ITT Goulds Pumps 3501 Installation, Operation And Maintenance Instructions Download Page 5 | Manualshive

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Preface

This manual provides instructions for the Installation, Operation, and Maintenance of the Goulds Model
3501 Optimix™ Medium Consistency Mixer. This manual covers the standard product plus common op-
tions that are available. For special options, supplemental instructions are supplied. This manual must be
read and understood before installation and start-up.

The design, materials, and workmanship incorporated in the construction of Goulds mixers makes them
capable of giving 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 moni-
toring and careful maintenance. This instruction manual was prepared to assist operators in understand-
ing the construction and the correct methods of installing, operating, and maintaining these mixers.

ITT - Goulds Pumps shall not be liable for physical injury, damage or delays caused by a failure to ob-
serve the instructions for Installation, Operation, and Maintenance contained in this manual.

Warranty is valid only when genuine ITT - Goulds 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 ITT - Goulds Pumps.

To assure proper installation, supervision from an authorized manufacturer's representative is recom-
mended.

Additional manuals can be obtained by contacting your local Goulds representative.

This manual explains:

•

Proper Installation

•

Start-Up Procedures

•

Operation Procedures

•

Routine Maintenance

•

Mixer Overhaul

•

Troubleshooting

•

Ordering Spare or Repair Parts

Table of Contents

3501 Installation, Operation, and Maintenance Instructions

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Summary of Contents for Goulds Pumps 3501

Page 1: ...Installation Operation and Maintenance Instructions 3501 ...

Page 2: ......

Page 3: ...ment 16 3 5 2 Parallel alignment 17 3 5 3 Complete alignment 18 3 6 Grout baseplate 19 3 6 1 Alignment check 20 3 7 Piping 20 3 7 1 General 20 3 7 2 Inlet piping 21 3 7 3 Outlet piping 21 3 7 4 Final piping check 21 3 8 Piping instructions 21 3 8 1 Liquid mixing 21 3 8 2 Gas mixing 22 3 9 Spring mounted baseplates 22 4 Operation 24 4 1 Preparation for start up 24 4 2 Check rotation 24 4 3 Couple m...

Page 4: ...oval of Taperbore PLUS seal chamber and mechanical seal 40 6 6 Disassembly of bearing frame 41 6 7 Inspections 42 6 8 Casing 42 6 9 Rotor 42 6 10 Seal chamber 42 6 11 Bearing frame 43 6 12 Reassembly 43 6 13 Reassembly of bearing frame 45 6 14 Reassembly of taperbore plus seal chamber and mechanical seal 51 6 15 Installation of rotor 51 6 16 Installation of casing foot and alignment pin 52 6 17 In...

Page 5: ...in understand ing the construction and the correct methods of installing operating and maintaining these mixers ITT Goulds Pumps shall not be liable for physical injury damage or delays caused by a failure to ob serve the instructions for Installation Operation and Maintenance contained in this manual Warranty is valid only when genuine ITT Goulds parts are used Use of the equipment on a service o...

Page 6: ...com en US Tools and Resources Litera ture or by contacting your nearest Goulds Pumps sales representative These manuals must be read and understood before installation and start up For additional information contact your nearest Goulds Pumps sales representative or visit our Web site at https www gouldspumps com 1 2 Safety Warnings Specific to pumping equipment significant risks bear reinforcement...

Page 7: ...mple Pump shall never be operated without coupling guard installed correctly CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury Example Throttling flow from the suction side may cause cavitation and pump damage Electrical Hazard WARNING Indicates the possibility of electrical risks if directions are not followed Example Lock out driver power to pr...

Page 8: ... equipment only at specifically identified lifting points or as instructed in the current IOM Current manuals are available at www gould spumps com literature_ioms html or from your local ITT Goulds Pumps sales representative Note Lifting devices eyebolts slings spreaders etc must be rated selected and used for the entire load being lifted WARNING Alignment Shaft alignment procedures must be follo...

Page 9: ...ns may create an explosive hazard due to vaporization of pumpage and can quickly lead to pump failure and physical in jury WARNING Ensure pump is isolated from system and pressure is relieved before disas sembling pump removing plugs opening vent or drain valves or disconnect ing piping WARNING Shutdown Disassembly and Reassembly Pump components can be heavy Proper methods of lifting must be emplo...

Page 10: ...ture Equipment and piping surfaces may exceed 130ºF 54ºC in operating proc ess plants Clear visual warnings or other indicators should alert personnel to surfaces that may reach a potentially unsafe temperature Do not touch hot surfaces Allow pumps operating at a high temperature to cool sufficiently be fore performing maintenance If touching a hot surface cannot be avoided personnel should wear a...

Page 11: ...frame The outboard bearing is 40 angular contact duplex set mounted back to back locked on the shaft by a threaded locknut and carries both radial and axial loads The frame is sealed with labyrinth seals as standard Flood oil lubrication is standard Grease lu brication is available as an option No special parts are required to convert from grease to oil lubrication Bearing frame cooling can be sup...

Page 12: ...Make notes of damaged or missing items on the receipt and freight bill File any claims with the transportation com pany as soon as possible 2 3 1 Storage Requirements Short Term Less than 6 months Goulds normal packaging procedure is designed to protect the mixer during shipping Upon receipt store in a covered and dry location 2 3 Receiving the mixer 10 3501 Installation Operation and Maintenance ...

Page 13: ...these steps could result in damage to the mechanical seal or shaft sleeve 2 3 2 Handling Use care when moving mixers Lifting equipment must be able to adequately support the entire assem bly Hoist bare mixer using a suitable sling under the suction and discharge flange and bearing frame Baseplate mounted units are moved with slings under the mixer casing flanges and driver See Figure 4 Bare mixer ...

Page 14: ...Figure 5 Baseplate mounted Figure 6 Baseplate and driver 2 3 Receiving the mixer 12 3501 Installation Operation and Maintenance Instructions ...

Page 15: ... mounting using sleeve type bolts Figure 8 Baseplate mounting using J type bolts 3 2 Level baseplate 1 Place two sets of wedges or shims on the foundation one set on each side of every foundation bolt The wedges should extend 20 mm 75 in to 40 mm 1 5 in above foundation to allow for ade quate grouting This will provide even support for the baseplate once it is grouted Figure 9 Shims or wedges side...

Page 16: ...t ambient tempera ture Final Alignment is done after operation when the mixer and driver are at operating temperature Alignment is achieved by adding or removing shims from under the feet of the driver and shifting equipment horizontally as needed NOTICE Proper alignment is the responsibility of the installer and user of the unit Accurate alignment of the equipment must be attained Trouble free op...

Page 17: ...ature Final Alignment During the installation phase however it is necessary to set the parallel alignment in the vertical direc tion to a different criteria due to differences in expansion rates of the mixer and driver For Model 3501 the Cold Setting of Parallel Vertical Alignment table shows recommended preliminary cold settings for electric motor driven mixers based on different pumpage temperat...

Page 18: ...p to Bottom 1 Zero indicator A at top dead center 12 o clock of coupling half Y 2 Rotate indicators to bottom dead center 6 o clock Observe needle and record reading 3 Negative Reading The coupling halves are further apart at the bottom than at the top Correct by either raising the driver feet at the shaft end add shims or lowering the driver feet at the other end remove shims shown below Figure 1...

Page 19: ...oes not vary by more than 05 mm 002 in as measured at four points 90 apart at operating temperature Note the preliminary vertical cold setting criteria refer to Table 2 Cold Setting of Parallel Vertical Alignment on page 15 Vertical Correction Top to Bottom 1 Zero indicator P at top dead center of coupling 12 o clock half Y see Figure 11 Dial indicator mounting on page 15 2 Rotate indicator to bot...

Page 20: ...ailure to slide motor evenly will affect horizontal angular correction 4 Repeat steps 1 through 3 until indicator P reads 05 mm 002 in or less 5 Re check both horizontal and vertical readings to ensure adjustment of one did not disturb the other Correct as necessary 3 5 3 Complete alignment A unit is in complete alignment when both indicators A angular and P parallel do not vary by more than 05 mm...

Page 21: ...ims at the appropriate corner s and realign Cannot obtain vertical Top to Bot tom alignment angular or parallel Baseplate not leveled properly probably bowed Determine if center of baseplate should be raised or lowered and correct by evenly adding or removing shims at the center of the baseplate 3 6 Grout baseplate 1 Clean areas of baseplate that will contact grout Do not use oil based cleaners be...

Page 22: ...xceed the limits of the mixer Contact your Goulds representative for information on the maximum flange loads 1 All piping must be supported independently of and line up naturally with the mixer flanges 2 Piping runs should be as short as possible to minimize friction losses 3 Do not connect piping to mixer until grout has hardened and mixer and driver hold down bolts have been tightened 4 It is su...

Page 23: ...from the source of supply 3 7 3 Outlet piping Isolation valves should be installed in outlet line The isolation valve is required for inspection and main tenance of mixer 3 7 4 Final piping check After connecting the piping to mixer 1 Rotate shaft several times by hand to be sure that there is no binding and all parts are free 2 Check alignment per the alignment procedure outlined previously to de...

Page 24: ...hermal expansion and high loading Steam addition and steam mixing can cause thermal expansion and high loading Mixer Flange Loads Allowable flange loads for the suction and discharge nozzles are available 3 9 Spring mounted baseplates 1 Raise or support the baseplate above the foundation floor Be sure to allow enough room under the baseplate to install the spring assemblies 2 Set the bottom adjust...

Page 25: ...ng nut Change the height by moving the lower adjusting nut When the baseplate is level tighten the top adjusting nuts just enough to make sure the top springs are not loose in their followers and then snug the lower and upper jam nuts NOTICE Suction and discharge piping must be individually supported The spring mounted baseplates are designed to support piping loads developed by thermal expansion ...

Page 26: ...xer is shipped with coupling spacer removed 3 Unlock driver power 4 Make sure everyone is clear Jog driver just long enough to determine direction of rotation Rotation must correspond to arrow on bearing housing 5 Lock out power to driver 4 3 Couple mixer and driver WARNING Lock out driver power to prevent accidental rotation and physical injury 1 Install and lubricate coupling per manufacturer s ...

Page 27: ...ame with oil through the filler connection located on top of bearing frame until the level reaches the mark in the middle of the oil level sight glass A high quality turbine type oil with rust and oxidation inhibitors should be used If the constant level oiler option is supplied it would be in the box of fittings which accompanies the mix er The oiler was adjusted before leaving the factory howeve...

Page 28: ...th this model is the cartridge type Cartridge seals are preset at the factory and require no field settings unless seal is removed Connection of Sealing Liquid For satisfactory operation there must be a liquid film between seal faces to lubricate them Refer to seal manufacturer s drawing for location of taps The primary method used to flush cool the seal is an external flush where a clean cool com...

Page 29: ...r seizure may not take place and continued operation under these conditions may create an explosive hazard due to confined vapor under high pressure and temperature 4 5 3 Operating under freezing conditions Exposure to freezing conditions while mixer is idle could cause liquid to freeze and damage the mixer Liquid inside mixer should be drained Liquid inside cooling coils if supplied should also b...

Page 30: ...d to pump through the mixer when it is not running since mixing will not be effective and chemical usage will be high The mixer runs only when the feed pump is running If the feed pump is down for more than five 5 minutes the mixer will shut down Seal water is required to operate the mixer The mixer has a cartridge mechanical seal with flush meter and alarm and cannot be operated with out seal wat...

Page 31: ...ould be no leakage Quarterly Inspections Check foundation and hold down bolts for tightness Oil should be changed at least every 3 months or more often if there are any adverse atmospheric conditions or other conditions which might contaminate or break down the oil Grease lubricated bearings should be regreased every 3 months Annual Inspections Check mixer capacity and power If mixer performance d...

Page 32: ...nditions bearing temperatures will run between 60 C 140 F and 82 C 180 F In this range an oil of ISO viscosity grade 68 at 40 C 105 F is recommended If bearing temperatures exceed 82 C 180 F use of ISO viscosity grade 100 is recommended Table 5 Lubricating Oil Requirements Lubricating Oil Requirements Bearing temper ature below 82 C 180 F Bearing tem perature above 82 C 180 F ISO Grade VG 68 VG 10...

Page 33: ...gs every 2000 operating hours or 3 months Refer to following table for re grease amounts Table 6 Grease Amounts Grease Amounts Frame Initial Grease Regrease Thrust Angular Contact Radial Cy lindrical Roll er Thrust An gular Con tact Radial Cy lindrical Roller Grams Oz Grams Oz Gram s Oz Gram s Oz M 290 10 180 7 0 115 4 0 70 2 5 L 475 17 280 10 200 7 0 115 4 0 XL 800 28 450 16 345 12 0 190 6 5 Amou...

Page 34: ...e of NLGI consistency No 2 is recom mended This grease is acceptable for fluid temperatures of 15 C to 110 C 5 F to 230 F Bearing tem peratures are generally about 25 C 45 F higher than bearing housing outer surface temperature Acceptable Greases Mobil Mobilux EP2 Exxon Unirex N2 Texaco Multifak 2 Shell Alvania 2 EP Grease 2 Sunoco Multipurpose EP SKF LGMT 2 CAUTION Never mix greases of different ...

Page 35: ...t is however not possible to give defi nite indications as to its life WARNING Never operate the mixer without liquid supplied to mechanical seal Running a mechanical seal dry even for a few seconds can cause seal damage and must be avoided Physical injury can occur if mechanical seal fails NOTICE For pumps supplied with cartridge mechanical seals be sure the set screws in the seal locking ring ha...

Page 36: ... a time backing the bearing housing 134A away from the bearing frame until the rotating assembly contacts the seal chamber cover 184 7 Record reading on dial indicator 8 Divide Total Travel reading determined in the previous step by 2 and adjust the dial indicator to that number 9 Loosen jack bolts 371A several turns 10 Tighten locking bolts 370C evenly until dial indicator reading is 0 11 Evenly ...

Page 37: ...ck into gap between bearing housing 134A and bearing frame 228 Tight en the locking bolts 370C evenly until bearing housing contacts the feeler gauge stack 11 Evenly tighten jack bolts 371A then locking bolts 370C while assuring that the feeler gauge does not bind or become loose 12 Tighten jam nuts 423B 13 Check shaft for free turning 14 Replace coupling guard NOTICE For pumps supplied with cartr...

Page 38: ...orn bearings Replace Inlet or outlet piping not anchored or prop erly supported Anchor per Hydraulic Institute Standards Manual recommendations Mixer is cavitating Locate and correct system problem May have insufficient back pressure on mixer Excessive leakage from seal cham ber Worn mechanical seal parts Replace worn parts Overheating mechanical seal Check lubrication and cooling lines Shaft slee...

Page 39: ...xic fluids Skin and eye protection are required Pre cautions must be taken to prevent injury or environmental contamination NOTICE Before disassembling the mixer for overhaul ensure all replacement parts are available 1 Lock out power supply to driver 2 Shut off all valves controlling flow to and from mixer 3 Drain liquid from piping flush mixer if necessary 4 Disconnect all auxiliary tubing and p...

Page 40: ...lace plug after oil is drained 6 3 Disassembly 1 Place sling from hoist around bearing frame 228 2 Remove bearing frame foot hold down bolts 3 Remove six 6 casing bolts 370A casing to seal chamber and eight 8 casing bolts 469Z frame to seal chamber to casing Figure 26 Placement of sling hoist 4 Use jack bolts 418 to remove the back pullout 6 3 Disassembly 38 3501 Installation Operation and Mainten...

Page 41: ... off shaft 182 using two bars opposite each other placed between cover and rotor shroud Another method of removing the rotor is using a rotor puller Figure 28 Rotor puller WARNING Do not use heat on the rotor to help remove severe bodily injury could occur CAUTION In order to prevent rotor damage use pry points under rotor vanes 6 4 Removal of rotor 3501 Installation Operation and Maintenance Inst...

Page 42: ...he seal chamber 184 Fig 31 4 Gently tap the seal chamber 184 with cartridge seal and mixer sleeve from the frame 228 using a soft blow hammer on the dry side of the cover Fig 31 5 Remove the four 4 hex nuts 355 and washers 354 from the seal gland plate 6 Loosen the set screws on the seal drive collar and slide the mixer sleeve 126 out of the seal 7 Service per the seal manufacturer s instructions ...

Page 43: ...2A 333A from each end of frame Fig 32 Figure 31 Coupling hub and guard end plate 6 Slide rotating element out of frame 228 If needed tap rotor end of shaft with a soft blow hammer to assist in removal Fig 33 Figure 32 Rotating element WARNING Support both ends of shaft to prevent rotating element from dropping when bearings are disen gaged from bores 7 Radial end cover 109A is installed permanentl...

Page 44: ...gs Fig 35 6 7 Inspections 6 8 Casing 1 Thoroughly clean gasket surfaces and alignment fits to remove rust and debris 2 Inspect for any unusual erosive wear inside casing 6 9 Rotor 1 Inspect leading and trailing edges of vanes for pitting and erosion or corrosion damage 2 Inspect keyway and bores for damage 6 10 Seal chamber 1 Thoroughly clean gasket surfaces and fits to remove rust and debris 2 In...

Page 45: ...CBY NUP317ECP 6 12 Reassembly Specifications Table 10 Model 3501 Fastener Information Item No Qty per Mixer Part Name Group Construc tion Goulds Part No Thread Size Hex Size mm Torque Value See Notes1 3 N m lb ft 3 Hex Head Cap Screw Coupling Guard Not shown All All A02818A89 2441 M10 x 1 50 17 3 Nut Hex Coupling Guard Not shown All All A02089A10 2441 M10 x 1 50 17 13 10 136 1 Locknut Bearing M Al...

Page 46: ...d Cap Screw Frame Foot to Frame M All A02818A102 2442 M12 x 1 75 19 66 49 L and XL A02818A124 2442 M16 x 2 00 24 164 121 370F 4 Hex Head Cap Screw Casing Foot to Cas ing Not shown M All A02818A102 2442 M12 x 1 75 19 66 49 L A02818A124 2442 M16 x 2 00 24 164 121 371A 3 Hex Tap Bolt Adjust ment M All A02818A106 2442 M12 x 1 75 19 66 49 4 L and XL A02818A128 2442 M16 x 2 00 24 164 121 372V 4 Hex Head...

Page 47: ...ds have been lubricated with a performance lubricant e g NeverSeez torque values should be decreased by 50 6 13 Reassembly of bearing frame NOTICE An induction type bearing heater is required to expand bearings to ease their installation on shaft Bearings should be heated to approximately 100 C 212 F CAUTION Do not use a flame to heat bearings this will damage bearing surfaces Figure 35 Bearing fr...

Page 48: ...aring locknut 136 6 Tighten bearing locknut 136 firmly with a spanner wrench clamping bearing 112 against shaft 122 shoulder 7 Bend lockwasher 382 tang into a slot that lines up on bearing locknut 136 8 If bearing lubrication is grease hand pack all three bearings with grease 9 Lubricate and install O ring 496 on thrust bearing housing 134A 10 Slide thrust bearing housing 134A over thrust bearing ...

Page 49: ...ted grease from oil return after plug is removed 13 If radial end cover 109A was removed degrease contact surfaces and those in bearing frame 228 and apply Loctite 518 to the outer diameter of cover 14 Tap radial end cover 109A in place using a soft blow hammer 15 Lightly lubricate bores of bearing frame 228 outer diameters of radial bearing 409 and thrust bearing housing 134A and housing O ring 4...

Page 50: ...l are on top Fig 41 Grease Lubrication Orient bearing housing so the words read top grease are on top Fig 41 Figure 40 Oil and grease lubrication housing orientation 18 Align holes in coupling guard end plate to bearing housing to frame holes in thrust bearing housing 134A and install hex cap bolts 370C Fig 42 Figure 41 Coupling guard end plate 6 13 Reassembly of bearing frame 48 3501 Installation...

Page 51: ... bearing frame 228 with hex head cap screws 370D 26 Oil Lubrication a Install four plugs 408E into bearing frame 228 as follows based on viewing from coupling end Figs 43 and 44 two on right side at coupling end one on left side one on top at seal chamber end b Install oil sight glass 319 on right side of bearing frame 228 as viewed from coupling end c Install oil drain plug 408B into bottom of be...

Page 52: ...coupling end c Install oil drain plug 408B into bottom of bearing frame 228 Fig 43 28 If equipped with an oil cooler install cooler assembly into bearing frame 228 based on viewing from coupling end as follows Fig 45 Figure 43 Oil cooler assembly a Install one tube fitting with straight bore on left side of frame 6 13 Reassembly of bearing frame 50 3501 Installation Operation and Maintenance Instr...

Page 53: ...sleeve 126 5 Rig lifting device to eyebolt in seal chamber 184 and install seal chamber 184 on bearing frame 228 6 Install hex head bolts 370B 7 Slide cartridge seal on gland studs 353 Assure that gland studs align with openings in gland and that the tap connections are in the correct orientation 8 Install gland stud washers 354 and nuts 355 and finger tighten the gland nuts Do not tighten the nut...

Page 54: ...s VIBRA TITE Formula 3 thread sealing compound to rotor nut set screws 222S 10 Install and tighten rotor nut set screws 222S 6 16 Installation of casing foot and alignment pin NOTICE Model 3501 6 and 8 mixers require a casing foot 131 The 12 mixer does not Model 3501 8 mixers require an alignment pin on the inlet flange to ensure that the chemical injection pipe 174 is properly oriented The 6 and ...

Page 55: ...nk plug into tapped hole in inlet flange and tighten 6 17 Installation of back pull out assembly NOTICE For pumps or back pull out assemblies supplied with cartridge mechanical seals the centering tabs must be in place and tightened and the set screw collar loosened Failure to take these steps could result in damage to the mechanical seal or shaft sleeve 1 Adjust rotor 101 so gap between rear roto...

Page 56: ... within criteria tighten remaining casing bolts and torque to specified value in a cross bolt pattern Refer to Table 8 Bearing Frame on page 43 8 Set rotor 101 axial clearance as described in Preventive Maintenance section 9 Install and tighten casing foot nut to baseplate bolts 372V 10 Determine gap if any between frame foot and baseplate with feeler gauges and shim accordingly 11 Install and tig...

Page 57: ...ical seals be sure the set screws in the seal locking ring have been tightened and the centering clips removed prior to startup Failure to take these steps could result in damage to the mechanical seal or shaft sleeve 6 17 Installation of back pull out assembly 3501 Installation Operation and Maintenance Instructions 55 ...

Page 58: ...ings required for one mixer 7 1 2 Recommended spare parts Mechanical Seal item 383 Shaft Sleeve item 126 Bearing items 112 409 Rotor Nut item 304 Impeller Key item 178 Bearing Locknut item 136 Bearing Lockwasher item 382 Shaft item 122 Gaskets and O rings required for one mixer 7 1 3 Minimum recommended spare parts Shaft Sleeve item 126 Bearing items 112 and 409 Bearing Locknut item 136 Bearing Lo...

Page 59: ...nium 131 1 Foot Casing Not Shown Steel Steel 134A 1 Housing Bearing Cast Iron Cast Iron 136 1 Locknut Bearing Steel Steel 174 1 Pipe Chemical Injection Not Shown 316LSS Titanium 178 1 Impeller Key 17 4PH 17 4PH 184 1 Seal Chamber 316SS Titanium 222S 2 Set Screw Impeller Nut 316LSS Titanium 228 1 Frame Bearing Cast Iron Cast Iron 236A 8 or 10 Socket Head Cap Screw Bearing Retainer to Bearing Housin...

Page 60: ...ng Foot to Casing Not Shown Steel Steel 371A 3 or 4 Hex Tap Bolt Adjustment Steel Steel 382 1 Lockwasher Bearing Steel Steel 400 1 Key Coupling Not Shown Steel Steel 408B 1 Plug Drain Steel Steel 408E 4 Plug Steel Steel 408H 1 Plug Oil Fill Steel Steel 409 1 Bearing Roller Steel Steel 412A 1 O ring Impeller Nut PTFE PTFE 412F 1 O ring Shaft Sleeve PTFE PTFE 418 2 Hex Head Cap Screw Jacking Steel S...

Page 61: ...Call 1 800 446 8537 Visit our Web site at http www gouldspumps com 7 4 Emergency service 3501 Installation Operation and Maintenance Instructions 59 ...

Page 62: ...nd more information www gouldspumps com ITT Goulds Pumps 240 Fall Street Seneca Falls NY 13148 USA 2022 ITT Corporation The original instruction is in English All non English instructions are translations of the original instruction Form IOM 3501 en us 2022 03 ...

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