Installation, Operation, and Maintenance Manual Model 3355
Table of Contents Table of Contents Introduction and Safety .......................................................................................................... Introduction ............................................................................................................................. Safety ...................................................................................................................................... Safety terminology and symbols ................................
Table of Contents Start the pump ...................................................................................................................... Pump operation precautions ................................................................................................. Shut down the pump ............................................................................................................. Make the final alignment of the pump and driver .........................................................
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.
Introduction and Safety Hazard levels Hazard level NOTICE: DANGER: Indication A hazardous situation which, if not avoided, will result in death or serious injury WARNING: A hazardous situation which, if not avoided, could result in death or serious injury CAUTION: A hazardous situation which, if not avoided, could result in minor or moderate injury • A potential situation which, if not avoided, could result in undesirable conditions • A practice not related to personal injury Hazard categories Haz
Introduction and Safety WARNING: Do NOT send the product to the ITT manufacturer if it has been contaminated by any nuclear radiation. Inform ITT so that accurate actions can take place. Electrical installation For electrical installation recycling requirements, consult your local electric utility. User safety General safety rules These safety rules apply: • Always keep the work area clean. • Pay attention to the risks presented by gas and vapors in the work area. • Avoid all electrical dangers.
Introduction and Safety Personnel requirements These are the personnel requirements for Ex-approved products in potentially explosive atmospheres: • All work on the product must be carried out by certified electricians and ITT-authorized mechanics. Special rules apply to installations in explosive atmospheres. • All users must know about the risks of electric current and the chemical and physical characteristics of the gas, the vapor, or both present in hazardous areas.
Introduction and Safety • Genuine ITT parts are used. • Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved products.
Transportation and Storage Transportation and Storage Inspect the delivery Inspect the package 1. Inspect the package for damaged or missing items upon delivery. 2. Note any damaged or missing items on the receipt and freight bill. 3. File a claim with the shipping company if anything is out of order. If the product has been picked up at a distributor, make a claim directly to the distributor. Inspect the unit 1. Remove packing materials from the product.
Transportation and Storage Lifting the pump Hoist a bare pump using suitable slings under the bearing housing saddle on each end. Figure 1: Example of the proper lifting method for a bare pump Figure 2: Example of the proper lifting method for a bare pump Baseplate-mounted units have lifting points for use with proper lifting devices.
Product Description Product Description General description The Goulds Model 3355 is a radially-split, segmented casing, multistage pump that is designed with modular interstage components. This pump is manufactured in cast iron and 316 stainless steel. This pump can be configured in two ways: • Radial suction (RS) configuration • End suction (ES) configuration Radial suction configuration This configuration features radial suction and discharge nozzles.
Product Description Part description Casing The pump consists of three pressure boundary parts: • Suction casing - available in an end suction (ES) or radial suction (RS) configuration The suction casing has 150 or 300 lb. flanges and the discharge casing has 300 or 600 lb. flanges.
Product Description Coupling guard Steel coupling guards are available and are designed to comply with OSHA requirements. Nameplate information Important information for ordering Every pump has a nameplate that provides information about the pump. The nameplate is located on the pump casing. When you order spare parts, identify this pump information: • Model • Size • Serial number • Item numbers of the required parts Refer to the nameplate on the pump casing for most of the information.
Product Description ATEX nameplate Nameplate field II 2 G/D T4 Explanation Group 2 Category 2 Pump can be used when gas and dust are present Temperature class Table 2: Temperature class definitions Code Maximum permissible surface temperature in °F (°C) T1 842 (450) T2 572 (300) T3 392 (200) T4 275 (135) T5 212 (100) T6 185 (85) Minimum permissible surface temperature in °F (°C) 700 (372) 530 (277) 350 (177) 235 (113) Option not available Option not available NOTICE: Make sure that the code classifica
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. • Electrical Connections must be made by certified electricians in compliance with all international, national, state, and local rules.
Installation • The foundation must weigh between two and three times the weight of the complete pump, baseplate, and drive assembly. • Provide a flat, substantial concrete foundation in order to prevent strain and distortion when you tighten the foundation bolts. • Sleeve-type and J-type foundation bolts are most commonly used. Both designs allow movement for the final bolt adjustment. Sleeve-type bolts 1. 2. 3. 4. 5. 6. Baseplate Shims or wedges Foundation Sleeve Dam Bolt 1. 2. 3. 4. 5.
Installation • Two sets of shims or wedges for each foundation bolt • Two machinist's levels • Baseplate-leveling worksheet 1. If you use sleeve-type bolts, fill the bolt sleeves with packing material or rags to prevent grout from entering the bolt holes. 2. Put the sets of wedges or shims on each side of each foundation bolt. Make sure that the wedges extend 0.75 in. (19 mm) to 1.5 in. (38 mm) above the foundation to provide adequate space for grouting.
Installation Types of alignment checks Type of check Initial alignment (cold alignment) check Final alignment (hot alignment) check When it is used Prior to operation when the pump and the driver are at ambient temperature. After operation when the pump and the driver are at operating temperature. Initial alignment (cold alignment) checks When Before you grout the baseplate After you grout the baseplate After you connect the piping Why This ensures that alignment can be accomplished.
Installation 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. 2. 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. 3. Adjust the indicators if necessary. Pump-to-driver alignment instructions Perform angular alignment for a vertical correction 1.
Installation When the reading value is... Negative Positive Then... The pump coupling half (X) is lower than the driver coupling half (Y). Remove shims of a thickness equal to half of the indicator reading value under each driver foot. The pump coupling half (X) is higher than the driver coupling half (Y). Add shims of a thickness equal to half of the indicator reading value to each driver foot. NOTICE: 4. Repeat the previous steps until the permitted reading value is achieved.
Installation 1. 2. 3. 4. Clean all the areas of the baseplate that will come into contact with the grout. Build a dam around the foundation. Thoroughly wet the foundation that will come into contact with the grout. Pour grout through the grout hole into the baseplate up to the level of the dam. When you pour the grout, remove air bubbles from it by using one of these methods: • Puddle with a vibrator. • Pump the grout into place. 5. Allow the grout to set. 1. 2. 3. 4. 5. 6. 7.
Installation General piping checklist Precautions CAUTION: • Never draw piping into place by using force at the flanged connections of the pump. This can impose dangerous strains on the unit and cause misalignment between the pump and driver. Pipe strain adversely affects the operation of the pump, which results in physical injury and damage to the equipment. • Vary the capacity with the regulating valve in the discharge line. Never throttle the flow from the suction side.
Installation Example: Piping installation with a vent line Suction-piping checklist Performance curve reference Net positive suction head available (NPSHA) must always exceed NPSH required (NPSHR) as shown on the published performance curve of the pump. Suction-piping checks Check Check that the distance between the inlet flange of the pump and the closest elbow is at least two pipe diameters. Check that elbows in general do not have sharp bends.
Installation Liquid source below the pump Check Explanation/comment Make sure that the suction piping This helps to prevent the occuris free from air pockets. rence of air and cavitation in the pump inlet. Check that the suction piping — slopes upwards from the liquid source to the pump inlet. If the pump is not self-priming, Use a foot valve with a diameter check that a device for priming the that is at least equivalent to the pump is installed. diameter of the suction piping.
Installation Check Re-check the alignment to make sure that pipe strain has not caused any misalignment. 24 Explanation/comment If pipe strain exists, then correct the piping.
Commissioning, Startup, Operation, and Shutdown Commissioning, Startup, Operation, and Shutdown Preparation for startup DANGER: Avoid death or serious injury. Explosion and/or seizure of pump can cause fire and/or burns. Never operate pump past the pressure and temperature limits shown on the nameplate on the pump. WARNING: • Any pressure-containing device can explode, rupture, or discharge its contents if it is overpressurized. Take all necessary measures to avoid over-pressurization.
Commissioning, Startup, Operation, and Shutdown • Bring variable-speed drivers to the rated speed as quickly as possible. • If temperatures of the pumped fluid will exceed 200°F (93°C), then warm up the pump prior to operation. Circulate a small amount of fluid through the pump until the casing temperature is within 100°F (38°C) 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).
Commissioning, Startup, Operation, and Shutdown Couple the pump and driver WARNING: • Always disconnect and lock out power to the driver before you perform any installation or maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical injury. • Electrical connections must be made by certified electricians in compliance with all international, national, state, and local rules.
Commissioning, Startup, Operation, and Shutdown 2. Put the pump-half of the coupling guard in place: a) Slightly spread the bottom apart. b) Place the coupling guard half over the pump-side end plate. 1. 2. 3. 4. Annular groove Pump-side end plate Driver Pump half of the coupling guard The annular groove in the coupling guard half must fit around the end plate. 1. Annular groove 2. End plate (pump end) 3. Guard half 3.
Commissioning, Startup, Operation, and Shutdown 1. Nut 2. Washer 3. Bolt 4. Put the driver half of the coupling guard in place: a) Slightly spread the bottom apart. b) Place the 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. 5. Place the driver-side end plate over the motor shaft. 6. Place the driver-side end plate in the annular groove of the driver-half of the coupling guard. 7.
Commissioning, Startup, Operation, and Shutdown 3. 4. 5. 6. Open the air vents in the seal covers. Open the valve in the outside supply line until only liquid escapes from the vent valves. Close the vent valves. Close the outside supply line. Other methods of priming the pump You can also use these methods in order to prime the pump: • Prime by ejector • Prime by automatic priming pump Start the pump WARNING:Immediately observe the pressure gauges.
Commissioning, Startup, Operation, and Shutdown Pump operation precautions General considerations CAUTION: • Vary the capacity with the regulating valve in the discharge line. Never throttle the flow from the suction side since this can result in decreased performance, unexpected heat generation, and equipment damage. Do not overload the driver. Driver overload can result in unexpected heat generation and equipment damage.
Commissioning, Startup, Operation, and Shutdown 2. Shut down and lock the driver to prevent accidental rotation. Make the final alignment of the pump and driver WARNING: • Always disconnect and lock out power to the driver before you perform any installation or maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical injury. • Electrical connections must be made by certified electricians in compliance with all international, national, state, and local rules.
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 bearings. • Inspect the seal.
Maintenance Bearing maintenance Ball bearing types Grease lubricated bearings Pump size Suction side, radial suction 1.5 x 2.5-7 2.5 x 4-8 4 x 5-10 5 x 6-11 6306-C3 6307-C3 6308-C3 6310-C3 Discharge side, radial and end suction 5306 A 5307 A C3 2x 7308 BECBM 2x 7310 BECBM Grease lubrication schedule Pump size 1.5 x 2.5-7 2.5 x 4-8 4 x 5-10 5 x 6-11 Grease quantity Suction side, Discharge in ounces side, in ounces 0.25 0.30 0.40 0.55 0.40 0.50 0.75 1.
Maintenance 4. Recheck the alignment. The bearing temperature usually rises after you regrease due to an excess supply of grease. Temperatures return to normal in about two to four operating hours as the pump runs and purges the excess grease from the bearings. Lubricate the bearings after a shutdown period 1. Flush out the bearings and bearing frame with a light oil to remove contaminants. During flushing, make sure to rotate the shaft slowly by hand. 2.
Maintenance Disassembly Disassembly precautions WARNING: • This manual clearly identifies accepted methods for disassembling units. These methods must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in their removal unless explicitly stated in this manual. • Always disconnect and lock out power to the driver before you perform any installation or maintenance tasks.
Maintenance Drain the pump CAUTION: • Allow all system and pump components to cool before you handle them to prevent physical injury. 1. Close the isolation valves on the suction and discharge sides of the pump. You must drain the system if no valves are installed. 2. Open the drain valve. Do not proceed until liquid stops coming out of the drain valve. If liquid continues to flow from the drain valve, the isolation valves are not sealing properly and you must repair them before you proceed. 3.
Maintenance NOTICE:Never re-use shaft nuts (136A). 9. Remove the ball bearings (409) with the bearing puller. 10. Check the shaft surface for damage. Grind away any furrows. Disassemble the pump body 1. 2. 3. 4. Loosen the nuts (357F) and remove the tie rod (356S). Remove the suction casing (100F) and remove the O-ring (412K). Loosen the impeller nuts (304) and remove the washer (199). Dismantle the impeller (101) and diffuser (150) and then remove the impeller key (178). Mark all parts for reassembly.
Maintenance Preassembly inspections Replacement guidelines Inspection Clean and check the condition of all parts that have been removed. In case of doubt, replace components. You must always replace wearing parts, such as ball bearings, and seals. Mechanical seal location Mechanical seals are located on the suction side for the (RS configuration and the discharge side for the RS and ES configurations.
Maintenance NOTICE:Standard O-rings made of EP rubber are not resistant to mineral oil or greases. 5. Slide on the shaft sleeve (104 and 126). When sliding on the shaft sleeve, make sure that the O-ring can slide easily into the groove. 6. Insert the O-ring (412H) in the casing and secure it with silicon grease. If possible, make sure that the O-ring is touching the outer diameter. You can pull the Oring in order to slightly enlarge it. 7. Carefully mount the seal cover (184).
Maintenance 2. Preheat the new bearing (112) to a maximum of 230°F (110°C) and slide it onto the shaft (122). 3. Tighten the new shaft nut (136A) while the bearing is still hot, then turn it back one quarter of a turn. 4. After the bearing cools down, pack the bearing completely with grease making sure that grease gets under the cage. When the pump is started the bearing will run hot for several minutes until the excess grease is purged. It will then return to a normal operating temperature.
Maintenance 2. Mount the intermediate bearing housing (134C) with the bearing bushing (197A) as for stage casing. 3. Mount the first stage of the pump and then secure the impeller (101) with a washer (199) and nuts (304). 4. Tighten the first nut (304) securely. 5. Turn the nut back a one-quarter turn and secure it with a counter nut. 6. Mount the suction casing (100F) with an O-ring (412K) and assemble the tie rod (356S) and nuts (357F) together slightly. 7.
Maintenance Assembly references Torque values Table 3: Maximum torque values, in ft-lbs (Nm) for 1.5 x 2.5-7 and 2.5 x 4-8 pumps Thread joint Tie bolt Screw 356S Bearing bracket 356A (228C) with suction casing (100F) or discharge casing (100D) Hexagonal nut Quality 357F 8.8 425 8.8 Pump size 1.5 x 2.
Maintenance Area D - Gap between the impeller and diffuser Pump size 1.5 x 2.5-7 2.5 x 4-8 4 x 5-10 5 x 6-11 Nominal diameter 3.346 4.134 5.315 6.693 Gap "new" (inches) All iron and stainless fitted Minimum Maximum 0.006 0.008 0.006 0.008 0.006 0.008 0.006 0.008 Stainless steel Minimum 0.012 0.012 0.012 0.012 Maximum permissible gap Maximum 0.014 0.014 0.014 0.014 0.020 0.020 0.020 0.020 Area E - Gap between the shaft and discharge casing Pump size 1.5 x 2.5-7 2.
Maintenance Radial suction End suction Maximum allowable nozzle loads Nozzle loads for the suction flange and discharge flange are separate. Do not exceed the stated permissible forces and moments. Nozzle configurati on Vertical nozzle perpendicular to the shaft (RS) Horizontal nozzle perpen dicular to the shaft (RS) Horizontal nozzle parallel to the shaft (ES) Flange size (in) Forces in lbf (N) Fx Fy Fz ΣF Moments in ft-lbs (Nm) Mx My Mz ΣM 1.5 2.5 4 5 6 1.5 2.5 4 5 6 2.
Maintenance Recommended minimum flows CAUTION: The recommended minimum flow is intended for brief periodic operation. It is not to be used as a design point. Extended operation at the minimum flow can cause pump damage. Pump Size 60 hertz 3600 rpm QMIN operation (gpm) 1.5 x 2.5-7A 33 1.5 x 2.5-7B 33 2.5 x 4- 8A 53 2.
Maintenance End suction Model 3355 Installation, Operation, and Maintenance Manual 47
Troubleshooting Troubleshooting Alignment troubleshooting Symptom Cause Horizontal (side-to-side) alignment cannot The driver feet are bolt-bound. be obtained (angular or parallel). Remedy Loosen the pump's hold-down bolts, and slide the pump and driver until you achieve horizontal alignment. The baseplate is not leveled properly and 1. is probably twisted. 2. 3. Vertical (top-to-bottom) alignment cannot The baseplate is not leveled properly and 1. be obtained (angular or parallel). is probably bowed. 2.
Troubleshooting Symptom Cause The flow rate stops after a period of time. The pump or suction/intake pipe is blocked. The NPSH is too low. The head is too low. The head is too high. Remedy Clean the pipes. Increase the liquid level. Increase the suction pressure. Reduce the resistance in the intake/suction pipe. Change the course and pipe size, open the shutoff valves, and clean the filters. Air is being sucked into the pipes. Increase the liquid level. Check that the suction pipe is vacuumtight.
Troubleshooting Symptom The drive mechanism is overloaded Cause The back pressure and discharge pressure are too low. The speed is too high. The impeller diameter is too large. The density and/or viscosity of the pumped liquid is too high. The shaft seal is worn. The pump is not running quietly. The pump casing becomes warm during operation. 50 Remedy Throttle the discharge valve. Reduce the speed. Compare the speed of the motor with the specified pump speed. See the rating plate.
Troubleshooting Symptom Cause The temperature in the shaft sealing area The shaft seal is worn. is too high. There are lines and rough spots on the shaft or shaft sleeve. There are deposits on the mechanical seal. The temperature at the bearing is too high. The coupling is not aligned. The back pressure is too high. The back pressure and the discharge pressure are too low. The speed is too high. The pump is leaking. Remedy Replace the mechanical seal.
Troubleshooting Symptom There are leaks at the shaft seal. 52 Cause The shaft seal is worn. Remedy Replace the mechanical seal. Check the sealing, flushing, and cooling pipes (pressure). Do not run the pump dry. There are deposits on the mechanical Clean the mechanical seal. seal. Replace the mechanical seal if necessary. Provide additional rinsing or quench if necessary. The impeller is out of balance. Remove any blocks or deposits. Replace the impeller is it is broken or unevenly worn.
Parts Listings and Cross-sectional Drawings Parts Listings and Cross-sectional Drawings Recommended spare parts Select spare parts that will last for two years of continuous operation. If no other guidelines are applicable, stock the number of parts listed in this table.
Parts Listings and Cross-sectional Drawings Radial suction all-iron cross-sectional 54 Model 3355 Installation, Operation, and Maintenance Manual
Parts Listings and Cross-sectional Drawings Radial suction all iron with stainless steel impeller cross sectional Model 3355 Installation, Operation, and Maintenance Manual 55
Parts Listings and Cross-sectional Drawings Radial suction stainless steel cross-sectional 56 Model 3355 Installation, Operation, and Maintenance Manual
Parts Listings and Cross-sectional Drawings End-suction all-iron cross-sectional Model 3355 Installation, Operation, and Maintenance Manual 57
Parts Listings and Cross-sectional Drawings End-suction all-iron with stainless steel impeller cross-sectional 58 Model 3355 Installation, Operation, and Maintenance Manual
Parts Listings and Cross-sectional Drawings End-suction stainless steel cross-sectional Model 3355 Installation, Operation, and Maintenance Manual 59
Parts Listings and Cross-sectional Drawings Radial suction (counterclockwise rotation) all-iron cross-sectional 60 Model 3355 Installation, Operation, and Maintenance Manual
Parts Listings and Cross-sectional Drawings Radial suction (counterclockwise rotation) all-iron with stainless steel impeller cross-sectional Model 3355 Installation, Operation, and Maintenance Manual 61
Parts Listings and Cross-sectional Drawings Radial suction (counterclockwise rotation) stainless steel crosssectional 62 Model 3355 Installation, Operation, and Maintenance Manual
Visit our website for the latest version of this document and more information: http://www.gouldspumps.com Goulds Pumps 240 Fall Street Seneca Falls, NY USA Tel. 1-800-446-8537 Fax (315) 568-2418 © 2010 ITT Corporation The original instruction is in English. All non-English instructions are translations of the original instruction. Form en-US.2013-07.IOM.
