ITT Goulds Pumps JC Installation, Operation And Maintenance Instructions
Installation, Operation and Maintenance Instructions
Model JC
Pump Safety Tips
Safety Apparel:
Insulated work gloves when handling
•
hot bearings or using bearing heater
Heavy work gloves when handling
•
parts with sharp edges, especially impellers
Safety glasses (with side shields) for
•
eye protection, especially in machine
shop areas
Steel-toed shoes for foot protection when
•
handling parts, heavy tools, etc.
Other personal protective equipment to protect
•
against hazardous/toxic fluids
Coupling Guards:
• Never operate a pump without a coupling guard
properly installed
Flanged Connections:
• Never force piping to make a connection with a
pump
• Use only fasteners of the proper size and material
Operation:
Do not operate below minimum rated flow, or with
suction/discharge valves closed
Do no open vent or drain valves, or remove plugs while
system is pressurized
Maintenance Safety:
Always lockout power
•
Ensure pump is isolated from system and pressure is
•
relieved before disassembling pump, removing plugs,
or disconnecting piping
Use proper lifting and supporting equipment to
•
prevent serious injury
Observe proper decontamination procedures
•
• Know and follow company safety regulations
• Never apply heat to remove impeller
• Observe all cautions and warnings highlighted in
pump instruction manual.
• Ensure there are no missing fasteners
•
Beware of corroded or loose fasteners
2 JC IOM 11/06
IMPORTANT SAFETY REMINDER
To: Our Valued Customers
Goulds' pumps will provide safe, trouble-free service when properly installed, maintained, and operated. We have an
extensive network of experienced sales and service professionals to assist in maximizing your satisfaction with our products.
Safe installation, operation, and maintenance of Goulds' equipment are an essential end user responsibility. This Instruction,
Operation, and Maintenance (IOM) manual identifies specific safety risks that must be considered at all times during product
life. Understanding and adhering to these safety warnings is mandatory to ensure person- nel, property, and/or the environment
will not be harmed. Adherence to these warnings alone, however, is not sufficient — it is anticipated that the end user will also
comply with industry and corporate safety standards. Identifying and eliminating unsafe installation, operating and maintenance
practices is the responsibility of all individuals involved in the installation, operation, and maintenance of industrial equipment.
Specific to pumping equipment, two significant risks bear reinforcement above and beyond normal safety precautions.
! WARNING
▲
Operation of any pumping system with a blocked suction and discharge must be avoided in all cases. Operation, even
for a brief period under these conditions, can cause superheating of enclosed pumpage and result in a violent
1
explosion. All necessary measures must be taken by the end user to ensure this condition is avoided.
! WARNING
▲
Pumping equipment Instruction, Operation, and Maintenance manuals clearly identify accepted methods for
disassembling pumping units. These methods must be adhered to. Specifically, applying heat to impellers and/or
2
impeller retaining devices to aid in their removal is strictly forbidden. Trapped liquid can rapidly expand and result
in a violent explosion and injury.
Please take the time to review and understand the safe installation, operation, and maintenance guidelines outlined in this
manual.
JC IOM 11/06
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4 JC IOM 11/06
TABLE OF CONTENTS
PAGE SECTION
7 SAFETY
11 GENERAL INFORMATION
13 INSTALLATION
17 OPERATION
21 PREVENTIVE MAINTENANCE
27 SPARE PARTS
1
2
3
4
5
6
31 APPENDIX
7
JC IOM 11/06 5
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6 JC IOM 11/06
SAFETY
DEFINITIONS......................................7
GENERAL PRECAUTIONS ..............................8
EXPLOSION PREVENTION .............................8
SPECIAL ATEX CONSIDERATIONS ........................8
ATEX IDENTIFICATION ...............................9
INTENDED USE ....................................9
CONDITION MONITORING .............................9
DEFINITIONS
1
These pumps have been designed for safe and reliable
operation when properly used and maintained in
accordance with instructions contained in this manual. A
pump is a pressure containing device with rotating parts
that can be hazardous. Operators and maintenance
personnel must realize this and follow safety measures.
ITT Industries Goulds Pumps is not liable for physical
injury, damage or delays caused by a failure to observe the
instructions in this manual.
Throughout this manual the words WARNING,
CAUTION, ELECTRICAL, ATEX, and NOTE are used
to indicate procedures or situations which require special
operator attention:
! WARNING
s
Operating procedure, practice, etc. which, if not
correctly followed, could result in personal injury or
loss of life.
! CAUTION
$
Operating procedure, practice, etc. which, if not
followed, could result in damage or destruction of
equipment.
EXAMPLES
! WARNING
s
Pump must never be operated without coupling guard
installed correctly.
$
Throttling flow from the suction side may cause
cavitation and pump damage.
Improper impeller adjustment could cause contact
!
between the rotating and stationary parts, resulting
in a spark and heat generation.
Lock out driver power to prevent electric shock,
"
accidental start-up and physical injury.
NOTE: Proper alignment is essential for long pump
life.
CAUTION
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.
Particular care must be taken when electrical power
"
source to the equipment is energized.
NOTE: Operating procedure, condition, etc. which is
essential to observe.
JC IOM 11/06
7
GENERAL PRECAUTIONS
NEVER apply heat to remove impeller. It may
!
s
explode due to trapped liquid.
NEVER use heat to disassemble pump due to risk
!
s
of explosion from trapped liquid.
NEVER operate pump without coupling guard
!
s
correctly installed.
NEVER operate pump beyond the rated
!
l
conditions to which the pump was sold.
NEVER start pump without proper prime or
!
l
proper liquid level in self-priming pumps.
Cooling systems such as those for bearing
lubrication, mechanical seal systems, et, where
provided, must be operating properly to prevent
excess hear generations, sparks, and premature
failure.
s
NEVER run pump below recommended
!
l
minimum flow or when dry.
ALWAYS lock out power to the driver before
!
performing pump maintenance.
NEVER operate pump without safety devices
!
s
installed.
NEVER operate pump with discharge valve
!
s
closed.
DO NOT change conditions of service without
approval of an authorized Goulds representative.
Rotate shaft by hand to ensure it rotates smoothly
and there is no rubbing which could lead to
excess hear generation and or sparks
Ensure that pump and systems are free of foreign
objects before operating and that objects cannot
enter the pump during operation. Foreign objects
in the pumpage or piping system can cause
blockage of flow which can result in excess heat
generation, sparks and premature failure.
EXPLOSION PREVENTION
In order to reduce the possibility of accidental explosions in atmospheres containing explosive gasses and/or dust, the
!
instructions under the ATEX symbol must be closely followed. ATEX certification is a directive enforced in Europe for
non-electrical and electrical equipment installed in Europe. ATEX requirements are not restricted to Europe, and are
useful guidelines for equipment installed in any potentially explosive environment.
SPECIAL ATEX CONSIDERATIONS
All installation and operation instructions in this manual
must be strictly adhered to. In addition, care must be taken
to ensure that the equipment is properly maintained. This
includes but is not limited to:
1. Monitoring the pump frame and liquid end
temperature.
2. Maintaining proper bearing lubrication.
3. Ensuring that the pump is operated in the intended
hydraulic range.
8 JC IOM 11/06
ATEX IDENTIFICATION
For a pumping unit (pump, seal, coupling, motor and pump
accessories) to be certified for use in an ATEX classified
environment, the proper ATEX identification must be
present.
The ATEX tag would be secured to the pump or the
baseplate on which it is mounted. A typical tag would look
like this:
The CE and the Ex designate the ATEX compliance. The
code directly below these symbols reads as follows:
II = Group 2
2 = Category 2
G/D = Gas and Dust present
T4 =
Temperature class, can be T1 to T6
(see Table 1)
Table 1
Maximum Process Temperature
to Achieve Desired T Rating
Maximum
T Rating
per EN
1127-1
T1 450 410
T2 300 260
T3 200 165
T4 135 100
T5 100 65
T6 85 50
The code classification marked on the equipment should be
in accordance with the specified area where the equipment
will be installed. If it is not, please contact your
ITT/Goulds representative before proceeding.
Surface
Temperature
in Celsius
Maximum
Process
Temperature
in Celsius
1
INTENDED USE
The ATEX conformance is only applicable when the pump
unit is operated within its intended use. All instructions
within this manual must be followed at all times.
Operating, installing or maintaining the pump unit in any
way that is not covered in this manual can cause serious
personal injury or damage to the equipment. This
CONDITION MONITORING
For additional safety precautions, and where noted in
this manual, condition monitoring devices should be
used. This includes, but is not limited to:
Pressure gauges
•
Flow meters
•
Level indicators
•
Motor load readings
•
Temperature detectors
•
Bearing monitors
•
Leak detectors
•
PumpSmart
•
®
control system
includes any modification to the equipment or use of parts
not provided by ITT/Goulds. If there is any question
regarding the intended use of the equipment, please contact
an ITT/Goulds representative before proceeding.
For assistance in selecting the proper instrumentation and
its use, please contact your ITT/Goulds representative.
Do not insulate bearing housings as this can result
!
in excess heat generation, sparks and premature
failure.
Check for magnetism on the pump shaft and
!
degauss the shaft if there is any detectable
magnetism. Magnetism will attract ferritic objects to
the impeller, seal and bearings which can result in
excess heat generation, sparks and premature
failure.
JC IOM 11/06
9
Leakage of process liquid may result in creating an
!
explosive atmosphere. Ensure the materials of the
pump casing, impeller, shaft, sleeves, gaskets and
seals are compatible with the process liquid.
Leakage of process liquid may result in creating an
!
explosive atmosphere. Follow all pump and seal
assembly procedures.
A build up of gases within the pump, sealing system
!
and or process piping system may result in an
explosive environment within the pump or process
piping system. Ensure process piping system, pump
and sealing system are properly vented prior to
operation.
10 JC IOM 11/06
GENERAL INFORMATION
INTRODUCTION ...................................11
IMPORTANCE OF INSTRUCTIONS ........................11
SPECIAL WARNINGS ................................11
RECEIVING INSPECTION - SHORTAGES ....................11
INTRODUCTION
This instruction manual is intended to assist those involved
with the installation, operation and maintenance of Goulds
Ashland Operations slurry pumps. It is recommended that
this manual be thoroughly reviewed prior to installing or
performing any work on the pump or motor.
IMPORTANCE OF INSTRUCTIONS
2
The design, material and workmanship incorporated in the
construction of Goulds Ashland Operations slurry 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 periodic inspection
SPECIAL WARNINGS
Goulds Ashland Operations will not be liable for any
damages or delay caused by failure to comply with the
provisions of this instruction manual. This pump is not to
be operated at speeds, working pressures, discharge
RECEIVING INSPECTION - SHORTAGES
Care should be taken when unloading pumps. If shipment is
not delivered in good order and in accordance with the bill
of lading, note the damage or shortage on both receipt and
freight bill. Make any claims to the transportation
company promptly.
and careful maintenance. This manual was prepared to
assist operators in understanding the construction and
correct methods of installing, operating, and maintaining
these pumps.
pressures, or temperatures higher than, nor used with
liquids other than, stated in the original order
acknowledgment, without written permission of the
Ashland Operations, Goulds Pumps, Inc.
JC IOM 11/06
11
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