Installation, Operation, and Maintenance Manual

Installation, Operation, and Maintenance Manual
Installation, Operation,
and Maintenance Manual
Model 3408
Table of Contents
Table of Contents
Introduction and Safety .......................................................................................................... 3
Introduction ............................................................................................................................. 3
Safety ...................................................................................................................................... 3
Safety terminology and symbols ........................................................................................... 4
Environmental safety ............................................................................................................ 5
User safety ........................................................................................................................... 5
Safety regulations for Ex-approved products in potentially explosive atmospheres ............. 6
Monitoring equipment ........................................................................................................... 7
Product warranty ..................................................................................................................... 8
Transportation and Storage ................................................................................................... 9
Inspect the delivery ................................................................................................................. 9
Inspect the package ............................................................................................................. 9
Inspect the unit ..................................................................................................................... 9
Transportation guidelines ........................................................................................................ 9
Lifting methods ..................................................................................................................... 9
Storage guidelines ................................................................................................................ 11
Pump storage requirements ............................................................................................... 11
Product Description .............................................................................................................. 13
General description ............................................................................................................... 13
Nameplate information .......................................................................................................... 14
Installation ............................................................................................................................. 17
Preinstallation ....................................................................................................................... 17
Pump location guidelines .................................................................................................... 17
Foundation requirements ................................................................................................... 18
Set the baseplate .................................................................................................................. 19
Pump-to-driver alignment ...................................................................................................... 19
Alignment checks ............................................................................................................... 20
Align the pump using a straight edge .................................................................................. 21
Align the pump using a dial indicator .................................................................................. 22
Grout the baseplate .............................................................................................................. 23
Piping checklists ................................................................................................................... 24
General piping checklist ..................................................................................................... 24
Suction piping checklist ...................................................................................................... 25
Suction-piping valve considerations ................................................................................... 27
Discharge piping considerations ......................................................................................... 28
Pressure gauges ................................................................................................................ 28
Pump doweling ..................................................................................................................... 29
Commissioning, Startup, Operation, and Shutdown ......................................................... 30
Preparation for startup .......................................................................................................... 30
Pump priming ........................................................................................................................ 31
Fill the system ....................................................................................................................... 31
Start the pump ...................................................................................................................... 32
Operational checklist ............................................................................................................. 32
Shut down the pump ............................................................................................................. 33
Freeze protection .................................................................................................................. 33
Maintenance ........................................................................................................................... 34
Maintenance schedule .......................................................................................................... 34
Flood-damaged pumps ......................................................................................................... 35
Model 3408 Installation, Operation, and Maintenance Manual
1
Table of Contents
Bearing maintenance ............................................................................................................ 35
Regrease the grease-lubricated bearings .......................................................................... 35
Lubricate the oil-lubricated bearings ................................................................................... 37
Bearing temperatures ......................................................................................................... 39
Coupling lubrication ............................................................................................................ 39
Shaft-seal maintenance ........................................................................................................ 39
Packed stuffing box maintenance ....................................................................................... 39
Mechanical seal maintenance ............................................................................................ 40
Disassembly ......................................................................................................................... 41
Disassembly precautions ................................................................................................... 41
Change the rotation ............................................................................................................ 41
Remove the upper half of the casing .................................................................................. 43
Remove the rotating element ............................................................................................. 43
Disassemble the pump with packing .................................................................................. 43
Disassemble the pump with mechanical seals on the shaft ................................................ 46
Disassemble the pump with mechanical seals on the shaft sleeve .................................... 49
Preassembly ......................................................................................................................... 51
Replace wear parts ............................................................................................................. 51
Reassembly .......................................................................................................................... 51
Assemble the pump with packing ....................................................................................... 51
Assemble the pump with mechanical seals on the shaft ..................................................... 55
Assemble the pump with mechanical seals on the shaft sleeves ....................................... 57
Install the bearings ............................................................................................................. 60
Install the gaskets ............................................................................................................... 61
Install the rotating element ................................................................................................. 62
Assemble the casing .......................................................................................................... 63
Complete the assembly with packing ................................................................................. 63
Install the packing (optional method) .................................................................................. 64
Vertical units ......................................................................................................................... 64
Remove the upper half of the casing .................................................................................. 64
Remove the rotating element ............................................................................................. 67
Assemble the rotating element ........................................................................................... 68
Assemble the casing .......................................................................................................... 68
Remove the complete pump ............................................................................................... 69
Spare parts ........................................................................................................................... 69
Troubleshooting .................................................................................................................... 71
Troubleshooting .................................................................................................................... 71
Parts Listings and Cross-Sectionals ................................................................................... 74
Exploded views ..................................................................................................................... 74
Parts list ................................................................................................................................ 77
Local ITT Contacts ................................................................................................................ 78
Regional offices .................................................................................................................... 78
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Model 3408 Installation, Operation, and Maintenance Manual
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.
Requesting other information
Special versions can be supplied with supplementary instruction leaflets. See the sales
contract for any modifications or special version characteristics. For instructions, situations, or
events that are not considered in this manual or in the sales documents, please contact the
nearest ITT representative.
Always specify the exact product type and identification code when requesting technical
information or spare parts.
Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is overpressurized. Take all necessary measures to avoid over-pressurization.
• Operating, installing, or maintaining the unit in any way that is not covered in this manual
could cause death, serious personal injury, or damage to the equipment. This includes any
modification to the equipment or use of parts not provided by ITT. If there is a question
regarding the intended use of the equipment, please contact an ITT representative before
proceeding.
•
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.
• If the pump/motor is damaged or leaking, do not operate as it may cause an electric shock,
fire, explosion, liberation of toxic fumes, physical harm, or environmental damage. Correct/
repair the problem prior to putting back in service.
• Do not change the service application without the approval of an authorized ITT
representative.
Model 3408 Installation, Operation, and Maintenance Manual
3
Introduction and Safety
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result in
physical injury, damage, or delays.
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. They are published to help prevent these
hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
Hazard levels
Hazard level
NOTICE:
DANGER:
Indication
A hazardous situation which, if not avoided, will
result in death or serious injury
WARNING:
A hazardous situation which, if not avoided,
could result in death or serious injury
CAUTION:
A hazardous situation which, if not avoided,
could result in minor or moderate injury
• A potential situation which, if not avoided,
could result in undesirable conditions
• A practice not related to personal injury
Hazard categories
Hazard categories can either fall under hazard levels or let specific symbols replace the
ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary hazard
levels and may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard
The Ex symbol
The Ex symbol indicates safety regulations for Ex-approved products when used in
atmospheres that are potentially explosive or flammable.
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Model 3408 Installation, Operation, and Maintenance Manual
Introduction and Safety
Environmental safety
The work area
Always keep the station clean to avoid and/or discover emissions.
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.
WARNING:
Do NOT send the product to the manufacturer if it has been contaminated by any nuclear
radiation. Inform ITT so that accurate actions can take place.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Recycling guidelines
Always follow local laws and regulations regarding recycling.
User safety
General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment within
the work area:
• Helmet
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other sections of this manual.
Model 3408 Installation, Operation, and Maintenance Manual
5
Introduction and Safety
Electrical connections
Electrical connections must be made by certified electricians in compliance with all international, national, state, and local regulations. For more information about requirements, see sections
dealing specifically with electrical connections.
Precautions before work
Observe these safety precautions before you work with the product or are in connection with
the product:
• Provide a suitable barrier around the work area, for example, a guard rail.
• Make sure that all safety guards are in place and secure.
• Allow all system and pump components to cool before you handle them.
• 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.
• Make sure that the product is thoroughly clean.
• Make sure that there are no poisonous gases within the work area.
• Make sure that you have quick access to a first-aid kit.
• Disconnect and lock out power before servicing.
• Check the explosion risk before you weld or use electric hand tools.
Precautions during work
Observe these safety precautions when you work with the product or are in connection with the
product:
• Never work alone.
• Always wear protective clothing and hand protection.
• Stay clear of suspended loads.
• Always lift the product by its lifting device.
• Beware of the risk of a sudden start if the product is used with an automatic level control.
• Beware of the starting jerk, which can be powerful.
• Rinse the components in water after you disassemble the pump.
Wash the skin and eyes
1. Follow these procedures for chemicals or hazardous fluids that have come into contact with
your eyes or your skin:
Condition
Chemicals or hazardous
fluids in eyes
Chemicals or hazardous
fluids on skin
Action
1.
2.
3.
Hold your eyelids apart forcibly with your fingers.
Rinse the eyes with eyewash or running water for at least
15 minutes.
Seek medical attention.
1.
2.
3.
Remove contaminated clothing.
Wash the skin with soap and water for at least 1 minute.
Seek medical attention, if necessary.
Safety regulations for Ex-approved products in potentially explosive
atmospheres
Description of ATEX
The ATEX directives are a specification enforced in Europe for electrical and non-electrical
equipment. ATEX deals with the control of potentially explosive atmospheres and the
standards of equipment and protective systems used within these atmospheres. The relevance
of the ATEX requirements is not limited to Europe. You can apply these guidelines to
equipment installed in any potentially explosive atmosphere.
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Model 3408 Installation, Operation, and Maintenance Manual
Introduction and Safety
Guidelines for compliance
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.
If there are any questions regarding these requirements, the intended use, or if the equipment
requires modification, contact an ITT representative before you proceed.
Personnel requirements
ITT disclaims all responsibility for work done by untrained and unauthorized personnel.
These are the personnel requirements for Ex-approved products in potentially explosive
atmospheres:
•
All work on the product must be carried out by certified electricians and ITT-authorized
mechanics. Special rules apply to installations in explosive atmospheres.
•
All users must know about the risks of electric current and the chemical and physical
characteristics of the gas and/or vapor present in hazardous areas.
•
Any maintenance for Ex-approved products must conform to international and national
standards (for example IEC/EN 60079-17).
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in
potentially explosive atmospheres:
• Only use the product in accordance with the approved motor data stated on the
nameplates.
• The Ex-approved product must never run dry during normal operation. Dry running during
service and inspection is only permitted outside the classified area.
• Before you start working with the product, make sure that the product and the control panel
are isolated from the power supply and the control circuit, so they cannot be energized.
• Do not open the product while it is energized or in an explosive gas atmosphere.
• Make sure that thermal contacts are connected to a protection circuit according to the
approval classification of the product.
• Intrinsically safe circuits are normally required for the automatic level-control system by the
level regulator if mounted in zone 0.
• The yield stress of fasteners must be in accordance with the approval drawing and the
product specification.
• Make sure that the equipment is properly maintained:
• Monitor the pump components and the end temperature of the liquid.
• Maintain proper bearing lubrication.
• Do not modify the equipment without approval from an authorized ITT representative.
• Only use parts that have been provided by an authorized ITT representative.
Equipment for monitoring
For additional safety, use condition-monitoring devices. Condition-monitoring devices include
but are not limited to these devices:
Monitoring equipment
For additional safety, use condition-monitoring devices. Condition-monitoring devices include
but are not limited to these devices:
• Pressure gauges
Model 3408 Installation, Operation, and Maintenance Manual
7
Introduction and Safety
•
•
•
•
•
•
•
Flow meters
Level indicators
Motor load readings
Temperature detectors
Bearing monitors
Leak detectors
PumpSmart control system
Product warranty
Coverage
ITT undertakes to remedy faults in products from ITT under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an ITT representative within the warranty period.
• The product is used only under the conditions described in this manual.
• The monitoring equipment incorporated in the product is correctly connected and in use.
• All service and repair work is done by ITT-authorized personnel.
• Genuine ITT parts are used.
• Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved
products.
Limitations
The warranty does not cover faults caused by these situations:
• Deficient maintenance
• Improper installation
• Modifications or changes to the product and installation made without consulting ITT
• Incorrectly executed repair work
• Normal wear and tear
ITT assumes no liability for these situations:
• Bodily injuries
• 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.
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Model 3408 Installation, Operation, and Maintenance Manual
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.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
4. Contact your sales representative if anything is out of order.
Transportation guidelines
Precautions
WARNING:
• Stay clear of suspended loads.
• Observe accident prevention regulations in force.
Lifting methods
WARNING:
• All lifting must be done in compliance with all applicable regulations/standards.
• Assembled units and their components are heavy. Failure to properly lift and support this
equipment can result in serious physical injury and/or equipment damage. Lift equipment
only at the specifically identified lifting points. Lifting devices such as hoist rings, shackles,
slings and spreaders must be rated, selected, and used for the entire load being lifted.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and
wear steel-toed shoes at all times.
• Do not attach sling ropes to shaft ends.
The unit must be unloaded and handled by lifting equally at four or more points on the
baseplate. The lugs on the upper half casing are designed for lifting the upper half of the casing
only.
Pumps mounted horizontally
Pump mounting
A bare pump
Lifting method
Place a nylon sling, chain, or wire rope around both bearing housings.
Model 3408 Installation, Operation, and Maintenance Manual
9
Transportation and Storage
Pump mounting
A pump mounted on a base that
has lifting holes
Lifting method
WARNING:
If the driver has been mounted on the
baseplate at the factory, then it is safe to
lift the entire assembly. However, if the
driver has not been mounted at the factory
and the overall baseplate length exceeds
100 in. (254 cm), then do not lift entire
assembly consisting of the pump, base,
and driver. This can cause damage to the
baseplate. You must lift the pump and
baseplate to its final location without the
driver, and then mount the driver.
CAUTION:
Take care to size equipment for unbalanced loads that may exist if the driver is
not mounted on the base at the time of
lifting. The driver may or may not be
mounted at the factory.
Attach nylon slings, chains, or wire rope to ANSI/OSHA Standard S
hooks. Then attach the hooks in the holes provided in the four corners
of the base. Make sure that the points of the hooks do not touch the
bottom of the pump base. Size the equipment for the load so that the
lift angle is less than 45° from the vertical.
A pump mounted on a base
Place one sling around the outboard bearing housing and place
that does not have lifting holes the another sling around the back-end of the driver as close to
the mounting feet as possible. Make certain that the sling will
not damage the housing cover or conduit boxes. Join the free
ends of the slings together and place over the lifting hook.
Figure 1: The proper lifting method for a horizontal pump on a base with lifting holes
Figure 2: The proper lifting method for a horizontal pump on a base without lifting holes
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Model 3408 Installation, Operation, and Maintenance Manual
Transportation and Storage
Pumps mounted vertically
Pump mounting
Half pedestal
Full pedestal
Lifting method
Place a 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 long enough to keep the lift angle less than 30° from the vertical.
Install eyebolts in the three holes provided at the top of the support
and tighten securely. Attach a chain or wire rope using a latch hook or
standard shackle and end loop. You must use shoulder eyebolts that
are manufactured per ANSI B18.15 and sized to fit the holes provided.
Be sure the lifting equipment is long enough to keep the lift angle less
than 30° from the vertical.
1. Nylon sling, chain, or wire rope
Figure 3: The proper lifting method for a vertical pump mounted on a half pedestal
1. Nylon sling, chain, or wire rope
Figure 4: The proper lifting method for a vertical pump mounted on a full pedestal
Storage guidelines
Pump storage requirements
Storage requirements depend on the amount of time that you store the unit. The normal
packaging is designed only to protect the unit during shipping.
Length of time in storage
Upon receipt/short-term (less than six months)
Model 3408 Installation, Operation, and Maintenance Manual
Storage requirements
• Store in a covered and dry location.
• Store the unit free from dirt and vibrations.
11
Transportation and Storage
Length of time in storage
Long-term (more than six months)
Storage requirements
• 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 drive unit and
coupling manufacturers for their long-term storage procedures.
You can purchase long-term storage treatment with the initial unit order or you can purchase it
and apply it after the units are already in the field. Contact your local ITT sales representative.
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Model 3408 Installation, Operation, and Maintenance Manual
Product Description
Product Description
General description
Product description
Goulds Model 3408 is a double-suction, horizontally split-case pump. This product line consists
of 39 sizes from size 2x3-11 through size 10x12-18.
Casing
The axially split, double-volute casing is constructed of cast iron, for working pressures up to
175 psig, or ductile iron, for working pressures up to 400 psig. Suction and discharge flanges
and mounting feet are cast integral with the lower half of the casing.
Tapped and plugged holes are provided for priming, vent, drain, and gauge connections. The
upper half of the casing can be removed without disturbing suction or discharge piping. Flanges
are ASA Standard 125/125#, 125/250#, or 250/250#. Suction and discharge are on a common
centerline in both the horizontal and vertical planes.
Impeller
•
•
•
•
•
•
Enclosed, double suction
Bronze
Statically and hydraulically balanced
Keyed to the shaft
Positioned axially by the shaft sleeves
Hub with sufficient metal thickness to allow machining for installation of impeller rings
Shaft
• The shaft is made of SAE 1045 steel, 316 stainless steel, or heat-treated 416 stainless
steel. AISI 4140 steel is standard on 4x6-11, 6x8-12M, and 8x10-20S/L, 10x12-18. These
sizes are not available in 1045 or 316.
• The shaft size allows for operation under load with a minimum of deflection.
Shaft sleeves
• Bronze, 420 hardened stainless steel (packing only), 316 stainless steel, or cast iron
• Protect the shaft from wear and from contact with the pumped fluid
• An O-ring under the sleeve to prevent leaks
Stuffing box
• Made of cast iron separate from the casing
• Mounted in cylindrical fits in the casing
• Drilled and tapped for drain connection
Casing rings
• Made of bronze, cast iron, or Nitronic 60 stainless steel
• Installed with an anti-rotation device
• Designed to restrict leakage across the ring fit
Bearings
• Grease lubricated or oil lubricated
• Inboard, or coupling end, bearing: single row ball bearing
• Outboard bearing: double row cylindrical roller bearing, retained by a bearing locknut and
lockwasher
Model 3408 Installation, Operation, and Maintenance Manual
13
Product Description
Bearing housing
The bearing housings are bolted to the ends of the bearing bracket/stuffing box and are malefemale fitted for a full 360 degrees to assure positive alignment.
The housings provide a fit for the inboard bearing that allows freedom for thermal expansion.
The outboard bearing is clamped in place in order to take all thrust loads and to keep the
rotating element in its proper axial location. Openings for adding new grease and draining old
grease are provided.
Baseplate
• Sufficiently rigid to support the pump and driver
• Steel construction
Coupling
The coupling is flexible. Coupling hubs are secured to the driver and driven shafts by a
setscrew located over the key.
NOTICE:
The coupling used in an ATEX classified environment must be properly certified.
Coupling guard
The coupling guard is all metal.
CAUTION:
You must use a coupling guard made of a non-sparking material in an ATEX classified
environment.
Rotation
The pump has a clockwise or counterclockwise rotation when viewed from the drive end.
Nameplate information
Important information for ordering
Every pump has nameplates that provide information about the pump. The nameplates are
located on the casing and the bearing frame.
When you order spare parts, identify this pump information:
• Model
• Size
• Serial number
• Item numbers of the required parts
Refer to the nameplate on the pump casing for most of the information. See Parts List for item
numbers.
Nameplate types
Nameplate
Pump casing
Pump
Bearing frame
14
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)
Provides information about the lubrication system used.
Model 3408 Installation, Operation, and Maintenance Manual
Product Description
Nameplate on the pump casing using English units
Figure 5: Nameplate on the pump casing using English units
Table 1: Explanation of nameplate on the pump casing
Nameplate field
Explanation
IMPLR. DIA.
Impeller diameter, in inches
MAX. DIA.
Maximum impeller diameter, in inches
GPM
Rated pump flow, in gallons per minute
FT HD
Rated pump head, in feet
RPM
Rated pump speed, revolutions per minute
MOD.
Pump model
SIZE
Size of the pump
STD. NO.
ANSI standard designation
MAT L. CONST.
Material of which the pump is constructed
SER. NO.
Serial number of the pump
MAX DSGN PSI @
Maximum pressure at 100ºF according to the pump design
100ºF
Nameplate on the pump casing using metric units
Figure 6: Metric units - nameplate on pump casing
Table 2: Explanation of the nameplate on the pump casing
Nameplate field
Explanation
IMPLR. DIA.
Impeller diameter
MAX. DIA.
Maximum impeller diameter
M3/HR
Rated pump flow, in cubic meters per hour
M HD
Rated pump head, in meters
RPM
Rated pump speed, in revolutions per minute
MOD.
Pump model
SIZE
Size of the pump
STD. NO.
MAT L. CONST
Material of which the pump is constructed
SER. NO.
Serial number of the pump
Model 3408 Installation, Operation, and Maintenance Manual
15
Product Description
Nameplate on the bearing frame
Figure 7: Nameplate on the bearing frame
Table 3: Explanation of the nameplate on the bearing frame
Nameplate field
Explanation
BRG. O. B.
Outboard bearing designation
BRG. I. B.
Inboard bearing designation
S/N
Serial number of the pump
LUBE
Lubricant, oil or grease
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Model 3408 Installation, Operation, and Maintenance Manual
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.
NOTICE:
Supervision by an authorized ITT representative is recommended to ensure proper installation.
Failure to do so may result in equipment damage or decreased performance.
Pump location guidelines
WARNING:
Assembled units and their components are heavy. Failure to properly lift and support this
equipment can result in serious physical injury and/or equipment damage. Lift equipment only
at the specifically identified lifting points. Lifting devices such as hoist rings, shackles, slings
and spreaders must be rated, selected, and used for the entire load being lifted.
Guideline
Keep the pump as close to the liquid source as
practically possible.
Make sure that the space around the pump is
sufficient.
If you require lifting equipment such as a hoist or
tackle, make sure that there is enough space above
the pump.
Protect the unit from weather and water damage
due to rain, flooding, and freezing temperatures.
If the possibility of freezing exists during a shutdown
period, then drain the pump completely and use
compressed air to blow out all passages and
pockets where liquid might collect.
Do not install and operate the equipment in closed
systems unless the system is constructed with
properly-sized safety devices and control devices.
Explanation/comment
This minimizes the friction loss and keeps the
suction piping as short as possible.
This facilitates ventilation, inspection, maintenance,
and service.
This makes it easier to properly use the lifting
equipment and safely remove and relocate the
components to a safe location.
This is applicable if nothing else is specified.
Acceptable devices:
• Pressure relief valves
• Compression tanks
• Pressure controls
• Temperature controls
• Flow controls
If the system does not include these devices,
consult the engineer or architect in charge before
you operate the pump.
Take into consideration the occurrence of unwanted The best pump location for noise and vibration
noise and vibration.
absorption is on a concrete floor with subsoil
underneath.
If the pump location is overhead, undertake special Consider a consultation with a noise specialist.
precautions to reduce possible noise transmission.
When possible, locate the pump below the fluid
This facilitates priming, ensures a steady flow of
level.
liquid, and provides a positive suction head on the
pump.
Model 3408 Installation, Operation, and Maintenance Manual
17
Installation
Guideline
Make sure there is a suitable power source available for the pump driver.
Explanation/comment
If the pump is motor-driven, then the electrical
characteristics of the power source should be identical to those shown on motor data plate.
The installation must be evaluated to determine that the Net Positive Suction Head Available
(NPSHA) meets or exceeds the Net Positive Suction Head Required (NPSHR), as stated by the
pump performance curve.
Foundation requirements
Requirements
• The foundation must be able to absorb any type of vibration and form a permanent, rigid
support for the unit.
• The foundation must weigh at least five times the weight of the pump unit.
• Provide a flat, substantial concrete foundation in order to prevent strain and distortion
when you tighten the foundation bolts.
• Allow the foundation to cure for several days before you proceed with the pump
installation.
• The foundation must be poured to within 0.75–1.5 in. (1.905–3.81 cm) of the finished
height.
Foundation bolts
• Foundation bolts must be embedded in the concrete to a depth of 8âM M 12 in. (20âM M 30
cm) and locked with either a hook around a reinforcing bar or a nut and washer at the
bottom.
• Foundation bolts must have a sleeve around them at least six times the bolt diameter in
length and at least two bolt sizes larger in ID.
• If a nut and washer are used for locking, then the washer must have an OD two sizes
larger than the sleeve.
• Foundation bolts must be sized 0.125 in. (3.175 mm) less than the anchor bolt holes in the
base.
Bolt installation diagram
1.
2.
3.
4.
5.
Baseplate
Grout
Alternate bolt and washer
Concrete
Bolt sleeve
Figure 8: Bolt installation
18
Model 3408 Installation, Operation, and Maintenance Manual
Installation
Set the baseplate
Pumps are checked at the factory for the ability to be aligned to the required tolerances. Due to
the flexibility of an ungrouted base and handling in shipment, do not assume that the unit is in
alignment when it is placed on the rough foundation. If these directions are followed, then the
required alignment must be readily achieved.
1. Perform the initial or rough alignment.
Rough alignment is designated as 0.020 in. (0.051 cm) TIR for parallel alignment and 0.009
in. (0.023 cm) TIR per inch of radius for angular alignment. Use blocks at the anchor bolts
and midway between to position the bottom of the base at a finished height with the
foundation bolts extending through the holes in the baseplate. Instead of blocks and shims,
you can also use metal wedges with a small taper.
2. If the unit has a non-flexible coupling, such as a Falk Gear coupling, then disconnect the
coupling halves.
This is usually not necessary on flexible-type couplings, such as Wood’s Sure-Flex
coupling.
3. Tighten all pump and motor bolts.
This ensures that bolts have not loosened or that a soft foot has not occurred due to base
distortion during shipment. A soft foot causes a change in the alignment when one bolt is
loosened.
4. If the driver is being installed in the field, then make sure it is centered in its bolt holes with
shims added to bring the driver into rough alignment with the pump.
Move the pump also, if necessary.
NOTICE:
Risk of improper alignment. Do not use more than six shims and use the thickest shims
possible. Place thin shims in between thick shims.
5. Level and plumb the pump shaft, coupling faces, and flanges by adding or removing shims
between the blocks and the bottom of the base.
6. Hand-tighten the anchor bolt nuts. Then tighten the nuts with a wrench, taking care not to
distort the base.
Do not reconnect the non-flexible coupling until after you complete the alignment operation.
The baseplate does not need to be level.
7. After the foundation bolts are lightly torqued, recheck the alignment requirements.
If the alignment must be corrected, then add or remove shims or wedges under the
baseplate.
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.
• Electrical connections must be made by certified electricians in compliance with all
international, national, state, and local rules.
• Refer to driver/coupling/gear manufacturers installation and operation manuals (IOM)
for specific instructions and recommendations.
Model 3408 Installation, Operation, and Maintenance Manual
19
Installation
NOTICE:
Proper alignment is the responsibility of the installer and the user of the unit. Check the
alignment of frame-mounted units before you operate the unit. Failure to do so can result in
equipment damage or decreased performance.
Alignment checks
When to perform alignment checks
You must perform alignment checks under these circumstances:
• The process temperature changes.
• The piping changes.
• The pump has been serviced.
Types of misalignment
Type of misalignment
Angular misalignment
Parallel offset misalignment
Description
Shafts have an axis concentric at the intersection but not parallel.
Shafts have an axis parallel but offset.
Check and correct angular misalignment before correcting parallel misalignment.
Permissible coupling misalignment
Type of misalignment
Parallel misalignment
Single element coupling
0.004 in. (0.1 mm) TIR (4 mils)
Angular misalignment
0.004 in. (0.1 mm) TIR per inch of
radius.
Double element (spacer) coupling
0.060 in. (1.52 mm) TIR per foot of
spacer length
0.002 in. (0.51 mm) TIR per inch of
radius
Types of alignment checks
Type of check
Initial alignment (cold alignment)
check
Final alignment (hot alignment)
check
When it is used
Prior to operation when the pump and the driver are at ambient
temperature.
After operation when the pump and the driver are at operating
temperature.
To make the final alignment, move and shim the motor on its base until the coupling hubs are
within the recommended tolerances measured in total runout. Take all measurements with the
pump and driver bolts tightened. Make the final alignment check after the unit has attained its
final operating temperature.
Initial alignment (cold alignment) checks
When
Before you grout the baseplate
After you grout the baseplate
After you connect the piping
Why
This ensures that alignment can be accomplished.
This ensures that no changes have occurred during the grouting
process.
This ensures that pipe strains have not altered the alignment.
Final alignment (hot alignment) checks
When
After the first run
Periodically
20
Why
This ensures correct alignment when both the pump and the driver
are at operating temperature.
This follows the plant operating procedures.
Model 3408 Installation, Operation, and Maintenance Manual
Installation
Cold settings for parallel vertical alignment
Introduction
This section shows the recommended preliminary (cold) settings for electric motor-driven
pumps based on different temperatures of pumped fluid. Consult driver manufacturers for
recommended cold settings for other types of drivers such as steam turbines and engines.
Recommended settings
Pumped fluid temperature
Ambient
100°F (38°C)
200°F (93°C)
300°F (149°C)
400°F (204°C)
Recommended setting for driver shaft
0.002 in. (0.05 mm) to 0.004 in. (0.102 mm), low
0.000 in. (0.00 mm) to 0.002 in (0.05 mm), high
0.004 in. (0.102 mm) to 0.006 in. (0.152 mm), high
0.008 in. (0.203 mm) to 0.010 in. (0.254 mm), high
0.012 in. (0.305 mm) to 0.014 in. (0.356 mm), high
Align the pump using a straight edge
Before you begin, you must have a straight edge and a taper gauge or set of feeler gauges.
Only use this method if the face and outside diameters of the coupling halves are square and
concentric with the coupling bores. If this condition does not exist or elastomeric couplings do
not make this method convenient, then use the dial indicator method.
1. Check for angular alignment by inserting the taper or feeler gauges between the coupling
faces at 90° intervals.
The unit is in angular alignment when these four measurements are the same or are within
recommended tolerances.
2. Check for parallel alignment by placing a straight edge across both coupling rims on all four
sides.
The unit is in parallel alignment when the straight edge rests evenly across both coupling
rims in all four positions.
1. Feeler gauge
Figure 9: Incorrect angular alignment
1. Straight edge
Figure 10: Incorrect parallel alignment
Model 3408 Installation, Operation, and Maintenance Manual
21
Installation
1. Straight edge
2. Feeler gauge
Figure 11: Correct alignment
Align the pump using a dial indicator
Before you begin, you must have a dial indicator with a mounting magnet and extension bars.
A dial indicator can provide more accurate alignment than a straight edge.
1. Fasten the indicator stand or magnetic base to the pump half of the coupling.
2. Adjust the assembly until the indicator button is resting on the periphery of the other
coupling half.
3. Set the dial to zero and use chalk to mark the coupling half where the button rests. Then
place a separator between the coupling halves so that the bearing slack does not affect the
readings.
Chalk and separators are not necessary on the elastomeric couplings that have not been
disconnected.
4. Rotate both shafts by the same amount.
All readings must be made with the button on the chalk mark.
The dial readings will indicate whether the driver must be raised, lowered, or moved to
either side. You can accurately align the shaft centers with this method even where faces or
outside diameters of the coupling are not square or concentric with the bores.
NOTICE:
Risk for rotation unbalance. Any gross deviation in squareness or concentricity must be
corrected.
5. After each adjustment, recheck both parallel and angular alignments.
1. Dial indicator
2. Reference mark
3. Separator to take up the bearing slack
Figure 12: Angular alignment
22
Model 3408 Installation, Operation, and Maintenance Manual
Installation
1. Dial indicator
2. Reference mark
3. Separator to take up the bearing slack
Figure 13: Parallel alignment
Grout the baseplate
CAUTION:
Do not grout until the initial alignment is made.
Grout compensates for an uneven foundation. Together with the baseplate, grout makes a very
rigid interface between the pump and the foundation by distributing the weight over the length
of the base and preventing shifting. Use an approved, non-shrinking grout such as Embeco 636
or 885 by Master Builders, Cleveland, Ohio, or the equivalent.
1.
2.
3.
4.
5.
6.
7.
Baseplate
Shims
Form
Concrete
Anchor bolt
Bolt sleeve
Grout
Figure 14: Baseplate grouting
1. Build a strong form around the foundation to contain the grout.
2. Soak the top of the foundation thoroughly, then remove surface water.
3. Completely fill the baseplate with grout.
Model 3408 Installation, Operation, and Maintenance Manual
23
Installation
If necessary, temporarily use air relief tubing or drill vent holes in order to remove trapped
air.
4. After the grout has completely hardened, tighten the foundation bolts.
It will take approximately 24 hours for the grout to harden.
5. Check the alignment.
6. Approximately fourteen days after the grout has been poured and the grout has completely
dried, apply an oil-based paint to the exposed edges of the grout in order to prevent air and
moisture from coming in contact with the grout.
Piping checklists
General piping checklist
Precautions
CAUTION:
• Never draw piping into place by using force at the flanged connections of the pump. This
can impose dangerous strains on the unit and cause misalignment between the pump and
driver. Pipe strain adversely affects the operation of the pump, which results in physical
injury and damage to the equipment.
• Vary the capacity with the regulating valve in the discharge line. Never throttle the flow
from the suction side. This action can result in decreased performance, unexpected heat
generation, and equipment damage.
• Do not move the pump to the pipe. This could make final alignment impossible.
CAUTION:
Flange loads from the piping system, including those from the thermal expansion of the
piping, must not exceed the limits of the pump. Casing deformation can result in contact with
rotating parts, which can result in excess heat generation, sparks, and premature failure.
Piping guidelines
Guidelines for piping are given in the Hydraulic Institute Standards available from the Hydraulic
Institute at 9 Sylvan Way, Parsippany, NJ 07054-3802. You must review this document before
you install the pump.
Checklist
Check
Check that all piping is supported
independently of, and lined up
naturally with, the pump flange.
Explanation/comment
This helps to prevent:
• Strain on the pump
• Misalignment between the pump and the drive unit
• Wear on the pump bearings, seal, and shafting
This helps to minimize friction losses.
Checked
Keep the piping as straight as
possible. Avoid unnecessary
bends. Use 45° or long radius 90°
fittings where necessary.
Check that only necessary fittings This helps to minimize friction losses.
are used.
Make sure that the inside diame- —
ters match properly when you use
flange joints.
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.
24
Model 3408 Installation, Operation, and Maintenance Manual
Installation
Check
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.
If the pump handles liquids at
elevated temperatures, make
sure that the expansion loops and
joints are properly installed.
Make sure that all piping components, valves and fittings, and
pump branches are clean prior to
assembly.
Explanation/comment
This prevents air from entering the piping system or
leaks that occur during operation.
Checked
This helps to prevent misalignment due to thermal
expansion of the piping.
—
Suction piping checklist
The sizing and installation of the suction piping is extremely important. It must be selected and
installed so that pressure losses are minimized and sufficient liquid flows into the pump when it
is started and operated. Many NPSH problems can be directly attributed to improper suction
piping systems.
CAUTION:
• Flange loads from the piping system, including those from the thermal expansion of the
piping, must not exceed the limits of the pump. Deformation can result in contact with
rotating parts, which can result in excess heat generation, sparks, and premature failure.
• Air pockets can form in the top of the reducer and the pipe when operating on suction lift.
Never use a concentric reducer in a horizontal line.
Piping checklist
Check
Check that the elbows in the suction
piping for horizontal double-suction
pumps are installed per the Hydraulics
Institute Standards since there is always an uneven turbulent flow around
an elbow.
Explanation/comment
Checked
When there is an elbow in a position other than
the vertical when in relation to the pump suction
nozzle, this causes more liquid to enter one side
of the impeller than the other. The result is highly
unequalized thrust loads that overheat the bearings and cause rapid wear, which adversely
affects the hydraulic performance. See the Example of unbalanced loading figure.
This avoids excessive turbulence and noise.
Check that pipe reducers on the inlet
side have no more than one pipe
diameter reduction in a single reducer.
When operating on a suction lift, check A horizontal suction line must have a gradual
that the suction pipe slopes upward to rise to the pump. Any high point in the pipe can
the pump nozzle.
become filled with air and prevent proper operation of the pump.
(Optional) You can install a short sec- This facilitates the cleansing of the liquid pastion of pipe adjacent to the suction
sage of the pump without dismantling the pump.
flange such as Dutchman or a spool
With this arrangement, anything that clogs the
piece that is designed so that it can be impeller is accessible with the removal of the
readily dropped out of the line.
spool piece or pipe section.
Example of unbalanced loading
CAUTION:
Risk of excessive axial load or cavitation. Do not install an elbow directly before the suction of
a double suction pump if the plane of the suction is parallel to the pump shaft. Alternatively,
install an elbow with straightening vanes to help evenly distribute the flow.
Model 3408 Installation, Operation, and Maintenance Manual
25
Installation
This figure shows the unbalanced loading of a double-suction impeller due to the uneven flow
around an elbow that is adjacent to the pump:
1.
2.
3.
4.
5.
Pump casing
Impeller
Pump suction flange
Suction elbow
Water velocity increases here and causes a greater flow to one side of the impeller.
Figure 15: Unbalanced loading of double-suction impeller
Examples
1.
2.
3.
4.
Level centerline of pipe
Check valve
Gate valve
Increaser
Figure 16: Suction pipe installed with a gradual rise to the pump – correct
1. Air pocket
Figure 17: Suction pipe installed with a gradual rise to the pump – incorrect
1. Air pocket
Figure 18: Suction pipe installed with a reducer – incorrect
26
Model 3408 Installation, Operation, and Maintenance Manual
Installation
1. Air pocket
Figure 19: Incorrect
1. No air pockets
2. Gradual rise
Figure 20: Correct
1. No air pockets
2. Eccentric reducer
3. Gradual rise
Figure 21: Gradual rise to the pump – correct
1. Distance plus eccentric reducer straightens the flow
Figure 22: Suction pipe above the pump – correct
1. Path of the water
Figure 23: Suction pipe above the pump – incorrect
Suction-piping valve considerations
Suction valves
CAUTION:
Never throttle the flow from the suction side. Only use suction valves to isolate the pump for
maintenance, and install such valves in positions to avoid air pockets.
Before you install suction valves in the suction piping, review these considerations:
Model 3408 Installation, Operation, and Maintenance Manual
27
Installation
• Make sure that the suction piping valves are placed right before the run of recommended
straight pipe.
• Never throttle the pump with the use of a valve on the suction side of the pump.
• Only use suction valves to isolate the pump for maintenance purposes.
• Always install the valve in a position that avoids the formation of air pockets.
Foot valves
If the pump operates under static suction lift conditions, you can install a foot valve in the
suction line in order to avoid the necessity of priming each time you start the pump.
Before you install foot valves in the suction piping, review these considerations:
• Make sure this valve is of the flapper type, rather than the multiple spring type, and that it is
sized to avoid excessive friction in the suction line.
• Size the foot valve and pipe in order to maximize NPSHA to the pump by minimizing
suction line losses.
• When foot valves are used, or where there are other possibilities of water hammer, close
the discharge valve slowly before you shut down the pump.
Check valves
In normal applications, check valves are placed in the discharge piping. Before you use a
check valve in the suction piping, consider the added pressure drop to the pump, the potential
of water hammer, and the chance of allowing the entire pump volute to be exposed to the
discharge pressure.
Gate valves
Where two or more pumps are connected to the same suction line, install gate valves so that
any pump can be isolated from the line.
Before you install gate valves, review these considerations:
• Always install gate valves on the suction side of the pumps with a positive pressure for
maintenance purposes.
• Always install gate valves with the stems in a horizontal position to avoid air pockets.
• Globe valves should not be used, particularly where NPSH is critical.
Discharge piping considerations
Before you construct discharge piping, review these considerations:
• If the discharge piping is short, then the pipe diameter can be the same as the discharge
opening.
• If the piping is long, then the pipe diameter should be one or two sizes larger than the
discharge opening.
• On long horizontal runs, it is desirable to maintain the most even grade possible.
• Avoid high spots, such as loops. High spots 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.
• The check valve is placed between the pump and the gate valve. This protects the
pump from excessive backpressure and prevents liquid from running back through the
pump in case of power failure.
• The gate valve is used for priming and starting and also shutting down the pump.
Pressure gauges
Install properly sized pressure gauges in both the suction and discharge nozzles in the gauge
taps provided. The gauges enable the operator to observe the operation of the pump and to
determine whether the pump is operating in conformance with the performance curve. If
cavitation, vapor binding, or other unstable operations occur, then widely fluctuating discharge
pressure will be noted.
28
Model 3408 Installation, Operation, and Maintenance Manual
Installation
Pump doweling
Pump units can be doweled on diagonally opposite feet. Do not do this until the unit has run for
a sufficient length of time and alignment is within the required alignment tolerance.
Model 3408 Installation, Operation, and Maintenance Manual
29
Commissioning, Startup, Operation, and Shutdown
Commissioning, Startup, Operation, and
Shutdown
Preparation for startup
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.
• Refer to driver/coupling/gear manufacturers installation and operation manuals (IOM)
for specific instructions and recommendations.
• Electrical connections must be made by certified electricians in compliance with all
international, national, state, and local rules.
• Never operate a pump without a properly installed coupling guard. Personal injury will
occur if you run the pump without a coupling guard.
• Check the rotation of the power unit and pump in relation to that of the drive as shown by
the arrows on the case. Rotate the drive manually before you apply power-checking
rotation. Do not operate in the reverse direction of these arrows as serious damage or
injury can occur.
CAUTION:
• Serious damage to the pump may result if it is started dry. Make sure that the pump is
completely filled with liquid before it is started.
System flushing
Flush new and old systems in order to eliminate all foreign matter. Heavy scale, welding
splatter, and wire or other large foreign matter can clog the pump impeller. This reduces the
capacity of the pump which then causes cavitation, excessive vibration, and/or damage to
close clearance parts such as wear rings, seals, and sleeves.
Pre-operation inspections
NOTICE:
Foreign objects in the pumped liquid or piping system can block the flow and cause excess
heat generation, sparks and premature failure. Make sure that the pump and systems are free
of foreign objects before and during operation.
Perform these inspections before you start the pump:
• Check the alignment between the pump and motor.
See Coupling alignment in the Installation chapter for alignment requirements.
• Check all connections to the motor and starting device against the wiring diagram.
Check the voltage, phase, and frequency on the motor nameplate against the line circuit.
• Check the suction and discharge piping and the pressure gauges for proper operation.
• Check that you can turn the rotating element by hand in order to verify that it rotates freely.
• Check the stuffing box adjustment, lubrication, and piping.
• Check the driver lubrication.
Refer to the driver Installation, Operation, and Maintenance manual.
30
Model 3408 Installation, Operation, and Maintenance Manual
Commissioning, Startup, Operation, and Shutdown
• Check that the pump bearings are properly lubricated.
• If the pump is oil lubrication, check that the oil level is correct prior to starting pump.
• If the pump is oil mist lubrication, check that the mist is flowing properly prior to starting
pump.
• Check that the coupling is properly lubricated, if required.
• Check that the pump is full of liquid and that all valves are properly set and operational,
with the discharge valve closed and the suction valve fully open. Purge all air from the top
of the casing.
• Check the direction of the rotation.
Be sure that the driver operates in the direction indicated by the arrow on the pump casing.
Serious damage can result if you operate the pump with the incorrect rotation. Check the
rotation each time you disconnect the motor leads.
Pump priming
CAUTION:
Do not run the pump dry.
When to prime the pump
You must prime the pump before startup. When it is possible, locate the pump below the fluid
level in order to facilitate priming and to ensure a steady flow of liquid. This condition provides a
positive suction head on the pump. It is also possible to prime the pump by pressurizing the
suction vessel.
Methods for pump priming
Pump installation
Positive head on the suction
Suction lift
Priming method
Open the suction valve and loosen the vent plug on top of the
casing. This allows air to be purged from the casing. While you
vent the air from the pump body, always rotate the pump shaft
a few times by hand.
Priming must be done by other methods such as foot valves,
ejectors, or by manually filling the casing and suction line.
Fill the system
DANGER:
All openings (e.g. pipe connections, flanges) must be sealed off with proper fitting and material
prior to filling pump. Failure to plug all openings will result in personal injury.
1. Locate the vents at the highest point so that trapped gases and air can escape.
However, if the gases are flammable, toxic, or corrosive, then vent them to an appropriate
place in order to prevent harm to personnel or to other parts of the system.
2. Check the pipe hangers and anchors to make sure that they are properly set to take the
additional weight of the pumped fluid.
3. Close all of the drains.
4. Fill the system slowly so that excessive velocities do not cause rotation of the pumping
elements.
Rotation of the pumping elements can cause damage to the pump or its driver.
5. Check the adequacy of the anchors and hangers:
a) Mount a dial indicator off of any rigid structure not tied to the piping.
Model 3408 Installation, Operation, and Maintenance Manual
31
Commissioning, Startup, Operation, and Shutdown
b) Set the indicator button on the pump flange in the axial direction of the nozzle.
If the indicator moves as the filling proceeds, then the anchors and supports are not
adequate or are not set properly. Take corrective measures.
Start the pump
1. Close the drain valves.
2. Completely open all valves in the suction and discharge lines.
3. Turn on the seal water to the stuffing box.
These lines must always be left open if the pumped fluid is dirty or if there is the possibility
of air leaks.
4. Prime the pump.
NOTICE:
Make sure that the pump is properly primed. If it is not, then shut down the pump and
correct the condition.
5. Start the pump driver.
Turbines and engines can require a brief warm-up period. Consult the instructions provided
by the engine manufacturer.
6. When the pump is operating at full speed, make sure that the check valve has opened.
The check valve must open five seconds or less after startup in order to prevent damage to
the pump by operating at zero flow.
7. Adjust the liquid seal valves to produce the recommended pressure for either the
mechanical seal or the packed stuffing box.
Operational checklist
Check
Driver rotation
Explanation/comment
Check the rotation each time the motor leads are disconnected.
Checked
WARNING:
Check the rotation of the power unit
and pump in relation to that of the
drive as shown by the arrows on
the case. Rotate the drive manually
before you apply power-checking
rotation. Do not operate in the reverse direction of these arrows as
serious damage or injury can occur.
Stuffing box adjustment
Flow
32
Make stuffing box packing gland and lubrication adjustments.
It is difficult to accurately measure flow rate (volume/
time). Any of the following methods of measuring can be
used:
• Venturi meters
• Flow nozzles
• Orifice plates
• Timing the draw down in the wet well
Record any reading for future reference.
Model 3408 Installation, Operation, and Maintenance Manual
Commissioning, Startup, Operation, and Shutdown
Check
Explanation/comment
Pressure
Check and record both suction and discharge pressure
gauge readings for future reference. Also record the
following:
• Voltage
• Amperage per phase
• Kilowatts (if an indicating wattmeter is available)
• Pump speed
Check and record bearing temperatures using a
thermometer. The temperature should not exceed 180°F
(82°C).
The acceptable vibration level of a centrifugal pump
depends on the rigidity of the pump and the supporting
structure. Recommended values for vibration can vary
between 0.20–0.60 ips (inches per second) velocity
depending on the operating characteristics and the
structure. Refer to the Centrifugal Pump section of the
Hydraulic Institute Standards for a complete description
and charts on various pumps.
Field sound levels are difficult to measure because of
background noise from piping, valves, drivers, gears,
and other parts. Follow the recommendations in the
Hydraulic Institute Standards.
Temperature
Vibration and sound
Checked
Shut down the pump
WARNING:
Always disconnect and lock out power before servicing to prevent unexpected startup. Failure
to do so could result in death or serious injury.
The pump can handle hazardous and toxic fluids. Identify the contents of the pump and
observe proper decontamination procedures in order to eliminate the possible exposure to any
hazardous or toxic fluids. Wear the proper personal protective equipment. Potential hazards
include, but are not limited to, high temperature, flammable, acidic, caustic, explosive, and
other risks. You must handle and dispose of pumped fluid in compliance with the applicable
environmental regulations.
1. Shut down the pump driver.
Consult the manufacturer instructions for special operations.
2. Close the suction and discharge valves.
3. Close the seal liquid valves.
However, in order to prevent contamination to the packing, leave these lines open unless
the pump is completely drained.
4. Open drain valves as required.
Freeze protection
Pumps that are shut down during freezing conditions must be protected using one of the
following methods:
• Drain the pump and remove all liquid from the casing.
• Keep fluid moving in the pump and insulate or heat the pump to prevent freezing.
NOTICE:
If heat is used to prevent the pump from freezing, then the temperature should not rise above
150°F (66°C).
Model 3408 Installation, Operation, and Maintenance Manual
33
Maintenance
Maintenance
Maintenance schedule
CAUTION:
Shorten the inspection intervals if the pumped liquid is abrasive or corrosive, or if the
environment is classified as potentially explosive.
NOTICE:
This timetable assumes that the unit has been constantly monitored after startup. Adjust the
timetable for any extreme or unusual applications or conditions.
Monthly inspections
Check the bearing temperature with a thermometer. Do not check the temperature by hand. If
the bearings are running over 180°F (82°C), then there is too much or too little lubricant.
If changing the lubricant or adjusting to the proper level does not correct the condition, then
disassemble and inspect the bearings.
Three-month inspections
Perform these tasks every three months:
• Check the oil on oil-lubricated units.
• Check the grease-lubricated bearings for saponification. This condition is usually caused
by the infiltration of water or other fluid. Saponification gives the grease a whitish color. If
this condition occurs, then wash out the bearings with a clean industrial solvent and
replace the grease with the proper type as recommended.
Six-month inspections
Perform these tasks every six months:
• Check the packing and replace if necessary. Use the grade recommended. Make 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.
• Check the shaft or shaft sleeve for scoring. Scoring accelerates packing wear.
• Check the alignment of the pump and driver. Shim the units if necessary. If misalignment
reoccurs frequently, then inspect the entire piping system. Unbolt the piping at the suction
and discharge flanges to see if it springs away, which indicates strain on the casing.
Inspect all piping supports for soundness and effective support of load. Correct as
necessary.
Annual inspections
Perform these inspections one time each year:
• Remove the upper half of the casing. Inspect the pump thoroughly for wear. Order
replacement parts if necessary.
• Check the wear ring clearances. Replace the wear rings when clearances become three
times their normal clearance or when you observe a significant decrease in discharge
pressure for the same flow rate.
• Remove any deposit or scaling.
• Clean out the stuffing box piping.
34
Model 3408 Installation, Operation, and Maintenance Manual
Maintenance
• Measure the total dynamic suction and discharge head in order to test pump performance
and pipe condition. Record the figures and compare them with the figures of the last test.
This is especially important where the pumped liquid tends to form a deposit on internal
surfaces.
• Inspect foot valves and check valves. A faulty foot or check valve will cause poor
performance. The check valve safeguards against water hammer when the pump stops.
Flood-damaged pumps
If the pump is properly sealed at all joints and connected to both suction and discharge, then it
will exclude outside liquid. Therefore, it is only necessary to service the bearings, stuffing box,
and coupling after flood damage.
Perform the following service on a centrifugal pump after a flooded condition:
• Dismantle the frame, and then inspect the bearings for any rusted or badly worn surfaces.
Clean as necessary. If the bearings are free from rust and wear, then reassemble and
relubricate them with one of the recommended lubricants. Depending on the length of time
the pump has remained in the flooded area, it is unlikely that bearing replacement is
necessary. Only replace the bearings if rust or worn surfaces appear.
• Inspect the stuffing box and clean out any foreign matter that will clog the box. Replace
packing that appears to be worn or no longer regulates leakage properly. Clean and
thoroughly flush mechanical seals.
• Dismantle and thoroughly clean the couplings. Lubricate the couplings where required with
one of the lubricants recommended by the coupling manufacturer.
Bearing maintenance
These bearing lubrication sections list different temperatures of the pumped fluid. If the
pump is ATEX-certified and the temperature of the pumped fluid exceeds the permitted
temperature values, then consult your ITT representative.
Regrease the grease-lubricated bearings
CAUTION:
Grease-lubricated bearings are lubricated at the factory. Do not grease too frequently.
NOTICE:
Make sure that the grease container, the greasing device, and the fittings are clean. Failure to
do this can result in impurities entering the bearing housing when you regrease the bearings.
Model 3408 Installation, Operation, and Maintenance Manual
35
Maintenance
1. Relief plug
2. Fitting
Figure 24: Grease lubricated bearings
1. Wipe dirt from the grease fittings.
2. Remove the two grease-relief plugs on the bearing housings.
3. Fill both of the grease cavities through the fittings with a recommended grease until the
fresh grease comes out of the relief holes.
4. Run the pump for about 30 minutes or until grease no longer comes out of the housing.
5. Reinstall the grease-relief plugs.
6. Wipe off any excess grease.
7. Recheck the alignment.
The bearing temperature usually rises after you regrease due to an excess supply of grease.
Temperatures return to normal in about two to four operating hours as the pump runs and
purges the excess grease from the bearings.
Lubricating-grease requirements
Grease-lubricated ball bearings are standard on this model. A grease-lubricated bearing can be
identified by grease fittings located on the bearing housing.
Precautions
NOTICE:
• Never mix greases of different consistencies (NLGI 1 or 3 with NLGI 2) or with different
thickeners. For example, never mix a lithium-based grease with a polyurea-based grease.
Doing so may result in decreased performance.
• Remove the bearings and old grease if you need to change the grease type or
consistency. Failure to do so may result in equipment damage or decreased performance.
Recommended grease types
• Mobilux EP No. 2
• Texaco Multifak EP-2
• ShellAlvania EP-2
Requirements
Keep the following points in mind when lubricating with grease:
• Grease must be of sodium or lithium base with a NLGI-2 consistency. Do not use graphite.
• Greases made from animal or vegetable oils are not recommended due to the danger of
deterioration and forming of acid.
36
Model 3408 Installation, Operation, and Maintenance Manual
Maintenance
• Additional or replacement lubricant must be added after 2,000 hours or at three-month
intervals.
• Replace the lubricant in the housings at least once annually. This must be done when an
overhaul is made.
• When greasing anti-friction bearings, do not use high-pressure equipment. High pressure
can damage the bearings or seals, cause unnecessary loss of grease, create a danger of
overheating due to over greasing, and produce unsightly conditions around the bearing.
• Excess grease is the most common cause of overheating. Maintain the grease level at
about the capacity of the bearing and 1/3 to 1/2 of the cavity between the bearing and
grease fitting. Any greater amount will be discharged by the seal or vent.
Lubricate the oil-lubricated bearings
Oil lubrication is optional. Oil-lubricated pumps are installed with Trico oilers. The oilers keep
the oil level in the housings constant at the proper level.
1.
2.
3.
4.
5.
6.
7.
Reservoir
Thumb screw
Level adjuster mechanism
Lower casting
Vent assembly
Bearing housing
Pipe plug
Figure 25: Oiler assembly
1.
2.
3.
4.
5.
6.
7.
8.
Remove the vent assembly from the top of the bearing housing.
Remove the pipe plug from the bottom of the bearing housing.
Unscrew and remove the reservoir.
Flush the oiler and bearing housing with a light grade of oil until all foreign particles are
removed.
Screw the pipe plug and vent assembly back into place.
Set the level adjuster mechanism using the heights specified in Level adjuster heights
(page 38).
Place the level adjuster back in the lower casting.
Fill the reservoir with a good grade of filtered mineral oil.
NOTICE:
Make sure to fill the oiler and bearing housing with oil through the oiler reservoir.
9. Back out the thumb screw on the side of the lower casting.
Model 3408 Installation, Operation, and Maintenance Manual
37
Maintenance
This ensures that the thumb screw will not interfere with setting the reservoir in the lower
casting.
10. Place your thumb over the reservoir spout, invert the reservoir, and place it onto the lower
casting while removing your thumb.
Allow the reservoir to empty as it fills the bearing housing. You will need to fill the reservoir
several times before the correct level is reached.
When the correct oil level is reached, no more oil will run out of the reservoir.
11. Retighten the thumb screw.
After you start the pump, make trial adjustments to the level adjuster mechanism in order to
prevent oil levels that are too high or too low. Adjust by repeating the appropriate steps in this
procedure.
A periodic filling of the reservoir is required. When the oil becomes dirty, repeat this procedure.
Lubricating-oil requirements
Oil specifications
Use oils that meet these specifications. These oils are furnished by all major oil companies. It is
the responsibility of the oil vendor to supply a suitable lubricant.
Do not mix oils from different suppliers.
Specification
Saybolt viscosity at 100°F (38°C)
Saybolt viscosity at 210°F (99°C)
Viscosity index, minimum
API gravity
Pour point, maximum
Flash point, minimum
Additives
ISO viscosity
Requirement
215 SSU – 240 SSU
49 SSU
95
28–33
+20°F (-6.7°C)
400°F (204°C)
Rust and oxidation inhibitors
46
Oil quality
The oil must be a well-refined, good grade, straight cut, filtered mineral oil. It must be free from
water, sediment, resin, soaps, acid, and fillers of any kind. It must also be non-foaming with a
viscosity of about 215-240 SSU at 100°F (38°C) (approximately SAE-20).
Lubrication schedule
In installations with moderate temperature changes, low humidity, and a clean atmosphere,
change the oil after approximately 1,000 hours of operation. Inspect the oil at this time to
determine the operating period before the next oil change. Oil change periods may be
increased up to 2,000–4,000 hours based on an 8,000-hour year. Check the oil frequently for
moisture, dirt or signs of breakdown, especially during the first 1,000 hours.
CAUTION:
Risk of bearings overheating and failing.
• Do not over oil the bearings.
• The maximum operating temperature for ball bearings is 180°F (82°C).
• If the temperature of the bearing frame exceeds 180°F (82°C) (measured by thermometer), shut down the pump to determine the cause.
• Do not mix oils from different suppliers.
Level adjuster heights
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Model 3408 Installation, Operation, and Maintenance Manual
Maintenance
Pump size
Inboard
2x3-11
4x6-9
4x6-12
4x6-14
6x6-9
6x8-9
6x8-12
4x6-10
6x8-13
4x6-11
6x8-10
6x8-17
6x8-18
6x8-12M
8x8-12
8x8-17
8x10-12
8x10-17
10x10-12
10x12-12
10x12-14
10x12-17
8x10-20
10x12-18
Dimension A
Outboard
1.12
1.12
0.53
0.56
1.22
0.53
Bearing temperatures
• Bearing temperatures up to 180°F (82°C) are normal. For accurate measurement, place a
contact-type thermometer against the bearing housing. Record the reading in a convenient
location for reference.
• The stability of the temperature, rather than the number of degrees, is the best indication
of normal operation. A sudden increase in temperature is an indication of danger and a
signal to investigate. Check the unit for abnormal hydraulic operation and unnecessary
loads, such as coupling misalignment. See Troubleshooting (page 71).
• Do not use the human hand as a thermometer. A temperature that feels hot to the hand
can vary from 120°F (49°C) to 130°F (54°C) depending upon the individual. Above this
temperature, the human hand can not accurately estimate temperature.
Coupling lubrication
Flexible couplings
Flexible couplings, such as Wood’s Sure-Flex or Falk Torus coupling, provide smooth
transmission of power. There is no rubbing action of metal against rubber to cause wear.
Couplings are not affected by abrasives, dirt, or moisture. This eliminates the need for
lubrication or maintenance and provides clean and quiet performance.
If other types of couplings are used, then follow the maintenance instructions provided by the
coupling manufacturer.
Shaft-seal maintenance
Packed stuffing box maintenance
Check or instruction
When starting a pump with fiber packing
for the first time, make sure that the
packing is slightly loose without causing
an air leak. As the pump runs in, gradually tighten the gland bolts evenly.
Model 3408 Installation, Operation, and Maintenance Manual
Explanation/comment
Never draw the gland to the point where the packing is
compressed too tightly and no leakage occurs. This will burn
the packing, score the shaft sleeve, and prevent circulation of
the liquid that cools the packing.
39
Maintenance
Check or instruction
Turn the rotating element by hand.
Explanation/comment
The stuffing box is improperly packed or adjusted if friction in
the box prevents turning the rotating element by hand. A
properly operated stuffing box runs lukewarm with a slow drip
of sealing liquid.
After the pump has been in operation for This indicates proper packing, shaft sleeve lubrication, and
some time and the packing is completely cooling.
run in, check that the stuffing box leaks at
the rate of 40–60 drops per minute.
NOTICE:
Eccentricity of the shaft or sleeve through the packing can
result in excess leakage. Make sure that the parts are properly
centered.
Check the packing frequently and replace Six months is a reasonable expected life, depending on
as service indicates.
operating conditions. Use a packing tool in order to remove all
old packing from the stuffing box. Never reuse old packing or
add new rings to old packing. Clean the stuffing box thoroughly before you install new packing.
Check the condition of the shaft or sleeve —
for possible scoring or eccentricity and
make replacements as necessary.
When placing new, non-asbestos pack- —
ing into the stuffing box, open the molded
rings sideways and push the joints into
the stuffing box first. Then install the rings
one at a time, making sure to seat each
ring firmly. Stagger the joints at a 90°
rotation from each preceding joint.
If coil packing is used, then cut one ring An accurately cut butt joint is superior to a poorly fitted mitered
to the accurate size with either a butt or joint.
mitered joint. Fit the ring over the shaft to Make sure that each ring is firmly seated.
assure the proper length, and then remove and cut all the rings to this first
sample. When you place the rings
around the shaft, make sure to form a
tight joint. Place the first ring in the
bottom of the stuffing box. Then install
each succeeding ring. Stagger the joints
at a 90° rotation.
If a seal cage is supplied, check that it is The function of the seal cage is to establish a liquid seal
properly located in the stuffing box under around the shaft, to prevent leakage of air through the stuffing
the sealing water inlet.
box, and to lubricate the packing. If it is not properly located,
then it serves no purpose.
Mechanical seal maintenance
Keep in mind the following general rules regarding mechanical seal maintenance. Refer to the
instructions provided by the seal manufacturer for detailed information.
• Mechanical seals are precision products that must be treated with care. Use special care
when handling seals. Make sure that oil and parts are clean in order to prevent scratching
the finely lapped sealing faces. Even light scratches on these faces can result in leaky
seals.
• Mechanical seals typically require no adjustment or maintenance except for routine
replacement of worn or broken parts.
• A used mechanical seal should not be put back into service unless the sealing faces have
been replaced or relapped. Relapping is practical only for seals that are 2 in. (5.1 cm) or
larger.
For optimum seal life, always follow these precautions:
• Keep the seal faces as clean as possible.
• Keep the seal as cool as possible.
• Make sure the seal always has proper lubrication.
• If the seal is lubricated with filtered fluid, then clean the filter frequently.
40
Model 3408 Installation, Operation, and Maintenance Manual
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. 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.
• Refer to driver/coupling/gear manufacturers installation and operation manuals (IOM)
for specific instructions and recommendations.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and
wear steel-toed shoes at all times.
• The pump can handle hazardous and toxic fluids. Identify the contents of the pump and
observe proper decontamination procedures in order to eliminate the possible exposure to
any hazardous or toxic fluids. Wear the proper personal protective equipment. Potential
hazards include, but are not limited to, high temperature, flammable, acidic, caustic,
explosive, and other risks. You must handle and dispose of pumped fluid in compliance
with the applicable environmental regulations.
• A small amount of liquid will be present in certain areas like the seal chamber.
NOTICE:
• Avoid injury. Worn pump components can have sharp edges. Wear appropriate gloves
while handling these parts.
• Make sure that all replacement parts are available before you disassemble the pump for
overhaul.
Change the rotation
CAUTION:
Risk of motor running hot. Make sure that the motor fan is bidirectional. If it is not bidirectional,
then turn it around or replace it.
These centrifugal pumps can be operated clockwise or counterclockwise when viewed from the
coupling end of the pump.
Model 3408 Installation, Operation, and Maintenance Manual
41
Maintenance
1. Discharge
2. Clockwise rotation
3. Suction
Figure 26: Clockwise rotation viewed from the coupling end
1. Suction
2. Counterclockwise rotation
3. Discharge
Figure 27: Counter\clockwise rotation viewed from the coupling end
Use the following instructions to reverse the suction and discharge nozzles, which changes the
rotation:
1. Remove the impeller from the shaft, turn it 180°, and replace it on the shaft.
Make sure to use the disassembly and assembly instructions in this manual.
2. With the rotating element out of the casing, remove the casing from the baseplate and turn
the casing 180°.
Factory-supplied baseplates are drilled for both rotations.
3. Put the rotating element back in the casing and reassemble the pump.
The impeller and casing are in the same relationship to each other as they were originally.
The shaft and motor are also in the same relationship to each other as they were originally.
4. Reassemble the pump and realign the coupling as specified in the alignment instructions.
5. Switch the motor leads in order to reverse the motor rotation.
If you do not reverse the motor rotation, then the impeller will not rotate in the right
direction.
42
Model 3408 Installation, Operation, and Maintenance Manual
Maintenance
Remove the upper half of the casing
1. Drain the pump by opening the vent plug and removing the drain plugs on the suction and
discharge nozzles.
1. Vent plug
2. Drain plug
3. Drain plug
Figure 28: Pump draining
2. Remove all casing main joint capscrews and dowels.
3. Remove the external tubing if applicable.
4. Insert a screwdriver or pry bar into the slots between the upper and lower casing halves
and separate the halves.
Some casings have jacking screws. If the casing has jackscrews, then you would use them
to separate the casing halves, instead of a pry bar.
5. Lift the upper half of the casing by the cast lugs.
Remove the rotating element
1. Tap the stuffing boxes with a soft-headed hammer in order to break the seal between the
stuffing box and lower half of the casing.
2. Lift the rotating element out of the lower half of the casing.
3. Move the rotating element to a suitable working location.
A spare rotating element can be installed at this point.
Figure 29: Rotating element
Disassemble the pump with packing
1. Remove the four capscrews (3-904-9) from each bearing housing (3-025-3 and 3-025-4),
and then remove the bearing housings from the shaft (3-007-0).
Model 3408 Installation, Operation, and Maintenance Manual
43
Maintenance
2. Remove the bearings:
a) Bend back the lockwasher tab and remove the locknut (3-516-4) and lockwasher (3517-4) from the outboard end of the shaft.
b) Use a puller to remove the outboard-end bearing (3-026-4) from the shaft.
c) Remove the inboard-end bearing (3-026-3) in the same manner.
Inboard bearings do not use a locknut, lockwasher, or thrust washer.
NOTICE:
Save the bearings for inspection. Do not reuse the bearings. Doing so may result in
decreased performance.
3. Slide both stuffing boxes (3-073-9) off the shaft. Work the deflector rings (3-136-9) off the
shaft at the same time.
Figure 30: Stuffing box removal
4. Remove the lip seals (3-177-9) from the stuffing boxes.
5. Remove the two gland bolts (1-904-9), gland halves (1-014-9), packing (1-924-9) and seal
cage (1-013-9) from each stuffing box.
Some pumps are not supplied with seal cages.
6. Remove the O-rings (3-914-1) from the stuffing boxes.
7. Remove the two casing rings (3-003-9) from the impeller (4-002-0), and then remove the Orings (3-914-2) from each casing ring.
Each casing ring on sizes 8x10-20 and 10x12-18 has 2 O-rings.
44
Model 3408 Installation, Operation, and Maintenance Manual
Maintenance
1.
2.
3.
4.
5.
O-ring
Impeller
Floating casing ring
Casing
O-ring
Figure 31: Casing rings
8. Loosen the setscrew (3-902-3) in the shaft nuts (3-015-9), and then remove the shaft nuts
with a pin spanner wrench.
Both shaft nuts have right-hand threads.
9. Remove the O-rings (3-914-9) from the counterbore in the shaft sleeves.
10. Hold the shaft vertically and tap it on a block of wood to remove the sleeve. The weight of
the impeller will force both the impeller and sleeve from the shaft.
There is a silicone adhesive/sealant between the sleeve and the impeller.
11. Remove the other shaft sleeve, nut, and sleeve O-ring as described in the previous three
steps.
Model 3408 Installation, Operation, and Maintenance Manual
45
Maintenance
12. If the impeller has replaceable rings, then cut the rings (0-004-0) with a cold chisel in order
to remove them.
•
•
•
•
•
•
3-009-9: Sleeve
0-004-4: Impeller ring
3-003-9: Casing ring
4-002-0: Impeller
2-001-0: Casing
3-943-9: Locking pin
Figure 32: Impeller with replaceable rings
13. Remove the impeller key (3-911-1) from the shaft.
Disassemble the pump with mechanical seals on the shaft
1. Remove the four capscrews (3-904-9) from each bearing housing (3-025-3 and 3-025-4),
and then remove the bearing housings from the shaft (3-007-0).
2. Remove the bearings:
a) Bend back the lockwasher tab and remove the locknut (3-516-4) and lockwasher (3517-4) from the outboard end of the shaft.
b) Use a puller to remove the outboard-end bearing (3-026-4) from the shaft.
c) Remove the inboard-end bearing (3-026-3) in the same manner.
Inboard bearings do not use a locknut, lockwasher, or thrust washer.
NOTICE:
Save the bearings for inspection. Do not reuse the bearings. Doing so may result in
decreased performance.
46
Model 3408 Installation, Operation, and Maintenance Manual
Maintenance
3. Slide both stuffing boxes (3-073-9) off the shaft. Work the deflector rings (3-136-9) off the
shaft at the same time.
Figure 33: Stuffing box removal
4.
5.
6.
7.
Remove the lip seals (3-177-9) and O-rings (3-914-1) from the stuffing boxes.
Drive both mechanical seal seats (3-401-0) from both the stuffing boxes.
Remove the mechanical seal head (3-402-0) from the pump shaft.
Remove the two casing rings (3-003-9) from the impeller (4-002-0), and then remove the Orings (3-914-2) from each casing ring.
Figure 34: Casing ring and O-ring removal
8. Remove the impeller from the shaft as follows:
a) Remove the impeller retaining ring (3-915-1) with retaining ring pliers.
Model 3408 Installation, Operation, and Maintenance Manual
47
Maintenance
b) Heat the impeller hub on both ends to a maximum of 350°F (176°C), and then pull or
push the impeller off the shaft.
Make sure to press away from the coupling end.
Instead of heating the impeller, you can also use a press to push the impeller off the
shaft.
Figure 35: Press to push impeller off shaft
9. If the impeller has replaceable rings, then cut the rings (0-004-0) with a cold chisel in order
to remove them.
•
•
•
•
•
•
48
3-009-9: Sleeve
0-004-4: Impeller ring
3-003-9: Casing ring
4-002-0: Impeller
2-001-0: Casing
3-943-9: Locking pin
Model 3408 Installation, Operation, and Maintenance Manual
Maintenance
Figure 36: Impeller with replaceable rings
10. Remove the impeller key (3-911-1) from the shaft.
Disassemble the pump with mechanical seals on the shaft sleeve
1. Remove the four capscrews (3-904-9) from each bearing housing (3-025-3 and 3-025-4),
and then remove the bearing housings from the shaft (3-007-0).
2. Remove the bearings:
a) Bend back the lockwasher tab and remove the locknut (3-516-4) and lockwasher (3517-4) from the outboard end of the shaft.
b) Use a puller to remove the outboard-end bearing (3-026-4) from the shaft.
c) Remove the inboard-end bearing (3-026-3) in the same manner.
Inboard bearings do not use a locknut, lockwasher, or thrust washer.
NOTICE:
Save the bearings for inspection. Do not reuse the bearings. Doing so may result in
decreased performance.
3. Slide both stuffing boxes (3-073-9) off the shaft. Work the deflector rings (3-136-9) off the
shaft at the same time.
Figure 37: Removal of stuffing boxes from shaft
4.
5.
6.
7.
Remove the lip seals (3-177-9) and O-rings (3-914-1) from the stuffing boxes.
Drive both mechanical seal seats (3-401-0) from both the stuffing boxes.
Remove the mechanical seal head (0-400-0) from the pump shaft sleeve.
If you must remove the set collar (3-421-9), then scribe a line on the shaft sleeve (3-009-9)
flush with the end of the seal to record the location of the mechanical seal.
8. Remove the two casing rings (3-003-9) from the impeller (4-002-0), and then remove the Orings (3-914-2) from each casing ring.
Model 3408 Installation, Operation, and Maintenance Manual
49
Maintenance
Figure 38: Removal of casing rings and O-rings
Each casing ring on sizes 8x10-20 and 10x12-18 has 2 O-rings.
1.
2.
3.
4.
5.
O-ring
Impeller
Floating casing ring
Casing
O-ring
Figure 39: Casing rings
9. Loosen the setscrew (3-902-3) in the shaft nuts (3-015-9), and then remove the shaft nuts
with a pin spanner wrench.
Both shaft nuts have right-hand threads.
10. Remove the O-rings (3-914-9) from the counterbore in the shaft sleeves.
11. Hold the shaft vertically and tap it on a block of wood to remove the sleeve. The weight of
the impeller will force both the impeller and sleeve from the shaft.
There is a silicone adhesive/sealant between the sleeve and the impeller.
12. Remove the other seal, shaft sleeve, sleeve O-ring, and nut as described in the previous
three steps.
50
Model 3408 Installation, Operation, and Maintenance Manual
Maintenance
13. If the impeller has replaceable rings, then cut the rings (0-004-0) with a cold chisel in order
to remove them.
•
•
•
•
•
•
3-009-9: Sleeve
0-004-4: Impeller ring
3-003-9: Casing ring
4-002-0: Impeller
2-001-0: Casing
3-943-9: Locking pin
Figure 40: Impeller with replaceable rings
14. Remove the impeller key (3-911-1) from the shaft.
Preassembly
Replace wear parts
When you reassemble the pump, make sure to do the following:
Replace all bearings, O-rings, lip seals, impeller rings, casing wear rings and the gasket with
new parts.Clean all reusable parts of foreign matter.Make the main casing joint gasket by using
the upper or lower half as a template:
a) Lay the gasket material on the casing joint.
b) Tap lightly with a ball peen hammer so that the gasket is trimmed flush with the inside
edges of the casing.
Reassembly
Assemble the pump with packing
1. Insert the impeller key (3-911-1) in the key slot on the shaft.
2. Check the impeller (4-002-0) and casing to determine the correct impeller rotation and
locate the impeller on the shaft using dimension A as specified in (page ).
Model 3408 Installation, Operation, and Maintenance Manual
51
Maintenance
For the correct impeller rotation, refer to Change the rotation (page 41).
3. If the impeller has replaceable rings, then heat each new ring (0-004-0) to approximately
300–400°F (149–204°C), and then slide them onto the impeller.
Wear gloves and hold the rings against the impeller until they cool.
4. Starting with the outboard end, apply a 1/4 in. (0.6 cm) bead of silicone sealant at the
impeller hub face.
Make sure to fill up the keyway.
5. Slide the sleeve (3-009-9) onto the shaft as you rotate the sleeve to evenly distribute the
sealant applied in the previous step.
Refer to Install the packing (optional method) (page 64) before mounting the sleeve on the
shaft.
NOTICE:
The pin in each shaft sleeve must seat in the impeller key slot.
6. Place the sleeve O-ring (3-914-9) onto the shaft and fit into the sleeve counterbore, and
then insert the shaft sleeve nut (3-015-9).
7. Repeat the previous three steps for the inboard shaft sleeve, O-ring, and nut.
Make sure to wipe off excess silicone sealant.
8. Verify that dimension A is maintained, and then use a pin spanner wrench and a hammer to
securely tighten the shaft sleeve nuts.
9. Drill a shallow recess in the shaft through the setscrew hole in each of the shaft sleeve
nuts, and lock each shaft sleeve nut in position with serrated head setscrews (3-902-3).
A low-strength sealant such as Loctite 271 can be used to retain the setscrews.
Figure 41: Shaft sleeve locking with setscrews
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Model 3408 Installation, Operation, and Maintenance Manual
Maintenance
10. Lubricate and roll an O-ring (3-914-2) into the groove in each casing ring (3-003-9) and
slide the casing rings over the impeller.
Figure 42: Slide casing rings over impeller
Each casing ring on sizes 8x10-20 and 10x12-18 has 2 O-rings.
1.
2.
3.
4.
5.
O-ring
Impeller
Floating casing ring
Casing
O-ring
Figure 43: Casing rings
11. Lubricate the lip seal with a lightweight oil, and then press a new lip seal (3-177-9) into
each stuffing box.
Seat the lip seals against the machined shoulder in the bracket. Make sure that the seal lip
points away from the bearings (3-026-3 and 3-026-4) if the bearings are grease-lubricated,
and that the seal lip points towards the bearings if the bearings are oil-lubricated.
Model 3408 Installation, Operation, and Maintenance Manual
53
Maintenance
NOTICE:
• Lip seals must seat against the machined shoulder in the bracket.
• Make sure that the seal lip either points away from the bearings if the bearings are
grease-lubricated, or points towards the bearings if the bearings are oil-lubricated.
Figure 44: Lip seal reassembly
12. Lubricate and roll an O-ring (3-914-1) into the groove of each stuffing box.
Setting dimensions for a pump with packing
Figure 45: Setting dimensions for a pump with packing
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Model 3408 Installation, Operation, and Maintenance Manual
Maintenance
Pump size
2x3-11
4x6-9
4x6-10
4x6-11
4x6-12
4x6-14
6x6-9
6x8-9
6x8-10
6x8-12
6x8-12M
6x8-13
6x8-17
6x8-18
8x8-12
8x8-17
8x10-12
8x10-17
8x10-20
10x10-12
10x12-12
10x12-14
10x12-17
10x12-18
Dimension A
8.755
9.312
10.625
10.750
9.755
9.312
9.755
10.625
9.755
Packing size
3/8
1/2
3/8
1/2
3/8
10.625
11.495
1/2
11.620
12.995
11.495
Assemble the pump with mechanical seals on the shaft
1. Insert the impeller key (3-911-1) in the key slot on the shaft.
2. Check the impeller (4-002-0) and casing to determine the correct relationship, and then
heat the impeller evenly to a maximum of 300°F (149°C) to expand the bore.
For the correct impeller rotation, refer to Change the rotation (page 41).
You can press the impeller onto the shaft instead of heating if a suitable press is available.
Figure 46: Pump reassembly
3. If the impeller has replaceable rings, then heat each new ring (0-004-0) to approximately
300–400°F (149–204°C), and then slide them onto the impeller.
Wear gloves and hold the rings against the impeller until they cool.
4. From the outboard end, slide the heated impeller (4-002-0) onto the shaft (3-007-0) against
the shaft shoulder, and then install the retaining ring (3-915-1).
Model 3408 Installation, Operation, and Maintenance Manual
55
Maintenance
CAUTION:
Wear insulated gloves when handling the impeller. The impeller will get hot and can cause
physical injury.
5. Lubricate and roll an O-ring (3-914-2) into the groove in each casing ring (3-003-9) and
slide the casing rings over the impeller.
6. Thoroughly clean the stuffing boxes (3-073-9) to prevent dirt from entering the seal during
startup.
7. Press the stationary seats (0-400-0) of the mechanical seals into both stuffing boxes with
the lapped surface facing the impeller. Lightly lubricate the stuffing box bore to ease
assembly.
Figure 47: Press mechanical seal stationary seats into stuffing boxes
8. Lubricate the lip seal with a lightweight oil, and then press a new lip seal (3-177-9) into each
stuffing box.
Seat the lip seals against the machined shoulder in the bracket. Make sure that the seal lip
points away from the bearings (3-026-3 and 3-026-4) if the bearings are grease-lubricated,
and that the seal lip points towards the bearings if the bearings are oil-lubricated.
9. Lubricate and roll an O-ring (3-914-1) into the groove of each stuffing box.
10. Lightly coat the outboard end of the shaft with STP motor oil treatment or equivalent and
slide the mechanical seal head (0-400-0) onto the shaft.
The standard mechanical seal for this arrangement is a modified John Crane Type 21
Mechanical Seal.
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Model 3408 Installation, Operation, and Maintenance Manual
Maintenance
NOTICE:
The bearings and gaskets must be installed within 10 to 12 minutes after this step is
completed. This assures proper placement of the mechanical seal. The mechanical seal
has an adhesive on the inner diameter of the elastomer. The rotating element must go into
the casing before this sealant bonds to the sleeve.
Figure 48: Slide mechanical seal head onto shaft
Assemble the pump with mechanical seals on the shaft sleeves
1. Insert the impeller key (3-911-1) in the key slot on the shaft.
2. Check the impeller (4-002-0) and casing to determine the correct relationship and locate
the impeller on the shaft according to dimension C as specified in Setting dimensions for a
pump with mechanical seals on the shaft sleeves.
For the correct impeller rotation, refer to Change the rotation (page 41).
3. If the impeller has replaceable rings, then heat each new ring (0-004-0) to approximately
300–400°F (149–204°C), and then slide them onto the impeller.
Wear gloves and hold the rings against the impeller until they cool.
4. Starting with the outboard end, apply a 1/4 in. (0.6 cm) bead of silicone sealant at the
impeller hub face.
Make sure to fill up the keyway.
5. Slide the sleeve (3-009-9) onto the shaft as you rotate the sleeve to evenly distribute the
sealant applied in the previous step.
NOTICE:
The pin in each shaft sleeve must seat in the impeller key slot.
6. Place the sleeve O-ring (3-914-9) onto the shaft and fit into the sleeve counterbore, and
then insert the shaft sleeve nut (3-015-9).
7. Repeat the previous three steps for the inboard shaft sleeve, O-ring, and nut.
Make sure to wipe off excess silicone sealant.
8. Verify that dimension C is maintained, and then use a pin spanner wrench and a hammer to
securely tighten the shaft sleeve nuts.
9. Drill a shallow recess in the shaft through the setscrew hole in each of the shaft sleeve
nuts, and lock each shaft sleeve nut in position with serrated head setscrews (3-902-3).
Model 3408 Installation, Operation, and Maintenance Manual
57
Maintenance
A low-strength sealant such as Loctite 271 can be used to retain the setscrews.
Figure 49: Shaft screw locking with setscrews
10. Lubricate and roll an O-ring (3-914-2) into the groove in each casing ring (3-003-9) and
slide the casing rings over the impeller.
Each casing ring on sizes 8x10-20 and 10x12-18 has 2 O-rings.
1.
2.
3.
4.
5.
O-ring
Impeller
Floating casing ring
Casing
O-ring
Figure 50: Casing rings
11. Thoroughly clean the stuffing boxes (3-073-9) to prevent dirt from entering the seal during
startup.
12. Press the stationary seats (0-400-0) of the mechanical seals into both stuffing boxes with
the lapped surface facing the impeller. Lightly lubricate the stuffing box bore to ease
assembly.
13. Lubricate the lip seal with a lightweight oil, and then press a new lip seal (3-177-9) into
each stuffing box.
Seat the lip seals against the machined shoulder in the bracket. Make sure that the seal lip
points away from the bearings (3-026-3 and 3-026-4) if the bearings are grease-lubricated,
and that the seal lip points towards the bearings if the bearings are oil-lubricated.
14. Lubricate and roll an O-ring (3-914-1) into the groove of each stuffing box.
15. Check dimensions A and B in Setting dimensions for a pump with mechanical seals on the
shaft sleeves (page 59) and scribe the dimensions on the shaft sleeve. Then install the set
collar (3-421-9) on the sleeve using the scribed marks as a guide.
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Model 3408 Installation, Operation, and Maintenance Manual
Maintenance
16. Drill a shallow recess in the shaft through the setscrew hole in each of the shaft sleeve
nuts, and lock each shaft sleeve nut in position with serrated head setscrews (3-902-3).
A low-strength sealant such as Loctite 271 can be used to retain the setscrews.
17. Lightly coat the outboard end of the shaft with STP motor oil treatment or equivalent and
slide the mechanical seal head (0-400-0) onto the shaft sleeve.
The bearings and gaskets must be installed within 10 to 12 minutes after this step is
completed. This assures proper placement of the mechanical seal. The mechanical seal
has an adhesive on the inner diameter of the elastomer. The rotating element must go into
the casing before this sealant bonds to the sleeve.
Setting dimensions for a pump with mechanical seals on the shaft sleeves
Figure 51: Setting dimensions for a pump with mechanical seals on the shaft sleeves
Pump size
A
2x3-11
4x6-9
4x6-10
4x6-11
4x6-12
4x6-14
6x6-9
6x8-9
6x8-10
6x8-12
6x8-12M
Type 1 mechanical Type 21 mechanical Type 1B mechanical
seal
seal (standard)
seal
Impeller
locating
dimensions
B
6.62
-
A
6.75
-
B
6.00
-
A
6.12
-
B
7.00
-
C
7.12
-
8.755
9.312
7.56
7.75
6.94
7.12
8.06
8.25
10.625
6.62
6.75
6.00
6.12
7.00
7.12
9.755
6.62
6.62
7.56
6.75
6.75
7.75
6.00
6.00
6.94
6.12
6.12
7.12
7.00
7.00
8.06
7.12
7.12
8.25
9.312
9.755
10.625
9.755
10.625
Model 3408 Installation, Operation, and Maintenance Manual
59
Maintenance
Pump size
A
6x8-13
6x8-17
6x8-18
8x8-12
8x8-17
8x10-12
8x10-17
8x10-20
10x10-12
10x12-12
10x12-14
10x12-17
10x12-18
Type 1 mechanical Type 21 mechanical Type 1B mechanical
seal
seal (standard)
seal
Impeller
locating
dimensions
B
A
B
A
B
C
7.31
7.50
6.69
6.88
7.81
8.00
10.625
7.88
8.00
7.06
7.18
8.25
8.36
11.495
7.88
8.00
7.06
7.18
8.25
8.36
12.995
7.88
8.00
7.06
7.18
8.25
8.36
11.495
Install the bearings
NOTICE:
There are several methods you can use to install bearings. The recommended method is to
use an induction heater that heats and demagnetizes the bearings. Bearings can get hot and
can cause physical injury.
CAUTION:
Wear insulated gloves when you use a bearing heater. Bearings get hot and can cause
physical injury.
1. Slide the outboard stuffing box onto the shaft so that the shaft end extends through the
packing area but does not enter the lip seal.
This will permit installation of the deflector (3-136-9).
2. Slide the deflector over the shaft end, and then carefully push the shaft end through the lip
seal and slide the stuffing box fully onto the shaft.
NOTICE:
Compress the seal spring only as far as required to install the bearings.
3. Heat the ball bearing (3-026-4).
Use either dry heat or a 10–15% soluble oil and water solution.
NOTICE:
Do not heat the bearings above 275°F (135°C).
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Model 3408 Installation, Operation, and Maintenance Manual
Maintenance
4. Using gloves, slide the heated bearing onto the shaft against the shaft shoulder.
Figure 52: Pump with packing
Figure 53: Pump with a mechanical seals on the shaft
Figure 54: Pump with mechanical seals on the shaft sleeves
5. Install the lockwasher (3-517-4) and locknut (3-516-4) on the outboard end of the shaft.
Make sure that the locknut is secured and then bend over the tabs on the lockwasher.
6. Allow the bearing to cool to room temperature.
7. On grease-lubricated bearings, do the following:
a) Coat the exposed sides with two or three ounces of recommended grease.
b) Coat the inside of the bearing housing (3-025-4) with grease and slide the housing into
place over the bearing.
8. Attach the bearing housing to the stuffing box with four capscrews (3-904-9).
9. Repeat the appropriate steps for the inboard end.
Inboard bearings do not use a locknut or lockwasher.
Install the gaskets
Precut casing gaskets minimize the amount of trimming and are available from ITT.
1. Clean the gasket surfaces of the casing.
2. Apply Scotch 3M-77 spray adhesive or equivalent to the lower half of the casing.
Model 3408 Installation, Operation, and Maintenance Manual
61
Maintenance
3. Within one minute of spraying, do the following:
a) Set the untrimmed gaskets (2-123-5 and -6) in place on the lower half of the casing.
b) Align the holes in the gaskets with the holes in the casing.
c) Press the gaskets firmly against the lower half of the casing face in the area coated by
the adhesive.
4. Trim the gaskets flush with the lower casing bores, if this has not been done yet.
NOTICE:
Avoid leakage around the stuffing box O-ring. Make sure that machined casing bores
remain sharp at the casing parting line. Make sure that the gaskets are flush with the bore
so that there is contact with the O-rings.
Install the rotating element
1. Set the rotating element in the pump casing (2-001-0), assuring the correct rotation.
Figure 55: Rotating element — pump with packing
Figure 56: Rotating element — pump with mechanical seals on the shaft
Figure 57: Rotating element — pump with mechanical seals on the shaft sleeves
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Model 3408 Installation, Operation, and Maintenance Manual
Maintenance
2. Place both stuffing box tongues in their respective casing grooves.
3. Place the pins (3-943-9) in the stuffing box and the casing wear rings in their respective
slots at the casing parting surface.
4. Correct any O-ring bulging.
CAUTION:
Do not cut or damage the O-rings when lowering the rotating element into position. Loose
casing rings indicate that all four anti-rotation pins are correctly located.
Assemble the casing
1. Lower the upper half of the casing (2-001-0) into place with the tapered dowel pins (2-9161).
2. Install the casing joint bolts (2-904-1) and tighten to the following torque values:
Screw type
5/8 in.-11 hex head capscrews (Grade 5)
7/8 in.-9 Ferry Cap Countrbor screws (Grade 8)
Torque
140 ft-lb (190 Nm) minimum
350 ft-lb (474.5 Nm) minimum
NOTICE:
Avoid leakage at the main joint. Tighten bolts to the proper values in the proper sequence
to obtain the proper gasket compression.
Figure 58: Bolt pattern
Complete the assembly with packing
Use the following procedure for a pump with packing.
Model 3408 Installation, Operation, and Maintenance Manual
63
Maintenance
1. Install twelve full rings of packing (six per stuffing box) so that there is no gap between the
packing and the stuffing box.
For the packing size, refer to Setting dimensions for a pump with packing (page 54).
Tamp the packing fully to the bottom of the stuffing box. Stagger the joints of each packing
ring at least 90 degrees. For the three adjacent rings, use the 4, 8, and 12 o’clock positions.
The last ring in each box may not be required until after the pump has operated for a period
of time.
NOTICE:
Make sure that the seal cage aligns with the seal water inlet when the packing is
compressed.
2. Assemble the glands (1-014-9), washers (0-909-0), and bolts (1-904-9) square with the
stuffing box and pull up tight.
3. Loosen the gland bolts (1-904-9) to permit the packing to expand, and then retighten finger
tight.
The final adjustment of the gland bolts must be done with the pump running. Allow thirty
minutes between adjustments. A good adjustment will allow approximately one drip per
second from each gland.
Install the packing (optional method)
1. Place the stuffing box (3-073-9) on a table or workbench with the opening of the stuffing
box facing up.
2. Assemble the packing as specified in Complete the assembly with packing (page 63) with
the shaft sleeve placed in the stuffing box.
3. Remove the shaft sleeve and continue to assemble the pump as specified in the
reassembly topics earlier in this section.
4. Place the entire assembly into position over the sleeve as specified in Install the bearings
(page 60).
Vertical units
Remove the upper half of the casing
Before you begin, the rotating element must be strapped to the lower half of the casing or to the
pedestal.
If only the upper half of the casing will be removed in order to inspect the rotating element, then
you do not need to remove the line shafting or motor.
1. Remove the larger of the two pipe plugs from the top of the upper half of the casing, and
then install an 18–24 in. (46–61 cm) solid bar that is threaded at one end into the exposed
tapped hole.
If a threaded bar is not available, then you can use standard pipe.
This bar will be used to stabilize the upper half during disassembly of upper half of the
casing.
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Model 3408 Installation, Operation, and Maintenance Manual
Maintenance
1. Stabilizer bar, 18–24 in. (46–61 cm)
Figure 59: Stabilizer
2. Disconnect the seal water lines at the stuffing boxes and remove the gland bolts.
3. Remove the dowel pins and all parting line bolts except for the two upper most and two
lower most.
1. Upper most bolts
2. Lower most bolts
Figure 60: Dowel pin and parting line bolts
Model 3408 Installation, Operation, and Maintenance Manual
65
Maintenance
4. Place nylon slings around upper-half casing ears and pull the slings taut so that they
cannot slip off.
Figure 61: Nylon sling placement
5. Remove the two lower most bolts, and then remove one of the two upper most bolts.
Maintain downward pressure on the stabilizing rod when removing these bolts.
6. While maintaining downward pressure on the stabilizer bar, loosen the remaining upper
most bolt.
WARNING:
Crush hazard. Do not remove the last bolt completely yet.
7. Separate the upper and lower halves with a pry bar between the two halves.
Alternately, you can use jacking screws if the top half is provided with tapped holes.
8. When the halves separate, slide the upper half away from the lower half, maintain
downward pressure on the stabilizing rod end furthest from the pump, and slowly remove
the remaining upper most bolt.
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Model 3408 Installation, Operation, and Maintenance Manual
Maintenance
9. While you balance the upper half with the stabilizing rod, lower the upper half to the ground
and allow it to rotate so that the main joint flange rests on the ground.
1. Rotate
2. Main joint flange
Figure 62: Rotating element
The rotating element is now ready for inspection or removal. If the element is inspected and
does not need to be removed, then refer to Assemble the casing (page 63).
Remove the rotating element
You must remove the line shafting or motor before you can remove the pump-half of the
coupling.
1. Thread a long bolt, washer, and nut through the hole at the end of the shaft.
1. Coupling-end of the shaft drilled through for a long bolt with nut and washer
Figure 63: Rotating element removal
2. Place a sling around the eye bolt, putting a slight amount of tension on the sling.
3. Remove the restraining straps if the rotating element is not securely fastened to lower half
of the casing.
4. Remove the four bolts that hold each bearing housing to the casing.
5. Lightly tap on the inboard and outboard bearing housings to spread them apart, and then
slide the rotating element away from the lower half of the casing.
Model 3408 Installation, Operation, and Maintenance Manual
67
Maintenance
6. Lower the rotating element to the ground by sliding the outboard bearing housing away
from the pedestal, allowing the element to rest on the floor with the shaft in a horizontal
position.
1. Lower
2. Rotate
3. Slide
Figure 64: Lowering of rotating element
The rotating element can now be serviced using the procedures in the Disassembly section.
Assemble the rotating element
1. Inspect the main joint gasket and replace it if necessary.
2. Place a sling around the bolt in the end of the pump shaft.
On full pedestals, the lifting sling must come through the hole in the top plate of the
pedestal.
3. When the rotating element is off the ground and in a vertical position, align any anti-rotation
pins in the casing rings and stuffing boxes for proper orientation in the slots in the lower half
of the casing.
4. Move the element toward the lower half of the casing and engage the stuffing box tongue.
5. As the stuffing box tongue begins to enter the respective casing fit, raise the inboard
bearing housing into its respective fit.
6. When the stuffing box tongues are firmly seated in their respective fits and all the antirotation pins are seated in their slots, restrain the rotating element to the lower half.
Assemble the casing
1. Place a sling around the lifting ears, and then lift the upper half off the ground and rotate it
so that the main joint flange is vertical.
Make sure a stabilizing rod is installed.
2. If the impeller was removed from the shaft, then double-check the rotation of the pump.
To determine the correct direction of rotation, refer to Change the rotation (page 41).
3. Move the upper half of the casing towards the lower half of the casing.
4. Before you connect the upper half to the lower half, use the dowel pins to guide the upper
half into its final exact position.
5. Reinstall all main joint bolts and tighten to the following torque values:
Screw type
Torque
5/8 in.-11 hex head cap140 ft-lb (190 Nm) minimum
screws (Grade 5)
7/8 in. -9 Ferry Cap Countr- 350 ft-lb (474.5 Nm) minimum
bor screws (Grade 8)
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Model 3408 Installation, Operation, and Maintenance Manual
Maintenance
NOTICE:
Avoid leakage at the main joint. Tighten bolts to the proper values in the proper sequence
to obtain the proper gasket compression.
Figure 65: Casing bolts
6. Rotate the shaft and make sure it spins freely.
If the motor or line shafting was removed, then you can now reinstall it.
Remove the complete pump
If you need to remove a complete pump, then you must remove the line shafting or motor.
1. Disconnect the pedestal from its anchor bolts.
2. Disconnect and remove all suction and discharge piping.
3. Turn the entire pedestal horizontal, allowing the complete pump to be removed from a
horizontal position.
Spare parts
Ordering parts
Repair orders will be handled with the minimum of delay if the following directions are followed:
• Specify the model number, pump size, and serial number. These can all be obtained from
the nameplate.
• List plainly the names, part numbers, and materials of the parts required. These names
and numbers must agree with those in the Parts list chapter of this manual.
• Specify the number of parts required.
• Specify definite billing and shipping instructions.
Model 3408 Installation, Operation, and Maintenance Manual
69
Troubleshooting
Troubleshooting
Troubleshooting
Symptom
The pump is not delivering liquid.
70
Cause
The pump is not primed.
Remedy
Re-prime the pump and check that the pump and suction
line are full of liquid.
The pump has lost prime.
Check for leaks in the suction pipe joints and fittings.
Vent the casing to remove accumulated air. Check the
mechanical seal or packing.
The impeller is clogged.
Back-flush the pump in order to clean the impeller.
The impeller is loose on the shaft.
Check the key, locknut, and setscrews.
The shaft is rotating in the wrong direction. Change the rotation. The rotation must match the arrow
on the bearing housing or pump casing.
The shaft is not rotating at all.
Check the power, coupling, line shaft, and shaft keys.
The foot valve or suction pipe opening is
Consult an ITT representative for the proper submersion
not submerged enough.
depth. Use a baffle to eliminate vortices.
The suction lift is too high.
Check for obstructions at the inlet and make sure the
suction valves are open. Check for pipe friction losses.
Use a vacuum or compound gauge to check the NPSH
available.
The motor speed is too low.
Make sure that the motor wiring is correct and receives
full voltage or that the turbine receives full steam
pressure. The motor can have an open phase.
The system static head is too high.
Check with ITT to determine whether a larger impeller
can be used. If not, then cut pipe losses, increase the
speed, or both. Do not overload the driver.
The system head or discharge head is too Check for pipe friction losses and that the valves are
high.
wide open. The condition can be corrected with larger
piping.
Model 3408 Installation, Operation, and Maintenance Manual
Troubleshooting
Symptom
Cause
The pump is not deliver- The suction piping has air leaks.
ing enough liquid or pressure.
The stuffing box has air leaks.
The motor speed is too low.
The discharge head is too high.
The suction lift is too high.
The impeller is clogged.
The amount of available NPSH is not
sufficient.
Remedy
If the pumped liquid is water or another non-explosive
and no explosive gas or dust is present, then test the
flanges for leaks with a flame or match. When explosive
liquids such as gasoline are present, then test the
suction line by shutting off or plugging the inlet and
putting the line under pressure. A gauge will indicate a
leak with a drop of pressure.
Check the packing or seal and replace if necessary.
Check for the proper amount of lubrication.
Make sure that the motor wiring is correct and receives
full voltage or that the turbine receives full steam
pressure. The motor can have an open phase.
Check for pipe friction losses and that the valves are
wide open. The condition can be corrected with larger
piping.
Check for obstructions at the inlet and make sure the
suction valves are open. Check for pipe friction losses.
Use a vacuum or compound gauge to check the NPSH
available.
Back-flush the pump in order to clean the impeller.
Increase the positive suction head by lowering the
pump or increasing the suction pipe and fittings size.
2. Sub-cool the suction piping at the inlet to lower the
temperature of liquid that is entering the pump.
3. Pressurize the suction vessel.
The impeller or wear rings are worn or
Inspect the impeller and wear rings and replace if any of
broken.
the following conditions are present:
• The impeller or wear rings are damaged.
• The vane sections are severely eroded.
• The wear ring clearance is three times normal.
The foot valve is too small or partially
Check the valve and replace with the correct size if
obstructed.
necessary.
The openings of the valve ports must be 1–1.5 times as
large as the suction pipe opening. If a strainer is used,
then the valve port openings must be 3–4 times as large
the suction pipe opening.
The suction inlet is not submersed deep
If the inlet cannot be lowered or if the problem persists
enough.
after the inlet is lowered, then chain a board to the
suction pipe. The board will be drawn into the eddies and
smother the vortex.
The shaft is rotating in the wrong direction. Change the rotation. The rotation must match the arrow
on the bearing housing or pump casing.
The system static head is too high.
Check with ITT to determine whether a larger impeller
can be used. If not, then you can cut pipe losses,
increase the speed, or both. Do not overload the driver.
The mechanical seal is worn or broken.
Repair or replace the seal as necessary.
The liquid passages are obstructed.
Make sure that the suction and discharge valves are fully
open. Disassemble the pump and inspect the passages
and casing. Remove the obstruction.
Air or gases are trapped in the liquid.
Install a gas separation chamber on the suction line near
the pump and periodically exhaust the accumulated gas.
The pump starts and then The amount of available NPSH is not
1. Increase the positive suction head by lowering the
stops pumping.
sufficient.
pump or increasing the suction pipe and fittings size.
2. Sub-cool the suction piping at the inlet to lower the
temperature of liquid that is entering the pump.
3. Pressurize the suction vessel.
The system static head is too high.
Check with ITT to determine whether a larger impeller
can be used. If not, then cut pipe losses, increase the
speed, or both. Make sure to not overload the driver.
The system head or discharge head is too Check for pipe friction losses and that the valves are
high.
wide open. The condition can be corrected with larger
piping.
The pump leaks excesThe shaft is bent.
Straighten the shaft or replace it if necessary.
sively at the stuffing box. The pump and driver are not aligned
Realign the pump and driver.
properly.
The bearings are worn out or improperly
Inspect the bearings and replace them if necessary.
lubricated.
Model 3408 Installation, Operation, and Maintenance Manual
1.
71
Troubleshooting
Symptom
The motor requires excessive power.
Cause
The discharge head has dropped below
the rated point and is pumping too much
liquid.
The liquid is heavier than expected.
The shaft is rotating in the wrong direction.
The impeller is damaged.
Rotating parts are binding.
The shaft is bent.
The motor speed is too high.
The stuffing box is improperly packed.
The bearings are worn out or improperly
lubricated.
The running clearances between the wear
rings are incorrect.
There is excessive pipe strain on the pump
casing.
The amount of available NPSH is not
sufficient.
The pump and driver are not aligned.
The suction inlet is not submersed deep
enough.
The casing is distorted due to excessive
strains from the suction and discharge
piping.
72
Remedy
Install a throttle valve. If this does not help, then trim the
impeller diameter.
If this does not help, then consult an ITT representative.
Check the specific gravity and viscosity.
Change the rotation. The rotation must match the arrow
on the bearing housing or pump casing.
Inspect the impeller and replace it if necessary.
Check the internal wearing parts for proper clearances.
Check the deflection of the rotor by turning it on the
bearing journals. The total indicator runout must not
exceed 0.002 in. (0.05 mm) on the shaft and 0.004 in.
(0.10 mm) on the impeller wearing surface.
Check the motor voltage or the steam pressure received
by turbines. Make sure the motor speed matches the
speed on the nameplate.
Check the packing and repack the stuffing box. If the
packing is too tight, then try releasing the gland pressure
and tightening again.
Inspect the bearings and replace them if necessary.
Check for the proper clearances. Replace the casing or
impeller wear rings if necessary.
Relieve the strain and check the alignment. Consult ITT if
necessary.
1.
Increase the positive suction head by lowering the
pump or increasing the suction pipe and fittings size.
2. Sub-cool the suction piping at the inlet to lower the
temperature of liquid that is entering the pump.
3. Pressurize the suction vessel.
Realign the pump and driver.
If the inlet cannot be lowered or if the problem persists
after the inlet is lowered, then chain a board to the
suction pipe. The board will be drawn into the eddies and
smother the vortex.
Check the alignment. Examine the pump for rubbing
between the impeller and the casing. Replace damaged
parts and redo the piping.
Model 3408 Installation, Operation, and Maintenance Manual
Parts Listings and Cross-Sectionals
Parts Listings and Cross-Sectionals
Exploded views
Pump with packing
Model 3408 Installation, Operation, and Maintenance Manual
73
Parts Listings and Cross-Sectionals
Pump with mechanical seals on the shaft
74
Model 3408 Installation, Operation, and Maintenance Manual
Parts Listings and Cross-Sectionals
Pump with mechanical seals on the shaft sleeves
Model 3408 Installation, Operation, and Maintenance Manual
75
Parts Listings and Cross-Sectionals
Parts list
76
Catalog
number
Part name
Packing
0-400-0*
0-910-0
0-912-0
0-944-0
0-950-0
0-952-0
1-013-9
1-014-9
1-904-9
1-924-9*
2-001-0
2-001-0
2-123-5*
2-123-6*
2-904-1
2-916-1
3-003-9*
3-007-0
3-009-9
3-015-9
3-025-3
3-025-4
3-026-3*
3-026-4*
3-073-9
3-136-9
3-177-9*
3-421-9
3-516-4
3-517-4
3-902-3
3-904-9
3-910-9
3-911-1
3-911-2
3-914-1*
3-914-2*
3-914-9*
3-915-1*
3-943-9
Mechanical seal
Pipe plug, casing
Pipe fitting
Spiral pin, shaft sleeve
Pipe nipple
Tubing and connectors
Seal cage
Gland, packing
Capscrew, gland
Packing
Casing, lower half
Casing, upper half
Gasket, casing suction
Gasket, casing discharge
Capscrew, casing
Taper pin
Casing ring
Shaft
Shaft sleeve
Shaft sleeve nut
Inboard bearing housing
Outboard bearing housing
Inboard bearing
Outboard bearing
Stuffing box
Deflector
Lip seal
Set collar
Locknut
Lockwasher
Setscrew
Capscrew, bearing housing
Piping plug, bearing housing
Impeller key
Coupling key
O-ring, stuffing box
O-ring, casing ring
O-ring, shaft sleeve
Impeller retaining ring
Spiral pin
5
3 (optional)
2
2 (optional)
2 (optional)
2 (optional)
2
4
12 rings
1
1
1
1
2
2
1
2
2
1
1
1
1
2
2
2
1
1
2
8
4
1
1
2
2
2
4
Quantity
Mechanical seal Mechanical seal
on the shaft
on the shaft
sleeves
2
2
5
5
3
3
2
2
2
2
2
1
1
1
1
1
1
1
1
Varies with pump size
2
2
2
2
1
1
2
2
1
1
1
1
1
1
1
12
2
2
2
2
2
2
1
1
1
1
6
8
8
4
4
1
1
1
1
2
2
2
2
2
1
4
4
Model 3408 Installation, Operation, and Maintenance Manual
Local ITT Contacts
Local ITT Contacts
Regional offices
Region
North America (Headquarters)
Asia Pacific
Europe
Latin America
Middle East and Africa
Address
ITT - Goulds Pumps
240 Fall Street
Seneca Falls, NY 13148
USA
ITT Industrial Process
10 Jalan Kilang #06-01
Singapore 159410
ITT - Goulds Pumps
Millwey Rise Industrial Estate
Axminster, Devon, England
EX13 5HU
ITT - Goulds Pumps
Camino La Colina # 1448
Condominio Industrial El Rosal
Huechuraba Santiago
8580000
Chile
ITT - Goulds Pumps
Achileos Kyrou 4
Neo Psychiko 115 25 Athens
Greece
Model 3408 Installation, Operation, and Maintenance Manual
Telephone
+1 315-568-2811
Fax
+1 315-568-2418
+65 627-63693
+65 627-63685
+44 1297-630250
+44 1297-630256
+562 544-7000
+562 544-7001
+30 210-677-0770
+30 210-677-5642
77
Visit our website for the latest version of this
document and more information:
http://www.gouldspumps.com
ITT - Goulds Pumps
240 Fall Street
Seneca Falls, NY 13148
USA
Tel. 1–800–446–8537
Fax (315) 568–2418
© 2015 ITT Corporation
The original instruction is in English. All non-English instructions are translations of the original instruction.
Form IOM.3408.EN-US.2015-11
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