ITT Goulds Pumps AF Installation, Operation And Maintenance Instructions Download Page 8 | Manualshive

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S-3

SAFETY

DEFINITIONS

Throughout this manual the words

WARNING

,

CAUTION

,

ELECTRICAL, and ATEX

are used to indicate

where special operator attention is required.

Observe all Cautions and Warnings highlighted in this Pump Safety Manual and the IOM provided with
your equipment.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Example:

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

Indicates the possibility of electrical risks if directions are not followed.

Example:

Lock out driver power to prevent electric shock, accidental start-up, and physical injury.

When installed in potentially explosive atmospheres, the instructions that follow the Ex symbol must be

followed. Personal injury and/or equipment damage may occur if these instructions are not followed. If there
is any question regarding these requirements or if the equipment is to be modified, please contact an ITT
Goulds Pumps representative before proceeding.

Example:

Improper impeller adjustment could cause contact between the rotating and stationary

parts, resulting in a spark and heat generation.

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Summary of Contents for Goulds Pumps AF

Page 1: ...Installation Operation and Maintenance Instructions Model AF 6 36 MXR Bearings ...

Page 2: ...o assist operators in understanding the construction and the correct methods of installing operating and maintaining these pumps Goulds shall not be liable for physical injury damage or delays caused by a failure to observe the instructions for Installation Operation and Maintenance contained in this manual Warranty is valid only when genuine Goulds parts are used Use of the equipment on a service...

Page 3: ...AF 6 36 IOM 6 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 4: ... 6 36 IOM 7 TABLE OF CONTENTS Page 9 11 15 31 37 45 67 69 SAFETY GENERAL INFORMATION INSTALLATION OPERATION PREVENTATIVE MAINTENANCE DISASSEMBLY RE ASSEMBLY SPARE PARTS APPENDIX 1 Section 1 2 3 4 5 6 7 8 ...

Page 5: ...AF 6 36 IOM 8 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 6: ...e 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 Please take the time to review and understand the safe ...

Page 7: ...condition is avoided WARNING The pump may handle hazardous and or toxic fluids Care must be taken to identify the contents of the pump and eliminate the possibility of exposure particularly if hazardous and or toxic Potential hazards include but are not limited to high temperature flammable acidic caustic explosive and other risks WARNING Pumping equipment Instruction Operation and Maintenance man...

Page 8: ...hrottling flow from the suction side may cause cavitation and pump damage ELECTRICAL HAZARD Indicates the possibility of electrical risks if directions are not followed Example Lock out driver power to prevent electric shock accidental start up and physical injury When installed in potentially explosive atmospheres the instructions that follow the Ex symbol must be followed Personal injury and or ...

Page 9: ...ve closed WARNING NEVER operate pump with suction valve closed WARNING DO NOT change service application without approval of an authorized ITT Goulds Pumps representative WARNING 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 Steel...

Page 10: ...rtridge mechanical seal the centering clips must be installed and set screws loosened prior to setting impeller clearance Failure to do so could result in sparks heat generation and mechanical seal damage WARNING The coupling used in an ATEX classified environment must be properly certified and must be constructed from a non sparking material WARNING Never operate a pump without coupling guard pro...

Page 11: ...ety precautions to prevent physical injury WARNING Lock out driver power to prevent accidental startup and physical injury CAUTION Allow all system and pump components to cool before handling them to prevent physical injury CAUTION If pump is a Model NM3171 NM3196 3198 3298 V3298 SP3298 4150 4550 or 3107 there may be a risk of static electric discharge from plastic parts that are not properly grou...

Page 12: ...re proceeding Current IOMs are available at www gouldspumps com literature_ioms html or from your local ITT Goulds Pumps Sales representative All pumping unit pump seal coupling motor and pump accessories certified for use in an ATEX classified environment are identified by an ATEX tag secured to the pump or the baseplate on which it is mounted A typical tag would look like this The CE and the Ex ...

Page 13: ... and most reliable operation of your pump ITT Goulds Pumps ISO certification and quality control procedures ensure the parts are manufactured to the highest quality and safety levels Please contact your local Goulds representative for details on genuine Goulds parts ...

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Page 15: ...s of a bearing housing bearings stuffing box cover locknuts lockwashers labyrinth oil seals shaft shaft sleeve w packing oil slinger 20 36 impeller keys shaft washer and a front and back foot Stuffing Box Cover The cast stuffing box cover is used to close the rear of the elbow and provide a mounting surface for a mechanical seal or stuffing box and gland Inside it has a machined flat face with a 3...

Page 16: ...of the bearing housing by a removable bottom plate and gasket It is generally used when process temperatures cause excessive heat build up in the bearing housing and or bearings Configurations and Drives Most AF pumps are V belt driven to allow for varying speeds V belts can be configured for side by side overhead under slung or vertical operation The pumps can also be configured with gear reducer...

Page 17: ...d be taken when uncrating or de skidding pumps If shipment is not delivered in good order and in accordance with the bill of lading note the damage or shortage on both the receipt and freight bill Make any claims to the transportation company promptly Instruction sheets as well as the instruction book for the pump is included in the shipment DO NOT DISCARD HANDLING WARNING Pump and components are ...

Page 18: ...ignment complete 21 28 V belt tension and alignment per drive mfgr 21 Coupling alignment per cplg mfgr 23 Piping installed and alignment rechecked 21 22 36 Mech seal adjusted per mfgr Mfgrs Mnl Seal flush connected 33 34 Impeller alignment and clearance set Inch Side 26 28 Pump shaft free turning 32 Bearing types and lubrication 12 32 39 V belt or coupling guards installed 60 61 Motor electrical c...

Page 19: ...ering complete disassembly and handling of equipment The pump should have a supply of clean liquid for packing or mechanical seal lubrication The pump shall be positioned to provide the most efficient pipeline system The AF pumps covered by these instructions may be designed to hang in the piping system furnished with spring loaded sub base bolts or have a sub base designed to be anchor bolted and...

Page 20: ...se are level Check the coupling faces as well as the suction and discharge flanges of the pump for horizontal and vertical position by means of a level Check also for any internal rubbing in the pump Correct if necessary by adjusting the supports or wedges under the sub base as required In most cases factory alignment will be regained by shimming under the sub base alone Provisions must be made to...

Page 21: ... vertically and change the amount of force the spring exerts against the spring retainer which is fastened to the sub base The stop nut is to limit the vertical up motion of the sub base in case part of the load is removed from the pump unit when the system is cold The jam nut keeps the stop nut from turning during normal operation when the sub base has been pushed down from the thermal expansion ...

Page 22: ...ed the base should be off the support blocks and level 5 Check the alignment of the impeller and the pump elbow If necessary correct the alignment by adjusting the springs or by using shims NOTE If the flange gap is over 1 32 turn the adjusting screws a uniform amount to close the gap For a gap of 1 32 or less omit this step 6 Tighten the vertical pipe flange bolts recheck the alignment and connec...

Page 23: ...filled pocket is the addition of a grease fitting and grease seal Adjustment and setting of the grease filled pocket are identical PIPE HUNG INSTALLATIONS PIPE SUPPORT DESIGN REQUIREMENTS 1 Piping supports must meet Hydraulic Institute ASME ANSI DIN requirements in conjunction with standard construction practices 2 Piping shall be stiff enough to prevent unwanted pump vibrations 3 Thermal expansio...

Page 24: ...ump resulting in physical injury and damage to the equipment Guidelines for piping are given in the Hydraulic Institutes Standards available from Hydraulic Institute 30200 Detroit Road Cleveland OH 44145 1967 and must be reviewed prior to pump installation WARNING Never draw piping into place by forcing at the flanged connections of the pump This may impose dangerous strains on the unit and cause ...

Page 25: ... Piping should be level or slope gradually downward from the source of supply 4 No portion of the piping should extend below pump suction flange 5 The size of entrance from supply should be one or two sizes larger than the suction pipe 6 The suction pipe must be adequately submerged below the liquid surface to prevent vortices and air entrainment at the supply Discharge piping 1 Isolation and chec...

Page 26: ...and properly installed V belt drives are capable of running for years AF pumps come in several different belt drive configurations i e side by side overhead underslung or Z mount Installation and alignment procedures are similar for all configurations Remove the guard or guards by referring to the assembly disassembly instructions There are a few items that should be checked during installation an...

Page 27: ...ive frequently during the first day by observing the slack side span After a few days of operation the belts will seat themselves in the sheave grooves and it may become necessary to readjust so that the drive again shows a slight bow in the slack side Other methods of determining proper belt tension can be obtained from the drive manufacturer 5 Use Belt Guards Belt guards protect personnel from d...

Page 28: ...ive ALIGNMENT PROCEDURE On gear driven AF pumps angular and parallel misalignment are corrected in the vertical direction by means of shims under the motor or gearbox mounting feet and in the horizontal direction by adjusting bolts that slide the motor or gearbox in the proper direction After each adjustment it is necessary to recheck the alignment of the coupling halves Adjustment in one directio...

Page 29: ...ds outlined below that are acceptable to achieve the desired alignment NOTE Equal amounts of shims must be added to or removed from each driver foot Otherwise the vertical angular alignment will be affected METHOD I Dial Indicator Method For the following steps refer to Fig 21 1 Zero the indicator P at position 1 of coupling half Y Mark this position on both flanges 2 Rotate both flanges 180 to po...

Page 30: ...y NOTE With experience the installer will understand the interaction between angular and parallel and will make corrections appropriately IMPELLER ALIGNMENT GENERAL Improper impeller adjustment could cause contact between the rotating and stationary parts resulting in a spark and heat generation The impeller clearance setting procedure must be followed Improperly setting the clearance or not follo...

Page 31: ...r adjusting bolts on either side are used to center the impeller left to right in the elbow 3 Move the back pullout relative to the elbow until the impeller is centered At this point it is recommended that the Impeller Alignment Worksheet on the following page be filled out and filed with the pump maintenance records for future reference 4 Tighten the bolts between the bearing housing and elbow an...

Page 32: ...28 AF 6 36 IOM ...

Page 33: ...motor should be wired and the direction of rotation checked A rotation arrow is located on the bearing housing 134C Serious damage could occur if the pump is run the wrong direction When installing in a potentially explosive environment ensure that the motor is properly certified 3 ...

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Page 35: ...g methods to check motor rotation Direct Connect 1 Lock out power to the driver 2 Remove the pump coupling guard 3 Make sure the coupling halves are securely fastened to shafts 4 Unlock driver power 5 Make sure everyone is clear Jog the driver just long enough to determine direction of rotation of the output shaft of the gearbox Rotation must correspond to an arrow on bearing housing 6 Lock out po...

Page 36: ...nterline is horizontal through the bearing housing GREASE Bearings are hand packed at the factory and have sufficient grease for at least 24 hours of operation after startup The bearings will run hotter than normal for the first few hours until the grease is worked out of the ball path and the bearings have run in Adding more grease during this period may increase the bearing temperature After the...

Page 37: ...e seal has been installed in the pump at the Goulds factory these clips have already been removed For other types of mechanical seals refer to the seal manufacturer s instructions for installation and setting Mechanical seals have a stationary and a rotating sealing face Commonly these sealing rings are of carbon and ceramic material brittle in nature and easily damaged As the sealing rings seat w...

Page 38: ... For additional cooling of the sealing elements an outlet pipe with a valve can be installed to allow more liquid to flow through the stuffing box Double mechanical seals have no leakage and usually require a lubricant flow through the stuffing box for cooling The lubricating flow should be regulated by the valve in the outlet pipe rather than by throttling the flow in the supply pipe DRIVER Start...

Page 39: ...pump below minimum rated flows or with a discharge valve closed This condition may create an explosive hazard due to vaporization of pumpage and can quickly lead to pump failure and physical injury Driver may overload if the pumpage specific gravity density is greater than originally assumed or the rated flow rate is exceeded Listed below are some causes for circulation loss Keep in mind that oper...

Page 40: ...ditions while pump is idle could cause liquid to freeze and damage the pump Liquid inside pump should be drained SHUTDOWN 1 Turn off power to pump motor 2 In case of necessary maintenance or pump inspection lock driver to prevent accidental rotation WARNING When handling hazardous and or toxic fluids skin and eye protection are required If pump is being drained precautions must be taken to prevent...

Page 41: ...or assistance in selecting the proper instrumentation and its use please contact your ITT Goulds representative MAINTENANCE SCHEDULE The preventive maintenance section must be adhered to in order to keep the applicable ATEX classification of the equipment Failure to follow these procedures will void the ATEX classification for the equipment Routine Maintenance Bearing lubrication Seal monitoring V...

Page 42: ...ssembled inspected and worn parts should be replaced otherwise a system inspection should be done MAINTENANCE OF BEARINGS Operation of the unit without proper lubrication will cause bearing failure and pump seizure Throughout this section on bearing lubrication different pumpage temperatures are listed If the equipment is ATEX certified and the listed temperature exceeds the applicable value shown...

Page 43: ...peration Re grease Procedure NOTE When re greasing there is danger of impurities entering the bearing housing The grease container the grease device and fittings must be clean 1 Wipe dirt from the grease fittings 2 Fill both grease cavities through the grease fittings 193A and 193B found on the bearing housing 134C Use recommended grease and fill until slight resistance is felt in the grease gun s...

Page 44: ... used to replace the packing 1 Drain the system or isolate the pumpage from the pump before replacing the packing 2 Remove the nuts from the gland studs that hold the gland in place 3 Use a packing puller remove the first 3 rows of packing from the box 4 Use threaded rods or a packing puller to remove the lantern ring from the box 5 Use a packing puller remove the final 2 rings of packing from the...

Page 45: ... and cool packing An external sealing liquid is required when 1 Abrasive particles in the pumpage could score the shaft sleeve 2 Stuffing box pressure is below atmospheric pressure due to pump running when suction source is under vacuum Under these conditions packing will not be cooled and lubricated and air will be drawn into the pump If an outside source of clean compatible liquid is required th...

Page 46: ...d rpm too low New drive or gear box to obtain higher pump speed Incorrect rotation Check motor wiring Incorrect impeller or impeller diameter Check vane angles and or impeller clearances System head too high Check system curve calculations reduce system resistance Instruments give erroneous readings Check and calibrate instruments replace if necessary Worn or broken impeller bent vanes Inspect and...

Page 47: ...ller clearances adjust if necessary Pump assembled incorrectly Compare pump assembly to instruction manual Pump run off design point Check head and flow AF s should be run at 75 BEP 115 Excessive shaft deflection Check shaft diameter sag and deflection consult factory Worn bearings Replace Suction or discharge piping not anchored or properly supported Anchor per Hydraulic Institute Standards manua...

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Page 49: ...ed for maintenance the elbow can remain in the piping WARNING Pump components can be heavy Proper methods of lifting must be employed to avoid physical injury and or equipment damage WARNING The AF may handle hazardous and or toxic fluids Skin and eye protection is required Precautions must be taken to prevent physical injury Pumpage must be handled and disposed of in conformance with applicable E...

Page 50: ...emove the hubs from the gear drive and pump shafts see Fig 30 8 Remove the pump to sub base bolts 372V and wrap lifting straps or chains around the bearing housing 134C and elbow 315A see Fig 31 Use care when lifting the pump from the subbase Be sure all lifting devices are rated for the pump weight If any shims are found under the bearing housing feet match mark and retain them for re assembly V ...

Page 51: ...ring housing feet retain them for re assembly later 12 Depending on the drive type remove the hub fasteners that hold the coupling or pump sheave to the shaft 122 Remove either a coupling half or pump sheave and key 400 If the coupling half is interference fit heat may be necessary to remove it from the shaft Drive instructions are included with the data package Follow the manufacturer s instructi...

Page 52: ...screws 356A Remove the bolts 789l 799O that secure the back pullout 903A to the elbow and discard the o ring 351 see Fig 37 Liner option 15 If the elbow 315A or casing 100 has an optional liner 103A now is the time to remove it Four tapped holes in the liner flange are used with screws to jack the liner from its seat If the liner has been in service this may require considerable effort due to corr...

Page 53: ...r 184 to the bearing housing 134C Remove the stuffing box cover from the bearing housing On larger pumps use a sling or hook and chain to securely support the weight of the stuffing box cover during removal Remove the adjusting bolts 356A and all four adjusting lugs 415 Be careful not to scuff or scar the pump shaft 122 during removal see Fig 41 Packed Box 19 With a packed box the gland nuts 353 g...

Page 54: ...39A Remove the screws 788Z that secure the thrust bearing retainer 119C to the bearing housing Remove the retainer and discard the gasket shims 331 or o ring 412Y see Fig 45 23 Using the eye bolt already threaded into the shaft pull the rotating assembly from the bearing housing see Fig 46 Once the rotating assembly has been removed place it on a set of wooden V blocks for bearing removal see Fig ...

Page 55: ...ng Use a bearing puller to remove the thrust bearing 112C Next remove the thrust bearing collar 443X and oil wheel 248 The oil wheel has one to three set screws 222N that hold it to the shaft 122 The collar and oil wheel must be removed prior to removing the inboard bearing Finally use a puller to remove the inboard radial bearing 168C from the drive end of the shaft Be careful not to damage the s...

Page 56: ...nd liner 103A should be inspected for excessive wear or pitting in the impeller and gasket areas They should be repaired or replaced if wear or corrosion exceeds the following criteria see Fig 50 1 Localized wear or grooving greater than 1 8 in 3 2mm deep 2 Pitting greater than 1 8 in 3 2mm deep 3 Inspect case gasket seat surface for irregularities IMPELLER 1 Inspect impeller vanes for damage 101 ...

Page 57: ...SHAFT SLEEVE 1 The shaft sleeve 126 should be replaced if badly grooved or worn Localized wear or grooving greater than 3 32 in 2 4 mm deep is cause for replacement see Fig 53 MECHANICAL SEAL RESTRICTOR BUSHING 1 Refer to the mechanical seal 383 vendor s manual for inspection instructions 2 The restrictor bushing 496B if necessary should be replaced during re assembly STUFFING BOX 1 Check the stuf...

Page 58: ...building the pump Replace them while pump is disassembled Critical Axial Flow Dimensions and Tolerances Impeller End Pump Size Inboard Housing Bore Outboard Housing Bore Inboard Bearing Seat Outboard Bearing Seat Mech Seal Seat Sleeve Seat 1st Step 2nd Step 6 1 2495 1 2485 8 10 3 5442 3 5433 3 9379 3 9370 1 9690 1 9686 1 7722 1 7718 1 750 1 748 1 687 1 685 1 3745 1 3735 12 1 9995 1 9985 2 0307 2 0...

Page 59: ...e Fig 57 and the sectional drawing at the end of this section WARNING Use insulated gloves when using a bearing heater Bearings get hot and can cause physical injury 2 Heat the inner thrust bearing 112C to 225 F The thrust bearings are mounted back to back so before placing the bearing on the shaft 122 be sure that the large diameter face of the inner race is facing the shaft shoulder 3 Heat the o...

Page 60: ...r 142B lock washer 382 with its tang in the groove on the shaft 122 and the lock nut 136 with tapered end toward the lock washer 382 Tighten the whole unit until snug Re tighten the lock nut 136 several times before the bearing cools completely Be sure no clearance exists between the inner race collar 443X and shaft shoulder 122 With the locknut secure align the slots with the tangs of the lock wa...

Page 61: ...the process Attach the stuffing box 220 and gasket 351W to the stuffing box cover 184 using screws 799E If removed re install the four studs 355 On larger pumps use a sling or hook and chain to support the weight of the stuffing box cover during installation Mount the stuffing box cover 184 to the register of the bearing housing 134C Be careful not to scuff or scar the pump shaft 122 or sleeve 126...

Page 62: ... all gland quench or flush tubing is connected see Fig 64 IMPELLER Standard Impeller 17 Install the shaft key 178 Slide the impeller 101 onto the shaft 122 and if necessary use a wooden mallet to set it in place against the shaft shoulder Install the shaft washer 199 and fasteners 198 tighten to lock the impeller 101 in place see Fig 65 Sealed Impeller 18 700mm and 36 sizes use an impeller cover a...

Page 63: ...w 100 or casing 100 has an optional liner 103A now is the time to install it The liner may require some effort to install try using a wooden mallet if resistance is noticed The liner is sealed when it is compressed against the pipe flange and requires no gasket If a replacement is necessary be sure to order the correct material for the pumpage see Fig 69 DRIVE GUARD 19 Insert the drive key 400 int...

Page 64: ...e guard cover 500 using screws 502 see Fig 73 24 Check impeller alignment and re align if necessary according to instructions on pg 28 of section 3 Direct Connect Configuration 25 Using a crane lift the pump into place on the sub base Be careful not to damage the pump by striking any beams or walls that may be near the pump If any shims were found under the bearing housing feet during disassembly ...

Page 65: ...se using screws 502 see Fig 76 29 Check impeller alignment and re align if necessary according to instructions on pg 28 of section 3 30 Fill pump with proper lubricant Refer to preventative maintenance for requirements 31 Connect all auxiliary piping and tubing 32 Fill system piping so pump impeller is submerged flush the pump if necessary 33 Open all valves controlling flow to and from the pump 3...

Page 66: ...62 AF 6 36 IOM AF SECTIONAL shown with optional restrictor bushing adapter Fig 77 ...

Page 67: ...02 5303 5309 351A Gasket Elbow Casing 5302 5303 5309 353 Gland stud 355 Gland nuts 2229 357G Nuts Casing 2210 2228 2229 2230 2248 2369 2150 2266 2155 2156 356A Adjusting bolts Steel 358U Oil fill plug Steel 360W Cover Oil Cooling Steel 361 Gasket Oil Cooling 5302 370F HHCS Oil Cooling Steel 370G HHCS Casing 2210 2228 2229 2230 2248 2369 2150 2266 2155 2156 370J HHCS Bearing Housing Elbow 2210 2228...

Page 68: ...64 AF 6 36 IOM AF OPTIONS Fig 78 351 370F 126 ...

Page 69: ...AF 6 36 IOM 65 MXR BEARING CONFIGURATIONS 1MXR 3MXR 4MXR 6MXR Fig 79 540C 6 ...

Page 70: ...66 AF 6 36 IOM AF WITH SEPARATE CASING sizes 700mm and 36 only BOX ALIGNMENT IMPELLER ALIGNMENT Fig 80 351A 251C ...

Page 71: ...ngs 496 496B 496C Shaft 122 Inboard Radial Bearing 168C Outboard Thrust Bearing or Bearings 112C Bearing Lockwasher 382 Bearing Locknut 136 Outboard Labyrinth Seal 332A Inboard Labyrinth Seal 332B Shaft Sleeve 126 Optional Sleeve O rings 412F Optional Stuffing Box Bushing 125Z Optional Lantern Ring 105 Optional Stuffing Box Packing 106 Optional Packing Gland 107 Optional HOW TO ORDER PARTS When or...

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Page 73: ...gnment collar is used to install the radial bearing on the 4MXR 5MXR and 6MXR bearing configurations It is recommended that you use this tool so as not to damage the radial bearing and or bearing housing during rotating assembly installation Fig 81 BEARING ALIGNMENT COLLAR 8 ...

Page 74: ...ds Representative Emergency parts service is available 24 hours day 365 days year Call 1 800 446 8537 Visit our website at www gouldspumps com HOW TO ORDER EMERGENCY SERVICE 2007 Goulds Pumps Incorporated a subsidiary of ITT Corporation Form No IAF 6 36 03 07 ...

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