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Symptom

Cause

Remedy

Density and/or viscosity of liquid han-
dled is too high

Seek assistance

Discharge stops after a time

Flow too little

Increase min. flow (open discharge
valve, bypass)

Pump or suction/intake pipe blocked

Clean

Suction height too big / NPSH of sys-
tem too small

•

Increase liquid level and admis-
sion pressure

•

Reduce resistance in the intake/
suction pipe (change course and
rated width, open shut-off valves,
clean filters)

Air being sucked in

•

Increase liquid level

•

Check if suction pipe is vacuum-
tight

Air being sucked in through shaft seal-
ing

•

Clean sealing pipe

•

Increase sealing pressure

•

Replace shaft sealing

Head too low

Back-pressure too low, discharge too
low

Throttle discharge valve

Speed too low

•

Increase speed (check available
motor power)

•

Compare speed of motor with
specified pump speed (rating
plate)

•

When adjusting speed (frequen-
cy transformer) check reference
value settings

Flow too little

Increase min. flow (open discharge
valve, bypass)

Impeller diameter too small

Use larger impeller (check available
motor power)

Pump and/or pipes not completely fil-
led with liquid

•

Fill

•

Vent

Pump or suction/intake pipe blocked

Clean

Air pocket in pipeline

•

Vent

•

Improve course of pipe

Suction height too big / NPSH of sys-
tem too small

•

Increase liquid level and admis-
sion pressure

•

Reduce resistance in the intake/
suction pipe (change course and
rated width, open shut-off valves,
clean filters)

Air being sucked in

•

Increase liquid level

•

Check if suction pipe is vacuum-
tight

Air being sucked in through shaft seal-
ing

•

Clean sealing pipe

•

Increase sealing pressure

•

Replace shaft sealing

Direction of rotation is wrong

Swap over two phases of power supply
(to be done by an electrician)

Inner components suffering from wear Replace worn parts

8.1 Operation troubleshooting

Model ICP, ICPI, ICPH, ICPIH Installation, Operation and Maintenance Instruction

Содержание Goulds Pumps ICP

Страница 1: ...Installation Operation and Maintenance Instruction Model ICP ICPI ICPH ICPIH ...

Страница 2: ......

Страница 3: ...allation 15 4 1 Pre installation 15 4 1 1 Pump location guidelines 15 4 1 2 Foundation requirements 16 4 2 Piping checklists 16 4 2 1 General piping checklist 16 4 2 2 Permitted Nozzle Loads and Torques at the Pump Nozzles 16 4 2 3 Final Control 18 4 2 4 Mounting of Pump Unit 18 4 2 5 Connection of Piping to the Pump 19 4 2 6 Coupling 20 4 3 Drive 24 4 4 Final Control 24 5 Commissioning Startup Op...

Страница 4: ...ack Pull Out Assembly 36 6 11 Removal of Impeller 36 6 12 Remove the Shaft Sealing 38 6 13 Removal of Bearing 38 6 14 Preassembly inspections 39 6 14 1 Reconditioning 39 6 15 Reassembly 40 6 15 1 Mounting 40 7 Recommended Spare Parts Spare Pumps 42 7 1 Spare Parts 42 7 2 Spare Parts Order 42 7 3 Stand by pumps 43 8 Troubleshooting 44 8 1 Operation troubleshooting 44 Table of Contents 2 Model ICP I...

Страница 5: ...Tools and Resources Litera ture or by contacting your nearest Goulds Pumps sales representative These manuals must be read and understood before installation and start up For additional information contact your nearest Goulds Pumps sales representative or visit our Web site at https www gouldspumps com 1 2 Safety warnings Specific to pumping equipment significant risks bear reinforcement above and...

Страница 6: ...dous situation which if not avoided could result in death or serious injury Example Pump shall never be operated without coupling guard installed correctly CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury Example Throttling flow from the suction side may cause cavitation and pump damage ELECTRICAL HAZZARD WARNING Indicates the possibility of ele...

Страница 7: ...afety devices installed WARNING NEVER operate pump with discharge valve closed WARNING NEVER operate pump with suction valve closed WARNING DO NOT change service application without approval of an authorized ITT Goulds Pumps representative WARNING Safety Apparel Insulated work gloves when handling hot bearings or using bearing heater Heavy work gloves when handling parts with sharp edges especiall...

Страница 8: ... of metal parts heat generation and breach of containment WARNING Lock out driver power to prevent accidental start up and physical injury WARNING The impeller clearance setting procedure must be followed Improperly setting the clear ance or not following any of the proper procedures can result in sparks unexpected heat generation and equipment damage WARNING If using a cartridge mechanical seal t...

Страница 9: ...ent accidental startup and physical injury CAUTION Allow all system and pump components to cool before handling them to prevent physi cal injury CAUTION If pump is a Model NM3171 NM3196 3198 3298 V3298 SP3298 4150 4550 or 3107 there may be a risk of static electric discharge from plastic parts that are not prop erly grounded If pumped fluid is non conductive pump should be drained and flushed with...

Страница 10: ...te on which it is mounted A typical tag would look like this Figure 1 ATEX nameplate The CE and the Ex designate the ATEX compliance The code below reads as follows II Group Non Mining Equipment 2G Category Category 2 Gas Ex required by ISO 80079 36 2016 h h indicates mechanical equipment IIB Gas Group T1 T4 Permitted Maximum Surface Temperature Gb Atmosphere Equipment Protrection Level Table 2 Te...

Страница 11: ... 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 6 Parts The use of genuine Goulds parts will provide the safest and most reliable operation of your pump ITT Goulds Pumps ISO certifica tion and quality control procedures ensure the parts are manufac tured to the highest quality and safety lev...

Страница 12: ...out of order 2 2 Transportation guidelines 2 2 1 Pump handling 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 of injury or equipment damage from use of inadequate lifting devices Ensure lifting devi ces such as chains straps forkli...

Страница 13: ...ng and handling and wear appropriate Personal Protective Equipment PPE such as steel toed shoes gloves etc at all times Seek assistance if necessary Safe lifting points are specifically identified in this manual It is critical to lift the equipment only at these points Integral lifting eyes or eye bolts on pump and motor components are intended for use in lifting the individual components only NOT...

Страница 14: ...ore in a covered and dry location Store the unit free from heat dirt and vibrations Rotate the shaft by hand several times at least every three months 2 3 2 Frostproofing Table 3 Situations when the pump is or is not frostproof Situation Condition Operating The pump is frostproof Immersed in a liquid The pump is frostproof Lifted out of a liquid into a temperature below freezing The impeller might...

Страница 15: ...acking of a stuffing box resp for the mounting and operation of mechanical seals can be found in the appendix of the particular Mounting Instructions of the Shaft Sealing NOTICE Packed stuffing boxes are not allowed in an ATEX classified environment Further details about packings and mechanical seals as well as the therewith connected accidental dan gers you can find in Monitoring and in 6 2 Mecha...

Страница 16: ...Pump Model SIZE Size of Pump STD DIM ANSI Std designation Not applicable ISO Pumps HYDRO PRESS Pump Test Pressure in kPag FLOW Rated pump 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...

Страница 17: ...dual 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 used for the entire load being lifted Guidel...

Страница 18: ...hecklist Precautions WARNING Risk of premature failure Casing deformation can result in misalignment and contact with rotating parts causing excess heat generation and sparks Flange loads from the piping system including those from the thermal expansion of the piping must not exceed the limits of the pump Risk of serious personal injury or property damage Fasteners such as bolts and nuts are criti...

Страница 19: ...40 950 1850 840 620 670 1230 40 620 560 700 1100 730 500 590 1060 65 40 250 65 1180 1040 950 1850 840 620 670 1230 40 620 560 700 1100 730 500 590 1060 65 40 315 65 1180 1040 950 1850 840 620 670 1230 40 620 560 700 1100 730 500 590 1060 80 50 160 80 1400 1260 1150 2200 900 650 730 1320 50 840 760 920 1450 780 560 650 1150 80 50 200 80 1400 1260 1150 2200 900 650 730 1320 50 840 760 920 1450 780 5...

Страница 20: ... acc to DIN 1045 or equal standard min BN 15 to ensure a secure functional mounting The concrete foundation must have set before the unit is errected Ist surface must be horizontal and even For the position and size of the pump feet and the foudation screws refer to the dimensional draw ing Concrete expansion bolts epoxy capsle anchor bolts or anchor bolts grouted with the foundation stone screws ...

Страница 21: ...line makes it easier to de aerate the pump before start up Item No Description 1 Vent line Figure 5 Vent line When laying the pipes make sure that the pump is accessible for maintenance installation and dis assembly Notice Permitted Forces on Flanges If expansion joints are used in the pipes they have to be supported in such a way that the pump is not loaded unduly high because of the pressure in ...

Страница 22: ...nufacturer s installation and operation manuals IOM for specific instructions and recommendations According to Accident Prevention Regulations the pump unit may only be operated when the coupling guard is mounted On operation in zone 1 and 2 a coupling with valid ATEX certification must be used The Operating Instructions of the manufacturer must be followed Alignment of coupling NOTICE The alignme...

Страница 23: ...m No Description 1 Ruler 2 Gauge Figure 6 Alignment of coupling with gauge and ruler Item No Description 1 Ruler 2 Gauge Figure 7 Alignment of coupling with spacer NOTICE Control alignment of coupling again in operation warm condition and on system pressure if available and correct if necessary Pay attention to Start up Operation Shut down before hand It must be possible to turn the unit easily an...

Страница 24: ...pecific information about safety devices in other sections of this manual The coupling guard used in an ATEX classified environment must be properly certi fied and constructed from a spark resistant material Assembly Item No Description 1 Coupling guard two equal halves 2 Adjusting piece Figure 8 Coupling guard parts 4 2 Piping checklists 22 Model ICP ICPI ICPH ICPIH Installation Operation and Mai...

Страница 25: ...bearing cover Figure 9 Coupling guard assembly Step 1 Item No Description 1 Insert part 3 with slot downwards with press axially to the motor Figure 10 Coupling guard assembly Step 2 4 2 Piping checklists Model ICP ICPI ICPH ICPIH Installation Operation and Maintenance Instruction 23 ...

Страница 26: ... 2 a motor with valid Atex certification must be used If in the process of the repair a new motor is used the following has to be noticed The motor must comply with the requirements stated in sheet 1220 1A608 order from manufactur er on demand Clean motor end and motor flange of new motor carefully remove varnish 4 4 Final Control Check alignment of coupling according to Alignment of coupling on p...

Страница 27: ...failure and or loss of prime WARNING Risk of death 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 gua...

Страница 28: ...nd noise b If the pump exceeds normal levels then shut down the pump immediately and correct the prob lem 7 Repeat steps 5 and 6 until the pump runs properly 5 3 Initial start up Before starting up the pump check if the following points were controlled and carried out 1 There is no need to lubricate the pump before starting it up 2 Pump and suction pipe must be filled completely with liquid when s...

Страница 29: ...eginning Reduce that slowly during the first operating hours by continuously fasten ing of gland see position 452 and 920 31 in sectional drawing when pump is running Assume 30 100 drops minute as approximate value NOTICE Dry running packings harden and destroy the shaft sealing resp the shaft NOTICE If pump does not reach attended head or if atypical sounds or vibrations do occur Switch off pump ...

Страница 30: ... Permitted number of starts Do not start the pump more than the number of times shown in this chart 1 10 100 1 10 100 1000 Motor power kW Maximum permitted starts per hour For pumps that use electric motors do not start the motor more than the number of times listed in the motor operation instructions If two different numbers are shown the lower number of starts is the limit 5 7 Pump operation pre...

Страница 31: ...ubrication on page 32 The pumps are delivered without oil Oil level sight glass standard design Remove oil fill plug 637 and fill oil into the connection opening GF1 Fill in oil up to the middle of the oil level sight glass 642 Figure 12 Oil level sight glass Keep level exactly Overfilling leads to increased bearing temperature and possibly oil leakage If oil level is too low this can cause shortc...

Страница 32: ... nipples 636 Bearing temperature measured at bearing bracket should lie max 50 C 122 F over ambient temperature and must not exceed 90 C 194 F control weekly at least On grease lubrication the bearing temperature can temporarily be higher by 5 to 10 C 41 to 50 F after regreasing till a pos sible surplus of grease in the bearings is cut 5 10 Shut down 1 Close the valve in discharge pipe right befor...

Страница 33: ...ck the pump and piping for leaks Analyze the vibration With double mechanical seals monitor pressure and flow rate in mechanical seal area check at least once a week Three month inspections Perform these tasks every three months Check that the foundation and the hold down bolts are tight Check the packing if the pump has been left idle and replace as required Annual inspections Perform these inspe...

Страница 34: ...rbidden 6 4 Lubrication and Change of Lubricant Oil lubrication Temperature at bearing First oil change after operating hours All further oil changes after operating hours up to 60 C 140 F 300 8760 60 C to 80 C 140 F to 176 F 300 4000 80 C to 100 C 176 F to 212 F 200 3000 at least 1x year In plants endangered to explosion the oil changing intervals must be kept under any circumstances Oil changing...

Страница 35: ...m3 48 23g 26cm3 42g 46cm3 If the pump is left non operational for a longer time the grease in the bearings should be changed after 2 years 6 5 Coupling Check the clearance in the coupling components regularly approx every 1000 operating hours but at least 1x year the radial clearance in the coupling parts must be checked For couplings with rubber pads the following applies Unless a clearance in th...

Страница 36: ...forming 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 Risk of serious personal injury Applying heat to impellers propellers or their retaining devi...

Страница 37: ...ry the pump must be flushed or decontaminat ed Laws must be observed otherwise danger to health is existing Before the disassembly the pump has to be secured in such a way that it can t be started The pump casing must be drained and without pressure All locking devices in the suction and discharge pipe must be closed All parts must have taken on the temperature of the environment NOTICE Secure dis...

Страница 38: ...ve spacer of the spacer type coupling 5 Loosen screws of support food 183 from the base frame 6 Hang the Back Pull Out Assembly onto a lifting device so that it won t sink down or press into the volute casing during the dismounting Figure 15 Back pull out removal 7 Loosen hex head bolt 901 11 from the casing 8 Using the jack screws provided 901 42 separate the Back Pull Out Assembly from the casin...

Страница 39: ...OTICE Be sure to align the pry bars with the impeller vanes in order to prevent damage to the impeller 3 For further dismounting the back pullout assembly should be placed in a vertical position Figure 17 Place back pull out assembly in vertical position CAUTION Dropping rolling or tipping units or applying other shock loads can cause property damage and or personal injury Ensure that the unit is ...

Страница 40: ... head bolt 901 41 Remove the bearing bracket lantern from bearing bracket 330 4 Dismount circlip 932 51 Therefore you need a snap ring plier according to DIN 5256 C Bearing bracket required snap ring pli er length i min of snap ring plier 24 size 94 C 40 200mm 32 42 size 94 C 85 250mm 48 Größe 94 C 85 300mm 5 Remove shaft 210 including anti friction bearing 320 51 and 320 52 and bearing nut 923 51...

Страница 41: ... the mechanical seal and the bearings Deposits on the impeller 230 in the volute casing 102V or on the casing cover must be re moved Clearance at impeller Suction side of impeller shown below left back vanes of impeller shown below right Figure 20 Suction side of impeller shown on left Back vanes of impeller shown on right 100 65 315 125 80 315 125 100 315 150 125 315 150 125 400 200 150 315 200 1...

Страница 42: ...ft sleeve 433 and shaft 210 or impeller 230 and shaft 210 as well as thread use a suitable anti galling compound e g Molykote Never Seeze so that the assembly and the next disassembly will be easier NOTICE Anti galling compound must be compatible with the pumpage Screws should be tightened with the following torque Location Screw Size Screw torque in Nm Lubricated threads Dry threads Casing screws...

Страница 43: ...be checked after mounting the impeller 230 and tightening the impeller nut 922 see Clearance at impellerchapter 8 After the mounting of the back pull out assembly and its assembly into the volute casing turn the shaft and control the free moving of the pump in this way The shaft sealing will cause slightly resist ance when turning but there must not be any contact between metal parts 9 Before star...

Страница 44: ...o other guidelines are ap plicable we recommend that you stock the number of parts listed below in accordance with DIN 24296 NOTICE To ensure optimum availability we recommend that suitable quantities of spare parts are held in stock especially if these are made from special materials and in the case of mechanical seals because of the longer delivery times 7 2 Spare Parts Order When ordering spare...

Страница 45: ...pump could endanger human life or cause damage to property or high costs Regu lar checks should be carried out to ensure that such pumps are always ready for use see Stor age longer periods of non operation NOTICE Store stand by pumps according to Storage longer periods of non operation 7 3 Stand by pumps Model ICP ICPI ICPH ICPIH Installation Operation and Maintenance Instruction 43 ...

Страница 46: ...vailable motor power Compare speed of motor with specified pump speed rating plate When adjusting speed frequen cy transformer check reference value settings Impeller diameter too small Use larger impeller check available motor power Pump and or pipes not completely fil led with liquid Fill Vent Pump or suction intake pipe blocked Clean Air pocket in pipeline Vent Improve course of pipe Suction he...

Страница 47: ...n adjusting speed frequen cy transformer check reference value settings Flow too little Increase min flow open discharge valve bypass Impeller diameter too small Use larger impeller check available motor power Pump and or pipes not completely fil led with liquid Fill Vent Pump or suction intake pipe blocked Clean Air pocket in pipeline Vent Improve course of pipe Suction height too big NPSH of sys...

Страница 48: ...ndation plate frame proper ly cast in place Electricity supply not right 2 phase running Check voltage of all phases Check cable connections and fuses Pump not running quietly Flow too little Increase min flow open discharge valve bypass Pump and or pipes not completely fil led with liquid Fill Vent Suction height too big NPSH of sys tem too small Increase liquid level and admis sion pressure Redu...

Страница 49: ... material check shaft or shaft sleeve for damage beforehand Deposits on mechanical seal Clean Replace mechanical seal if nec essary If necessary provide additional rinsing or quench Temperature at the bearing too high Back pressure too low discharge too low Throttle discharge valve Flow too big Reduce flow throttle discharge valve Inner components suffering from wear Replace worn parts Coupling gu...

Страница 50: ... suitable material check shaft or shaft sleeve for damage beforehand Deposits on mechanical seal If necessary provide additional rinsing or quench Impeller out of balance Remove blocks deposits Replace impeller if broken or un evenly worn Check shafts to ensure that they are running true Coupling not aligned Align pump unit better Forces in pipeline too high pump unit under strain Change support p...

Страница 51: ...nd more information www gouldspumps com ITT Goulds Pumps 240 Fall Street Senenca Falls NY 13148 USA 2020 ITT Corporation The original instruction is in English All non English instructions are translations of the original instruction Form IOM ICP en US 2020 02 ...

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