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7 Troubleshooting

7.1 Operation troubleshooting

Symptom

Cause

Remedy

The pump is not
delivering liquid.

The pump is not primed.

Re-prime the pump and check
that the pump and suction line are
full of liquid.

The suction line is clogged.

Remove the obstructions.

The impeller is clogged.

Back-flush the pump in order to
clean the impeller.

The shaft is rotating in the
wrong direction.

Change the rotation. The rotation
must match the arrow on the
bearing housing or pump casing.

The foot valve or suction pipe
opening is not submerged
enough.

Consult an ITT representative for
the proper submersion depth.
Use a baffle in order to eliminate
vortices.

The suction lift is too high.

Shorten the suction pipe.

The pump is not producing the
rated flow or head.

The gasket or O-ring has an air
leak.

Replace the gasket or O-
ring.

The stuffing box
has an air leak.

Replace or readjust the mechani-
cal seal.

The impeller is
partly clogged.

Back-flush the pump in order to
clean the impeller.

The clearance be-
tween the impeller
and the pump cas-
ing is excessive.

Adjust the impeller clearance.

The suction head
is not sufficient.

Make sure that the suction-line
shutoff valve is fully open and that
the line is unobstructed.

The impeller is
worn or broken.

Inspect and replace the impeller if
necessary.

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 suction line has air or va-
por pockets.

Rearrange the piping in order to
eliminate air pockets.

The suction line has an air leak. Repair the leak.

The bearings are
running hot.

The pump and driver are not
aligned properly.

Realign the pump and driver.

There is not sufficient lubrica-
tion.

Check the lubricant for suitability
and level.

The lubrication was not cooled
properly.

Check the cooling system.

The pump is noisy
or vibrates.

The pump and driver are not
aligned properly.

Realign the pump and driver.

The impeller is partly clogged.

Back-flush the pump in order to
clean the impeller.

The impeller or shaft is broken
or bent.

Replace the impeller or shaft as
necessary.

7 Troubleshooting

Model ICO i-FRAME, ICOH i-FRAME Installation, Operation, and Maintenance Manual

Содержание GOULDS PUMPS ICO i-FRAME

Страница 1: ...Installation Operation and Maintenance Manual Model ICO i FRAME ICOH i FRAME ...

Страница 2: ......

Страница 3: ...itor 16 3 3 Nameplate information 17 4 Installation 18 4 1 Pre installation 18 4 1 1 Pump location guidelines 18 4 1 2 Foundation requirements 18 4 2 Baseplate mounting procedures 19 4 2 1 Prepare the baseplate for mounting 19 4 2 2 Prepare the foundation for mounting 19 4 2 3 Install the baseplate using shims or wedges 19 4 2 4 Install the baseplate using jackscrews 20 4 2 5 Install the baseplate...

Страница 4: ... a packed stuffing box 53 5 8 Pump priming 54 5 8 1 Prime the pump with the suction supply above the pump 54 5 8 2 Prime the pump with the suction supply below the pump 54 5 8 3 Other methods of priming the pump 56 5 9 Start the pump 56 5 10 i ALERT 2 Equipment Health Monitor 57 5 11 Pump operation precautions 57 5 12 Shut down the pump 58 5 13 Deactivate the i ALERT 2 Equipment Health Monitor 58 ...

Страница 5: ...hamber and stuffing box cover inspection 79 6 7 5 Bearings inspection 80 6 8 Reassembly 80 6 8 1 Assemble the rotating element and bearing frame 80 6 8 2 Install the impeller and casing 83 6 8 3 Shaft sealing 85 6 8 4 Install the back pull out assembly 92 6 8 5 Post assembly checks 93 6 8 6 Assembly references 93 7 Troubleshooting 98 7 1 Operation troubleshooting 98 7 2 Alignment troubleshooting 9...

Страница 6: ...nal 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 adhered to Never apply heat to aid in their removal unless explicitly stated in this manual The operator must be aware of the pumpage and take appropriat...

Страница 7: ...and or unstable operation Do not change the service application without the approval of an authorized ITT representative 1 2 1 Safety terminology and symbols About safety messages It is extremely important that you read understand and follow the safety messages and regulations carefully before handling the product They are published to help prevent these hazards Personal accidents and health probl...

Страница 8: ... of the processed liquid in compliance with applicable environmental regula tions Clean up all spills in accordance with safety and environmental procedures Report all environmental emissions to the appropriate authorities WARNING If the product has been contaminated in any way such as from toxic chemicals or nuclear radi ation do NOT send the product to ITT until it has been properly decontaminat...

Страница 9: ...arrier around the work area for example a guard rail Make sure that all safety guards are in place and secure Make sure that you have a clear path of retreat Make sure that the product cannot roll or fall over and injure people or damage property Make sure that the lifting equipment is in good condition Use a lifting harness a safety line and a breathing device as required Allow all system and pum...

Страница 10: ...in and eyes 1 Follow these procedures for chemicals or hazardous fluids that have come into contact with your eyes or your skin Condition Action Chemicals or hazardous fluids in eyes 1 Hold your eyelids apart forcibly with your fingers 2 Rinse the eyes with eyewash or running water for at least 15 minutes 3 Seek medical attention Chemicals or hazardous fluids on skin 1 Remove contaminated clothing...

Страница 11: ...fication enforced in Europe for electrical and non electrical equipment installed in Europe ATEX deals with the control of potentially explosive atmospheres and the standards of equipment and protective systems used within these atmospheres The relevance of the ATEX re quirements is not limited to Europe You can apply these guidelines to equipment installed in any poten tially explosive atmosphere...

Страница 12: ...and long life However should the need arise for a warranty claim then contact your ITT representative 1 5 ATEX Considerations and Intended Use Special care must be taken in potentially explosive environments to ensure that the equipment is proper ly maintained This includes but is not limited to 1 Monitoring the pump frame and liquid end temperature 2 Maintaining proper bearing lubrication 3 Ensur...

Страница 13: ...l equipment IIB Gas Group T1 T4 Permitted Maximum Surface Temperature Gb Atmosphere Equipment Protrection Level Table 1 Temperature class definitions Code Maximum permissible surface temperature in C F Minimum permissible surface temperature in C F T1 450 842 372 700 T2 300 572 277 530 T3 200 392 177 350 T4 135 275 113 235 T5 100 212 Option not available T6 85 185 Option not available For variable...

Страница 14: ...ified area where the equipment will be installed If it is not do not operate the equipment and contact your ITT Goulds Pumps sales representative before proceeding 1 5 ATEX Considerations and Intended Use 12 Model ICO i FRAME ICOH i FRAME Installation Operation and Maintenance Manual ...

Страница 15: ...moving the pump Use care when moving pumps Consult with a lifting and rigging specialist before lifting or moving the pump to avoid possible damage to the pump or injury to personnel WARNING Dropping rolling or tipping units or applying other shock loads can cause property damage and or personal injury Ensure that the unit is properly supported and secure during lifting and handling CAUTION Risk o...

Страница 16: ...fting equipment supports the entire assembly and is only used by au thorized personnel Do not attach sling ropes to shaft ends Lifting the pump Hoist the pump using a suitable sling under solid points such as the casing flanges or frame Figure 2 Example of proper lifting method 2 3 Storage guidelines 2 3 1 Long term storage If the unit is stored for more than 6 months these requirements apply Stor...

Страница 17: ...Seal chamber Wide choice of sealing arrangements for maximum sealing flexibility Patented cyclone seal chamber for improved lubrication heat removal and solids handling Confined casing gasket Power end Redesigned i FRAME large capacity oil sump reduces oil temperature for extended bearing life Heavy duty cast iron frame gives rigid support to the shaft and bearings for longer service Magnetic drai...

Страница 18: ...d monitoring device that con tinuously measures the vibration and temperature of the pump power end The i ALERT 2 sensor uses blinking red LEDs and wireless notification to alert the pump operator when the pump exceeds vibration and temperature limits This allows the pump operator to make changes to the process or the pump be fore a catastrophic failure occurs The Condition Monitor is also equippe...

Страница 19: ...mp flow in cubic metres per hour RPM Rated pump speed in revolutions per minute MAX DESIGN WORKING PRESS Maximum Design pressure in kPag at rated temperature in degrees Centigrade HEAD Rated pump head in metres MATL Material of which the pump is constructed IMP DIA Impeller diameter fitted CONT ITEM NO Contract or tag number MAX DIA Maximum impeller diameter 3 3 Nameplate information Model ICO i F...

Страница 20: ...re intended for use in lifting the individual components only WARNING Assembled units and their components are heavy Failure to properly lift and support this equipment can result in serious physical injury and or equipment damage Lift equipment only at the specifically identified lifting points Lifting devices such as swivel hoist rings shackles slings and spreaders must be rated selected and use...

Страница 21: ...leeves 3 If the baseplate uses sleeve type bolts then fill the sleeves with a non binding moldable material Seal the sleeves in order to prevent the grout from entering 4 Coat the exposed portion of the anchor bolts with a non bonding compound such as paste wax in order to prevent the grout from adhering to the anchor bolts Do not use oils or liquid wax 5 If recommended by the grout manufacturer c...

Страница 22: ...screws Tools required Anti seize compound Jackscrews Bar stock Two machinist s levels Baseplate leveling worksheet This procedure is applicable to the fabricated steel baseplate 1 Apply an anti seize compound on the jackscrews The compound makes it easier to remove the screws after you grout 2 Lower the baseplate carefully onto the foundation bolts and perform these steps a Cut the plates from the...

Страница 23: ... machinist s level across the ends of the two pads c Level the pads by adjusting the four jackscrews in the corners Make sure that the machinist s level readings are as close to zero as possible both lengthwise and across Use the baseplate leveling worksheet when you take the readings 1 2 3 4 5 6 Item Description 1 Machinist s levels 2 Driver s mounting pads 3 Foundation bolts 4 Jackscrews 5 Grout...

Страница 24: ...ounting pads are level and adjust the jackscrews and the foundation bolts if necessary The correct level measurement is a maximum of 0 167 mm m 0 002 in ft 4 2 5 Install the baseplate using spring mounting NOTICE The spring mounted baseplate is designed only to support piping loads from thermal expan sion Ensure that the suction and discharge piping are supported individually Failure to do so may ...

Страница 25: ...justing nut by hand 4 Thread the upper jam nut onto the spring stud by hand 5 Repeat steps 2 through 4 for all the spring assemblies 6 Lower the baseplate so that the spring assemblies fit into the foundation pads 7 Level the baseplate and make the final height adjustments a Loosen the upper jam nuts and adjusting nuts b Adjust the height and level the baseplate by moving the lower adjusting nuts ...

Страница 26: ...the base plate c Put a washer onto the lower adjusting nut 3 Install the stilt assembly on the baseplate a Insert the stilt assembly into the baseplate s anchorage hole from below b Put a washer onto the stilt c Fasten the stilt assembly with the upper adjusting nut by hand 4 Screw the upper jam nut onto the stilt by hand 5 Repeat steps 2 through 4 for all the stilt assemblies 6 Lower the baseplat...

Страница 27: ...lt bolt 4 Foundation cups 5 Washer 6 Upper adjustment nut 7 Mounting washer 8 Mounting bolt Figure 10 Example of an installed stilt assembly 4 2 Baseplate mounting procedures Model ICO i FRAME ICOH i FRAME Installation Operation and Maintenance Manual 25 ...

Страница 28: ..._____ 7 ____________________ 8 ____________________ 9 ____________________ 10 ___________________ 11 ___________________ 12 ___________________ 13 ___________________ 14 ___________________ 15 ___________________ 16 ___________________ 17 ___________________ 18 ___________________ Level measurements 4 2 Baseplate mounting procedures 26 Model ICO i FRAME ICOH i FRAME Installation Operation and Main...

Страница 29: ...rical 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 4 4 1 Alignment checks When to perform alignment checks You must perform alignment checks under these circumstances The process temperature chang...

Страница 30: ...the piping installations Make sure that the hold down bolts for the driver are tight when you take indicator measurements This keeps the driver stationary since move ment causes incorrect measurement Make sure that the hold down bolts for the driver are loose before you make alignment corrections This makes it possible to move the driver when you make alignment corrections Check the alignment agai...

Страница 31: ... order to lower the feet of the driver at the other end Positive The coupling halves are closer at the bottom than at the top Perform one of these steps Remove shims in order to lower the feet of the driver at the shaft end Add shims in order to raise the feet of the driver at the other end 4 4 5 2 Perform angular alignment for a horizontal correction 1 Set the angular alignment indicator A to zer...

Страница 32: ...ver foot 4 Repeat the previous steps until the permitted reading value is achieved NOTICE The specified permitted reading values are valid only at operating temperature For cold set tings other values are permitted The correct tolerances must be used Failure to do so can result in misalignment Contact ITT for further information 4 4 5 4 Perform parallel alignment for a horizontal correction A unit...

Страница 33: ...ght side 180 from the start position 3 o clock 3 Record the indicator readings 4 Make corrections according to the separate instructions for angular and parallel alignment until you obtain the permitted reading values 4 5 Grout the baseplate Required equipment Cleaners Do not use an oil based cleaner because the grout will not bond to it See the instructions provided by the grout manufacturer Grou...

Страница 34: ...8 hours 1 5 4 2 3 Item Description 1 Baseplate 2 Grout 3 Foundation 4 Dam 5 Bolt Figure 13 Fill remainder of baseplate with grout 7 Remove the leveling jackscrews after the grout hardens in order to remove any stress points 8 Tighten the foundation bolts 9 Make sure that treatment of the concrete is in accordance with DIN 1045 4 5 Grout the baseplate 32 Model ICO i FRAME ICOH i FRAME Installation ...

Страница 35: ... pump and driver Pipe strain ad versely affects the operation of the pump which results in physical injury and damage to the equipment Flange loads from the piping system including those from the thermal expansion of the pip ing must not exceed the limits of the pump Casing deformation can result in contact with rotat ing parts which can result in excess heat generation sparks and premature failur...

Страница 36: ...n the table The data in the following table has the following characteristics The data complies with the Europump Recommendation for pumps according to ISO 5199 The data is only valid for static piping loads The values are valid for pump units with standard IC base frames ungrouted All of the values refer to standard materials EN GJS400 18LT and 1 4408 Permitted nozzle loads and torques at the pum...

Страница 37: ...00 517 1 050 774 770 568 840 620 1 550 1 143 65 40 250 65 1 470 330 1 300 292 1 200 270 2 300 517 1 050 774 770 568 840 620 1 550 1 143 65 40 315 65 1 470 330 1 300 292 1 200 270 2 300 517 1 050 774 770 568 840 620 1 550 1 143 80 50 160 80 1 750 393 1 580 355 1 440 324 2 760 620 1 120 826 800 590 910 671 1 650 1 217 80 50 200 80 1 750 393 1 580 355 1 440 324 2 760 620 1 120 826 800 590 910 671 1 6...

Страница 38: ...850 7 350 1 652 2 280 1 682 1 610 1 187 1 850 1 364 3 350 2 471 200 150 31 5 200 4 700 1 057 4 200 944 3 780 850 7 350 1 652 2 280 1 682 1 610 1 187 1 850 1 364 3 350 2 471 200 150 40 0 200 4 700 1 057 4 200 944 3 780 850 7 350 1 652 2 280 1 682 1 610 1 187 1 1 850 364 3 350 2 471 Table 3 Discharge nozzle Sizes Ø DN Forces in N lbf Torques in Nm ft lb Fx Fy Fz ΣF Mx My Mz ΣM 40 25 160 25 530 119 4...

Страница 39: ... 1 820 1 342 125 100 25 0 100 2 100 472 1 900 427 2 350 528 3 670 825 1 230 907 880 649 1 020 752 1 820 1 342 125 100 31 5 100 2 100 472 1 900 427 2 350 528 3 670 825 1 230 907 880 649 1 020 752 1 820 1 342 125 100 40 0 100 2 100 472 1 900 427 2 350 528 3 670 825 1 230 907 880 649 1 020 752 1 820 1 342 150 125 25 0 125 2 500 562 2 240 504 2 750 618 4 350 978 1 470 1 084 1 050 774 1 330 981 2 140 1...

Страница 40: ...eter of 1 6 mm 1 16 in are recommended Liquids with specific gravity less than 0 60 a pressure drop across the suction strainer may be due to ice buildup Ice buildup can cause turbulence low pres sure areas and pumpage vaporization If more than one pump operates from the same liquid source check that separate suction piping lines are used for each pump This recommendation helps you to achieve a hi...

Страница 41: ...rence of air and cavita tion in the pump inlet Check that the piping is level or slopes downward from the liquid source Make sure that no part of the suction pip ing extends below the suction flange of the pump Make sure that the suction piping is ade quately submerged below the surface of the liquid source This prevents air from entering the pump through a suction vortex Example Elbow close to th...

Страница 42: ...ump Reduce risk of pumpage vaporization and vapor locking at low flow rates for low specific gravity liq uids See Example Discharge piping equipment for illustra tions Check that a check valve is installed in the discharge line between the isolation valve and the pump discharge outlet The location between the isolation valve and the pump allows inspection of the check valve The check valve prevent...

Страница 43: ...Provide a bypass line for systems that require operation at reduced flows for prolonged periods Connect a bypass line from the discharge side before any valves to the source of suction When to install a minimum flow orifice You can size and install a minimum flow orifice in a bypass line in order to prevent bypassing excessive flows Consult your ITT representative for assistance in sizing a minimu...

Страница 44: ... may need to install auxiliary piping for bearing cooling seal chamber cover cooling mechanical seal flush or other special features supplied with the pump Consult the pump data sheet for specific auxiliary piping recommendations Checklist Check Explanation comment Checked Check that the minimum flow for each component is 4 lpm 1 gpm Check that the cooling water pressure does not exceed 7 0 kg cm2...

Страница 45: ...ath serious personal injury and property damage Heat and pressure buildup can cause explosion rupture and discharge of pumpage Never operate the pump with suction and or discharge valves closed Running a pump without safety devices exposes operators to risk of serious personal in jury or death Never operate a unit unless appropriate safety devices guards etc are properly installed Failure to disco...

Страница 46: ...ng box bushing If temperatures of the pumped fluid will exceed 93 C 200 F then warm up the pump pri or to operation Circulate a small amount of fluid through the pump until the casing tem perature is within 38 C 100 F of the fluid temperature Accomplish this by flowing fluid from pump inlet to discharge drain optionally the casing vent can be included in warm up circuit but not required Soak for 2...

Страница 47: ...n 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 Make sure that the coupling spacer is removed The pump ships with the coupling spacer removed 4 Unl...

Страница 48: ...re performing any installa tion 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 WARNING The coupling guard used in an ATEX classified environment must be properly cert...

Страница 49: ...ng guard half must fit around the end plate 1 2 3 Item Description 1 Annular groove 2 End plate pump end 2 Guard half Figure 16 Annular groove in coupling guard 3 Use a bolt a nut and two washers to secure the coupling guard half to the end plate Tighten se curely 5 5 Install the coupling guard Model ICO i FRAME ICOH i FRAME Installation Operation and Maintenance Manual 47 ...

Страница 50: ...e driver half of the coupling guard over the pump half of the coupling guard The annular groove in the coupling guard half must face the motor Annular Driver Guard half groove Figure 18 Placement of driver half of coupling guard 5 Place the driver side end plate over the motor shaft 5 5 Install the coupling guard 48 Model ICO i FRAME ICOH i FRAME Installation Operation and Maintenance Manual ...

Страница 51: ... on the driver side of the coupling guard half 8 Slide the driver half of the coupling guard towards the motor so that the coupling guard completely covers the shafts and coupling Slide to fit Driver Figure 20 Slide driver half of coupling guard towards motor 9 Use a nut a bolt and two washers to secure the coupling guard halves together 10 Tighten all nuts on the guard assembly 5 5 Install the co...

Страница 52: ... 4 mm2 sec 0 0713 0 006 in 2 sec Flash point Cleveland 175 C 347 F Setting point Pourpoint 15 C 5 F Application temperature Contact your ITT representative to determine a suitable type of lubrication if ambient temperatures are below 10 C 14 F Higher than permitted bearing temperature Oil quantity requirements Bearing frame size Oil quantity in liters quarts 24 i FRAME 0 5 0 53 32 i FRAME 1 1 1 16...

Страница 53: ...h an optional oiler NOTICE Maintain an exact oil level If the oil level is too high the bearing temperature can increase If the oil level is too low the bearing will not be properly lubricated and could cause operational problems The constant level oiler is supplied loose 1 Unscrew the reservoir from the main body right threaded and set aside 2 Seal the main body to the bearing frame at the connec...

Страница 54: ...ease from the housing before regreasing Grease quality requirements Use a high quality grease lubricant corresponding to NLGI Grade 2 Grease lubrication Consider this information when you lubricate with grease Pumps are delivered from the manufacturer with lubricated bearings and are ready to be used The bearings are filled with lithium based grease which is suitable for a temperature range from 3...

Страница 55: ...s the seal gland External flush Run the piping so that the pump injects a clean cool compatible liquid directly into the seal gland The pressure of the flushing liquid must be 0 35 to 1 01 kg cm2 5 to 15 psi greater than the seal chamber pres sure The injection rate must be 2 to 8 lpm 0 5 to 2 gpm Other You can use other methods that employ multiple gland or seal cham ber connections Refer to the ...

Страница 56: ...f clean compatible liquid is required You must connect the piping to the lantern ring connection with a 40 to 60 drops per minute leak rate The pressure must be 1 01 kg cm2 15 psi above the stuffing box pressure 5 8 Pump priming 5 8 1 Prime the pump with the suction supply above the pump 1 Slowly open the suction isolation valve 2 Open the air vents on the suction and discharge piping until the pu...

Страница 57: ...outside supply line 1 2 3 4 5 Item Description 1 Discharge isolation valve 2 Shutoff valve 3 From outside supply 4 Foot valve 5 Check valve Figure 24 Pump priming with suction supply below pump with foot valve and an outside supply 5 8 Pump priming Model ICO i FRAME ICOH i FRAME Installation Operation and Maintenance Manual 55 ...

Страница 58: ... failure and breach of containment Ensure all flush and cool ing systems are operating correctly prior to starting pump NOTICE Risk of equipment damage due to dry operation Immediately observe the pressure gauges If discharge pressure is not quickly attained stop the driver immediately reprime and attempt to restart the pump On frame mounted units ensure that the oil level is correct prior to star...

Страница 59: ...plosive hazard and risk of personal injury Heating to high temperatures could cause com bustion of the condition monitor Never heat the condition monitor to temperatures in excess of 149 C 300 F or dispose of in a fire For all information refer to the i ALERT 2 Equipment Health Monitor Installation Operation and Mainte nance manual http www ittproservices com aftermarket products monitoring i aler...

Страница 60: ...quids freeze at different temperatures Some pump designs do not drain completely and may require flushing with a liquid that doesn t freeze 5 12 Shut down the pump WARNING 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 en...

Страница 61: ...e 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 manu facturer You must check the final alignment after the pump and driver are at operating temperature For initial alignment instructions see the Installation chapter 1 Run the unit under actual operating condition...

Страница 62: ...noise vibration and bearing temperatures Check the pump and piping for leaks Analyze the vibration Inspect the discharge pressure Inspect the temperature 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 Three month inspections Perform these tasks every three mo...

Страница 63: ...ears if the pump is left idle Oil change schedule Oil must be changed at least once a year Bearing temperature First oil change Subsequent oil changes Up to 60 C 140 F After 300 hours of operation Every 8760 hours of operation 60 C to 80 C 140 F to 176 F After 300 hours of operation Every 4000 hours of operation 80 C to 100 C 176 F to 212 F After 200 hours of operation Every 3000 hours of operatio...

Страница 64: ...ge or decreased performance Never mix greases of different consisten cies NLGI 1 or 3 with NLGI 2 or with different thickeners For example never mix a lithium based grease with a polyurea based grease If it is necessary to change the grease type or consistency remove the rotor and old grease from the housing before regreasing Grease quality requirements Use a high quality grease lubricant correspo...

Страница 65: ... Three month inspections Annual inspections Shorten the inspection intervals appropriately if the pumped fluid is abrasive or corrosive or if the envi ronment is classified as potentially explosive Routine maintenance Perform these tasks whenever you perform routine maintenance Lubricate the bearings Inspect the seal Routine inspections Perform these tasks whenever you check the pump during routin...

Страница 66: ...tion Lubrication intervals Oil lubricated bearings Add oil before you install and start the pump Change the oil after 200 300 hours of oper ation depending on bearing temperature See the Oil change schedule table Grease lubricated bear ings N A Every 4000 hours of operation or once a year whichever comes first Every two years if the pump is left idle Oil change schedule Oil must be changed at leas...

Страница 67: ...in plug 903 51 2 Drain the oil 3 Flush the pump with fresh oil 4 Clean the oil drain plug 5 Close the oil drain 6 Fill the pump with new oil See Lubricate the bearings with oil in the Commissioning Startup Oper ation and Shutdown chapter 7 Dispose of used oil in accordance with local environmental regulations 6 4 3 Lubricating grease requirements Precautions NOTICE Avoid equipment damage or decrea...

Страница 68: ...by 5 C to 10 C 9 F to 18 F 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 6 5 Shaft seal maintenance 6 5 1 Mechanical seal maintenance WARNING The mechanical seal must have an appropriate seal flush system Failure to do so will result in excess heat generation an...

Страница 69: ... out driver power may result in serious physical injury Nev er attempt to replace the packing until the driver is properly locked out Accepted leakage rate It is not necessary to shut down or disassemble the pump to inspect the packing operation During nor mal operation the packing should leak approximately 30 100 drops per minute Adjustment of gland Adjust the gland if the leakage rate is greater...

Страница 70: ...ctive 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 from rapid depressurization Ensure pum...

Страница 71: ...bly WARNING Lifting and handling heavy equipment poses a crush hazard Use caution during lifting and handling and wear appropriate Personal Protective Equipment PPE such as steel toed shoes gloves etc at all times Seek assistance if necessary 1 Is your bearing frame oil lubricated If No Proceed to step 2 If Yes 1 Remove the bearing frame drain plug 903 51 in order to drain oil from the bearing fra...

Страница 72: ...ll out assembly from the casing 102V 8 Mark and remove the shims from under the frame foot and save them for reassembly 9 Remove and discard the casing gasket You will insert a new casing gasket during reassembly 10 Remove the jackscrews 11 Clean all gasket surfaces Clean surfaces prevent the casing gasket from partially adhering to the casing due to binders and adhesives in the gasket material 6 ...

Страница 73: ...nd components are heavy Ensure all equipment is properly supported while working Wear appropriate Personal Protective Equipment PPE such as steel toed shoes gloves etc at all times CAUTION Risk of physical injury from sharp edges Wear heavy work gloves when handling impellers 1 the axial clearance a between the impeller and the casing cover Figure 28 Back clearance check 6 6 Disassembly Model ICO ...

Страница 74: ... NOTICE Remove shaft guard using a prying tool Be sure to align the pry bars with the impeller vanes in order to prevent damage to the impeller 4 Remove the impeller key 5 Place the back pull out assembly in a vertical position before you proceed with the disassembly 6 6 Disassembly 72 Model ICO i FRAME ICOH i FRAME Installation Operation and Maintenance Manual ...

Страница 75: ... ceramic components are brittle and easily bro ken 5 Remove shims from shaft check sleeve to ensure no shims were retained after removal 6 Remove the rotary portion of the seal from the sleeve by loosening the setscrews and sliding it off the sleeve Refer to the mechanical seal instructions for more information 7 Remove the gland 452 the stationary portion of the seal and the O ring 412 21 6 6 Dis...

Страница 76: ... ensure no shims were retained after removal 6 Remove the packing 461 and lantern ring 458 from the stuffing box cover 161 902 31 461 524 452 161 412 21 920 31 458 Figure 32 Packing and lantern ring removal 6 6 10 Disassemble the power end 1 Loosen and remove the hexagon bolts 901 41 that hold the frame adapter to the bearing frame 2 Remove the frame adapter 344 from the bearing frame 330 6 6 Disa...

Страница 77: ... the designated snap ring pliers Use snap ring pliers according to DIN 5256 C Refer to this table for the correct size Bearing frame size Pliers size Minimum length of pliers 24 i FRAME 94 C 40 200 mm 8 in 6 6 Disassembly Model ICO i FRAME ICOH i FRAME Installation Operation and Maintenance Manual 75 ...

Страница 78: ...the information in these pre assembly topics before you reas semble your pump Replace any part that does not meet the required criteria Make sure that the parts are clean Clean the pump parts in solvent in order to remove oil grease and dirt NOTICE Protect machined surfaces while cleaning the parts Failure to do so may result in equipment damage 6 7 1 Replacement guidelines Casing check and replac...

Страница 79: ...16 in or When worn evenly more than 0 8 mm 1 32 in Pumpout vanes When worn or bent more than 0 8 mm 1 32 in Vane edges When you see cracks pitting or corrosion damage Frame adapter check and replacement Replace the frame adapter if it has cracks or excessive corrosion damage Make sure the O ring surface is clean Oil seal replacement Replace the oil seal if it has cuts or cracks 6 7 Pre assembly in...

Страница 80: ...ion of the product Ensure appropriate use of fasteners during installation or reassembly of the unit Use fasteners of the proper size and material only Replace all corroded fasteners Ensure that all fasteners are properly tightened and that there are no missing fasteners 6 7 2 Shaft replacement guidelines Straightness check 210 Figure 35 Straightness check Replace the shaft 210 if runout exceeds t...

Страница 81: ... the bearing frame inside and outside surface Figure 37 Inside and outside inspection locations 6 7 4 Seal chamber and stuffing box cover inspection Checklist Perform these checks when you inspect the seal chamber and stuffing box cover Make sure that these surfaces are clean Seal chamber and stuffing box cover Mounting Make sure there is no pitting or wear greater than 3 2 mm 1 8 in deep Replace ...

Страница 82: ...otate them Investigate any bearing damage to determine the cause If the cause is not normal wear correct the issue before you return the pump to service 6 8 Reassembly 6 8 1 Assemble the rotating element and bearing frame WARNING Lifting and handling heavy equipment poses a crush hazard Use caution during lifting and handling and wear appropriate Personal Protective Equipment PPE such as steel toe...

Страница 83: ... prevent vibration damage to the bearing d Apply Thread EZE to the bearing locknut threads on the shaft e Thread the bearing locknut 923 51 onto the thrust end of the shaft The bearing nut is right hand threaded and is self locking It can be reused up to five times if han dled properly f Allow the bearing to cool for 10 minutes and retighten 923 51 302 52 932 51 Figure 40 Shaft assembly 2 Install ...

Страница 84: ...1 onto the shaft The bearing slides easily into place against the shoulder on the shaft h Place the frame adapter 344 over the radial bearing Allow the radial bearing to cool for at least 10 minutes i When bearing is cool gently tap the frame adapter until the radial bearing is properly seated in the frame adapter Make sure that the bolt holes are aligned 923 51 302 52 932 51 330 320 51 344 j Remo...

Страница 85: ...e back pull out assembly cannot tip over CAUTION Risk of physical injury from sharp edges Wear heavy work gloves when handling impellers For the fitting threads and for tight tolerances use a suitable anti seize compound Use this for example between the shaft sleeve and the shaft or between the impeller and the shaft This makes the assembly and the next disassembly easier to perform NOTICE Anti se...

Страница 86: ...nsure no binding occurs Use casing bolts 901 11 to maintain a consistent gap between casing 102V and cas ing cover 161 during assembly 7 Where possible verify front clearance between casing 102V and impeller 230 through the dis charge nozzle Table 6 Acceptable front clearances Size mm 160 0 38 0 12 0 00 200 0 38 0 12 0 00 250 0 38 0 00 12 315 0 38 0 00 12 400 0 38 0 00 12 8 If using a cartridge se...

Страница 87: ...opriately sized blocks See Figure 44 Assembly arrange ment on page 86 WARNING Crush hazard Make sure that the back pull out assembly cannot tip over 3 Frame adapter 344 and flinger 507 should already be installed at this stage of reassembly 4 If casing cover 161 to frame adapter 344 retention studs 920 32 are supplied install and tighten in cover 161 NOTICE For the fitting threads and for tight to...

Страница 88: ...e casing 102V with suction eye down 12 Ensure the impeller 230 is centered in the casing 102V by spinning and or shifting the impeller 230 until full contact between vanes and casing 102V has been achieved NOTICE There should be no rocking or tipping of the impeller once centered This is imperative for ac curate shim 525 measurements 13 With components assembled and oriented as defined take measur...

Страница 89: ...ings but is not a required tool Figure 45 Goulds gauge bar method Figure 46 Generic gauge bar method 17 Measure from top of bar to impeller 230 back hub face as shown in Figure 45 Goulds gauge bar method on page 87 and record in A1 field 18 Measure from top of bar to casing 102V gasket surface as shown in Figure 45 Goulds gauge bar method on page 87 and recorded in A2 field 6 8 Reassembly Model IC...

Страница 90: ...cover to sleeve measurement 23 Place bar Goulds or Generic across casing cover 161 as shown in Figure 47 Casing cover to sleeve measurement on page 88 measure top of bar to sleeve 524 shoulder and record in B1 field 24 Subtract H from B1 and record in field B B B1 H Refer to Figure 47 Casing cover to sleeve measurement on page 88 25 Refer to Table 7 C Value table on page 96 and match pump size wit...

Страница 91: ...surement on page 88 1 Sleeve 2 Shims as required Figure 48 Shim and sleeve assembly 6 8 3 2 Seal the shaft with a packed stuffing box WARNING Packed stuffing boxes are not allowed in an ATEX classified environment WARNING Failure to disconnect and lock out driver power may result in serious physical injury Never at tempt to replace the packing until the driver is properly locked out Pumps are ship...

Страница 92: ...h a cartridge mechanical seal WARNING The mechanical seal used in an Ex classified environment must be properly certified The mechanical seal must have an appropriate seal flush system Failure to do so will result in excess heat generation and seal failure CAUTION Running a mechanical seal dry even for a few seconds can cause seal failure and physical injury Never operate the pump without liquid s...

Страница 93: ...nitial measurement L1 Figure 50 Initial seal measure ment 1 Sleeve face 2 Seal rotating component 3 Set screw 4 Seal offset L1 L1K Figure 51 Setting seal at deter mined value 3 Consult seal instructions for component L1K dimensions and subtract L1K from L1 L1 L1K Seal Offset See Figure 50 Initial seal measurement on page 91 4 Install Stationary seal component in casing cover 161 using appropriate ...

Страница 94: ...screws NOTICE Do not overtighten the casing jackscrews Doing so may result in equipment damage 5 Turn the shaft by hand in order to make sure that it moves freely The shaft seal can cause a slight resistance but there must not be any metal to metal contact 6 Reinstall the shims under the frame foot and tighten the frame foot to the baseplate Make sure that you use the proper shim Mount a dial indi...

Страница 95: ...lt size Torque for lubricated threads in Nm lb ft Torque for dry threads in Nm lb ft Casing screws M12 35 26 50 37 M16 105 77 150 111 M20 210 155 305 225 All other screws M10 40 30 50 37 M12 60 44 90 66 M16 150 111 220 162 Nut torque values This table provides the recommended nut torque values Location Frame size Torque for lubricated threads in Nm lb ft Torque for dry threads in Nm lb ft Impeller...

Страница 96: ...ack 2 2 2 3 3 4 50 see calculation note Lantern ring 1 1 2 2 2 3 30 see calculation note Packing ring 16 16 24 24 24 32 100 see calculation note Casing gaskets 4 6 8 8 9 12 150 see calculation note Other gaskets 4 6 8 8 9 10 100 see calculation note Mechanical seals 1 1 2 2 2 3 25 see calculation note Power end bear ing frame adapter shaft bearings and other parts 2 Calculation note In order to de...

Страница 97: ...bar on page 95 for a generic bar see Fig ure 54 Generic gauge bar on page 95 Gasket type Fluid temp ______ _ ______ _ 2 Select appropriate length gauge bar to match pump features measure height record in H H ______ _ 3 If using ITT Goulds gauge bar K14153A kit proceed to Step 8 4 Measure from top of bar to impeller hub feature as shown in Figure 54 Generic gauge bar on page 95 and record in A1 fie...

Страница 98: ...m thick D ______ _ 14 Determine shim height for your application by using following formula shim height A B C D Shim ______ _ 15 With the ideal shim thickness determined combine shims as needed to approximate this value 16 Refer to IOM or ICO assembly procedure for additional assembly details Pump size __________________ By ________________ Date ___________ Table 7 C Value table Bea ring fra me si...

Страница 99: ... 44 100 65 315 125 80 315 125 100 31 5 150 125 31 5 29 26 29 27 29 30 29 33 29 36 29 38 29 41 29 44 125 80 400 125 100 40 0 150 125 40 0 33 26 33 27 33 30 33 33 33 36 33 38 33 41 33 44 48 200 150 31 5 200 150 40 0 53 26 53 27 53 30 53 34 53 37 53 40 53 43 53 46 Table 8 D Value Table Bearing frame size Pump size Gasket type D mm D in All All AFM 34 NBR 0 05mm 0 00 0 000 GYLON 3500 FAWN 0 8mm 0 26 0...

Страница 100: ... the impeller and the pump cas ing is excessive Adjust the impeller clearance The suction head is not sufficient Make sure that the suction line shutoff valve is fully open and that the line is unobstructed The impeller is worn or broken Inspect and replace the impeller if necessary The pump starts and then stops pumping The pump is not primed Re prime the pump and check that the pump and suction ...

Страница 101: ... di ameter If this does not help then contact your ITT representative The liquid is heavier than ex pected Check the specific gravity and viscosity The stuffing box packing is too tight Readjust the packing If the pack ing is worn then replace the packing Rotating parts are rubbing against each other Check the parts that are wearing for proper clearances The impeller clearance is too tight Adjust ...

Страница 102: ...t is not seated properly Re seat the frame adapter and make sure that the adapter to frame gasket is seated properly There is excessive seal chamber or stuffing box cover runout The seal chamber or the stuffing box cover is not properly seated in the frame adapter Re seat the seal chamber or stuff ing box cover There is corrosion or wear on the seal chamber or stuffing box cover Replace the seal c...

Страница 103: ...ts Listings and Cross Sectional Drawings 8 1 Parts list Cross sectional drawings 8 Parts Listings and Cross Sectional Drawings Model ICO i FRAME ICOH i FRAME Installation Operation and Maintenance Manual 101 ...

Страница 104: ...8 1 Parts list 102 Model ICO i FRAME ICOH i FRAME Installation Operation and Maintenance Manual ...

Страница 105: ...8 1 Parts list Model ICO i FRAME ICOH i FRAME Installation Operation and Maintenance Manual 103 ...

Страница 106: ...yrinth Seal Steel Bronze 524 Shaft Sleeve 316LSS Duplex Alloy 20 Hastelloy Titanium 525 Shims Duplex 637 Oil Vent Filler Plug Steel 642 Oil Level Sight Glass Glass Plastic 901 11 Casing Bolts Hex Screw Cap Stainless Steel 901 12 Support Foot Bolt Hex Cap Screw Carbon Steel 901 31 Lantern Cover Hex Cap Screw Stainless Steel 901 41 Brg Bracket to Lantern Bolts Hex Cap Screw Carbon Steel 901 42 Jacki...

Страница 107: ... 1 562 695 8523 Asia Pacific ITT Fluid Technology Asia Pte Ltd 1 Jalan Kilang Timor 04 06 Singapore 159303 65 627 63693 65 627 63685 Europe ITT Goulds Pumps Millwey Rise Industrial Estate Axminster Devon England EX13 5HU 44 1297 639100 44 1297 630476 Latin America ITT Goulds Pumps Camino La Colina 1448 Condominio Industrial El Rosal Huechuraba Santiago 8580000 Chile 562 544 7000 562 544 7001 Middl...

Страница 108: ...information http www gouldspumps com ITT Goulds Pumps Inc 240 Fall Street Seneca Falls NY 13148 USA 2020 ITT Inc The original instruction is in English All non English instructions are translations of the original instruction Form IOM ICOiframe ICOHiframe en US 2020 02 ...

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