Goulds Pumps Installation, Operation, and Maintenance Manual Model 3171
Table of Contents Table of Contents Introduction and Safety...................................................................................................................................................3 Introduction.......................................................................................................................................................................3 Inspect the package.......................................................................................................
Table of Contents Check the rotation...........................................................................................................................................................28 Thrust bearing lubrication.............................................................................................................................................29 Flush the steady bearings..........................................................................................................................
Introduction and Safety Introduction and Safety Introduction Purpose of this manual The purpose of this manual is to provide necessary information for: • Installation • Operation • Maintenance CAUTION: Read this manual carefully before installing and using the product. Improper use of the product can cause personal injury and damage to property, and may void the warranty. NOTICE: Save this manual for future reference, and keep it readily available at the location of the unit. Inspect the package 1. 2. 3.
Introduction and Safety (Continued) • Incorrectly executed repair work • Normal wear and tear ITT assumes no liability for these situations: • Bodily injuries • Material damages • Economic losses Warranty claim ITT products are high-quality products with expected reliable operation and long life. However, should the need arise for a warranty claim, then contact your ITT representative. Safety WARNING: • The operator must be aware of safety precautions to prevent physical injury.
Introduction and Safety (Continued) Safety message level Electrical Hazard: NOTICE: Indication The possibility of electrical risks if instructions are not followed in a proper manner • A potential situation which, if not avoided, could result in an undesirable result or state • A practice not related to personal injury Environmental safety The work area Always keep the pump station clean to avoid and/or discover emissions. Recycling guidelines Always recycle according to these guidelines: 1.
Introduction and Safety (Continued) The work area Observe these regulations and warnings in the work area: • 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. Product and product positioning requirements Observe these requirements for the product and the product positioning: WARNING: • Only use fasteners of the proper size and material.
Introduction and Safety (Continued) Wash the skin and eyes Do the following if chemicals or hazardous fluids have come into contact with your eyes or your skin: If you need to wash your... Then... Eyes 1. Hold your eyelids apart forcibly with your fingers. Skin 2. 3. Rinse the eyes with eyewash or running water for at least 15 minutes. Seek medical attention. 1. 2. 3. Remove contaminated clothing. Wash the skin with soap and water for at least one minute. Seek medical attention, if required.
Introduction and Safety (Continued) • Never start a pump without the proper priming. • Before you start working with the product, make sure that the product and the control panel are isolated from the power supply and the control circuit, so they cannot be energized. • Do not open the product while it is energized or in an explosive gas atmosphere. • Make sure that thermal contacts are connected to a protection circuit according to the approval classification of the product.
Transportation and Storage Transportation and Storage Receive the unit 1. 2. 3. Inspect the package for damaged or missing items upon delivery. Note any damaged or missing items on the receipt and freight bill. File a claim with the shipping company if anything is out of order. Unpack the unit 1. 2. 3. Remove packing materials from the unit. Dispose of all packing materials in accordance with local regulations. Inspect the unit to determine if any parts have been damaged or are missing.
Transportation and Storage (Continued) Examples Figure 1: Example of lifting motor properly with lifting lugs Figure 2: Example of lifting pump properly with sling Pump storage requirements Requirements Vertical pumps require proper preparation for storage and regular maintenance during storage. The pump is considered in storage when it has been delivered to the job site and is awaiting installation. For specific requirements for storing motors, gearheads, and engines, contact the equipment manufacturer.
Transportation and Storage (Continued) Condition Rotation of the pump and bowl assembly shaft Proper preparation • Rotate the pump 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. Controlled storage facilities • Maintain an even temperature of 10°F (6°C) or higher above the dew point. • Keep the relative humidity to less than 50%.
Product Description Product Description General description Product description The 3171 is a vertical submerged bearing sump and process pump. This model is based on three bearing frames with 17 hydraulic sizes. The S/ST group has identical bearings with a slightly different shaft on the impeller end for the S and ST. The M/MT group is identical in all aspects for the power end. However, the liquid end of the MT is common with the S group except that the MT is modified to accept a larger shaft.
Product Description (Continued) Bearings The thrust bearing is a grease-lubed, double-row, angular contact ball bearing. The bearing is shouldered and locked to the shaft and housing. This enables the bearing to carry all of the thrust loads and some of the radial load. All fits are precision-machined to industry standards. The steady bearings are press fit sleeve bearings. Fits are designed for optimum life under all operating conditions.
Product Description (Continued) Table 1: Explanation of the nameplate Nameplate field MODEL Explanation Pump model SIZE Size of the pump S/N Serial number of the pump STD. DIM. Standard dimension HYDRO PRESS. PSI @ 100°F Hydrotest pressure in pounds per square inch at 100°F FLOW GPM Rated pump flow, in gallons per minute R.P.M. Rated pump speed, revolutions per minute MAX. .DES. WORKING PRESS., PSI @°F. Maximum design working pressure, pounds per square inch at °F HEAD FT.
Product Description (Continued) NOTICE: The code classification marked on the equipment must be in accordance with the specified area where you plan to install the equipment. If it is not, contact your ITT representative before you proceed.
Installation Installation Preinstallation Precautions WARNING: • When installing in a potentially explosive environment, make sure that the motor is properly certified. • You must earth (ground) all electrical equipment. This applies to the pump equipment, the driver, and any monitoring equipment. Test the earth (ground) lead to verify that it is connected correctly. NOTICE: Supervision by an authorized ITT representative is recommended to ensure proper installation.
Installation (Continued) Guideline Make sure that the space around the pump is sufficient. Explanation/comment This facilitates ventilation, inspection, maintenance, and service. If you require lifting equipment such as a hoist or This makes it easier to properly use the lifting tackle, make sure that there is enough space above equipment. the pump. Protect the unit from weather and water damage due to rain, flooding, and freezing temperatures. This is applicable if nothing else is specified.
Installation (Continued) • Located in accordance with the dimensions given in the example drawing • Enough space inside the pipe sleeves to allow the final position of the foundation bolts to align with the holes in the sub-base flange 1 2 3 4 5 6 1. 2. 3. 4. 5. 6. Hex nut Washer Support plate 0.5 in. (12.
Installation (Continued) Support plate type Tank flange Action Install the supplied gasket between the two flanges. Make sure that the mating flange on the tank is level. Use gasket material between the flanges in order to make minor adjustments. Figure 4: Layout for a standard support plate with the vapor-proof option 4. 5. Hand tighten the anchor bolts. Check the level and re-shim if necessary. Tighten all anchor bolts in a star pattern in order to avoid distorting the support plate.
Installation (Continued) Check Explanation/comment If the pump handles corrosive — fluids, make sure that the piping allows you to flush out the liquid before you remove the pump. Checked If the pump handles liquids at This helps to prevent misalignment due to linear elevated temperatures, make sure expansion of the piping. that the expansion loops and joints are properly installed. Make sure that all piping components, valves and fittings, and pump branches are clean prior to assembly.
Installation (Continued) Check For outside tank mount and dry pit applications, install an isolation valve in the suction line at least two pipe diameters from the suction. Explanation/comment This allows the line to be closed for pump inspection and maintenance. The isolation valve must be kept fully open during operation. Checked Make sure that the entrance to the suction This prevents vortices and air entrainment. pipe is kept adequately submerged below the free liquid surface.
Installation (Continued) Final piping checklist Check Check that the shaft rotates smoothly. Explanation/comment Rotate the shaft by hand. Make sure there is no rubbing that can lead to excess heat generation or sparks. Checked Re-check the alignment to make sure that If pipe strain exists, then correct the piping. pipe strain has not caused any misalignment. Stuffing box installation This pump is a seamless design.
Installation (Continued) Install the packed stuffing box The stuffing box is packed at the factory. The packing is lubricated by a grease cup supplied with the pump. 1. Fill the grease cup with any lithium-based #2 grease. 2. Install the grease cup on the tapped opening 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. Install the pump, driver, and coupling 1. 2. 3.
Installation (Continued) Types of alignment checks Type of check When it is used Initial alignment (cold alignment) Prior to operation when the pump and the driver are at ambient check temperature. Final alignment (hot alignment) check After operation when the pump and the driver are at operating temperature. Initial alignment (cold alignment) checks When Before you grout the baseplate Why This ensures that alignment can be accomplished.
Installation (Continued) This indicator is used to measure parallel misalignment. b) Attach the other indicator (A) so that the indicator rod comes into contact with the inner end of the driver coupling half. This indicator is used to measure angular misalignment. P A Y 2. 3. X Rotate the pump coupling half (X) in order to check that the indicators are in contact with the driver coupling half (Y) but do not bottom out. Adjust the indicators if necessary.
Installation (Continued) If the first pump fails to keep up with demand, or not come on at all, then a continued rise in the level turns both pumps on. Both pumps run until the low-water level is reached. If both pumps are unable to keep up with the demand, then an optional high-water alarm switch can be 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.
Installation (Continued) 1. 2. 3. 4. 5. 4 3 2 5 1 6. 7. Diameter of the coverplate (A) Radius (B) CL of the pump Radius of 7.0 in. (178.0 mm) 1.25 in. (31.8 mm) NPT float switch NTG column 0.38 in. (9.5 mm) NPT for the float rod guide 8 in. (203.0 mm) diameter of float (standard) 6 7 Figure 5: Location of the float, rod, and switch Number 1 2 3 1. 2. 3. 4. Coverplate diameter (A) 22 in. (559 mm) 26.50 in. (673 mm) 31.00 in. (787 mm) Radius (B) 14.50 in. (368 mm) 16.50 in. (419 mm) 18.50 in.
Commissioning, Startup, Operation, and Shutdown Commissioning, Startup, Operation, and Shutdown Preparation for startup WARNING: • Failure to follow these precautions before you start the pump will lead to serious personal injury and equipment failure. • Do NOT operate the pump below the minimum rated flows or with the suction or discharge valves closed. These conditions can create an explosive hazard due to vaporization of pumped fluid and can quickly lead to pump failure and physical injury.
Commissioning, Startup, Operation, and Shutdown (Continued) 5. 6. Make sure that everyone is clear, and then jog the driver long enough to determine that the direction of rotation corresponds to the arrow on the bearing housing or close-coupled frame. Lock out power to the driver. Thrust bearing lubrication WARNING: Make sure to properly lubricate the bearings. Failure to do so can result in excess heat generation, sparks, and premature failure.
Commissioning, Startup, Operation, and Shutdown (Continued) 197 Steady bearings 213 Housing, steady bearings 333H Lip seal 369 Retaining ring, steady bearing Lubricate the sealed bearings with grease cups For models with grease-lubricated bearings, the spring-operated automatic grease cups are designed to maintain constant lubrication of the intermediate pump bearings that are fixed to the vertical pump housing.
Commissioning, Startup, Operation, and Shutdown (Continued) NOTICE: • The mechanical seal must have an appropriate seal-flush system. Otherwise, excess heat generation and seal failure can occur. • Cooling systems such as those for bearing lubrication and mechanical-seal systems must be operating properly to prevent excess heat generation, sparks, and premature failure. • Sealing systems that are not self-purging or self-venting, such as plan 23, require manual venting prior to operation.
Commissioning, Startup, Operation, and Shutdown (Continued) Pump priming WARNING: These pumps are not self priming and must be fully primed at all times during operation. Loss of prime can lead to excessive heat and severe damage to the pump and seal. CAUTION: Do not run the pump dry, because this might damage the pump and/or the steady bearings. Never start the pump until it has been properly primed. Fully submerge the pump casing prior to starting the pump. For dry pit/outside tank mount units: 1.
Commissioning, Startup, Operation, and Shutdown (Continued) Start the pump CAUTION: • Immediately observe the pressure gauges. If discharge pressure is not quickly attained, stop the driver, reprime, and attempt to restart the pump. • Observe the pump for vibration levels, bearing temperature, and excessive noise. If normal levels are exceeded, shut down the pump and resolve the issue. 1. 2. 3. 4. 5. 6. 7. 8. Fully close or partially open the discharge valve, depending on system conditions.
Commissioning, Startup, Operation, and Shutdown (Continued) CAUTION: • Avoid excessive vibration levels. Excessive vibration levels can damage the bearings, stuffing box or seal chamber, and the mechanical seal, which can result in decreased performance. • Avoid increased radial load. Failure to do so can cause stress on the shaft and bearings. • Avoid heat build-up. Failure to do so can cause rotating parts to score or seize. • Avoid cavitation.
Maintenance Maintenance Maintenance schedule Maintenance inspections A maintenance schedule includes these types of inspections: • Routine maintenance • Routine inspections • Three-month inspections • Annual inspections Shorten the inspection intervals appropriately if the pumped fluid is abrasive or corrosive or if the environment is classified as potentially explosive. Routine maintenance Perform these tasks whenever you perform routine maintenance: • Lubricate the thrust bearings.
Maintenance (Continued) Thrust bearings The 3171 comes with a grease-lubricated duplex thrust bearing. The bearing is pre-lubricated at the factory. Regrease the bearing according to the schedule in the following table. Table 2: Lubricating intervals in operating hours Drive-unit size group S/ST Below 1800 RPM 1800 RPM 3000 RPM 3600 RPM 2,000 2,000 1,200 750 M/MT 2,000 1,800 800 450 L 2,000 1,200 - - Lubricate the bearings after a shutdown period 1. 2.
Maintenance (Continued) Regrease the thrust bearing NOTICE: Make sure that the grease container, the greasing device, and the fittings are clean. Failure to do this can result in impurities entering the bearing housing when you regrease the bearings. 1. 2. 3. 4. 5. 6. 7. Wipe dirt from the grease fittings. Remove the two grease-relief plugs from the bottom of the frame. Fill both of the grease cavities through the fittings with a recommended grease until the fresh grease comes out of the relief holes.
Maintenance (Continued) Before you start the pump Check the seal and all flush piping. If the pump is shipped 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. • Never attempt to replace the packing until the driver is properly locked out and the coupling spacer is removed.
Maintenance (Continued) Tools required In order to disassemble the pump, you need these tools: • Bearing puller • Brass drift punch • Cleaning agents and solvents • Dial indicators • Feeler gauges • Hydraulic press • Induction heater • Lifting sling • Micrometer • Rubber mallet • Screwdriver • Snap-ring pliers • Torque wrench with sockets • Wrenches Drain the pump CAUTION: • Allow all system and pump components to cool before you handle them to prevent physical injury. 1. 2. 3. 4. 5. 6. 7.
Maintenance (Continued) 501L 501 338 371L 240 2. 3. 4. 5. 6. 7. Place the sling on the motor lifting lugs and remove the motor. Remove the support plate anchor bolts. Attach the eyebolts to the support plate. Use properly-sized slings in order to lift the pump from the sump. Refer to the Installation chapter for the proper handling procedure. Lay the pump horizontally on proper supports where there is sufficient clearance to disassemble the pump.
Maintenance (Continued) Remove the impeller CAUTION: Wear heavy work gloves when you handle impellers. The sharp edges can cause physical injury. 1. 2. 3. Loosen the set screw at the end of the impeller nut. Loosen and remove the impeller nut. The impeller nut has left-hand threads. Pull the impeller from the shaft. Use a spanning-type puller if required. 100 101 178 199 198 122 4. 5. Remove the impeller key. Save the key for reassembly unless it is damaged.
Maintenance (Continued) 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 (213), and deflectors (123) one at a time.
Maintenance (Continued) 6. 7. 8. 9. Slide the bearing shell (134) off the bearing and shaft. Remove the locknut (136) and the lockwasher (382). Use a suitable bearing puller in order to remove the bearing (112). Make sure to save the bearing for inspection. 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.
Maintenance (Continued) Shaft surface check Check the shaft surface for damage, especially in areas indicated by the arrows in the following figure. Replace the shaft if it is damaged beyond reasonable repair. Bearings inspection Condition of bearings Do not reuse bearings. The condition of the bearings provides useful information on operating conditions in the bearing frame. Checklist Perform these checks when you inspect the bearings: • Inspect the bearings for contamination and damage.
Maintenance (Continued) Table 4: Thrust bearing fits Group S/ST Shaft OD 0.9848/0.9844 (25.0139/25.0038) Shell ID 2.4416/2.4409 (62.0166/61.9989) M/MT 1.5755/1.5749 (40.0177/40.0025) 3.5442/3.5433 (90.0227/89.9998) L 2.1660/2.1655 (55.0164/55.0037) 4.7253/4.7240 (120.0226/119.9896) Shaft runout tolerances The following shaft runout tolerances apply to all size groups: • Coupling end: 0.002 in. (0.051 mm) • Shaft body: 0.0005 in./ft. • Impeller end: 0.005 in. (0.
Maintenance (Continued) Assemble the rotating element CAUTION: Two people should handle any shaft over 9 feet long. Improper handling can bend the shaft. 370C 193B 134 382 112 M/MT/L Only 369A 136 332A 1. 2. 361A 370D 415 113 333 122 400 For all groups except S/ST, install the retaining ring (369A) on the shaft (122). Install the thrust bearing (112) on the shaft. There are several methods that you can use in order to install bearings.
Maintenance (Continued) 2. 3. A snap ring (369) is no longer required due to the fits. If your pump has a snap ring, then it is not necessary to reinstall it. However, the snap ring is still required on sealed bearings. Slide the casing assembly onto the shaft and seat the casing flange against the column flange. Make sure the discharge nozzle is aligned with the discharge pipe hole in the support plate. Install the bolts (371G). Assemble the impeller, suction cover, and strainer 1. 2. 3.
Troubleshooting Troubleshooting Operation troubleshooting Symptom Cause The pump is not delivering The pump is not primed. liquid. Remedy Make sure the pit is filled with liquid above the casing. On dry pit units, the casing and suction pipe must be completely filled. The discharge head it too high. Check the total head, particularly friction loss. The motor speed is too low. Check the motor speed. The suction line is clogged. Remove the obstructions.
Troubleshooting (Continued) Symptom The pump is noisy or vibrates. Cause Remedy 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. The foundation is not rigid. Tighten the hold-down bolts of the pump and motor. Make sure that the base plate is properly grouted without voids or air pockets.
Parts Listings and Cross-Sectional Drawings Parts Listings and Cross-Sectional Drawings Dimensional drawings 332A 136 382 338 337 232 235 233 361A 370D 415 333 193B 240 242 112 370C 113 134 358Z 189 122 370M 192 370L 132 195 Figure 6: 3171 exploded view (part 1 of 2) 50 Model 3171 Installation, Operation, and Maintenance Manual
Parts Listings and Cross-Sectional Drawings (Continued) 123 197 213 357X 306 543E 370G 123 197 528D 357V 100 155 101 178 351 182 187 317N 372B 370H 315 351A 358B 427G 536H 199 198 Figure 7: 3171 exploded view (part 2 of 2) Parts list Table 6: Parts list with materials of construction Item Quantity Part name Casing All iron Bronze Carbon CD4-fitted steel fitted 1000 1212 1216 1000 100 1 101 1 Impeller 1018 112 1 Thrust bearing Double row angular contact 122 1 Shaft 2205 123 1 Deflect
Parts Listings and Cross-Sectional Drawings (Continued) Item Quantity Part name 195 1 Discharge pipe All iron Bronze Carbon CD4-fitted steel fitted 6501 - 197 1 Steady bearings Carbon or as specified 198 1 Impeller screw 199 1 213 1 240 316SS Alloy 20 6506 Hast. B Hast.
Parts Listings and Cross-Sectional Drawings (Continued) Goulds code 2230 ASTM number B743 20CB3 Carpenter 20 2247 B335 Type B-2 Hastelloy B 2248 B574 C-276 Hastelloy C 2263 B335 B-2 Hastelloy B Ground and Polished 2264 B574 C-276 Hastelloy C Ground and Polished 3122 Aluminum 3201 A283 Grade D Carbon Steel Plate 3211 A240 316 Steel Plate 6501 A53 Type F Carbon Steel Schedule 40 Pipe 6506 B464 C20CB3 Carpenter 20 Schedule 40 Pipe 6511 Red Brass Pipe SPS 6519 B622 Hastelloy B Schedule 4
Parts Listings and Cross-Sectional Drawings (Continued) Cross-sectional diagrams S/ST and M/MT groups 232 371 235 338 233 240 370C 193B 112 370L 134 332A 370D 382 136 415 113 361A 369A 333 242 132 189 192 122 123 370M 190 372B 536E 357X 213 197 775E 306 123 370G 536G 357V 155 100 101 351 199 533 317N 54 190 197 195 315 370H 198 187 178 182 351A Model 3171 Installation, Operation, and Maintenance Manual
Parts Listings and Cross-Sectional Drawings (Continued) L group 338 240 332A 370D 371 232 235 136 415 113 134 193B 233 370C 382 193B 132 370N 189 361A 370L 370M 112 189D 369A 333 192 122 775E 123 372B 536E 357X 197 195 190 213 306 370G 108A 197 178 155 370 100 101 315 351 317N 199 187 198 182 427G 536H Model 3171 Installation, Operation, and Maintenance Manual 370H 571E 351A 55
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