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Commissioning, Startup, Operation, and Shutdown

Model API 3171 Installation, Operation, and Maintenance Manual

29

Commissioning, Startup, Operation, and
Shutdown

Preparation for startup

WARNING:

• Risk of serious physical injury or death. Exceeding any of the pump operating limits (e.g. -

pressure, temperature, power, etc.) could result in equipment failure, such as explosion,
seizure, or breach of containment. Assure that the system operating conditions are within
the capabilities of the pump.

• Risk of death or serious injury. Leaking fluid can cause fire and/or burns. Ensure all

openings are sealed prior to filling the pump.

• Breach of containment can cause fire, burns, and other serious injury. Failure to follow

these precautions before starting the unit may lead to dangerous operating conditions,
equipment failure, and breach of containment.

• Risk of explosion and serious physical injury. Do not operate pump with blocked system

piping or with suction or discharge valves closed. This can result in rapid heating and
vaporization of pumpage.

• Risk of breach of containment and equipment damage. Ensure the pump operates only

between minimum and maximum rated flows. Operation outside of these limits can cause
high vibration, mechanical seal and/or shaft failure, and/or loss of prime.

• Avoid mechanical seal failure or pump seizure by:

• increasing speed at startup to at least 65% of rated speed within 5 seconds and
• decreasing speed at shutdown from 65% of rated speed to 0 within 5 seconds

WARNING:

• Running a pump without safety devices exposes operators to risk of serious personal

injury or death. Never operate a unit unless appropriate safety devices (guards, etc.) are
properly installed.

• Failure to disconnect and lock out driver power may result in serious physical injury or

death. Always disconnect and lock out power to the driver before performing any
installation or maintenance tasks.
• Electrical connections must be made by certified electricians in compliance with all

international, national, state, and local rules.

• Refer to driver/coupling/gear manufacturer's installation and operation manuals (IOM)

for specific instructions and recommendations.

• Risk of seizure, breach of containment, or explosion. Ensure balance line is installed and

piped back to either the pump suction or suction vessel. This prevents rapid vaporization of
the pumped fluid.

Precautions

NOTICE:

• Verify the driver settings before you start any pump.

• Excessive warm-up rates can cause equipment damage. Ensure the warm-up rate does

not exceed 1.4°C | 2.5°F per minute.

You must follow these precautions before you start the pump:

• Flush and clean the system thoroughly to remove dirt or debris in the pipe system in order

to prevent premature failure at initial startup.

• Bring variable-speed drivers to the rated speed as quickly as possible.

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Содержание Goulds Pumps API 3171

Страница 1: ...Installation Operation and Maintenance Manual Model API 3171 ...

Страница 2: ......

Страница 3: ...all the packed stuffing box 21 Install the pump driver and coupling 21 Motor installation and coupling alignment 22 Float control installation 23 Install the Square D 9036 simplex and 9038 duplex float controls 25 Piping checklists 26 Commissioning Startup Operation and Shutdown 29 Preparation for startup 29 Check the rotation Frame Mounted 30 Lubricate bearings 30 Thrust bearing lubrication 30 Sh...

Страница 4: ...tion 48 Bearing fits and tolerances 49 Reassembly 49 Assemble the column and support plate 49 Assemble the rotating element 50 Assemble the column 51 Assemble the impeller suction cover and strainer 51 Troubleshooting 53 Troubleshooting 53 Operation troubleshooting 53 Assembly troubleshooting 54 Parts Listings and Cross Sectionals 55 Cross sectional diagram 55 Dimensional drawings 56 Parts list 57...

Страница 5: ...T If there is any uncertainty regarding the appropriate use of the equipment please contact an ITT representative before proceeding Risk of serious personal injury Applying heat to impellers propellers or their retaining devices can cause trapped liquid to rapidly expand and result in a violent explosion This manual clearly identifies accepted methods for disassembling units These methods must be ...

Страница 6: ...tion which if not avoided will result in death or serious injury WARNING A hazardous situation which if not avoided could result in death or serious injury CAUTION A hazardous situation which if not avoided could result in minor or moderate injury NOTICE A potential situation which if not avoided could result in undesirable conditions A practice not related to personal injury Hazard categories Haz...

Страница 7: ...ng requirements consult your local electric utility Recycling guidelines Always follow local laws and regulations regarding recycling User safety General safety rules These safety rules apply Always keep the work area clean Pay attention to the risks presented by gas and vapors in the work area Avoid all electrical dangers Pay attention to the risks of electric shock or arc flash hazards Always be...

Страница 8: ... Seek medical attention Chemicals or hazardous fluids on skin 1 Remove contaminated clothing 2 Wash the skin with soap and water for at least 1 minute 3 Seek medical attention if necessary Ex approved products Follow these special handling instructions if you have an Ex approved unit Personnel requirements These are the personnel requirements for Ex approved products in potentially explosive atmos...

Страница 9: ...ts intended use Do not change the conditions of the service without the approval of an ITT representative When you install or maintain explosion proof products always comply with the directive and applicable standards for example IEC EN 60079 14 Product warranty Coverage ITT undertakes to remedy faults in products from ITT under these conditions The faults are due to defects in design materials or...

Страница 10: ...anes etc are rated to sufficient capacity Lifting methods WARNING Risk of serious personal injury or equipment damage Proper lifting practices are critical to safe transport of heavy equipment Ensure that practices used are in compliance with all applicable regulations and standards Safe lifting points are specifically identified in this manual It is critical to lift the equipment only at these po...

Страница 11: ...Model API 3171 Installation Operation and Maintenance Manual 9 Examples Figure 1 Example of a proper lifting method Figure 2 Example of lifting motor properly with lifting lugs Figure 3 Example of lifting pump properly with sling ...

Страница 12: ...der to prevent distortion Keep identification markings readily visible Immediately replace any cover you remove for internal access Rotation of the pump and bowl assem bly shaft Rotate the shaft and bowl assembly shaft counterclockwise once a month at a minimum Never leave the shaft in a previous position or in the extreme raised or lowered lateral position Make sure that the shaft rotates freely ...

Страница 13: ...ely fasten the nozzle to the discharge elbow 4 Install a moisture indicator near the perimeter of the unit 5 Cover the unit with black polyethylene with a minimum thickness of 6 0 mil 0 15 mm and seal it with tape 6 Provide a small ventilation hole approximately 12 0 mm 0 5 in diameter 7 Provide a roof or shed shelter in order to protect the unit from direct exposure to the elements ...

Страница 14: ... code classifications on the pump are compatible with the specific environment in which the equipment is to be installed If they are not compatible do not operate the equipment and contact an ITT representative before proceeding Casing The casing has these features A tangential discharge Is self venting Has an integral bearing retainer Is precision bored in order to ensure permanent alignment betw...

Страница 15: ...e contamination Carbon PTFE casing collar This seal is installed immediately behind the impeller in the casing in order to minimize recirculation back to the sump and maximize hydraulic efficiency Motor support Motor supports are cast construction and precision machined in order to maintain proper alignment between the motor and pump shaft with minimal shimming Motor supports are designed for vert...

Страница 16: ...all times 1 Flush Inlet connection 1 4 pressure 3 PSI P PSI 2 Maximum liquid level P PSI above suction Nameplate information Important information for ordering Every pump has a nameplate that provides information about the pump The nameplate is located on the motor support When you order spare parts identify this pump information Model Size Serial number Item numbers of the required parts Item num...

Страница 17: ...AT L CONST Material of which the pump is constructed SER NO Serial number of the pump MAX DSGN PSI 100ºF Maximum pressure at 100ºF according to the pump design Nameplate on the pump casing using metric units Figure 5 Metric units nameplate on pump casing Table 2 Explanation of the nameplate on the pump casing Nameplate field Explanation IMPLR DIA Impeller diameter MAX DIA Maximum impeller diameter...

Страница 18: ...in which the equipment is to be installed If they are not compatible do not operate the equipment and contact an ITT representative before proceeding Permissible temperatures Code Maximum permissible surface temperature Maximum permissible liquid temperature T1 450 C 842 F 372 C 700 F T2 300 C 572 F 277 C 530 F T3 200 C 392 F 177 C 350 F T4 135 C 275 F 113 C 235 F T5 100 C 212 F Option not availab...

Страница 19: ...l connections must be made by certified electricians in compliance with all international national state and local regulations Supervision by an authorized ITT representative is recommended to ensure proper installation Improper installation may result in equipment damage or decreased perfor mance Inspect the pump 1 Remove the plastic shipping plugs from the vent holes in the head column and the c...

Страница 20: ...r architect in charge before you operate the pump Take into consideration the occurrence of unwanted noise and vibration The best pump location for noise and vibration absorption is on a concrete floor with subsoil underneath Concrete foundation requirements Requirements Make sure that you meet these requirements when you prepare the pump foundation The foundation must be able to absorb any vibrat...

Страница 21: ...r tight seal 1 Carefully lower the pit cover onto the foundation bolts 2 Use as long a level as possible in order to level the pit cover in all directions with shims or wedges 3 Hand tighten the anchor bolts Check the level and re shim if necessary 4 Tighten all anchor bolts in a star pattern in order to avoid distorting the pit cover 5 If access to the bottom side is possible carefully lower the ...

Страница 22: ...Check the level and re shim if necessary 5 Tighten all anchor bolts in a star pattern in order to avoid distorting the support plate Stuffing box installation This pump is a sealless design Therefore when temperatures exceed 82 C 180 F you must move the thrust bearing away from the heat source in the pump by adding the upper stuffing box Air can then circulate around the bearing in order to keep i...

Страница 23: ...ening on the stuffing box 3 Turn the cap on the grease cup several turns in order to inject the grease into the packing 4 Hand tighten the gland nuts 105 Lantern ring 353 Gland stud 106 Packing set 355 Gland nuts 107 Gland 355C Insert nuts 190G Pipe nipple 364A Packed box insert 193I Grease cup 367B Insert gasket 221 Stuffing box support 494V Pipe elbow Figure 10 Packed stuffing box Install the pu...

Страница 24: ...reased performance Install the motor Use NEMA Vertical C face motors with this pump P base motor adapters and IEC motor adapters are available as options 1 Install both coupling halves before you mount the motor Refer to the instructions from the coupling manufacturer 2 Use the lifting lugs on the motor in order to carefully lower the motor onto the pump Make sure to align the bolt holes 3 Before ...

Страница 25: ...ls IOM for specific instructions and recommendations Misalignment can cause decreased performance equipment damage and even catas trophic failure of frame mounted units leading to serious injury Proper alignment is the responsibility of the installer and the user of the unit Check the alignment of all drive components prior to operating the unit Follow the coupling installation and operation proce...

Страница 26: ...supplied in the alternator to close a switch if the water level rises past the second pumps on the level This switch can be wired into a customer supplied alarm horn or light APEX high level alarm The APEX high level alarm is an independent device used to sense fluid level and close a switch that activates a separate alarm The switch is mounted on a pipe above the support plate The pipe must exten...

Страница 27: ...over is supplied with the pump the float switch support pipe 435 and the upper rod guide 337 are installed by the factory If the pit cover is supplied by others you must locate drill and tap the holes before you install the switch Figure 12 Location of the float rod and switch 1 Diameter of the coverplate A 2 Radius B 3 CL of the pump 4 Radius of 178 0 mm 7 0 in 5 31 8 mm 1 25 in NPT float switch ...

Страница 28: ...exceed the limits of the pump CAUTION Do not move the pump to the pipe This could make final alignment impossible NOTICE Vary the capacity with the regulating valve in the discharge line Never throttle the flow from the suction side This action can result in decreased performance unexpected heat generation and equipment damage Checklist Check Explanation comment Checked Check that all piping is su...

Страница 29: ... the driver is turned off Use cushioning devices This protects the pump from surges and water hammer if quick closing valves are installed in the system Alignment criteria for pump flanges Type Criteria Axial The flange gasket thickness is 0 8 mm 0 03 in Parallel Align the flange to be within 0 025 mm mm to 0 8 mm mm 0 001 in in to 0 03 in in of the flange diameter Concentric You can easily instal...

Страница 30: ... discharge jackets Determine which method to use in order to connect the steam lines There are two methods you can use in order to connect the steam lines You can use both steam lines as input for steam preferred method You can use one steam line as input for steam while the other steam line is used as a feed through to additional pumps Only use this method if absolutely necessary because it is di...

Страница 31: ...e or pump seizure by increasing speed at startup to at least 65 of rated speed within 5 seconds and decreasing speed at shutdown from 65 of rated speed to 0 within 5 seconds WARNING Running a pump without safety devices exposes operators to risk of serious personal injury or death Never operate a unit unless appropriate safety devices guards etc are properly installed Failure to disconnect and loc...

Страница 32: ...nstallation or maintenance tasks Electrical connections must be made by certified electricians in compliance with all international national state and local rules Refer to driver coupling gear manufacturer s installation and operation manuals IOM for specific instructions and recommendations 1 Lock out power to the driver 2 Make sure that the coupling hubs are fastened securely to the shafts 3 Mak...

Страница 33: ...must be able to deliver 1 to 2 GPM to each bearing 3 Turn on the water in order to begin the flush Sealed bearings Sealed bearings have a lip seal above and below the bearing in order to keep grit out of the bearing Sealed bearings use a spring loaded grease cup for lubrication The bearings are pre lubricated at the factory but the grease cups ship in a separate box in order to prevent shipping da...

Страница 34: ... complete these steps a Unthread the top lid in order to remove the top of the grease cup b Inspect the plunger for defects If all the grease is found on the reverse or back side of the plunger then it is defective and must be replaced Adjust the flow preferred method 1 Unthread the wing nut completely against the zerk fitting of the center stem 2 Unlock the hex nut of the throttling screw and tur...

Страница 35: ...mmonly used Cartridge seals are preset by the seal manufacturer and require no field settings Cartridge seals installed by the user require disengagement of the holding clips prior to operation allowing the seal to slide into place Customers should always check to make sure the clips have been disengaged prior to starting the pump Other mechanical seal types For other types of mechanical seals ref...

Страница 36: ...njury or death Never operate a unit unless appropriate safety devices guards etc are properly installed Failure to disconnect and lock out driver power may result in serious physical injury or death Always disconnect and lock out power to the driver before performing any installation or maintenance tasks Electrical connections must be made by certified electricians in compliance with all internati...

Страница 37: ...fter confirming Before you start the pump you must perform these tasks Open any recirculation or cooling lines Start the external bearing flush if specified Make sure the shaft rotates freely 1 Fully close or partially openthe discharge valve depending on system conditions 2 Start the driver 3 Slowly open the discharge valve until the pump reaches the desired flow 4 Immediately check the pressure ...

Страница 38: ...ause rotating parts to score or seize Observe pump for excessive heat build up If normal levels are exceeded shut down and resolve NOTICE Cavitation can cause damage to the internal surfaces of the pump Ensure net positive suction head available NPSHA always exceeds NPSH required NPSH3 as shown on the published performance curve of the pump Operation under freezing conditions NOTICE Do not expose ...

Страница 39: ...en catas trophic failure of frame mounted units leading to serious injury Proper alignment is the responsibility of the installer and the user of the unit Check the alignment of all drive components prior to operating the unit Follow the coupling installation and operation procedures from the coupling manufactur er You must check the final alignment after the pump and driver are at operating tempe...

Страница 40: ... vibration and bearing temperatures Check the pump and piping for leaks Analyze the vibration Inspect the discharge pressure Inspect the temperature Check the float controls for the proper setting and operation Check the seal chamber and stuffing box for leaks Ensure that there are no leaks from the mechanical seal Adjust or replace the packing in the stuffing box if you notice excessive leaking T...

Страница 41: ...rature For the majority of operating conditions bearing temperatures run between 49 C 120 F and 82 C 180 F and you can use an oil of ISO viscosity grade 68 at 38 C 100 F If temperatures exceed 82 C 180 F refer to the table for temperature requirements Table 5 Oil requirements based on temperature Temperature Oil requirement Bearing temperatures exceed 82 C 180 F Use ISO viscosity grade 100 Pumped ...

Страница 42: ...ith the drains located at the bottom 5 Reinstall the grease relief plugs 6 Wipe off any excess grease 7 Recheck the alignment The bearing temperature usually rises after you regrease due to an excess supply of grease Temperatures return to normal in about two to four operating hours as the pump runs and purges the excess grease from the bearings Steady bearings Check the ID of the casing collar 15...

Страница 43: ...d with oil lubricated seals keep the seal faces lubricated with oil at all times Packed stuffing box maintenance WARNING Packed stuffing boxes are not allowed in an ATEX classified environment Failure to disconnect and lock out driver power may result in serious physical injury Never attempt to replace the packing until the driver is properly locked out Lubrication intervals The lubrication interv...

Страница 44: ...ing and wear appropriate Personal Protective Equipment PPE such as steel toed shoes gloves etc at all times Precautions must be taken to prevent physical injury The pump may handle hazardous and or toxic fluids Proper personal protective equipment should be worn Pumpage must be handled and disposed of in conformance with applicable environmental regulations Risk of serious physical injury or death...

Страница 45: ... close the drain valve until the reassembly is complete 2 Remove the coupling guard 3 Disconnect the coupling Remove the pump from the sump 1 Remove the motor bolts 371 Figure 16 Motor bolts removal 2 Place the sling on the motor lifting lugs and remove the motor 3 Remove the support plate anchor bolts 4 Attach the eyebolts to the support plate 5 Use properly sized slings in order to lift the pump...

Страница 46: ...arge elbow casing bolts 370H 10 Disconnect any steady bearing flush tubing 190 Remove the impeller CAUTION Risk of physical injury from sharp edges Wear heavy work gloves when handling impellers 1 Loosen the set screw at the end of the impeller nut 2 Loosen and remove the impeller nut The impeller nut has left hand threads 3 Pull the impeller 101 from the shaft Use a spanning type puller if requir...

Страница 47: ... long Improper handling can bend the shaft Disassemble the column 1 Remove the column down to the steady bearing housing bolts 372B If your pump has no intermediate steady bearings only one column section then skip this step since you do not have any column extension 306 or steady bearing housing 213 a Start at the casing end of the pump and remove the column extensions 306 steady bearing housings...

Страница 48: ...e locknut 136 and the lockwasher 382 8 Use a suitable bearing puller in order to remove the bearing 112 Make sure to save the bearing for inspection 9 Set the shaft on a table where it is adequately supported You do not need to disassemble the pump any further unless you need to replace bad parts Preassembly inspections Replacement guidelines Casing check and replacement WARNING Risk of death or s...

Страница 49: ...Inspect the casing to column connection area for any cracks or excessive corrosion damage Replace if any of these conditions exist Irregularities in the casing gasket seat surface Casing areas to inspect Impeller replacement This table shows the criteria for replacing the impeller Impeller parts When to replace Impeller vanes When grooved deeper than 1 6 mm 1 16 in or When worn evenly more than 0 ...

Страница 50: ...ck Check the bearing fits of the shaft If any are outside the tolerances shown in the Bearing fits and tolerances table then replace the shaft Shaft inspection Check the shaft straightness Use V blocks or balance rollers to support the shaft on the bearing fit areas Replace the shaft if runout exceeds 0 03 mm 0 001 in NOTICE Do not use shaft centers for the runout check as they may have been damag...

Страница 51: ... 2 256 2 258 41 173 4 1 224 1 621 1 623 53 873 5 3 924 2 121 2 123 76 048 7 6 098 2 994 2 996 0 102 1 051 0 004 0 002 0 102 1 051 0 004 0 002 0 140 0 076 0 0055 0 003 Fluted elasto mer 28 600 2 8 702 1 126 1 130 41 326 4 1 453 1 627 1 632 57 226 5 7 328 2 253 2 257 41 173 4 1 224 1 621 1 623 53 873 5 3 924 2 121 2 123 76 048 7 6 098 2 994 2 996 0 089 0 013 0 0035 0 0005 0 114 0 025 0 0045 0 001 0 ...

Страница 52: ...bolts 370M You do not use the stuffing box Attach the head column 192 to the motor support with bolts 370M Make sure that the vent holes are closer to the motor support Assemble the rotating element CAUTION Two people should handle any shaft over 9 feet long Improper handling can bend the shaft 1 For all groups except S ST install the retaining ring 369A on the shaft 122 2 Install the thrust beari...

Страница 53: ... and the holes in the bearing do not need to line up with the holes in the housing A recessed area inside the housing 213 allows lubricants to find the opening in the bearing a Remove the snap ring 369 if applicable b Use a hydraulic press in order to press out the old steady bearing 197 c Press in the new steady bearing A snap ring 369 is no longer required due to the fits If your pump has a snap...

Страница 54: ...e elbow 315 using bolts 370H Accurate alignment of the elbow is critical in order to make sure that there is no obstruction to the flow through the connection 7 Install the discharge pipe 195 pipe nuts 242 and flange 195S if used Make sure that the pipe nuts are tight and that there is no strain on the pump 8 Rotate the shaft by hand in order to make sure that there is no binding 9 Connect all aux...

Страница 55: ...e has air or vapor pockets Rearrange the piping in order to eliminate air pockets The amount of available NPSH is not suffi cient Check the amount of NPSH available and required and adjust accordingly The pump starts and then stops pumping The pump is not primed Re prime the pump and check that the pump and suction line are full of liquid The float controls are not adjusted properly Check the floa...

Страница 56: ...cessive shaft end play The internal clearance of the bearings is excessive Replace the bearings with a bearing of the correct type The thrust bearing end cover is loose Tighten the screws There are too many shims under the thrust bearing end cover Remove the individual shims to ob tain the proper thickness The runout for the shaft is excessive The shaft is bent Replace the shaft The runout for the...

Страница 57: ...on Operation and Maintenance Manual 55 Parts Listings and Cross Sectionals Cross sectional diagram A A Main pump components B B2 Upper stuffing box with me chanical seal Grease lube only B B1 Upper stuffing box with packing C C Detail of B B1 M and MT groups only ...

Страница 58: ...Parts Listings and Cross Sectionals Model API 3171 Installation Operation and Maintenance Manual 56 Dimensional drawings Exploded view A Exploded view B ...

Страница 59: ...Bearing shell A216 WCB 1212 136 1 Bearing locknut Steel 155 1 Casing bushing Carbon filled PTFE PTFE 178 1 Impeller key 2229 2248 182 1 Suction cover A216 WCB 1212 A743 CF8M 1203 A890 Grade 4A 1360 A890 Grade 5A 1361 187 1 Strainer 3211 A890 Grade 4A 1360 A890 Grade 5A 1361 189 1 Support plate 3201 190 1 Flush tubing As specified 190G 1 Pipe nipple Steel 192 1 Head column A53 Grade F 6501 A312 316...

Страница 60: ...cified 540M 1 Gasket upper stuffing box As specified 543E 1 Tube fitting support plate As specified 571E 1 Discharge elbow flange L group only A216 WCB 1212 A351 CF3M 1296 A890 Grade 4A 1360 1 The quantity depends on pump length Table 10 Material code cross reference Goulds code ASTM number 1000 A48 CL25B cast iron 1007 A436 Type 2 Ni Resist 1018 A536 84 60 42 10 ductile iron 1203 A743 CF8M 316 st...

Страница 61: ... API 3171 Installation Operation and Maintenance Manual 59 Other Relevant Documentation or Manuals Other Relevant Documentation or Manuals For additional documentation For any other relevant documentation or manuals contact your ITT representative ...

Страница 62: ...ucts Operation 3951 Capitol Avenue City of Industry CA 90601 1734 USA 1 562 949 2113 1 562 695 8523 Asia Pacific ITT Industrial Process 10 Jalan Kilang 06 01 Singapore 159410 65 627 63693 65 627 63685 Europe ITT Goulds Pumps Millwey Rise Industrial Estate Axminster Devon England EX13 5HU 44 1297 630250 44 1297 630256 Latin America ITT Goulds Pumps Camino La Colina 1448 Condominio Industrial El Ros...

Страница 63: ......

Страница 64: ... more information http www gouldspumps com Goulds Pumps 240 Fall Street Seneca Falls NY 13148 USA 2018 ITT Corporation The original instruction is in English All non English instructions are translations of the original instruction Form IOM API3171 en US 2018 12 ...

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