Xylem IMDWT R02 User Manual
InstructIon Manual
IMDWTR02
MODEL DWT
DEEP WELL TURBINE PUMPS
InstallatIon, operatIon and MaIntenance InstructIons
Foreward
This manual provides instructions for the Installation, Operation, and Maintenance of Goulds Water Technology
Deep Well Turbine (DWT) 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 DWT 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 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 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 Water Technology.
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:
2
Table of Contents
SUBJECT PAGE
Safety .......................................................................................................................................................................... 4
Safety Instructions ..................................................................................................................................................... 4
General Precautions ...................................................................................................................................................4
General Information .................................................................................................................................................... 4
Introduction .............................................................................................................................................................. 4
Receiving and Checking ............................................................................................................................................4
Materials and Equipment Required ...........................................................................................................................5
Storage ...................................................................................................................................................................... 5
General Description .................................................................................................................................................. 6
Installation .................................................................................................................................................................. 6
Well Conditions ......................................................................................................................................................... 6
Foundation / Piping ................................................................................................................................................. 10
Installing the Bowl Assembly ................................................................................................................................... 11
Installing the Column .............................................................................................................................................. 12
Installing the Discharge Head .................................................................................................................................. 13
Installing the Stuffing Box .......................................................................................................................................14
Installing the Tension Plate ...................................................................................................................................... 15
Installing the Driver ................................................................................................................................................ 16
Pump Start Up and Operation ................................................................................................................................... 18
Preventive Maintenance ........................................................................................................................................... 19
Packing Adjustment and Replacement ...................................................................................................................... 19
Seasonal Shutdown .................................................................................................................................................. 19
Preventive Maintenance Schedule ............................................................................................................................ 20
Recommended Lubricants .......................................................................................................................................20
Troubleshooting ...................................................................................................................................................... 22
Disassembly and Reassembly .....................................................................................................................................24
Disassembly ............................................................................................................................................................. 24
Inspection and Reassemble ......................................................................................................................................25
Repair Parts ............................................................................................................................................................... 26
Limited Warranty ...................................................................................................................................................... 28
3
DANGER
WARNING
CAUTION
WARNING
Hazardous voltage
can shock, burn or
cause death.
WARNING
CAUTION
WARNING
CAUTION
Safety Instructions
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.
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
Electric supply MUST match pump’s
nameplate specifications. Incorrect
voltage 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
edges especially impellers.
• Safety glasses (with side shields) for eye protection.
• Steel-toed shoes for foot protection when handling
parts, heavy tools, etc.
4
• Other personal protective equipment to protect against
hazardous/toxic fluid.
Maintenance Safety:
• Always lock out power.
• 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.
• Observe all decontamination procedures.
General Information
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 DWT
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.
Study thoroughly and carefully follow the instructions
for installing and operating. For questions on trouble
shooting and maintenance, see the "Preventive
Maintenance" Section. 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.
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 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.
Storage Preparation
Goulds Water Technology DWT 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.
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 DWT pumps. These procedures are necessary
to protect the precision parts of the pumps. Specific
procedures for storing motors, gearheads, and engines,
should be obtained from the equipment manufacturer.
This section is intended to be of general assistance to
users of Goulds Water Technology DWT pumps. It shall
not modify, amend and/or otherwise alter the scope
of Goulds Water Technology DWT pumps warranty
responsibilities to the purchaser in any way whatsoever.
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.
5
Uncontrolled Long Term Storage Preparations
CAUTION
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 piping and either fill the piping with
rust preventative oil, or re-coat the piping periodically to
prevent corrosion.
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.
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.
Provide a roof or shed shelter to protect from direct
exposure to the elements.
GENERAL DESCRIPTION
The model DWT pump is a vertical turbine lineshaft
pump, which is designed to meet wide ranges of service
with maximum dependability. See Figure 1 for open
lineshaft pump and Figure 2 for enclosed lineshaft pump.
Drivers
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.
Installation
WELL CONDITIONS
When the DWT pump is to be installed in a well,
consideration must be given to the well before
installation. Check the inside diameter of the well and
the maximum outside diameter of the bowl and column
assemblies to determine that there is adequate clearance
to install the pump assembly in the well casing. Also
insure that the well is deep enough to receive the full
length of pump.
1. The DWT pump unit must be operated in a straight
portion of the well.
Installing a unit in a crooked well may
bind and distort the pump column with
potential resulting malfunction.
2. When the straightness of the well is not known,
the well should be “gauged” prior to installation
by lowering a dummy assembly, slightly longer and
larger diameter than the bowl assembly. Gauging is
also important when a stepped well casing is used,
with the lower part of the well casing having small
inside diameter.
Discharge Head
The discharge head is either a cast iron head or a
fabricated Steel head. Ports are provided for connecting
the pressure gauge, stuffing box bypass return and
lubricator connections. The driver support portion of the
discharge head is designed with large windows for easy
stuffing box or tension plate adjustment. The windows
are covered with coupling guards for safe operation.
Column
Threaded or flanged column construction provides
positive shaft and bearing alignment. Bearings are spaced
to provide vibration free operation below the shaft. This
will insure long bearing life and reduced shaft wear. For
open lineshaft, the shaft is supported within the column
by using bearing retainers in the column assembly.
For enclosed lineshaft, the bearings are also the tube
couplings of the shaft-enclosing tube. The shaft-enclosing
tube is stabilized in the column pipe by tube stabilizer.
3. The well should be developed with a test pump
prior to installing the permanent pump. Test
pumping the well serves several purposes. It
removes the excess sand encountered during the
initial pumping of the well. Pumping sand or other
abrasives with a DWT pump will shorten the life of
the pump and can void the warranty.
4. The test pumping also provides a means of
determining the capacity and drawdown. The well
capacity should equal or exceed the pump capacity.
If the pump removes water at a higher rate than
the well produces, the drawdown will be excessive
and the pump will cavitate or ‘starve’ resulting in
damage to the pump.
5. The pump must be equipped with enough column
pipe to assure that the bowl assembly remains
submerged during operation.
6
DISCHARGE HEAD ASSEMBLY
608
757
618
616
779
617
649
646
647
656
664
760
677
631
652
604
730
645
660
661
622
620
637
673
680
670
600
642
ITEM DESCRIPTION
608 HEADSHAFT
604 ADJUSTING NUT
730 GIB KEY
622 SLINGER
600 DISCHARGE HEAD
617 STUFFING BOX BEARING
616 STUFFING BOX
779 STUFFING BOX GASKET
618 SPLIT GLAND
757 GLAND ADJUSTING NUT
620 PACKING
637 COLUMN FLANGE
COLUMN ASSEMBLY
631 COLUMN NIPPLE
645 COLUMN COUPLING
642 COULMN PIPE
646 LINESHAFT
647 LINESHAFT SLEEVE
652 BEARING RETAINER
656 LINESHAFT BEARING
649 LINESHAFT COUPLING
BOWL ASSEMBLY
660 BOWL SHAFT
661 DISCHARGE BOWL
664 DISCHARGE BEARING
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
698 SUCTION STRAINER
747 PLUG
672
690
698
692
688
747
Figure 1 Open Lineshaft Pump
7
HEAD ASSEMBLY
608
604
730
623
600
630
625
779
629
620
637
649
646
658
631
645
665
654
660
664
760
661
673
680
692
688
677
672
690
747
698
639
668
659
670
642
656
ITEM DESCRIPTION
608 HEADSHAFT
604 ADJUSTING NUT
730 GIB KEY
600 DISCHARGE HEAD
630 OIL RESERVOIR
623 TENSION NUT
625 TENSION PLATE
779 TENSION PLATE GASKET
620 O’RING
637 COLUMN FLANGE
COLUMN ASSEMBLY
639 COLUMN LOCK RING
631 COLUMN NIPPLE
645 COLUMN COUPLING
642 COLUMN PIPE
629 TUBE NIPPLE
654 OIL TUBE
658 TUBE STABLIZER
646 LINESHAFT
647 LINESHAFT SLEEVE
656 LINESHAFT BEARING
649 LINESHAFT COUPLING
BOWL ASSEMBLY
660 BOWL SHAFT
668 TUBE ADAPTER BEARING
665 OIL SEAL
659 COLUMN ADAPTER
661 DISCHARGE BOWL
664 DISCHARGE BEARING
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
698 SUCTION STRAINER
747 PLUG
8
Figure 2 Enclosed Lineshaft Pumps
HEAD ASSEMBLY
ITEM DESCRIPTION
608 HEADSHAFT
604 ADJUSTING NUT
730 GIB KEY
600 DISCHARGE HEAD
630 OIL RESERVOIR
623 TENSION NUT
625 TENSION PLATE
779 TENSION PLATE GASKET
620 O’RING
637 COLUMN FLANGE
COLUMN, OIL TUBE AND LINESHAFT ASSEMBLY
639 COLUMN LOCK RING
631 COLUMN NIPPLE
645 COLUMN COUPLING
642 COLUMN PIPE
629 TUBE NIPPLE
654 OIL TUBE
658 TUBE RETAINER
646 LINESHAFT
647 LINESHAFT SLEEVE
656 LINESHAFT BEARING
649 LINESHAFT COUPLING
BOWL ASSEMBLY
660 BOWL SHAFT
668 TUBE ADAPTER BEARING
665 OIL SEAL
659 COLUMN ADAPTER
661 DISCHARGE BOWL
664 DISCHARGE BEARING
670 INTERMEDIATE BOWL
672 INTER. BOWL BEARING
673 IMPELLER
677 IMPELLER, TAPERLOCK
680 WEAR RING (OPTIONAL)
760 HEX BOLT
692 SAND COLLAR
688 SUCTION BOWL/BELL
690 SUCTION BEARING
698 SUCTION STRAINER
747 PLUG
Figure 3 Enclosed Lineshaft Pumps
9
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