Installation, Operation, and Maintenance Manual Model 3600, API 610 8th, 9th, 10th & 11th Editions (ISO 13709)
Table of Contents Table of Contents Introduction and Safety .......................................................................................................... Introduction ............................................................................................................................. Safety ...................................................................................................................................... Safety terminology and symbols ................................
Table of Contents Commissioning, Startup, Operation, and Shutdown ......................................................... 32 Preparation for startup .......................................................................................................... 32 Remove the coupling guard .................................................................................................. 33 Check the rotation - Frame Mounted .....................................................................................
Table of Contents Post-assembly checks ........................................................................................................ 93 Assembly references .......................................................................................................... 94 Troubleshooting .................................................................................................................... 96 Operation troubleshooting ........................................................................
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 Safety terminology and symbols About safety messages It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product.
Introduction and Safety Waste and emissions regulations Observe these safety regulations regarding waste and emissions: • Appropriately dispose of all waste. • Handle and dispose of the processed liquid in compliance with applicable environmental regulations. • Clean up all spills in accordance with safety and environmental procedures. • Report all environmental emissions to the appropriate authorities.
Introduction and Safety • • • • • • • • • • Provide a suitable barrier around the work area, for example, a guard rail. Make sure that all safety guards are in place and secure. Make sure that you have a clear path of retreat. Make sure that the product cannot roll or fall over and injure people or damage property. Make sure that the lifting equipment is in good condition. Use a lifting harness, a safety line, and a breathing device as required.
Introduction and Safety • Do not modify the equipment without approval from an authorized ITT representative. • Only use parts that are provided by an authorized ITT representative. Description of ATEX The ATEX directives are a specification enforced in Europe for electrical and non-electrical equipment installed in Europe. ATEX deals with the control of potentially explosive atmospheres and the standards of equipment and protective systems used within these atmospheres.
Introduction and Safety • 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.
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 Figure 2: Example of the proper lifting method for a bare pump Baseplate-mounted units have lifting points for use with proper lifting devices.
Transportation and Storage Storage guidelines Long-term storage If the unit is stored for more than 6 months, these requirements apply: • Store in a covered and dry location. • Store the unit free from heat, dirt, and vibrations. • Rotate the shaft by hand several times at least every three months. Treat bearing and machined surfaces so that they are well preserved. Refer to the drive unit and coupling manufacturers for their long-term storage procedures.
Product Description Product Description General description Product description Model 3600 is a high-pressure, multistage, between the bearings, horizontal centrifugal pump that meets the requirements of API 610 11th Edition (ISO 13709). Casing The casing is near-centerline mounted with side-suction and side-discharge nozzles. The standard flanges are ASME Class 900 raised-face serrated with a 125-250 RMS finish.
Product Description • Constant-level oilers and labyrinth seals are standard. • No machining is required to convert the standard ring oil lube to either purge-oil or pure-oil mist (pure-oil mist applications require minor bearing housing modifications). • Pressure lubrication is required with hydrodynamic thrust bearings.
Product Description Nameplate types Nameplate Pump casing ATEX Description Provides information about the hydraulic characteristics of the pump. The formula for the pump size is: Discharge x Suction - Nominal Maximum Impeller Diameter in inches. (Example: 2x3-8) If applicable, your pump unit might have an ATEX nameplate affixed to the pump, the baseplate, or the discharge head. The nameplate provides information about the ATEX specifications of this pump.
Product Description Nameplate on the pump casing using metric units Nameplate field MODEL SIZE FLOW HEAD RPM HYDRO PRESS MAX. DES. WORKING PRESS S/N CONT./ITEM NO. IMP. DIA. MAX. DIA. STD. DIM.
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 • 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 NOTICE: You may need to sandblast the surfaces of a baseplate that come in contact with grout, and then coat those surfaces with a primer that is grout-compatible. Make sure to remove all equipment before sandblasting. 3. Make sure that all machined surfaces are free from burrs, rust, paint, or any other type of contamination. If necessary, use a honing stone to remove burrs. Prepare the foundation for mounting 1. Chip the top of the foundation to a minimum of 1.0 in. (25.
Installation 1. Jackscrews Figure 6: Jackscrew locations, top view 1. Lower the baseplate carefully onto the foundation bolts. The baseplate will rest on top of the foundation on the jackscrews provided on the baseplate. 2. Adjust the leveling jackscrews, located adjacent to the foundation bolt holes, until the baseplate rests 1 to 2 in. (25 to 50 mm) above the foundation in order to allow for adequate grouting. This provides even support for the baseplate after grouting. 3.
Installation Pump-to-driver alignment Precautions WARNING: • Follow shaft alignment procedures in order to prevent catastrophic failure of drive components or unintended contact of rotating parts. Follow the coupling installation and operation procedures from the coupling manufacturer. • 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.
Installation Final alignment (hot alignment) checks When After the first run Periodically Why This ensures correct alignment when both the pump and the driver are at operating temperature. This follows the plant operating procedures. Permitted indicator values for alignment checks NOTICE: The specified permitted reading values are valid only at operating temperature. For cold settings, other values are permitted. You must use the correct tolerances.
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. Perform angular alignment for a vertical correction 1.
Installation 2. Rotate the indicator through the top-center position to the right side, 180° from the start position (3 o’clock). 3. Record the indicator reading. When the reading value is... Negative Positive Then... The coupling halves are farther apart on the right side than the left. Perform one of these steps: • Slide the shaft end of the driver to the left. • Slide the opposite end to the right. The coupling halves are closer together on the right side than the left.
Installation 1. Shims Figure 9: Example of incorrect vertical alignment (side view) 4. Repeat the previous steps until the permitted reading value is achieved. Perform parallel alignment for a horizontal correction A unit is in parallel alignment when the parallel indicator (P) does not vary by more than 0.002 in. (0.05 mm) as measured at four points 90° apart at the operating temperature. 1.
Installation Perform complete alignment for a horizontal correction A unit is in complete alignment when both the angular indicator (A) and the parallel indicator (P) do not vary by more than 0.002 in. (0.05 mm) as measured at four points 90° apart. 1. Set the angular and parallel dial indicators to zero at the left side of the driver coupling half (Y), 90° from the top-center position (9 o’clock). 2.
Installation 6. Fill the remainder of the baseplate with grout, and allow the grout to set for at least 48 hours. 1. 2. 3. 4. 5. Baseplate Grout Foundation Dam Bolt 7. Remove the leveling jackscrews after the grout hardens in order to remove any stress points. 8. Tighten the foundation bolts. 9. Recheck the alignment. Piping checklists General piping checklist Precautions CAUTION: • Never draw piping into place by using force at the flanged connections of the pump.
Installation Check Check that only necessary fittings are used. Do not connect the piping to the pump until: • The grout for the baseplate or sub-base becomes hard. • The hold-down bolts for the pump are tightened. Make sure that all the piping joints and fittings are airtight. If the pump handles corrosive fluids, make sure that the piping allows you to flush out the liquid before you remove the pump.
Installation Check Check that the suction piping is one or two sizes larger than the suction inlet of the pump. Install an eccentric reducer between the pump inlet and the suction piping. Check that the eccentric reducer at the suction flange of the pump has the following properties: • Sloping side down • Horizontal side at the top When suction strainers or suction bells are used, check that they are at least three times the area of the suction piping.
Installation Discharge piping checklist Checklist Check Check that an isolation valve is installed in the discharge line. Explanation/comment Checked The isolation valve is required for: • Priming • Regulation of flow • Inspection and maintenance of the pump Check that a check valve is installed in The location between the isolation valve and the the discharge line, between the isola- pump allows inspection of the check valve.
Installation Checklist Check Explanation/comment Check that the minimum flow for – each component is 1 gpm (4 lpm). If the bearing and seal chamber cover cooling are provided, then the auxiliary piping must flow at 2 gpm (8 lpm). Check that the cooling water pres- – sure does not exceed 100 psig (7.0 kg/cm2). Checked Final piping checklist Check Check that the shaft rotates smoothly. Re-check the alignment to make sure that pipe strain has not caused any misalignment.
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: • Failure to follow these precautions before you start the unit will lead to serious personal injury and equipment failure.
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 Coupling guard assembly Precautions WARNING: • Never operate the pump without the coupling guard correctly installed. • Avoid death or serious injury. Assure mechanical seal guard is properly installed using supplied fastening hardware. • 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.
Commissioning, Startup, Operation, and Shutdown f) Replace the coupling hub (if removed) and the spacer portion of the coupling. Refer to the instructions from the coupling manufacturer for assistance. Complete any coupling adjustments before you proceed with the coupling guard assembly. 2. Slightly spread the opening of the coupling guard half and place it over the pump end plate. The annular groove in the guard is located around the end plate.
Commissioning, Startup, Operation, and Shutdown 1. Driver 2. Coupling guard half 6. Slightly spread the opening of the remaining coupling guard half and place it over the installed coupling guard half so that the annular groove in the remaining coupling guard half faces the driver. 1. Annular groove 2. Coupling guard half 3.
Commissioning, Startup, Operation, and Shutdown 7. Place the end plate over the driver shaft and locate the end plate in the annular groove at the rear of the coupling guard half. 1. Annular groove 2. End plate 8. Repeat steps 3 through 5 for the rear end of the coupling guard half, except that you hand tighten the nut. 9. Slide the rear coupling guard half towards the motor so that it completely covers the shafts and coupling. 1. Driver 2. Slide to fit 10.
Commissioning, Startup, Operation, and Shutdown Bearing lubrication Precautions WARNING: Make sure to properly lubricate the bearings. Failure to do so can result in excess heat generation, sparks, and premature failure. NOTICE: Avoid equipment damage. Refer to driver/coupling/gear manufactures IOM for instructions and recommendations for lubrication. Pumps are shipped without oil You must lubricate oil-lubricated bearings at the job site. Ring oil lubrication Ring oil-lubricated bearings are standard.
Commissioning, Startup, Operation, and Shutdown Lubricating-oil requirements Oil quality requirements Use a high-quality turbine oil with rust and oxidation inhibitors with rated viscosity shown below at 100°F (38°C). Oil requirements based on temperature For the majority of operating conditions, bearing temperatures run between 120°F (49°C) and 180°F (82°C), and you can use an oil of ISO viscosity grade 68 at 100°F (38°C).
Commissioning, Startup, Operation, and Shutdown 2. Check that the oil level is correct. The correct oil level is centered in the bullseye sight glass, when the pump is not in operation. During operation, bullseye sight gives a false oil level reading. Shown is general schematic. Oil level is below outer race of bearing. 1. Plug 2. Reservoir 3. Main body Lubricate the bearings with pure or purge-oil mist (optional) NOTICE: Do not expose an idle pump to freezing conditions.
Commissioning, Startup, Operation, and Shutdown Note that only one of the two connection ports in the radial bearing housing (134) is used (immediately above the single row radial bearing). You must connect to both connections on the thrust bearing housing, because there are two rows of bearings. A. B. C. Oil-mist connections Radial and thrust Thrust only Radial and thrust drain 3. For pure-oil mist, connect the drain lines to the outlet connections. This is not required for purge-oil mist.
Commissioning, Startup, Operation, and Shutdown 2. On the thrust housing, replace the 1/4 in. NPT plug with an oil-mist fitting. Replace the 1/2 in. NPT plug with a 1/2 in. to 1/4 in. bushing and insert an oil-mist fitting provided by the oilmist system manufacturer. A. B. C. Oil-mist connections Radial and thrust (1/4 in.) Thrust only (1/2 in.) Radial and thrust drain NOTICE: In both housings, the inboard channel beneath the 1/4 in. NPT connection must be 1/4 in.
Commissioning, Startup, Operation, and Shutdown 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 1. Discharge isolation valve 2. Check valve 3. Suction isolation valve Start the pump WARNING:Immediately observe the pressure gauges. If discharge pressure is not quickly attained, stop the driver immediately, reprime, and attempt to restart 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.
Commissioning, Startup, Operation, and Shutdown 7. Repeat steps 5 and 6 until the pump runs properly. 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 CAUTION: • The pump and system must be free of foreign objects. If pump becomes plugged, shut down and unplug prior to restarting pump. • 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.
Commissioning, Startup, Operation, and Shutdown Doweling the pump casing You must dowel the pump casing to the baseplate pedestals in order to maintain the proper pump position. There are two methods for doweling the pump casing, depending on whether the pump is used in a cold application or a hot application. Use this table to determine whether hot doweling is required. Stage length Pump size 3 all others 6x8-14 8x10-13 10x12-14.5 all others 6x8-11D 6x8-13 6x8-14 8x10-13 10x12-14.
Commissioning, Startup, Operation, and Shutdown Stage length Pump size 8 3x4-8 3x4-9 3x6-9/10 4x6-10 4x6-10D 4x6-11 4x6-11D 6x8-11 6x8-11D 6x8-13 6x8-14 3x4-8 3x4-9 3x6-9/10 3x4-12.5 4x6-12 4x6-10 4x6-10D 4x6-11 4x6-11D 6x8-11 6x8-11D 3x4-8 3x4-9 3x6-9/10 3x4-12.5 4x6-12 4x6-10 4x6-10D 4x6-11 4x6-11D 6x8-11 6x8-11D 3x4-8 3x4-9 3x6-9/10 4x6-10 3x4-12.5 4x6-12 4x6-10D 4x6-11 4x6-11D 3x4-8 3x4-9 3x6-9/10 3x4-12.5 4x6-12 4x6-10 4x6-10D 4x6-11 4x6-11D 3x4-8 3x4-9 3x6-9/10 3x4-12.
Commissioning, Startup, Operation, and Shutdown Stage length Pump size 14 3x4-8 3x4-9 3x6-9/10 3x4-12.5 4x6-12 Temperature threshold for hot doweling 280°F (138°C) 250°F (121°C) 210°F (99°C) When the driver is mounted at the factory, the pump is doweled for both cold and hot applications; the driver is not doweled in order to allow for final field alignment. When the driver is mounted in the field, the pump is not doweled.
Commissioning, Startup, Operation, and Shutdown 1. Drill two holes through the pump foot and pump pedestal. Position each hole between the hold-down bolt and the end of the pump foot at the coupling end on both sides. 2. Ream the holes with a number 7 taper pin reamer to the proper fit with the taper dowel pins. Insert the pins deep enough so that only the threaded portions are exposed when the pins are fully seated. 3. Seat the taper pins firmly in the holes with a hardwood block or soft-faced hammer.
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 Bearing lubrication schedule Type of lubrication Ring oil Purge oil Pure oil Forced oil First lubrication Add oil before you install and start the pump. Change the oil after 200 hours for new bearings. Follow the recommendations from the manufacturer. Lubrication intervals After the first 200 hours, change the oil every 2000 operating hours or every three months. Follow the recommendations from the manufacturer.
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 Prepare for disassembly 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. 2. Drain the liquid from the piping; flush the pump if necessary. 3. Disconnect all auxiliary piping, tubing, and equipment that will interfere with the removal of the head and the rotor. 4. Remove the oil drain plugs (408A) from the bottom of the bearing housings (134) and drain the oil.
Maintenance Disassemble the radial end (ball bearing pumps) 1. Unbolt and remove the cover bolts (371C) and the outboard end cover (160). Loosen the inboard end cover (160) and cover bolts (371C). The outboard labyrinth seal (332A) and the bearing housing gasket (360A) will come off with the outboard cover (160). 2. Remove the dowel pins (469J) between the bearing housing flange and the casing flange. The connection point of the housing to the casing is referred to as the saddle. 3.
Maintenance 8. Use a bearing puller in order to remove the radial bearing (168) from the shaft. 9. Remove the inboard bearing cover (160), the inboard labyrinth seal (333A), and the inner bearing cover bolts (371C). 10. Remove the seal plate nuts (355) and the mechanical seal (250). Refer to the instructions provided by the mechanical seal manufacturer. 11. (Optional) Remove the cooling plate bolts (388K and 388G), the cooling plate (490), and the cooling plate gaskets (360U and 360S not shown).
Maintenance The bearing housing gaskets (360A) will remain on the end covers (109A or 160). 2. Remove the dowel pins (469J) between the bearing housing flange and the head flange. The connection point of the housing to the casing is referred to as the saddle. 3. Unbolt the bearing housing from the saddle by removing the four nuts (427J). 4. Remove the studs (371T). Rotate the bearing housing in order to remove the inboard end cover bolts (371C). 5. Remove the oil ring (114). 6.
Maintenance Disassemble the radial end (sleeve/ball bearing pumps) 1. Remove the two dowel pins between the upper and lower halves of the bearing housing (134). 2. Remove the hex screws that connect the upper and lower halves of the bearing housing. 3. Tighten the two jackscrews on the horizontal parting flanges of the bearing housing in order to separate the two halves. 4. Remove the top half of the bearing housing with the upper half of the sleeve bearing (117).
Maintenance 5. Remove the dowel pins (469J) that hold the lower half of the bearing housing to the casing flange. 6. Loosen and remove the nuts (427J) that hold the bearing housing in place. 7. Rotate the lower half of the sleeve bearing (117) around the shaft (122) in order to remove the bearing from the lower housing. 8. Remove the lower half of the bearing housing. 9. Remove the outboard labyrinth seal (332A), the two oil rings (323), and the inboard labyrinth seal (333A).
Maintenance Disassemble the thrust end (sleeve/ball bearing pumps) 1. Remove the outboard end cover (109A) by removing the end cover bolts (371C). 2. Remove the upper half of the bearing housing (134A) from the lower half: a) Remove the dowel pins between the upper and lower halves of the bearing housing (134A). b) Remove the hex head screws that connect the upper and lower halves of the bearing housing (134A). c) Tighten the jackscrews in order to separate the housing halves.
Maintenance d) Remove the top half of the thrust bearing (134A) housing with the upper half of the sleeve bearing (117). Notice that the bearing is pinned to the housing. 3. Remove the outboard oil ring (114).
Maintenance 4. Remove the dowel pins (469J) that hold the lower half of the bearing housing to the casing flange. 5. Loosen the nuts (427J) that hold the bearing housing in place. The bearing housing will rest on the studs. 6. Rotate the lower half of the sleeve bearing (117) around the shaft (122) in order to remove it from the lower bearing housing. 7. Remove the nuts (427J). 8. Remove the lower half of the bearing housing (134A) using a crane. Remove the studs (371T). 9.
Maintenance Remove the rotating element * 164A for 4x6-10 and 4x6-11 pumps. 165B for all other pump sizes. 1. Loosen and remove the casing nuts (425) and taper pins. 2. Use the jacking bolts (provided with the pump) to loosen the upper half from the lower half of the casing (100). WARNING: Never use heat to disassemble the pump due to the risk of an explosion from trapped liquid. 3. Insert eyebolts (not supplied) in the pre-drilled threaded holes in the perimeter of the upper half of the casing.
Maintenance 4. Position one sling between the throttle bushing (129) and the impeller, and another sling between the first-stage impeller (101) and the seal chamber (221). Lift the rotating assembly slightly to remove contact with the wear parts. 5. Remove the socket head capscrews from the center bushing (155). * 164A for 4x6-10 and 4x6-11 pumps. 165B for all other pump sizes. 6. Remove the center bushing (155), all stage rings (144), and the diaphragm (146), if supplied.
Maintenance Disassemble the rotating element 1. Remove throttle bushing sleeve (128): a) Remove the snap ring (361F). b) Slide the sleeve towards the center of the rotor, exposing the locating ring (361H). c) Remove the locating ring (two halves) and the throttle bushing sleeve. 2. Depending on the pump size, do the following to remove the first-stage impeller: CAUTION: Burn hazard. The impeller will get hot. Wear insulated gloves when handling the impeller. If the pump is... 6x8-13 Then... 1. 2. 3.
Maintenance If the pump is... All others Then... 1. 2. 3. 4. Remove the snap ring (361F) from the first-stage impeller (101). Heat the impeller to 300°F–400°F (150°C–200°C) and slide it towards the center of the rotor in order to expose the locating ring (361H). For double-suction, first-stage impellers (except 4x6-10 and 4x611), remove the impeller and retrieve the locating ring (361H). Quickly remove the locating ring and the impeller. Remove the subsequent casing ring(s) (164, 164A, 164B). 3.
Maintenance NOTICE: Allow the shaft and impeller to cool to ambient temperature before assembling the next impeller. 5. After all the impellers are removed, remove the center sleeve (205). This step does not apply to 6x8-13 pumps. Preassembly inspections Replacement guidelines Casing check and replacement WARNING: Avoid death or serious injury. Leaking fluid can cause fire and/or burns. Inspect and assure gasket sealing surfaces are not damaged and repair or replace as necessary.
Maintenance Impeller replacement This table shows the criteria for replacing the impeller: Impeller parts Impeller vanes Pumpout vanes Vane edges Wear ring surfaces When to replace • When grooved deeper than 1/16 in. (1.6 mm), or • When worn evenly more than 1/32 in. (0.8 mm) When worn or bent more than 1/32 in. (0.
Maintenance Cartridge mechanical seal replacement Cartridge-type mechanical seals should be serviced by the seal manufacturer. Refer to the instructions from the mechanical seal manufacturer for assistance. Coupling guard replacement Repair or replace the coupling guard if you notice corrosion or other defects. Gaskets, O-rings, and seats replacement WARNING: Avoid death or serious injury. Leaking fluid can cause fire and/or burns. Replace any damaged or worn gaskets/o-rings.
Maintenance Shaft surface check Check the shaft surface for damage. Replace the shaft if it is damaged beyond reasonable repair. Rotor Allowable runouts of the fully assembled rotor are listed in the Shaft and rotor runout requirements table. Table 1: Shaft and rotor runout requirements Characteristic Flexibility factor, L4/D2 Allowable shaft runout, TIR Component fit to shaft Allowable rotor radial runout, TIR* Requirement >1.9x109 mm (3.0x106 in.) 40 µm (0.0015 in.) Interference 60 um (0.0025 in.
Maintenance Pump size Radial bearing Thrust bearing 3x6-9 3x6-10 4x6-10 3x4-12.5 4x6-11 4x6-12 6x8-11 6x8-13 6x8-14 8x10-13 10x12-14.5 6312 7312/BECBM 6313 7313/BECBM 6314 7314/BECBM 6216 7313/BECBM Bearing housing bore 5.1181 5.1191 5.5118 5.5128 5.9055 5.9065 Shaft turn 5.5118 5.5128 2.5597 thrust 2.5592 thrust 3.1502 radial 3.1497 radial 2.3631 2.3626 2.5597 2.5592 2.7565 2.
Maintenance a) Clean the wear-ring seats thoroughly to make sure that they are smooth and free of scratches. b) Heat the new impeller wear rings to 180°F–200°F (82°C–93°C) using a uniform method for heating, such as an oven, and place them on the impeller (101-101M) wear-ring seats. CAUTION: Wear insulated gloves when you handle rings. Rings will be hot and can cause physical injury. c) Tack weld each ring in place in three equidistant places. 3.
Maintenance Minimum running clearances Table 3: Diametrical clearance in inches (millimeters) This table gives diametrical clearance data for wear parts. Impeller wear ring Pump size Goulds standard API 610 3x4-12.5 0.010 (0.254) 4x6-12 0.010 (0.254) 3x4-8 3x4-9 0.010 (0.254) 3x6-9 3x6-10 0.010 (0.254) 4x6-10 0.010 (0.254) 4x6-11 0.010 (0.254) 6x8-11 0.010 (0.254) 6x8-13 0.010 (0.254) 6x8-14 0.010 (0.254) 8x10-13 0.010 (0.254) 10x12-14.5 0.010 (0.254) Ring diameter 0.016 (0.406) 0.
Maintenance NOTICE: Make sure that all parts and threads are clean and that you have followed all directions under the Preassembly inspections section. 1. Assemble the center impeller (101M) onto the shaft. The impeller is interference fit. a) Use an electric induction heater to preheat the impeller to 300°F–400°F (150°C–200°C). b) Slide the impeller past the locating ring groove, put the locating rings (361H) in place, and slide the impeller back so that it is snug against the locating ring.
Maintenance b) Install the snap ring (361F). 5. On 6x8-13 pumps only, assemble the diaphragm sleeve (204) snug against the shaft shoulder and install the snap ring (361). 6. Assemble the first-stage impeller (101) as in Step 1. 7. On double-suction pumps only (except 4x6-10 and 4x6-11), install the locating ring (361H), then slide on the first-stage impeller and install the snap ring (361F). 8.
Maintenance CAUTION: 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. 10. Measure the total indicated runout (TIR) on the impeller wear rings, center sleeve, throttle sleeve, diaphragm sleeve, and bearing fits. The shaft is the datum point; measure the runout of wear rings and impeller nuts to the shaft with a dial indicator.
Maintenance 3. Position one sling between the throttle bushing sleeve (128) and the impeller and a second sling in front of the first stage impeller (101). Lower the rotating assembly into the lower half of the casing to the point where the stationary-groove locks engage. 4. Assemble the first-stage impeller casing ring (164A), the final-series casing ring (164), the throttle bushing (129), and both seal chambers (220, 221). * 164A for 4x6-10 and 4x6-11 pumps. 165B for all other pump sizes. 5.
Maintenance c) Pull the rotating element towards the thrust end until it stops. d) Again, measure the distance from the thrust bearing shoulder on the shaft to the bearing housing face on the casing. The difference between the two measurements is the total travel of the rotating element. e) Calculate the average of these dimensions. f) Measure the shoulder depth on the inboard cover (160) and subtract the calculated average dimension.
Maintenance 2. Measure the depth of the ring bores noted in the figure and record the measurements in the table row "Actual depth." 1. 2. 3. 4. 5. 6. 7. 8. Inboard seal chamber Last ring bore First ring, inboard side Inboard center bushing bore Outboard center bushing bore Last ring, outboard side First ring bore Outboard seal chamber A. Lower half casing flange B. Inboard end C. Outboard end Location Design depth Actual depth Difference Pump size 1 and 8 3x4-8B 3x4-9 3x6-9/10 3x4-12.
Maintenance 4. Plot the "Difference" points on the chart. 5. Draw a straight line from point 1 to point 8. This is the seal chamber centerline. 6. Draw a trend line through points 2 through 7 and investigate any deviations greater than 0.002 in. (0.051 mm). This is the casing ring centerline. 7. Adjust the nominal 0.005 in. (0.127 mm) thickness of the center case shim by the difference between the seal chamber centerline and the ring bore centerline at points 4 and 5.
Maintenance 7. Keep the bearing housing level from side to side during the bearing housing adjustment in order to ensure the correct oil level setting. 8. Double-check the centering of the rotor with a feeler gauge between the casing rings and impeller rings and confirm the clearance around the circumference. For standard clearance use a 0.003 in. (0.076 mm) feeler gauge. For API clearance use a 0.006 in. (0.152 mm) feeler gauge. Make minor adjustments to the bearing housings accordingly. 9.
Maintenance NOTICE: Apply an anti-seize compound to the studs and to the face of the casing where the nuts make contact. * 164A for 4x6-10 and 4x6-11 pumps. 165B for all other pump sizes. 2. Torque the casing nuts (425) to the values found in the Maximum torque values for fasteners table in Assembly references. Start at the center of the casing and work from side to side towards each end. 3. Mount the cartridge mechanical seals (250) on the shaft.
Maintenance Figure 13: Mount the cartridge mechanical seal on the thrust end Assemble the thrust end (ball bearing pumps) 1. Assemble the inboard labyrinth seal (333A) into the inboard thrust end cover (160): a) Clean the end cover with a solvent. b) Fit the labyrinth seal (333A) into the bore of the cover (160). c) Tap the seal in with a hammer. NOTICE: Make sure that the expulsion port is at the 6 o'clock position and is properly seated. 2.
Maintenance a) Preheat the bearings to 250°F (120°C) with an induction-type bearing heater. Be sure to also demagnetize the bearings after heating. CAUTION: • Wear insulated gloves when you use a bearing heater. Bearings get hot and can cause physical injury. NOTICE: Do not use a torch and do not force. b) Install the bearings (112A), the oil ring sleeve (443B), and the bearing locknut (136) onto the shaft.
Maintenance h) When you have achieved the proper bearing assembly, set the lockwasher tab in the slot in the locknut. 4. Install the bearing housing (134) over the bearings. Finger-tighten the nuts (427J) on the studs (371T). Insert the dowel pins (469J); then tighten the nuts (427J). The bearing housing is doweled to the casing (100) during the original build to assure the correct running position of the shaft.
Maintenance Assemble the radial end (ball bearing pumps) 1. Assemble the inboard labyrinth seal (333A) into the inboard radial-end cover (160): a) Clean the end cover with a solvent. b) Fit the labyrinth seal (333A) into the bore of the cover (160). c) Tap the seal in with a hammer. NOTICE: Make sure that the expulsion port is at the 6 o'clock position and is properly seated. 2. Assemble the inboard end cover (160) and the inboard bearing end-cover gasket (360A) onto the shaft. 3.
Maintenance 4. Install the oil-ring sleeve (324) and tighten the setscrew (388L). 5. Install the bearing housing (134). The bearing housing is doweled to the casing (100) during the original build to assure the correct running position of the shaft. NOTICE: The bearing housing flange must fit metal-to-metal (no gap) to the bearing saddle flange. 6. Install the oil ring (114). 7. Install the end-cover gasket on the outboard side (360A). 8.
Maintenance Assemble the thrust end (sleeve/ball bearing pumps) 1. Install the inboard labyrinth seal (333A).
Maintenance NOTICE: Make sure that the expulsion port is at the 6 o'clock position and is properly seated. 2. Place the inboard oil rings (114) on the shaft. 3. Assemble the thrust bearings (112A) in a back-to-back arrangement onto the shaft (122): The bearings are interference fit. a) Preheat the bearings to 250°F (120°C) with an induction-type bearing heater. Be sure to also demagnetize the bearings after heating. CAUTION: • Wear insulated gloves when you use a bearing heater.
Maintenance b) Install the dowel pins in the pre-drilled dowel pin holes between the housing flange and the head-bearing flange. c) Tighten the nuts (427J) on the bearing housing to the head studs (371T). d) Place the upper half of the sleeve bearing (117) on the shaft, moving the oil rings aside. When the bearing top half is in place, move the oil rings back into the bearing housing and sleeve grooves. 8. Install the upper half of the bearing housing (134A). 9.
Maintenance 3. Place the outboard labyrinth seal (333A) in the lower half of the bearing housing (134), which is not yet attached. 4. Lift the lower half of the housing into place, positioning the inner oil rings (323) in the bearing housing grooves. 5. Place the installed inboard labyrinth seal (333A) in the lower housing. NOTICE: Make sure that the expulsion port is at the 6 o'clock position and is properly seated. 6.
Maintenance NOTICE: Make sure that the expulsion port is at the 6 o'clock position and is properly seated. 9. Install the upper half of the bearing housing (134). 10. Position the dowel pins between the upper and lower halves of the bearing housing. Tighten the bearing-housing hex screws.
Maintenance Assembly references Maximum torque values for fasteners Lubricated values are 2/3 of the unlubricated values. Fastener size (diameter in inches) – threads per inch 3/8 –16 7/16 –14 1/2 –13 9/16 –12 5/8 –11 3/4 –10 7/8 –9 1 –8 1-1/4 –8 1-3/8 –8 1-1/2 –8 1-3/4 –8 2-1/8 –8 2-1/2–8 2210 material ft-lb (Nm) Lub. Unlub.
Maintenance • • • • • • • • • Casing wear rings (164, 164A, 164B) Radial bearing (168) (ball bearing construction only) Impeller wear rings (202, 202A, 202B, 203) Center sleeve (205) Labyrinth seal, outboard (332A) Labyrinth seal, inboard (333A) Casing gasket (351) Bearing lockwasher (382) Bearing end-cover gasket (360A) Model 3600, API 610 8th, 9th, 10th & 11th Editions (ISO 13709) Installation, Operation, and Maintenance Manual 95
Troubleshooting Troubleshooting Operation troubleshooting Symptom The pump is not delivering liquid. Cause The pump is not primed. The suction line is clogged. The impeller is clogged. The shaft is rotating in the wrong direction. The foot valve or suction pipe opening is not submerged enough. The pump is not producing the rated flow or head. The suction lift is too high. The gasket or O-ring has an air leak. The stuffing box has an air leak. The impeller is partly clogged.
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. 3.
Parts Listings and Cross-Sectionals Parts Listings and Cross-Sectionals Parts list Table 4: Parts list with materials of construction for sleeve/ball bearing arrangement The materials in this table are typical. Refer to the order documentation for the actual materials furnished.
Parts Listings and Cross-Sectionals Table 5: Parts list with materials of construction for ball bearing arrangement The materials in this table are typical. Refer to the order documentation for the actual materials furnished.
Parts Listings and Cross-Sectionals Cross-sectional diagrams Model 3600 single suction – ball/ball 100 Model 3600, API 610 8th, 9th, 10th & 11th Editions (ISO 13709) Installation, Operation, and Maintenance Manual
Parts Listings and Cross-Sectionals Model 3600 double suction – ball/ball Model 3600, API 610 8th, 9th, 10th & 11th Editions (ISO 13709) Installation, Operation, and Maintenance Manual 101
Parts Listings and Cross-Sectionals Model 3600 single suction – sleeve/ball 102 Model 3600, API 610 8th, 9th, 10th & 11th Editions (ISO 13709) Installation, Operation, and Maintenance Manual
Parts Listings and Cross-Sectionals Model 3600 double suction – sleeve/ball Model 3600, API 610 8th, 9th, 10th & 11th Editions (ISO 13709) Installation, Operation, and Maintenance Manual 103
Parts Listings and Cross-Sectionals Model 3600 single suction – sleeve/Kingsbury 104 Model 3600, API 610 8th, 9th, 10th & 11th Editions (ISO 13709) Installation, Operation, and Maintenance Manual
Parts Listings and Cross-Sectionals Model 3600 double suction – sleeve/Kingsbury Model 3600, API 610 8th, 9th, 10th & 11th Editions (ISO 13709) Installation, Operation, and Maintenance Manual 105
Other Relevant Documentation or Manuals Other Relevant Documentation or Manuals For additional documentation For any other relevant documentation or manuals, contact your ITT representative.
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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 13148 USA Tel. 1–800–446–8537 Fax (315) 568–2418 © 2014 ITT Corporation The original instruction is in English. All non-English instructions are translations of the original instruction. Form en_US.2014.10.IOM.
