Installation, Operation and Maintenance Instructions Model 3996
FOREWORD This manual provides instructions for the Installation, Operation, and Maintenance of the Goulds Model 3996 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. The design, materials, and workmanship incorporated in the construction of Goulds pumps makes them capable of giving trouble-free service.
TABLE OF CONTENTS 9 SAFETY 1 13 GENERAL INFORMATION 2 17 INSTALLATION 3 21 OPERATION 4 27 PREVENTATIVE MAINTENANCE 5 33 DISASSEMBLY/REASSEMBLY 6 45 TROUBLESHOOTING 7 3996 IOM 9/2010 7
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.
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SAFETY DEFINITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SPECIAL ATEX CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . . . 10 ATEX IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL PRECAUTIONS ! s WARNING Personal injuries will result if procedures outlined in this manual are not followed. NEVER apply heat to remove impeller, It C may explode to due trapped liquid. NEVER use heat to disassemble pump due to C risk of explosion from trapped liquid. NEVER operate pump without coupling A C guard correctly installed. NEVER operate pump beyond the rated A D conditions to which the pump was sold. NEVER start pump without proper prime.
ATEX IDENTIFICATION For a pumping unit (pump, seal, coupling, motor and pump accessories) to be certified for use in an ATEX classified environment, the proper ATEX identification must be present. Table 1 Code Max permissible surface temperature F ( C) o The ATEX tag will be secured to the pump or the baseplate on which it is mounted.
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GENERAL INFORMATION INTRODUCTION . . . . . . . . Importance of Instructions . . . Receiving Inspection. . . . . . Preservation and Storage . . . Handling Techniques . . . . . RECEIVING THE PUMP . . . . NAMEPLATE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEIVING THE PUMP Inspect the pump 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. Units with drivers mounted are moved with slings under the pump casing and driver (Figs. 2 and 3). STORAGE REQUIREMENTS Short Term (Less than 6 months) Goulds normal packaging procedure is designed to protect pump during shipping.
NAMEPLATE INFORMATION Every pump has two Goulds nameplates that provide information about the pump. The tags are located on the casing and bearing frame. Description Fig. No. When ordering spare parts, you will need to identify pump model, size, serial number, and the item number of required parts. Information can be taken from the pump casing tag. Item numbers can be found in this manual. Example 2 Pump Casing Tag - provides information about the pump’s hydraulic characteristics.
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INSTALLATION SITE/FOUNDATION . . . Location . . . . . . . . . Foundation and Baseplate PIPING . . . . . . . . . . . ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUCTION PIPING CAUTION ! As NPSH must always exceed NPSH as shown on Goulds performance curves received with order. (Reference Hydraulic Institute for NPSH and pipe friction values needed to evaluate suction piping). A A$ R CAUTION Suction Head/Flooded Suction Conditions 1. An isolation valve should be installed in the suction line at least two (2) pipe diameters from the pump suction to permit closing of the line for pump inspection and maintenance. 2. Keep suction pipe free from air pockets. 3.
AUXILIARY PIPING FINAL PIPING CHECK Auxiliary piping may be required for seal chamber cover cooling, mechanical seal flush or other special features supplied with the pump. Consult pump data sheet for specific auxiliary piping recommendations. After connecting the piping to pump: If seal chamber cover cooling is required, follow guidelines listed below. 1. Flows of 4 l/min. (1 GPM) will generally satisfy cooling requirements. 2. Cooling water pressure should not exceed 7.0 kg/cm (100 psig). 1.
NOTE: Tighten coupling bolts and hub set screw onto shaft. Torquing of these components is not done at the factory, yet is required at the site. Please reference the coupling manufacturers instructions for correct torque levels. Table 3 Fastener Size and Recommended Torque Values Fastener Standard SAE Fastner Nominal Size Recommended Torque1 lb.-ft.
OPERATION PREPERATION FOR STARTUP Checklist . . . . . . . . . . . . . STARTING PUMP. . . . . . . . . OPERATION . . . . . . . . . . . . SHUTDOWN . . . . . . . . . . . . FINAL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Packing must not run dry. If the pumped liquid is clean, gland leakage of 40-60 drops per minute is satisfactory. If the liquid is dirty, connect a clean liquid flush to the lantern ring connection to keep solids out of the packing. Occasionally, the stuffing box is below atmospheric pressure (suction under vacuum, etc.). Under these conditions, supply sealing liquid through a line from the discharge of the pump to the lantern ring connection.
! s coupling used in an ATEX classified ! The environment must be properly certified. a. WARNING Never operate a pump without coupling guard properly installed. Refer to Appendix II for coupling guard installation instructions. Personal injury will occur if pump is run without coupling guard. Install and lubricate coupling per manufacturer’s instructions. 8. Priming - Never start the pump until it has been properly primed.
START-UP PRECAUTIONS 1. All equipment and personal safety related devices and controls must be installed and operating properly. 2. To prevent premature pump failure at initial start-up due to dirt or debris in the pipe system, ensure the pump can be run continuously at full speed and flow for 2 to 3 hours. 3. Variable speed drivers should be brought to rated speed as quickly as possible. 4.
STARTING 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. A $! 4. Slowly open discharge valve until the desired flow is obtained. A $! 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.
SHUTDOWN 1. Slowly close discharge valve. 2. Shut down and lock driver to prevent accidental rotation. ! s WARNING When handling hazardous and/or toxic fluids, proper personal protective equipment should be worn. If pump is being drained, precautions must be taken to prevent physical injury. Pumpage must be handled and disposed of in conformance with applicable environmental regulations. FINAL ALIGNMENT ! 1. 26 Alignment procedures must be followed to prevent unintended contact of rotating parts.
PREVENTIVE MAINTENANCE GENERAL COMMENTS . . . . . . . . MAINTENANCE SCHEDULE . . . . . LUBRICATION . . . . . . . . . . . . . MAINTENANCE OF BEARINGS . . . IMPELLER CLEARANCE SETTING. VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION Pump bearings are normally grease lubricated and are lubricated at the factory. Regrease at approximately 3-6 month intervals, until grease comes out the oil caps which serve as grease relief fittings. Use a sodium or lithium base grease, NLGI #2 consistency. Follow motor and coupling manufacturer's lubrication instructions. MAINTENANCE OF BEARINGS ! Do not insulate bearing housings as this can result in excess heat generation, sparks, and premature failure.
PURE OIL MIST LUBRICATED BEARINGS (OPTIONAL) ! s WARNING Pumps are shipped without oil. Oil mist lubricated bearings must be lubricated at the job site. 1. Follow oil mist system supplier’s instructions. 2. Connect oil mist supply lines to upper and center tapped connection. 3. Connect drain line to bottom tapped connection (Fig. 12).
! s 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. PACKED STUFFING BOX stuffing boxes are not allowed in an ATEX ! Packed classified environment. Packing operation can be inspected without shutting down or disassembling the pump. During normal operation the packing should leak approximately one drop per minute.
IMPELLER CLEARANCE SETTING ! The impeller clearance setting procedure 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. ! s WARNING Lock out driver power to prevent accidental startup and physical injury. A change in pump performance may be noted over time by a drop in head or flow or an increase in power required. Performance can usually be renewed by adjusting the impeller clearance.
VIBRATION It is good practice to periodically monitor vibration of the pump. Normally, vibration level will be well below accepted standards. Of equal 32 importance is that the vibration level not increase. If a problem with vibration is encountered, refer to Trouble Shooting.
DISASSEMBLY AND REASSEMBLY REQUIRED TOOLS . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . INSPECTION AND REPLACEMENT. REASSEMBLY. . . . . . . . . . . . . . ADDITIONAL DETAILS . . . . . . . . Engineering Data Construction Details SECTIONAL VIEWS . . . . . . . . . . HIGH PRESSURE CAPABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. 9. Unscrew impeller (101) from shaft (122). The threads are right-hand. Prevent the shaft turning by using a wrench on coupling “flats”. Do not lose or damage the O-ring (412A) which seals between the impeller (101) and shaft (122) or shaft sleeve (126). 12. Slide deflector (123) off shaft (122). On units with mechanical seal (383). 14. Remove bearing housing bolts (370C).
INSPECTION AND REPLACEMENT 1. Impeller (101) – Replace if impeller shows excessive erosion (especially on ejector vanes on back side of impeller), corrosion, extreme wear or vane breakage. O-ring groove and impeller hub must be in good condition. Check impeller balance. 2. Shaft (122) – Check for runout to see that shaft has not been bent. On pumps without shaft sleeves, shaft surface in stuffing box area must be smooth and free of grooves.
REASSEMBLY This procedure covers reassembly of pump after complete disassembly. Make sure all directions in Inspection and Replacement section have been followed. Refer to Figure 17 for applicable item number. Before mounting any seals, wipe the seal faces carefully with a clean soft cloth and lubricate with clean oil. 1. A preliminary impeller adjustment must be performed to assure proper positioning of the mechanical seal. Oil bearing seat on coupling end of shaft (122).
shaft or sleeve. Do not tighten set screws. 3. Assemble gland (250), gaskets, and stationary seat and slide assembly on shaft or sleeve. 4. Place stuffing box cover (184) against frame making sure that the studs (370H) align with the proper holes in frame. Firmly tighten nuts. 5. Place gland assembly against face of stuffing box and firmly tighten stud nuts. 6. Slide rotary portion toward gland until it contacts stationary seat. Compress the rotary. Tighten screws. Double Seal 1.
e. Compress rotary portion of seal to correct dimension as shown on seal manufacturer’s drawing and tighten set screws. f. Remove visegrip and refer to Step 9 for further instructions.
Pump End Shaft Deflection Load Factor (M) 3 x 4 -1 3 7/32" 3/8" 5/8" 7/32" 3/8" 5/8" 1" 4 x 6 -1 3 2 x 3 -1 3 3 -1 3 3 x 4 -1 0 7/16" 1 1/2 x 2 x 3 -1 0 3 -1 0 1 1/2 x 3-8 1 1/2 x 11/32" 7/13" 3/8" 11/32" 7/16" 2 -1 0 2-8 1 1/2 x 2 x 3 -6 3-6 1 1/2 x 3996MT 1 1/2 x Maximum Diameter Solids 2-6 Pump End 1 1/2 x 3996ST 8.7 11.1 9.5 8.7 11.1 11.1 5.6 9.5 15.9 5.6 9.5 15.9 25 3500 RPM 3 6.2 7 6 7.8 7.2 8.6 9.8 15 10 15.7 35.5 - 1750 RPM 0.8 1.6 1.8 1.
SECTIONAL VIEWS SPARE AND REPAIR PARTS ITEM NO. QTY.
DYNAMIC SEAL / SELF DRAINING COVERS OPTIONS SECTIONAL VIEWS 6 * RECOMMENDED SPARE PARTS 3996 IOM 9/2010 41
BEARING OPTIONS - SECTIONAL VIEW * RECOMMENDED SPARE PARTS 42 3996 IOM 9/2010
HIGH PRESSURE CAPABILITY Fig, 17 6 Fig, 18 Code For Pressure - Temperature Chart A B C D E I 316SS, Hast. B.C. Monel Nickel Titanium Ductile Iron GA-20 NOTE: Ratings of 150 lb. flanges in Material Code A are per ANSI B 16.5 - 1973. For equipment designed to ANSI B 16.5 - 1968, higher ratings may apply.
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TROUBLESHOOTING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Causes and Corrective Measures . . . . . . . . . . . . . . . . . . . . . . . . . . 45 TROUBLESHOOTING Problem Possible Causes and Corrections A. No liquid delivered, not enough liquid delivered, or not enough pressure. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 18, 19, 20. B. Pump works a while and then quits. 4, 5, 7, 8, 9, 11, 12, 20. C. Pump takes too much power.
13 Impeller clearance too great. Check for proper clearance. 14 Impeller damaged. Inspect and replace as required. 15 Rotating parts bind. Check internal wearing parts for proper clearance. 16 Shaft bent. Straighten or replace as required. 17 Coupling or pump and driver misaligned Check alignment and realign if required. 18 Impeller diameter too small Consult factory for proper impeller diameter. 19 Improper pressure gauge location Check correct position and discharge nozzle or pipe.
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HOW TO ORDER PARTS When ordering parts, call 1-800-446-8537 or your local ITT Industries - Goulds Representative EMERGENCY SERVICE Emergency parts service is available 24 hours / day 365 days / year . . . Call 1-800-446-8537 Visit our Website at www.gouldspumps.
