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TROUBLESHOOTING

ANSIFAM IOM - 12/03

Problem

Probable Cause

Remedy

No liquid delivered.

Pump not primed.

Reprime pump, check that pump and suction line
are full of liquid.

Suction line clogged.

Remove obstructions.

Impeller clogged with foreign material.

Back flush pump to clean impeller.

Wrong direction of rotation.

Change rotation to concur with direction
indicated by arrow on bearing housing or pump
casing.

Foot valve or suction pipe opening not
submerged enough.

Consult factory for proper depth. Use baffle to
eliminate vortices.

Suction lift too high.

Shorten suction pipe.

No liquid delivered (3796)

Vent line not connected.

Pipe in vent line to expel air.

Pump not producing rated flow or head.

Air leak thru gasket.

Replace gasket.

Air leak thru stuffing box

Replace or readjust packing/mechanical seal.

Impeller partly clogged.

Back flush pump to clean impeller.

Excessive impeller-to-casing clearance.

Adjust impeller clearance.

Insufficient suction head.

Ensure that suction line shutoff valve is fully open
and line is unobstructed.

Worn or broken impeller.

Inspect and replace if necessary.

Pump starts then stops pumping

Improperly primed pump.

Reprime pump.

Air or vapor pockets in suction line.

Rearrange piping to eliminate air pockets.

Air leak in suction line.

Repair (plug) leak.

Bearings run hot

Improper alignment.

Realign pump and driver.

Improper lubrication.

Check lubricant for suitability and level.

Lube cooling.

Check cooling system.

Pump is noisy or vibrates

Improper pump/driver alignment.

Align shafts.

Partly clogged impeller causing imbalance.

Back-flush pump to clean impeller.

Broken or bent impeller or shaft.

Replace as required.

Foundation not rigid.

Tighten hold down bolts of pump and motor or
adjust stilts.

Worn bearings.

Replace.

Suction or discharge piping not anchored or
properly supported.

Anchor per Hydraulic Institute Standards Manual
recommendations

Pump is cavitating.

Locate and correct system problem.

Excessive leakage from stuffing box.

Packing gland improperly adjusted.

Tighten gland nuts.

Stuffing box improperly packed.

Check packing and repack box.

Worn mechanical seal parts.

Replace worn parts.

Overheating mechanical seal.

Check lubrication and cooling lines.

Shaft sleeve scored.

Remachine or replace as required.

Motor requires excessive power.

Head lower than rating. Pumps too much liquid.

Consult factory. Install throttle valve,
trim impeller diameter.

Liquid heavier than expected.

Check specific gravity and viscosity.

Stuffing box packing too tight.

Readjust packing. Replace if worn.

Rotating parts bind.

Check internal wearing parts for proper
clearances.

Содержание Goulds Pumps 3196

Страница 1: ...Installation Operation and Maintenance Instructions ANSI FAMILY ...

Страница 2: ...g to make a connection with a pump Use only fasteners of the proper size and material Ensure there are no missing fasteners Beware of corroded or loose fasteners Operation Do not operate below minimum rated flow or with suction discharge valves closed Do not open vent or drain valves or remove plugs while system is pressurized Maintenance Safety Always lock out power Ensure pump is isolated from s...

Страница 3: ...ding 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 When intalled in potentially explosive atmospheres the instructions that follow the Ex symbol must be followed Personal in...

Страница 4: ...4 ANSIFAM IOM 12 03 ...

Страница 5: ...s for Goulds ANSI B15 1 Coupling Guards 125 III Set Up and Alignment 129 IV Labyrinth Seal Installation Instructions 131 V C Face Adapter Installation Instructions 133 VI 3198 Teflon Sleeve Field Replacement Procedure 135 VII 1 Double Row Angular Contact Bearing Installation Instructions 137 VII 2 Duplex Angular Contact Bearing Installation Instructions 139 VIII Inpro Labyrinth Oil Seal Installati...

Страница 6: ...6 ANSIFAM IOM 12 03 ...

Страница 7: ... in personal injury or loss of life l CAUTION Operating procedure practice etc which if not followed could result in damage or destruction of equipment 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...

Страница 8: ... closed DO NOT change conditions of service without approval of an authorized Goulds representative 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 specification enforced in Europe for non electrical and electrical equipment...

Страница 9: ...led If it is not please contact your ITT Goulds representative before proceeding 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 th...

Страница 10: ...10 ANSIFAM IOM 12 03 ...

Страница 11: ...nted overhung open impeller centrifugal pump that meets the requirements of ANSI B73 1 STX MTX LTX XLTX 6 16 17 5 LF 3196 The model is based on 3 power ends and 4 hydraulic pump sizes The LF 3196 is a horizontal overhung open impeller centrifugal pump that meets the requirements of ANSI B73 1 It is designed specifically for low flow high head applications STX MTX LTX 2 2 2 NM 3196 The model is bas...

Страница 12: ...This Page Intentionally Left Blank 12 ANSIFAM IOM 12 03 ...

Страница 13: ...re based on the same power end All of the metallic units share the same stuffing box covers and seal chambers The non metallic units all have unique casings impellers and seal chambers The chart on the following pages demonstrates the parts commonality and the relationship between the model lines ...

Страница 14: ...eanout The gasket is fully confined An integral foot support is used for maximum resistance to misalign ment and distortion from piping loads ANSI class 150 flat face serrated flanges are standard on all sizes The casing is top centerline discharge and self venting The gasket is fully confined An integral foot support is used for maximum resistance to misalignment and distortion from piping loads ...

Страница 15: ...apter The ductile iron frame adapter has a machined rabbet fit to the seal chamber stuffing box cover and a precision dowel pin fit to the bearing frame The 3198 frame adapter has the same features but different dimensions to accommodate the pump s Teflon lining Shaft The shaft is available with or without a sleeve When supplied with a Teflon sleeve the 3198 shaft is knurled under the sleeve to pr...

Страница 16: ...this manual 16 ANSIFAM IOM 12 03 Description Fig No Example Pump Casing Tag provides information about the pump s hydraulic characteristics Note the format of the pump size Discharge x Suction Nominal maximum Impeller Diameter in inches Example 2x3 8 Figs 1 2 Fig 1 English Fig 2 Metric Bearing Frame Tag provides information on the lubrication system used Fig 3 Fig 3 ATEX Tag If applicable your pum...

Страница 17: ...n be applied to pumps already in the field that were not treated at the factory This service can be supplied by contacting your local Goulds sales representative HANDLING s WARNING Pump and components are heavy Failure to properly lift and support equipment could result in serious physical injury or damage to pumps Steel toed shoes must be worn at all times Use care when moving pumps Lifting equip...

Страница 18: ...llic units with integral suction flanges that do not have a way to secure the strap on the suction flange the strap shown in Figures 4 6 around the suction flange should be secured around the frame adapter Fig 7 18 ANSIFAM IOM 12 03 Fig 7 ...

Страница 19: ...ECTION 1 Remove all equipment 2 Completely clean the underside of baseplate It is sometimes necessary to coat the underside of the baseplate with an epoxy primer This may have been purchased as an option 3 Remove the rust preventative solution from the machined pads with an appropriate solution SITE FOUNDATION A pump should be located near the supply of liquid and have adequate space for operation...

Страница 20: ...ut manufacturer s recommendations LEVEL BASEPLATE CAST IRON PERMABASE FAB STEEL 1 Place two sets of wedges or shims on the foundation one set on each side of every foundation bolt The wedges should extend 75 in 20mm to 1 50 in 40mm above foundation to allow for adequate grouting This will provide even support for the baseplate once it is grouted 2 Remove water and or debris from anchor bolt holes ...

Страница 21: ...as close to zero as possible in both directions by adjusting the four jack screws 6 Next turn down the center jack screws so that they are resting on their metal discs on the foundation 7 Place the two levels on the pump pads one lengthwise on a single pump pad and another across the middle of both pump pads Fig 14 8 Level the pump pads as close to zero as possible in both directions by adjusting ...

Страница 22: ... each spring stud to the desired height 3 Insert a washer between the bottom adjusting nut and the spring follower Install a spring and another follower Install this subassembly from the bottom of the baseplate 4 Install the upper half of the spring assembly consisting of a follower a spring another follower and a flat washer Now install the top adjusting nut and jam nut Tighten finger tight 5 Rep...

Страница 23: ...ymer concrete material used in the manufacture of the Polyshield ANSI Combo has been formulated for application in a wide range of corrosive fluid handling services The material is not however universally corrosion resistant A comprehensive corrosion guide is available Refer to Pricebook Page 766 7 It is strongly recommended that this bulletin be reviewed prior to specifying or installing a Polysh...

Страница 24: ...g straps that hold the Polyshield unit to the wooden pallet Slip slings under each end of the Polyshield unit as a harness Fig A Lift the Polyshield unit a few inches off the pallet and verify that it hangs reasonably level and that the slings are not prone to slipping out of position s WARNING Keep hands and feet out from under the Polyshield unit during these steps If slings slip and the unit ti...

Страница 25: ...ystem incorporates the Polyloc Transverse Jack Bolt system The Polyloc system provides transverse motor adjustment The side mounted adjusters allow for shaft alignment to critical tolerances with minimal disturbance of indicators The adjusters make contact with a solid motor mounting block not the foot of the motor Polyshield ANSI and Custom Combos Installation Procedures NEW CONSTRUCTION 1 Remove...

Страница 26: ...new installation Rebar tie wire Fast set cement Polyshield ANSI Combo Sealing Kit Epoxy Novolac EN Instructions Each Kit contains Polyshield EN Resin Polyshield EN Hardener Stir Sticks LATEX Gloves Instruction Sheet MSDS Material Safety Data Sheet Application Instructions The Polyshield EN Sealing Kit is intended for use in 1 bonding the plug into the grout hole at the top of the combo and 2 seali...

Страница 27: ... irritation of eyes and respiratory tract Area must be ventilated Wear protective clothing including gloves For details on safety information refer to the Material Safety Data Sheets of these products Shelf Life and Storage Store resin and hardener in their unopened containers in a dry cool place away from open flames heat or sources of ignition Shelf life is limited to 60 days if stored in a cool...

Страница 28: ...BASEPLATE LEVELING WORKSHEET 28 ANSIFAM IOM 12 03 ...

Страница 29: ...ensure pipe strains haven t altered alignment If changes have occurred alter piping to remove pipe strains on pump flanges Final Alignment Hot Alignment After First Run To obtain correct alignment when both pump and driver are at operating temperature Thereafter alignment should be checked periodically in accordance with plant operating procedures NOTE Alignment check must be made if process tempe...

Страница 30: ...3 33 high 0 000 013 33 high N A N A 013 33 high 550 F 228 C 017 43 high 017 43 high 0 000 017 43 high N A N A 017 43 high 650 F 343 C 021 53 high 021 53 high 0 000 021 53 high N A N A N A 700 F 371 C 023 58 high 023 58 high 0 000 023 58 high N A N A N A NOTE For the HT 3196 the cold setting of parallel vertical is 0 0 for all pumpage temperatures due to centerline mounting Table 2 Problem Problem ...

Страница 31: ...sing methods previously described PIPING GENERAL Guidelines for piping are given in the Hydraulic Institute Standards available from Hydraulic Institute 9 Sylvan Way Parsippany NJ 07054 3802 and must be reviewed prior to pump installation s 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 misalignment bet...

Страница 32: ...ves received with order Reference Hydraulic Institute for NPSH and pipe friction values needed to evaluate suction piping Properly installed suction piping is a necessity for trouble free pump operation Suction piping should be flushed BEFORE connection to the pump 1 Use of elbows close to the pump suction flange should be avoided There should be a minimum of two pipe diameters of straight pipe be...

Страница 33: ...pump must be provided such as a foot valve except for the 3796 self priming pump Suction Head Flooded Suction Conditions 1 An isolation valve should be installed in the suction line at least two pipe diameters from the suction to permit closing of the line for pump inspection and maintenance 2 Keep suction pipe free from air pockets 3 Piping should be level or slope gradually downward from the sou...

Страница 34: ... through the pump when the driver is turned off 2 Increasers if used should be placed between pump and check valves 3 Cushioning devices should be used to protect the pump from surges and water hammer if quick closing valves are installed in system FINAL PIPING CHECK After connecting the piping to pump 1 Rotate shaft several times by hand to be sure that there is no binding and all parts are free ...

Страница 35: ...ong enough to determine direction of rotation Rotation must correspond to arrow on bearing housing 5 Lock out power to driver The impeller clearance setting procedure must be followed Improperly setting the clearance or not following any of the proper procedures can result in sparks unexpected heat generation and equipment damage CHECK IMPELLER CLEARANCE Prior to operating the pump impeller cleara...

Страница 36: ...15 0 38 0 015 0 38 Up to 250 F 121 C 0 006 0 16 0 009 0 23 0 016 0 41 0 016 0 41 Up to 300 F 149 C 0 007 0 19 0 010 0 26 0 017 0 44 0 017 0 44 Up to 350 F 177 C 0 009 0 22 0 012 0 29 0 019 0 47 0 019 0 47 Up to 400 F 204 C 0 010 0 25 0 013 0 32 0 020 0 50 0 020 0 50 Up to 450 F 232 C 0 011 0 28 0 014 0 35 0 021 0 53 0 021 0 53 Up to 500 F 260 C 0 012 0 30 0 015 0 38 0 022 0 56 0 022 0 56 Up to 550...

Страница 37: ...tion will cause bearing failure and pump seizure SHAFT SEALING The mechanical seal used in an ATEX classified environment must be properly certified Cartridge Mechanical Seals 1 Slide the cartridge seal onto the shaft or sleeve until it contacts the inboard labyrinth oil seal 2 Assemble the seal chamber per the instructions in Section 6 Disassembly Reassembly 3 Slide the cartridge seal into the se...

Страница 38: ...nnection of Sealing Liquid For satisfactory operation there must be a liquid film between seal faces to lubricate them Refer to the seal manufacturer s drawing for the location of the taps Some methods which may be used to flush cool the seal are a Product Flushing In this arrangement the pumpage is piped from the casing and cooled in an external heat exchanger when required then injected into sea...

Страница 39: ... operating The repeller acts as a pump to prevent liquid from entering the stuffing box during pump operation The repeller does not require a flush except for services which allow a build up of solids on the repeller A flush connection can be provided for this purpose A drain connection can also be supplied to drain the repeller chamber if a danger of freezing exists Secondary Seals The secondary ...

Страница 40: ...everal different methods of priming can be used depending upon type of installation and service involved Suction Supply Above Pump 1 Slowly open the suction valve Fig 30 2 Open air vents on the suction and discharge piping until water flows out 3 Close the vent valves Suction Supply Below Pump except 3796 A foot valve and outside source of liquid may be used to prime the pump Outside source of liq...

Страница 41: ...iable speed drivers should be brought to rated speed as quickly as possible 4 Variable speed drivers should not be adjusted or checked for speed governor or overspeed trip settings while coupled to the pump at initial start up If settings have not been verified uncouple the unit and refer to driver manufacturer s instructions for assistance 5 Running a new or rebuilt pump at slow speeds may not pr...

Страница 42: ...he rated flow rate is exceeded l CAUTION Always operate the pump at or near the rated conditions to prevent damage resulting from cavitation or recirculation OPERATING AT REDUCED CAPACITY s WARNING DO NOT operate pump below minimum rated flows or with suction and or discharge valve closed These conditions may create an explosive hazard due to vaporization of pumpage and can quickly lead to pump fa...

Страница 43: ...cedures must be followed to prevent unintended contact of rotating parts Follow coupling manufacturer s coupling installation and operation procedures 1 Run the unit under actual operating conditions for a sufficient length of time to bring the pump and driver and associated system up to operating temperature 2 Remove coupling guard Refer to coupling guard installation and disassembly instructions...

Страница 44: ...44 ANSIFAM IOM 12 03 ...

Страница 45: ...ANCE SCHEDULE ROUTINE MAINTENANCE Bearing lubrication Seal monitoring Vibration analysis Discharge pressure Temperature monitoring ROUTINE INSPECTIONS Check level and condition of oil through sight glass on bearing frame Check for unusual noise vibration and bearing temperatures Inspect pump and piping for leaks Check seal chamber stuffing box leakage Mechanical Seal Should be no leakage Packing E...

Страница 46: ...CATED BEARINGS s WARNING Pumps are shipped without oil Oil lubricated bearings must be lubricated at the job site Remove fill plug 113A and add oil until level is at the center of the sight glass 319 Replace fill plug Fig 34 See Table 4 Change the oil after 200 hours for new bearings thereafter every 2000 operating hours or 3 months whichever comes first Table 4 Oil Volumes Frame Qts Oz ml STX 0 5...

Страница 47: ...sure frame seals are seated in bearing housing and if not press in place with drains located at the bottom NOTE The bearing temperature usually rises after regreasing due to an excess supply of grease Temperatures will return to normal after pump has run and purged the excess from the bearings usually two to four hours For most operating conditions a lithium based mineral oil grease of NLGI consis...

Страница 48: ...embling the pump During normal operation the packing should leak approximately one drop per minute If the drip rate is higher or lower than one drop per minute then an adjustment of the gland may be required To slow down the leakage rate the two gland bolts should be tightened evenly one quarter turn each until the desired leakage rate is obtained NEVER over tighten packing to the point where less...

Страница 49: ...ller clearance Two techniques are given to set the impeller clearance the dial indicator method and the feeler gauge method DIAL INDICATOR METHOD all but CV 1 Remove coupling guard Refer to coupling guard instructions Appendix II 2 Remove coupling 3 Set indicator so that button contacts either the shaft end or against face of coupling Fig 38 4 Loosen jam nuts 423 on jack bolts 370D and back bolts ...

Страница 50: ...urn shaft to ensure contact is made 4 Using a feeler gauge set the gap between the three locking bolts 370C and bearing housing 134A per impeller clearances in Table 3 5 Evenly back out bearing housing 134A using the three jack bolts 370D until it contacts the locking bolts 370C Evenly tighten jam nuts 423B 6 Check shaft for free turning 7 Replace coupling guard FEELER GAUGE METHOD CV 1 Remove cou...

Страница 51: ...23 0 59 Up to 600 F 316 C 0 014 0 36 0 017 0 44 0 024 0 62 0 024 0 62 Up to 650 F 343 C 0 016 0 39 0 019 0 47 0 026 0 65 0 026 0 65 Up to 700 F 371 C 0 017 0 42 0 020 0 50 0 027 0 68 0 027 0 68 Table 3 cont d Impeller Clearances Cold Temperature Clearances for Various Service Temperatures inches mm Service Temperature CV 31961 3796 NM 3196 3198 STX MTX LTX XLTX STX MTX LTX STX MTX LTX STX MTX LTX ...

Страница 52: ... line Rearrange piping to eliminate air pockets Air leak in suction line Repair plug leak Bearings run hot Improper alignment Realign pump and driver Improper lubrication Check lubricant for suitability and level Lube cooling Check cooling system Pump is noisy or vibrates Improper pump driver alignment Align shafts Partly clogged impeller causing imbalance Back flush pump to clean impeller Broken ...

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