Installation, Operation, and Maintenance Instructions Model 3501 Mixer
FOREWORD This manual provides instructions for the Installation, Operation, and Maintenance of the Goulds Model 3501 Optimix™ Medium Consistency Mixer. 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. The design, materials, and workmanship incorporated in the construction of Goulds mixers makes them capable of giving trouble-free service.
TABLE OF CONTENTS PAGE SECTION 7 SAFETY 1 9 GENERAL INFORMATION 2 13 INSTALLATION 3 21 OPERATION 4 25 PREVENTIVE MAINTENANCE 5 31 DISASSEMBLY & REASSEMBLY 6 41 SPARE PARTS 7 3501 IOM 11/10 5
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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 MIXER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 NAMEPLATE INFORMATION . . . . . . . . . . . . . . . . . . . . . 10 RECEIVING THE MIXER . . . . . . . . . . . . . . . . . . . . . . . . 11 MIXER DESCRIPTION Casing - Casings are side suction, side discharge, back pull-out designs, utilizing a spacer coupling to allow for one craft maintenance. The alignment fit is protected from the pumpage with a confined gasket between the casing and the seal chamber cover.
NAMEPLATE INFORMATION Every mixer has two Goulds nameplates that provide information about the mixer. The tags are located on the casing and bearing frame. When ordering spare parts you will need to identify the mixer model, size, serial number, and the number of required parts. Mixer Casing Tag - provides information about the mixer’s hydraulic characteristics (Fig. 1 or 2). Bearing Frame Tag - provides recommended type of lubrication the mixer should use (Fig. 3). Fig. 1 (English) Fig. 2 (Metric) Fig.
RECEIVING THE MIXER Inspect the mixer as soon as it is received. Carefully check that everything is in good order. Make notes of damaged or missing items on the receipt and freight bill. File any claims with the transportation company as soon as possible. Storage Requirements Short Term: (Less than 6 months): Goulds normal packaging procedure is designed to protect the mixer during shipping. Upon receipt store in a covered and dry location. 2 Long Term: (More than 6 months): Requires special precautions.
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INSTALLATION SITE/FOUNDATION . . . . . . . . . . . . . . . . . LEVEL BASEPLATE . . . . . . . . . . . . . . . . ALIGNMENT AND ALIGNMENT PROCEDURE Alignment Checks . . . . . . . . . . . . . . . . . Alignment Criteria . . . . . . . . . . . . . . . . . Set Up. . . . . . . . . . . . . . . . . . . . . . . . Measurement . . . . . . . . . . . . . . . . . . . . Angular Alignment . . . . . . . . . . . . . . . . . Parallel Alignment . . . . . . . . . . . . . . . . . Complete Alignment . . . . . . . . . . . . . . . .
LEVEL BASEPLATE 1. 2. Place two sets of wedges or shims on the foundation, one set on each side of every foundation bolt. The wedges should extend 20 mm (.75 in.) to 40 mm (1.5 in.) above foundation, to allow for adequate grouting. This will provide even support for the baseplate once it is grouted (Fig. 9 and Fig. 10). 3. Carefully lower baseplate onto foundation bolts. 4. Level baseplate to within 3.2 mm (.125in.) over length of the baseplate and to within 1.5 mm (.060 in.
2. ALIGNMENT CRITERIA Good alignment is achieved when the dial indicator readings as specified in the alignment procedure are .05 mm (.002 in.) Total Indicated Reading (T.I.R.) or less when the mixer and driver are at operating temperature (Final Alignment). During the installation phase, however, it is necessary to set the parallel alignment in the vertical direction to a different criteria due to differences in expansion rates of the mixer and driver.
Positive Reading - The coupling halves are closer together on the right side than the left. Correct by either sliding the shaft end of the driver to the right or the other end to the left (Fig. 13). NOTE: Equal amounts of shims must be added to or removed from each driver foot. Otherwise the vertical angular alignment will be affected. 4. Repeat steps 1 through 3 until indicator P reads within .05 mm (.002 in.) or less when hot, or per Table 1 when cold. Horizontal Correction (Side-to-Side) 1.
Horizontal Correction (Side-to-Side) 1. Zero indicators A and P on the left side of coupling half Y, 90° from top dead center (9 o’clock). 2. 3. Make corrections as outlined previously. 4. Recheck both vertical and horizontal readings to ensure adjustment of one did not disturb the other. Correct as necessary. Rotate indicators through top dead center to the right side, 180° from the start (3 o’clock). Observe the needle, measure and record the reading.
PIPING GENERAL ! p INLET PIPING WARNING Never draw piping into place by forcing at the flanged connections of the mixer. This may impose dangerous strains on the unit and cause misalignment between mixer and driver. Pipe strain will adversely effect the operation of the mixer resulting in physical injury and damage to the equipment. ! p Properly installed inlet piping is a necessity for trouble-free mixer operation. Inlet piping should be flushed BEFORE connection to the mixer. 1.
Chemical Injection Pipe Valves · Control valve is typically before the mixer. · If additional back pressure is required, the control valve may be after the mixer. · Shut off valves should be after the mixer. GAS MIXING Pipe · · · · · Gas addition should always be added in the chemical addition point of the chemical injection pipe supplied with the mixer. If flow velocity is higher than 9 ft/s, special 8° increasers are required after the mixer.
NOTE: The foundation pads are supplied by the customer. They are to be 16-20 micro-inch surface finish 316 stainless steel plate. 7. Level the baseplate while making final height adjustments. Adjust the baseplate height by loosening the top jam nut and adjusting nut. Change the height by moving the lower adjusting nut. When the baseplate is level, tighten the top adjusting nuts just enough to make sure the top springs are not loose in their followers and then snug the lower and upper jam nuts.
OPERATION PREPARATION FOR START-UP . . Check Rotation . . . . . . . . . . . . Check Rotor Axial Clearance . . . . Couple Mixer and Driver . . . . . . . Lubricating Bearings . . . . . . . . . Shaft Sealing . . . . . . . . . . . . . STARTING MIXER . . . . . . . . . . OPERATION . . . . . . . . . . . . . . General Considerations. . . . . . . . Operating at Reduced Capacity . . . Operating under Freezing Conditions SHUTDOWN . . . . . . . . . . . . . . FINAL ALIGNMENT . . . . . . . . . INTERLOCKS . . . . . . . .
LUBRICATING BEARINGS Oil Lubrication: Mixers are shipped without oil. Fill the bearing frame with oil, through the filler connection (located on top of bearing frame), until the level reaches the mark in the middle of the oil level sight-glass. A high quality turbine type oil with rust and oxidation inhibitors should be used. If the constant level oiler option is supplied, it would be in the box of fittings which accompanies the mixer.
OPERATION GENERAL CONSIDERATIONS Damage occurs from: Driver may overload if the fluid specific gravity (density) is greater than originally assumed or the rated flow rate is exceeded. 1. Increased Vibration Levels - Affects bearings, seal chamber, and mechanical seal. 2. Increased Radial Thrusts - Stresses on shaft and bearings. 3. Heat Build Up - Vaporization causing rotating parts to score or seize. 4. Cavitation - Damage to internal surfaces of mixer.
INTERLOCKS Mixer interlocks are additions to the feed pumping system interlocks and alarms and vary mill by mill. Typically, they depend upon what instruments are available. The following are the basic guidelines for interlocks. Steady pulp flow must be maintained before adding any chemicals or steam. · · Installation of flow and consistency measurement in the feed line is recommended. Chemicals or steam can be added only when the minimum flow and consistency levels are satisfied.
PREVENTIVE MAINTENANCE GENERAL COMMENTS . . . . . . . . . . MAINTENANCE SCHEDULE . . . . . . . MAINTENANCE OF BEARINGS . . . . . Oil Lubricated Bearings . . . . . . . . . . Grease Lubricated Bearings . . . . . . . . MAINTENANCE OF SHAFT SEALS . . . ROTOR AXIAL CLEARANCE SETTING. Dial Indicator Method . . . . . . . . . . . Feeler Gauge Method. . . . . . . . . . . . Mixer Washdown. . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE OF BEARINGS OIL LUBRICATED BEARINGS Oil lubricated bearings must be lubricated at the job site. Remove fill plug (408H) and add oil until level is at the center of the sight glass (319). Replace fill plug (Fig. 21). Table 4 Lubricating Oil Requirements ISO Grade Approx. SSU at 38°C (100°F) 300 470 DIN 51517 C68 C100 Kinematic viscosity at 40°C (105°F) mm2/sec 68 100 Acceptable Oils Exxon Fig.
GREASE LUBRICATED BEARINGS Grease lubricated bearings are pre-lubricated at the factory. We recommend regreasing bearings every 2000 operating hours or 3 months. Refer to Table 5 for re-grease amounts. Table 5 Grease Amounts Thrust (Angular Contact) Run mixer for about 2 hours or until grease stops emitting from housing and replace two (2) relief plugs (408C). NOTE: The bearing temperature usually rises after regreasing due to an excess supply of grease.
MAINTENANCE OF SHAFT SEALS MECHANICAL SEALS Separate seal manufacturer’s drawings are included with the mixer data package. 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 mixer is disassembled. To properly prepare seal for operation, various cooling and flushing lines may have to be connected. Connect cooling and flushing lines to seal as directed in manufacturer’s instructions.
10. Insert feeler gauge stack into gap between bearing housing (134A) and bearing frame (228). Tighten the locking bolts (370C) evenly until bearing housing contacts the feeler gauge stack. FEELER GAUGE METHOD 1. Remove coupling guard. 11. Evenly tighten jack bolts (371A), then locking bolts (370C) while assuring that the feeler gauge does not bind or become loose. 12. Tighten jam nuts (423B). 13. Check shaft for free turning. 14. Replace coupling guard.
Table 6 TROUBLESHOOTING Problem Probable Cause Improper alignment. Bearings run hot. Remedy Re-align mixer and driver. Improper lubrication. Check lubricant for suitability and level. Lube cooling. Check cooling system. Improper mixer/driver alignment. Align shafts. Partly clogged rotor causing imbalance. Back-flush mixer to clean rotor. Broken or bent rotor or shaft. Replace as required. Foundation not rigid. Tighten hold down bolts of mixer and motor or adjust stilts. Worn bearings.
DISASSEMBLY & REASSEMBLY REQUIRED TOOLS . . . . . . . . . . . PREPARATION FOR DISASSEMBLY DISASSEMBLY. . . . . . . . . . . . . . INSPECTIONS . . . . . . . . . . . . . . REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY Fig. 28 Fig. 26 1. Place sling from hoist around bearing frame (228) (Fig. 26). 2. Remove bearing frame foot hold-down bolts. 3. Remove six (6) casing bolts (370A, casing- to-seal chamber) and eight (8) casing bolts (469Z, frame-to-seal chamber to casing) (Fig. 26). 4. Use jack bolts (418) to remove the back pullout. ! p WARNING ! p CAUTION Do not use heat on the rotor to help remove, severe bodily injury could occur.
2. Thread a 10 mm eye bolt into the tapped hole provided in the seal chamber (184) and sling to a hoist (Fig. 30). Fig. 31 6. Slide rotating element out of frame (228). If needed, tap rotor end of shaft with a soft blow hammer to assist in removal (Fig. 32). Fig. 30 3. Remove the two (2) hex head bolts (370B) from the seal chamber (184) (Fig. 30). 4. Gently tap the seal chamber (184) with cartridge seal and mixer sleeve from the frame (228) using a soft blow hammer on the dry side of the cover (Fig.
10. Disengage thrust bearing lock washer (382) from locknut (136) and remove both from shaft (122) (Fig 34). 11. Remove bearings (112, 409) from shaft (122) using a suitable puller that only contacts inner races of bearings (Fig. 34). Fig. 34 INSPECTIONS CASING SEAL CHAMBER 1. Thoroughly clean gasket surfaces and alignment fits to remove rust and debris. 1. Thoroughly clean gasket surfaces and fits to remove rust and debris. 2. Inspect for any unusual erosive wear inside casing. 2.
REASSEMBLY Table 9 - Model 3501 Fastener Information Specifications Item No. Qty per Mixer — 3 Part Name Hex Head Cap Screw – Coupling Guard (Not shown) Group Construction Goulds Part No. Thread Size Hex Size (mm) A02818A89 2441 M10 x 1.50 17 -- -- All All A02089A10 2441 M10 x 1.50 17 13 10 8601-0012 8601-3015 8601-3018 N12 AN15 AN18 N/A N/A N/A 112 214 356 83 158 263 A02819A74 2440 A02819A74 2156 A05092A47 2443 M10 x 1.50 M10 x 1.50 M6 x 1.
9. REASSEMBLY OF BEARING FRAME NOTE: An induction type bearing heater is required to expand bearings to ease their installation on shaft. Bearings should be heated to approximately 100°C (212°F). ! p Lubricate and install O-ring (496) on thrust bearing housing (134A). 10. Slide thrust bearing housing (134A) over thrust bearing (112) (Fig. 35). CAUTION Do not use a flame to heat bearings, this will damage bearing surfaces. Fig. 36 11.
Fig. 40 Fig.38 13. If radial end cover (109A) was removed, degrease contact surfaces and those in bearing frame (228) and apply Loctite 518 to the outer diameter of cover. 14. Tap radial end cover (109A) in place using a soft blow hammer. 18. Align holes in coupling guard end plate to bearing housing to frame holes in thrust bearing housing (134A) and install hex cap bolts (370C) (Fig. 41). 19. Adjust housing (134A) so there is a gap of approximately 3 mm (1/8 in.) between housing and bearing frame (228).
· two on right side (at coupling end) · one on left side · one on top at seal chamber end 27. If equipped with an oil cooler, install cooler assembly into bearing frame (228), based on viewing from coupling end as follows (Fig. 44): b. Install oil sight glass (319) on right side of bearing frame (228) as viewed from coupling end. c. d. a. Install one tube fitting with straight bore on left side of frame. Install oil drain plug (408B) into bottom of bearing frame (228). b.
4. Install cartridge seal on sleeve (126). 5. Rig lifting device to eyebolt in seal chamber (184) and install seal chamber (184) on bearing frame (228). ! p CAUTION Failure to torque rotor nut can result in serious mechanical damage. 6. Install hex head bolts (370B). 7. Slide cartridge seal on gland studs (353). Assure that gland studs align with openings in gland, and that the tap connections are in the correct orientation. 10. Install and tighten rotor nut set screws (222S). 8.
3. Install hex cap screws (370F) and tighten to torque value in Table A-1. 4. For 8" mixers, degrease threads in casing (100) inlet flange, and apply ND Industries VIBRA-TITE thread sealing compound to threads on alignment pin. 5. Install alignment pin (shank plug) into tapped hole in inlet flange and tighten.
SPARE PARTS RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . . . . . . 3501 MIXER CROSS SECTIONAL . . . . . . . . . . . . . . . . . . . . 3501 MIXER PARTS LIST WITH MATERIAL OF CONSTRUCTION HOW TO ORDER PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 42 43 44 RECOMMENDED SPARE PARTS To insure against possible long and costly downtime period, especially on critical services, it is advisable to have spare parts on hand.
3501 MIXER CROSS SECTIONAL 42 3501 IOM 11/10
Table 10 3501 MIXER PARTS LIST WITH MATERIALS OF CONSTRUCTION Material 316SS Titanium Item No.
HOW TO ORDER When ordering parts call 1-800-446-8537 or your local Goulds 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.com Form No.