Installation, Operation and Maintenance Instructions Model 3410
FOREWORD This manual provides instructions for the Installation, Operation, and Maintenance of the Goulds Model 3410 Double Suction, Horizontally Split Case Pump. This manual covers the standard product plus common options that are available. For special options, supplemental instructions are supplied. This manual must be read and understood before installation and start-up.
TABLE OF CONTENTS PAGE SECTION S1-S8 SAFETY 11 GENERAL INFORMATION 2 15 INSTALLATION 3 25 OPERATION 4 37 PREVENTIVE MAINTENANCE 5 43 DISASSEMBLY & REASSEMBLY 6 51 SPARE AND REPAIR PARTS 7 3410 IOM 1/2010 5
6 3410 IOM 1/2010
Industrial Process Pump Safety Manual IMPORTANT SAFETY NOTICE To: Our Valued Customers User safety is a major focus in the design of our products. Following the precautions outlined in this manual will minimize your risk of injury. ITT Goulds pumps will provide safe, trouble-free service when properly installed, maintained, and operated. Safe installation, operation, and maintenance of ITT Goulds Pumps equipment are an essential end user responsibility.
SAFETY WARNINGS Specific to pumping equipment, significant risks bear reinforcement above and beyond normal safety precautions. WARNING A pump is a pressure vessel with rotating parts that can be hazardous. Any pressure vessel can explode, rupture, or discharge its contents if sufficiently over pressurized causing death, personal injury, property damage, and/or damage to the environment. All necessary measures must be taken to ensure over pressurization does not occur.
SAFETY DEFINITIONS Throughout this manual the words WARNING, CAUTION, ELECTRICAL, and ATEX are used to indicate where special operator attention is required. Observe all Cautions and Warnings highlighted in this Pump Safety Manual and the IOM provided with your equipment. WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Example: Pump shall never be operated without coupling guard installed correctly.
GENERAL PRECAUTIONS WARNING A pump is a pressure vessel with rotating parts that can be hazardous. Hazardous fluids may be contained by the pump including high temperature, flammable, acidic, caustic, explosive, and other risks. Operators and maintenance personnel must realize this and follow safety measures. Personal injuries will result if procedures outlined in this manual are not followed.
General Precautions WARNING WARNING CAUTION Alignment: Shaft alignment procedures must be followed to prevent catastrophic failure of drive components or unintended contact of rotating parts. Follow coupling manufacturer’s coupling installation and operation procedures. Before beginning any alignment procedure, make sure driver power is locked out. Failure to lock out driver power will result in serious physical injury.
General Precautions CAUTION Never attempt to replace packing until the driver is properly locked out and the coupling spacer is removed. WARNING WARNING WARNING Never operate the pump without liquid supplied to mechanical seal. Running a mechanical seal dry, even for a few seconds, can cause seal damage and must be avoided. Physical injury can occur if mechanical seal fails. WARNING WARNING Dynamic seals are not allowed in an ATEX classified environment.
ATEX CONSIDERATIONS and INTENDED USE Special care must be taken in potentially explosive environments to ensure that the equipment is properly maintained. This includes but is not limited to: 1. 2. 3. Monitoring the pump frame and liquid end temperature. Maintaining proper bearing lubrication. Ensuring that the pump is operated in the intended hydraulic range. The ATEX conformance is only applicable when the pump unit is operated within its intended use.
PARTS The use of genuine Goulds parts will provide the safest and most reliable operation of your pump. ITT Goulds Pumps ISO certification and quality control procedures ensure the parts are manufactured to the highest quality and safety levels. Please contact your local Goulds representative for details on genuine Goulds parts.
GENERAL INFORMATION PUMP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 NAMEPLATE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 PUMP DESCRIPTION PUMP SERVICES The Goulds 3410 model line is designed for a wide range of Industrial, Municipal, and Marine Services to include: • Process – Quench Water, Stripper Bottoms, Reboiler Circulation, and Cooling Tower. 2 Vertical Application.
DOUBLE VOLUTE CASINGS 4x6-11 8x10-21 4x6-11H 10x12-12 6x8-11 10x12-12H* 8x10-12 10x12-14 8x10-14 10x12-17 8x10-17 10x12-15 8x10-17H 12x14-14 12x14-15 *Casing uses a partial splitter. 125# flat face flanges are standard with 250# flat face available as an option. The casings are standard with two jack screws (except S group), two lifting lugs, two tapered dowel pins for alignment, and a 0.030 inch (.0762 cm) parting gasket.
NAMEPLATE INFORMATION Every pump has a Goulds nameplate that provides information about the pump. The tags are located on the pump casing. Description Fig. No. Pump Casing Tag - provides information about the pump’s hydraulic characteristics. Note the format of the pump size: Discharge x Suction - Nominal maximum Impeller Diameter in inches. (Example: 2x3-11) (Fig. 2). Fig. 2 ATEX Tag - If applicable, your pump unit may have the following ATEX tag affixed to the pump and/or baseplate.
14 3410 IOM 1/2010
INSTALLATION RECEIVING THE PUMP . . . . . . . . Storage Requirements . . . . . . . . Lifting the Pump . . . . . . . . . . . Horizontal . . . . . . . . . . . . . . Vertical . . . . . . . . . . . . . . . . STORAGE . . . . . . . . . . . . . . . . . Temporary . . . . . . . . . . . . . . Long Term . . . . . . . . . . . . . . LOCATION . . . . . . . . . . . . . . . . FOUNDATION . . . . . . . . . . . . . . SETTING THE BASEPLATE . . . . . . Grouting Procedure. . . . . . . . . . ALIGNMENT . . . . . . . . . . . . . .
LIFTING THE PUMP ! s Bases supplied with lifting holes Large bases are supplied with lifting holes in the sides or the ends of the base. (See Fig. 5) WARNING Pump and components are heavy. Failure to properly lift and support the equipment could result in serious physical injury, or damage to the pump(s). Steel-toed shoes must be worn at all times. The following instructions are for the safe lifting of your pump.
VERTICAL Full Pedestal Half Pedestal 2. 1. Place nylon sling chain or wire rope around both flanges. Use a latch hook or standard shackle and end loops. Be sure the lifting equipment is of sufficient length to keep the lift angle less than 30° from the vertical. (See Fig. 7) Install eyebolts in the three holes provided at the top of the support, being sure to tighten securely. Attach chain or wire rope using latch hook or standard shackle and end loop.
LOCATION ! All equipment being installed must be properly grounded to prevent unexpected static electric discharge. The pump should be installed as near the suction supply as possible, with the shortest and most direct suction pipe practical. The total dynamic suction lift (static lift plus friction losses in suction line) should not exceed the limits for which the pump was sold. The pump must be primed before starting.
NOTE: The baseplate does not have to be level. After foundation bolts are lightly torqued, recheck alignment requirements once more. Follow requirements outlined at the beginning of this section. If alignment must be corrected, add or remove shims or wedges under the baseplate. The unit can then be grouted. (See Fig. 10) Grout compensates for the uneven foundation.
ALIGNMENT ! Alignment procedures must be followed to prevent unintended contact of rotating parts. Follow coupling manufacturer’s installation and operation procedures. ! BA s WARNING Before beginning any alignment procedure, make sure driver power is locked out. Failure to lock out driver power may result in serious physical injury. Alignment is achieved by adding or removing shims from under the feet of the driver and shifting equipment horizontally as needed.
Fig. 10 3 Fig. 11 Method 2 - Dial Indicators (Fig. 12): A dial indicator can be used to attain more accurate alignment. Fasten the indicator stand or magnetic base to the pump half of the coupling and adjust the assembly until the indicator button is resting on the other half coupling periphery. Set the dial to zero and chalk mark the coupling half where the button rests. Also place a separator between the coupling halves so bearing slack does not affect the readings.
DOWELING Pump units may, if desired, (or required in specification) be doweled on diagonally opposite feet. This should not be done until the unit has been run for a sufficient length of time and alignment is within the above alignment tolerance. SUCTION AND DISCHARGE PIPING ! Do not “spring” piping when making any connections. Flange loads from the piping system, including those from thermal expansion of the piping, must not exceed the limits of the pump.
When operating on a suction lift, the suction pipe should slope upward to the pump nozzle. A horizontal suction line must have a gradual rise to the pump. Any high point in the pipe can become filled with air and prevent proper operation of the pump. When reducing the piping to the suction opening diameter, use an eccentric reducer with the eccentric side down to avoid air pockets.
DISCHARGE PIPING If the discharge piping is short, the pipe diameter can be the same as the discharge opening. If the piping is long, the pipe diameter should be one or two sizes larger than the discharge opening. On long horizontal runs, it is desirable to maintain as even a grade as possible. Avoid high spots, such as loops, which will collect air and throttle the system or lead to erratic pumping. A check valve and an isolating gate valve should be installed in the discharge line.
OPERATION PREPARATION FOR STARTUP . . . . . . Checking Rotation . . . . . . . . . . . . . . Couple Pump and Driver . . . . . . . . . . Lubricating Bearings . . . . . . . . . . . . Shaft Sealing Packing . . . . . . . . . . . . Connection of Sealing Liquid (Packed Box) Mechanical Seal Flushing/Cooling Piping . Connection of Drain Piping . . . . . . . . . Priming the Pump . . . . . . . . . . . . . . STARTING THE PUMP . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . SHUTDOWN . . . . . . . . .
LUBRICATING BEARINGS must be lubricated properly in order to ! Bearings prevent excess heat generation, sparks and premature failure. ! Do not insulate bearing housings as this can result in excess heat generation, sparks and premature failure. Grease Lubrication (Standard). Grease lubricated pumps can be identified by grease fittings located on bearing housing. Sufficient lubricant is inserted at factory for 2,000 hours of operation. See Preventive Maintenance for grease lubrication instructions.
SHAFT SEALING PACKING Packing stuffing boxes are not allowed in an ATEX ! Packed classified environment. 1. Before packing stuffing box, make sure box is clean and contains no foreign material. 2. Install gland studs into the casing if not already installed. 3. Stuffing box packing furnished in box of fittings which accompanies pump. When packing stuffing box arrangement of packing and lantern rings is: two packing rings, lantern ring; then last three packing rings, as shown in Fig. 16. Fig. 18 6.
Mechanical Seals mechanical seal used in an ATEX classified ! The environment must be properly certified. When mechanical seals are furnished, description and identification is indicated on order write-ups. Separate seal manufacturer’s installation drawings are attached to pump. Most seals are installed and adjusted at the factory. Manufacturer’s drawings should be filed for future use in maintaining seal and in adjusting seal when pump is disassembled.
CONNECTION OF SEALING LIQUID (PACKED BOX) General If stuffing box pressure is above atmospheric pressure and pumpage is clean, normal gland leakage of 40 to 60 drops per minute is usually sufficient to lubricate and cool packing and sealing liquid is not required. Clean sealing liquid is required when: Fig. 25 • Figure 24 shows a single inside unbalanced mechanical seal mounted in the S group standard stuffing box.
MECHANICAL SEAL FLUSHING/ COOLING PIPING ! The mechanical seal must have an appropriate seal flush system. Failure to do so will result in excess heat generation and seal failure. systems that are not self purging or self ! Sealing venting, such as plan 23, require manual venting prior to operation. Failure to do so will result in PRIMING THE PUMP must be fully primed at all times during ! Pumps operation.
idle will permit pump to lose its time. During long idle periods, pump can also lose its prime through leakage from stuffing boxes. 3. Bypassing Around Discharge Check Valve (Fig. 30). This method can be used only when there is liquid under some pressure in discharge line. The original prime must be affected from some outside source. After subsequent idle periods, open air vents and open valve in bypass line around discharge check and gate valves until liquid flows air vent openings.
Fig. 31 Fig. 32 Priming by Automatic Primer Pump Where there is a fluctuating suction lift that occasionally might drop below normal limits of pump, or for installations where there is any quantity of air entrained in pumpage, system shown in Fig. 32 is very well adapted. 32 A vacuum tank and a vacuum gauge can be installed near primer pump and vacuum switch set to automatically start or stop primer pump according to vacuum required to keep system primed.
STARTING THE PUMP 1. Make sure suction valve and any recirculation or cooling lines are open. 2. Fully close or partially open discharge valve as dictated by system conditions. 3. Start Driver. $! 4. Slowly open discharge valve until the desired flow is obtained. $! CAUTION Observe pump for vibration levels, bearing temperature and excessive noise. If normal levels are exceeded, shut down and resolve. CAUTION Immediately observe pressure gauges.
INITIAL INSPECTION AFTER STARTING Packed Box With pump running at rated speed, stuffing box gland can be adjusted. Draw gland nuts up evenly and only 1/6 of a turn at a time, allowing sufficient time between adjustments for packing to adjust itself and effect on leakage to be observed. If any sign of heating is evident, shut down the pump and allow the box to cool. Several starts may be necessary before box runs cool.
PREVENTIVE MAINTENANCE GENERAL MAINTENANCE AND PERIODIC INSPECTION . MAINTENANCE TIMETABLE . . . . . . . . . . . . . . . . . . MAINTENANCE OF FLOOD DAMAGED PUMPS . . . . . . . LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . Grease Lubrication . . . . . . . . . . . . . . . . . . . . . . . . Oil Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricant Recommendations . . . . . . . . . . . . . . . . . . . Initial Oil Lubrication of New Bearings. . . . . . . . . . . . . .
EVERY 6 MONTHS Check the packing and replace if necessary. Use the grade recommended. Be sure the seal cages are centered in the stuffing box at the entrance of the stuffing box piping connection. Take vibration readings on the bearing housings. Compare the readings with the last set of readings to check for possible pump component failure (e.g. bearings). Check shaft or shaft sleeve for scoring. Scoring accelerates packing wear. Check alignment of pump and driver. Shim up units if necessary.
LUBRICATION ! Throughout this section on bearing lubrication, different pumpage temperatures are listed. If the equipment is ATEX certified and the listed temperature exceeds the applicable value shown in Table 1 under SAFETY, then that temperature is not valid. Should this situation occur, please consult with your ITT/Goulds representative. GREASE LUBRICATION Grease lubricated ball bearings are standard on all Model 3410 pumps.
BEARING TEMPERATURES All bearings operate at some temperature above that of the surrounding atmosphere, unless cooled. Heat is generated within the bearing due to rolling friction, churning of oil, and the drag of the race. Do not use the human hand as a thermometer. A temperature which feels hot varies from 120°F (49°C) to 130°F (54°C) depending upon the individual. Above this temperature, the human hand is worthless in estimating temperature. Fig. 34 INITIAL OIL LUBRICATION OF NEW BEARINGS 1.
2. 3. Blow dry with clean, filtered compressed air. Hold the two races together, but allow the inner race to rotate a few turns now and then to dislodge the kerosene from the retainer pockets. When bearing has been blown dry, oil immediately with a good grade of clean machine oil to prevent corrosion or rust. If there is any question as to the condition of bearings, it is always best to replace them. This may prevent an unplanned shutdown. Check bearing housing seals and replace as required.
TROUBLESHOOTING INTRODUCTION The troubleshooting table lists common malfunctions, which you may find during the operation or maintenance of the Model 3410. You should perform tests/inspections and corrective actions in the order listed. Use the following symptom index to locate troubleshooting procedures. 1. The Symptom column identifies the most common malfunctions. 2.
Troubleshooting Table Key Cause Corrective Measures 1 Pump not primed or properly vented. Check that casing and suction pipe are completely filled with liquid. 2 Speed too low. Check whether motor wiring is correct and receives full voltage or turbine receives full steam pressure. 3 System head too high Check system head (particularly friction losses). 4 Suction lift too high. Check NPSH Available (suction piping too small or long may cause excessive friction losses).
Troubleshooting Table Key 42 Cause Corrective Measures 24 Stuffing box not properly packed (insufficient packing, not properly inserted or run in, packing too tight). Check packing and repack stuffing box. 25 Incorrect packing or mechanical seal. Consult the factory. 26 Damaged mechanical seal. Inspect and replace as required. Consult factory. 27 Shaft sleeve scored. Remachine or replace as required. 28 Cavitation. Increase NPSH Available. Consult factory. 29 Pump capacity too low.
DISASSEMBLY & REASSEMBLY DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 of process liquid may result in creating an explosive atmosphere. Follow all pump and seal assembly ! Leakage procedures. DISASSEMBLY ! s Pump components can be heavy.
NOTE: Refer to Fig. 38 and 39 at the end of this chapter for illustrated detail of the following procedures. ! s WARNING Never attempt to lift entire pump using lifting lugs. 9. Remove upper casing using sling and hoist or lift and lifting lugs. Remove and discard gaskets. prevent damage to lapped seal faces. If unit has packed stuffing boxes, remove nuts (355), gland (107), packing (106), lantern rings (105), and stuffing box bushings (125). 15. Slide casing wear ring (103) off impeller and shaft. 16.
INSPECTION O-RINGS Table 5 RADIAL CLEARANCE Inspect O-rings (497) and replace if damaged (M, L, XL Groups only). WEAR RINGS The original radial clearance between the impeller and the casing wear rings is shown in Fig. 37 and Table 5. When hydraulic performance is reduced substantially, the casing rings should be replaced. Group Pump Iron & Bronze Steel 2x3-11 3x4-10 4x6-9 S 4x6-11 .005 - .007" .009 - .011" (.013 - .018 mm) (.022 - .
IMPELLER WEAR RINGS (OPTIONAL) If the unit has impeller wear rings (142) and it is necessary to replace rings (Fig. 38), proceed as follows: NOTE: If impeller was supplied without wear rings and excessive wear requires, wear rings may be fitted in the field. Fitting wear rings will require remachining of impeller. Contact your local Goulds representative for details. 1. Remove old rings by removing three set screws (320) and pulling ring (142) off impeller hub. 2. Clean hub and press on new ring (142).
REASSEMBLY for magnetism on the pump shaft and degauss ! Check the shaft if there is any detectable magnetism. Magnetism will attract ferritic objects to the impeller, seal and bearings which can result in excess heat generation, sparks and premature failure. • Insert key (178) in shaft (122). • Determine correct positioning of impeller (101) on shaft (122). Facing coupling end of shaft, determine proper rotation of unit (clockwise or counterclockwise). Fig.
! 2. Using the same pattern, increase torque to: The impeller and wear ring clearance setting procedures must be followed. Improperly setting the clearance or not following any of the proper procedures can result in sparks, unexpected heat generation and equipment damage. c. Ensure stuffing box bushings (125) are aligned properly in stuffing boxes. • To torque bearing housing to lower casing on each side for all 3410 models, proceed as follows: a. Install and tighten screws (372U) until snug. b.
3410 EXPLODED VIEW 6 Fig.
3410 RETAINING RING CONFIGURATION Fig.
SPARE PARTS SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 ORDERING SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 PARTS LIST AND MATERIALS OF CONSTRUCTION . . . . . . . . . . . . . 54 SPARE PARTS To insure against possible long and costly downtime period, especially on critical services, it is advisable to have spare parts on hand.
PARTS LIST AND MATERIALS OF CONSTRUCTION Item Qty per Pump 101 102 103 105 1 Upper 1 Lower 1 2 2 2 106 1 set 107 109 109A 112 113 113A 122 123 124 125 126 134 142 168 178 222B 2 2 1 1 2 2 1 1 1 2 2 2 2 1 1 4 100 2 250 2 251 2 317 317A 2 1 320 6 332 1 332A 1 333 2 333A 1 351 353 1 4 353B 2 355 356A 4 4 4 360 2 360Q 361 8 1 361H 2 371C 372U 418 425 8 4 2 4 52 Part Name Bronze Fitted All Iron Casing 1003 1003 Impeller Seal Tubing (optional) Wear Ring, Casing Lantern
PARTS LIST AND MATERIALS OF CONSTRUCTION Item Qty per Pump 426 var. 428 2 445A 2 469G 494 2 2 497 2 Part Name Hex Cap Screw, Parting Gasket, Sleeve to Impeller (M, L, and XL only) Anti-Rotation Pin, Casing Wear Ring Tapered Pin W/Hex Nut Cooling Assembly (Optional) O-Ring - Sleeve Nut (M, L, and XL only) Bronze Fitted All Iron Iron / 316 Rot. El.
HOW TO ORDER When ordering parts call 1-800-446-8537, or your local Goulds Pumps Representative EMERGENCY SERVICE Emergency Parts Service is available 24 hours / day, 365 days / year ... Call 1-800-446-8537 Visit our Web site at www.gouldspumps.
