80 100 x 80 x 298 4x3-11.7 PF2 XHD 125 150 x 125 x 412 6x5-16.2 PF3 XHD 150 200 x 150 x 530 8x6-20.9 PF4 XHD 200 250 x 200 x 684 10x8-27 PF4 XHD 250 300 x 250 x 800 12x10-31.5 PF5 XHD 300 350 x 300 x 1000 14x12-39.4 PF5

Casing

Discharge Tangential with multiple positions for most pump and driver size combina-

tions.

Mounting method Overhung configuration with casing attached to the pedestal. Flanges Flanges are slotted to meet these standards:

Detachable split flanges for the XHD and XHD Value Option sizes 150 and above

Outer casing halves Outer suction and gland casing halves are constructed of ductile iron and

designed to accommodate a standard rating of 250 PSIG at 20ºC.

Liners and seal ring For the XHD and XHD Value Option:

For the XHD:

Product Description

• Vertical up (0º)

• Between vertical up and top horizontal (45º)

• Top horizontal (90º)

• Bottom horizontal (270º)

• Between bottom horizontal and vertical up (315º)

• ANSI

• DIN

• SABS

• Table D

• Other existing slurry pump standards

• Replaceable HC600 casing volute and suction side liners

• Options for 1269, 1650 and CD4MCuN liners

• Adjustable HC600 suction seal ring for increased wear performance of the suction side liner and other wet end components

Impeller

The chrome iron impeller is:

• Enclosed with front and rear "pump out" vanes

• Threaded onto the shaft

The threads are sealed by an impeller hub o-ring on the sleeve side for the XHD and XHD Value Option.

Ease of impeller removal is facilitated by the two-piece knock-off collar seated on the shaft.

XHD Installation, Operation, and Maintenance Manual 15

Product Description

Heaviest pump component weight

Size Item no. Part name Weight (lb) Weight (kg) Wet end Bare pump

XHD80 100A Suction half 131 60 473 (215) 938 (431)

XHD125 100A Suction half 267 121 1063 (483) 1750 (796)

XHD150 100A Suction half 611 277 2566 (1164) 4016 (1826)

XHD200 100A Suction half 1210 549 4590 (2081) 2823 (6210)

XHD250 100A Suction half 1764 800 7130 (3234) 9800 (4445)

XHD300 100A Suction half 3221 1461 12348 (5600) 15107 (6866)

Seal cover / stuffing box

Both the XHD and XHD Value Option stuffing box are designed to accommodate multiple packing configurations (full and low flush) as well as most conventional slurry mechanical seals.

The XHD also features a fully detachable split stuffing box for ease of maintenance and replacement of packing and lantern rings.

Part Description

Pedestal The ductile iron pedestal has:

Bearing housing For the XHD and XHD Value Option:

Shaft and shaft sleeve

Bearings The inboard and outboard bearings:

weight lbs (kg) weight less

motor base/ motor lbs (kg)

casing

• A compact footprint that can be easily adapted to new or existing mounting requirements using a pedestal spacer.

• Adjustment plates and hardware for ease of impeller clearance setting.

• Oil lubrication is standard

• No machining is required to convert from oil to grease lubrication.

• Bellville washers and shims used to set bearing preload

For XHD:

• The power end is sealed with labyrinth seals

For XHD Value Option:

• The power end is sealed with grease-packed double lip seals.

• The shaft has an API-style tapered rapid release impeller thread

• The shaft is through-hardened 420 stainless steel providing 400 BHN

• The shaft sleeve is sealed with an o-ring to provide a "dry shaft" design protecting the shaft fro slurry exposure

• Are single row, tapered roller design

• Carry both radial and axial loads

• Mounted back-to-back in an opposed pair configuration on the shaft shoulders

• Are the same size and type for each power frame

• Have L10 lives exceeding 100,000 hours

Hardware

All fasteners and tapped connections are metric.

Direction or rotation

The direction of rotation is clockwise (right hand) when viewed from the driver end.

16 XHD Installation, Operation, and Maintenance Manual

General description i-ALERT™ Condition Monitor

Description

The i-ALERT Condition Monitor is a compact, battery-operated monitoring device that continuously measures the vibration and temperature of the pump power end. The condition monitor uses blinking red LEDs to alert the pump operator when the pump exceeds pre-set vibration and temperature limits. This allows the pump operator to make changes to the process or the pump before a catastrophic failure occurs. The condition monitor is also equipped with a single green LED to indicate when it is operational and has sufficient battery life.

Software License Agreement

BY USING THE i-Alert™ CONDITION MONITOR, YOU AGREE TO BE BOUND BY THE TERMS AND CONDITIONS OF THE FOLLOWING LICENSE AGREEMENT. PLEASE READ THIS AGREEMENT CAREFULLY.

ITT Corporation and its subsidiaries, affiliates, either directly, or through its authorized sublicensees ("ITT") grants you a limited, non-exclusive license to use the software embedded in this device ("Software") in binary executable form in the normal operation of the i-Alert™ condition monitor for monitoring the condition of an Goulds Pump Inc. model. Title, ownership rights, and intellectual property rights in and to the Software remain in ITT or its third-party providers. You agree that this license agreement does not need to be signed for it to take effect.

You acknowledge that this Software is the property of ITT and is protected under United States of America copyright laws and international copyright treaties. You further acknowledge that the structure, organization, and code of the Software are valuable trade secrets of ITT and/or its third-party providers and that the Software in source code form remains a valuable trade secret of ITT. You agree not to decompile, disassemble, modify, reverse assemble, reverse engineer, or reduce to human readable form the Software or any part thereof or create any derivative works based on the Software. You agree not to export or re-export the Software to any country in violation of the export control laws of the United States of America.

Product Description

Alarm mode

The condition monitor enters alarm mode when either vibration or temperature limits are exceeded over two consecutive readings within a ten minute period. Alarm mode is indicated with two red flashing LEDs within two second intervals.

Temperature and vibration limits

Variable Limit

Temperature 195°F (91°C) Vibration 100% increase over the baseline level

Battery life

The i-ALERT Condition Monitor battery is not replaceable. You must replace the entire unit

once the battery runs out of power. The battery life is not covered as part of the standard five-year pump warranty.

This table shows the average condition monitor battery life under normal and alarm-mode operating conditions.

Condition monitor operational state Battery life

Normal operating and environmental conditions Three to five years Alarm mode One year

XHD Installation, Operation, and Maintenance Manual 17

Product Description

Nameplate information

Important information for ordering

Every pump has nameplates that provide information about the pump. The nameplates are located on the casing and the bearing frame.

When you order spare parts, identify this pump information:

• Model

• Size

• Serial number

• Item numbers of the required parts

Refer to the nameplate on the pump casing for most of the information. See Parts List for item numbers.

Nameplate on the pump casing using English units

Table 2: Explanation of nameplate on the pump casing

Nameplate field Explanation

IMPLR. DIA. Impeller diameter, in inches MAX. DIA. Maximum impeller diameter, in inches GPM Rated pump flow, in gallons per minute FT HD Rated pump head, in feet RPM Rated pump speed, revolutions per minute MOD. Pump model SIZE Size of the pump STD. NO. Does not apply MAT L. CONST. Material of which the pump is constructed SER. NO. Serial number of the pump MAX DSGN PSI Maximum pressure at 100ºF according to the pump design

@ 100ºF

18 XHD Installation, Operation, and Maintenance Manual

Nameplate on the pump casing using metric units

Table 3: Explanation of the nameplate on the pump casing

Nameplate field Explanation

IMPLR. DIA. Impeller diameter MAX. DIA. Maximum impeller diameter M3/HR Rated pump flow, in cubic meters per hour M HD Rated pump head, in meters RPM Rated pump speed, in revolutions per minute MOD. Pump model SIZE Size of the pump STD. NO. Does not apply MAT L. CONST Material of which the pump is constructed SER. NO. Serial number of the pump MAX. DSGN KG/ Kilograms per square centimeter at 20°C

CM2@20°C

Product Description

Nameplate on the bearing frame

Table 4: Explanation of the nameplate on the bearing frame

Nameplate field Explanation

BRG. O. B. Outboard bearing designation BRG. I. B. Inboard bearing designation S/N Serial number of the pump LUBE Lubricant, oil or grease

ATEX nameplate

Nameplate field Explanation

II Group 2 2 Category 2 G/D Pump can be used when gas and dust are present T4 Temperature class

XHD Installation, Operation, and Maintenance Manual 19

Product Description

NOTICE:

Make sure that the code classifications on the pump are compatible with the specific environment in which you plan to install the equipment. If they are not compatible, do not operate the equipment and contact your ITT representative before you proceed.

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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.

Installation

Guideline Explanation/comment

Keep the pump as close to the liquid source as This minimizes the friction loss and keeps the practically possible. suction piping as short as possible.

Make sure that the space around the pump is This facilitates ventilation, inspection, maintenance, sufficient. and service.

If you require lifting equipment such as a hoist or This makes it easier to properly use the lifting tackle, make sure that there is enough space above equipment and safely remove and relocate the the pump. components to a safe location.

Protect the unit from weather and water damage This is applicable if nothing else is specified. due to rain, flooding, and freezing temperatures.

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

Take into consideration the occurrence of unwanted The best pump location for noise and vibration noise and vibration. absorption is on a concrete floor with subsoil

If the pump location is overhead, undertake special Consider a consultation with a noise specialist. precautions to reduce possible noise transmission.

Foundation requirements

Requirements

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

• 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.

underneath.

XHD Installation, Operation, and Maintenance Manual 21

Installation

Sleeve-type bolts

• 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.

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

NOTICE:Slurry Pumps are typically driven with motors mounted overhead, coupled with Vbelts and sheaves. This configuration does not require the pump to be mounted and grouted into place. The pump pedestal can be bolted onto a concrete foundation using J-type bolts or Sleeve-type bolts, thru the pedestal or mounting feet.

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.

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.

22 XHD Installation, Operation, and Maintenance Manual

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

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).

Installation

1. Shims or wedges

Figure 5: Top view

1. Shims or wedges

Figure 6: 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.

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.

XHD Installation, Operation, and Maintenance Manual 23

Installation

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.

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. b) Put the other machinist's level across the ends of the two pads.

24 XHD Installation, Operation, and Maintenance Manual

Installation

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.

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).

XHD Installation, Operation, and Maintenance Manual 25

Installation

Direct-coupled baseplate-leveling worksheet

26 XHD Installation, Operation, and Maintenance Manual

Install pump, driver, and v-belt drive

Install and align the sheaves

Before installing the driver onto an overhead motor mount or side-by-side base, ensure that Foundation requirements and baseplate mounting procedures sections are complete.

1. Mount and fasten the pump on the pedestal spacer, foundation, or baseplate as applicable. Use appropriate hardware.

2. For a motor that is mounted overhead, install the overhead motor mount.

3. For a motor that is mounted to the side of the pump, fasten the motor slide base on the baseplate or pump. Fasten the motor slide base on the baseplate or foundation, as applicable. Use appropriate hardware.

4. Mount the driver on the overhead motor mount or slide base, as applicable. Use appropriate hardware.

5. Install the v-belt drive bushings and sheaves. See the installation instructions from the vbelt drive manufacturer.After the v-belt drive bushings and sheaves are installed, check the sheave alignment using a straight edge as shown in the following diagram.

Installation

1. Straight edge

2. Incorrect

3. Correct

NOTICE:

Make sure that the sheaves are properly aligned. Proper alignment is necessary to guarantee the correct power transmission and speed ratio, and ensures minimum vibration and long drive life.

Install and tension the belt

1. After alignment of the sheaves, reduce the center distance between the pump and motor shafts so that the belts can be easily mounted into the sheave grooves.

For... Reduce the center distance by...

Overhead mounted motors Adjusting the leveling nuts Side mounted motors Adjusting the motor slide base

Make sure that the center distance between the pump and motor shaft is reduced to the point where the belts can be put on the sheaves without the use of force. Never roll or pry the belts into place, as this could damage the belt cords.

2. After the belts are seated in the sheave grooves, increase the center distance between the pump and motor shafts to tension the belts.

XHD Installation, Operation, and Maintenance Manual 27

Installation

Refer to pump general arrangement drawing for center distance ranges.

Figure 7: V-belt tension

Many v-belt drive manufacturers offer tension measurement tools that can aid in setting proper belt tension. Contact the v-belt drive manufacturer for more information.

3. Secure the overhead motor mount on slide base in place once the belts are properly tensioned.

4. Install the unit after installation to ensure that the belts and sheaves do not come into contact with the guard.

CAUTION:

The unit must not be operated without the proper drive guard in place. Operating the unit without the drive guard in place could result in personal injury to operating personnel.

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 pump-to-driver alignment before you operate the unit. Failure to do so can result in equipment damage or decreased performance.

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.

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