ITT Goulds Pumps ICP Operation Manual

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ITT Goulds Pumps ICP Operation Manual | Manualzz

Installation, Operation, and

Maintenance

Model ICP i-FRAME

Table of Contents

Table of Contents

1 Introduction and Safety ....................................................................................................................................4

1.1 Introduction................................................................................................................................................4

1.1.1 Requesting other information ..........................................................................................................4

1.2 Safety ........................................................................................................................................................4

1.2.1 Safety terminology and symbols ..................................................................................................... 5

1.2.2 Environmental safety.......................................................................................................................6

1.2.3 User safety ......................................................................................................................................6

1.2.4 Hazardous liquids............................................................................................................................8

1.2.5 Wash the skin and eyes ..................................................................................................................8

1.2.6 Ex-approved products ....................................................................................................................9

1.3 Product approval standards ....................................................................................................................10

1.4 Product warranty .....................................................................................................................................10

1.5 ATEX Considerations and Intended Use................................................................................................ 11

2 Transportation and Storage............................................................................................................................13

2.1 Inspect the delivery .................................................................................................................................13

2.1.1 Inspect the package ......................................................................................................................13

2.1.2 Inspect the unit..............................................................................................................................13

2.2 Transportation guidelines ........................................................................................................................13

2.2.1 Pump handling and lifting..............................................................................................................13

2.3 Storage guidelines...................................................................................................................................14

2.3.1 Long-term storage.........................................................................................................................14

3 Product Description ........................................................................................................................................15

3.1 General description .................................................................................................................................15

3.2 Nameplate information ............................................................................................................................16

4 Installation........................................................................................................................................................18

4.1 Pre-installation.........................................................................................................................................18

4.1.1 Pump location guidelines ..............................................................................................................18

4.1.2 Foundation requirements ..............................................................................................................19

4.2 Baseplate-mounting procedures .............................................................................................................19

4.2.1 Prepare the baseplate for mounting.............................................................................................. 19

4.2.2 Prepare the foundation for mounting............................................................................................. 19

4.2.3 Install the baseplate using shims or wedges................................................................................. 20

4.2.4 Install the baseplate using jackscrews .......................................................................................... 20

4.2.5 Install the baseplate using spring mounting .................................................................................. 22

4.2.6 Install the baseplate using stilt mounting ...................................................................................... 23

4.2.7 -leveling worksheet .......................................................................................................................25

4.3 Install the pump, driver, and coupling...................................................................................................... 26

4.4 Pump-to-driver alignment ........................................................................................................................26

4.4.1 Alignment checks ..........................................................................................................................26

4.4.2 Permitted indicator values for alignment checks........................................................................... 26

4.4.3 Alignment measurement guidelines .............................................................................................. 27

4.4.4 Attach the dial indicators for alignment ......................................................................................... 27

4.4.5 Pump-to-driver alignment instructions........................................................................................... 27

4.5 Grout the baseplate.................................................................................................................................29

4.6 Piping checklists......................................................................................................................................30

Model ICP i-FRAME Installation, Operation, and Maintenance 1

Table of Contents

4.6.1 General piping checklist ................................................................................................................30

4.6.2 Permitted nozzle loads and torques at the pump nozzles............................................................. 30

4.6.3 Suction-piping checklist.................................................................................................................30

4.6.4 Discharge piping checklist.............................................................................................................32

4.6.5 Bypass-piping considerations .......................................................................................................33

4.6.6 Auxiliary-piping checklist ...............................................................................................................33

4.6.7 Final piping checklist .....................................................................................................................34

5 Commissioning, Startup, Operation, and Shutdown ................................................................................... 35

5.1 Preparation for startup.............................................................................................................................35

5.2 Remove the coupling guard ....................................................................................................................36

5.3 Check the rotation ...................................................................................................................................36

5.4 Couple the pump and driver ....................................................................................................................36

5.5 Install the coupling guard ........................................................................................................................37

5.6 Bearing lubrication...................................................................................................................................39

5.6.1 Lubricating oil requirements ..........................................................................................................39

5.6.2 Lubricate the bearings with oil.......................................................................................................40

5.6.3 Lubricating-grease requirements .................................................................................................. 41

5.7 Shaft-sealing options...............................................................................................................................41

5.7.1 Mechanical seal options................................................................................................................42

5.7.2 Connection of sealing liquid for mechanical seals ........................................................................ 42

5.7.3 Packed stuffing box option ............................................................................................................42

5.7.4 Connection of sealing liquid for a packed stuffing box .................................................................. 42

5.8 Pump priming ..........................................................................................................................................43

5.8.1 Prime the pump with the suction supply above the pump............................................................. 43

5.8.2 Prime the pump with the suction supply below the pump ............................................................. 43

5.8.3 Other methods of priming the pump.............................................................................................. 43

5.9 Start the pump.........................................................................................................................................43

5.10 Pump operation precautions .................................................................................................................44

5.11 Shut down the pump..............................................................................................................................45

5.12 Make the final alignment of the pump and driver .................................................................................. 45

6 Maintenance.....................................................................................................................................................46

6.1 Maintenance schedule ............................................................................................................................46

6.2 Bearing maintenance ..............................................................................................................................46

6.2.1 Lubricating oil requirements ..........................................................................................................47

6.2.2 Change the oil ...............................................................................................................................47

6.2.3 Lubricating-grease requirements .................................................................................................. 48

6.2.4 Regrease the grease-lubricated bearings ..................................................................................... 48

6.3 Disassembly ............................................................................................................................................48

6.3.1 Disassembly precautions ..............................................................................................................48

6.3.2 Tools required................................................................................................................................49

6.3.3 Drain the pump..............................................................................................................................49

6.3.4 Remove the coupling ....................................................................................................................49

6.3.5 Remove the back pull-out assembly ............................................................................................. 49

6.3.6 Remove the coupling hub .............................................................................................................50

6.3.7 Remove the impeller .....................................................................................................................51

6.3.8 Remove the seal-chamber cover ................................................................................................. 51

6.3.9 Remove the stuffing-box cover .................................................................................................... 51

6.3.10 Disassemble the power end........................................................................................................52

2 Model ICP i-FRAME Installation, Operation, and Maintenance

Table of Contents

6.4 Pre-assembly inspections .......................................................................................................................52

6.4.1 Replacement guidelines................................................................................................................52

6.4.2 Shaft replacement guidelines........................................................................................................53

6.4.3 Bearing-frame inspection ..............................................................................................................53

6.4.4 Seal chamber and stuffing box cover inspection........................................................................... 53

6.4.5 Bearings inspection.......................................................................................................................53

6.5 Reassembly.............................................................................................................................................54

6.5.1 Assemble the rotating element and bearing frame ....................................................................... 54

6.5.2 Shaft sealing .................................................................................................................................55

6.5.3 Install the back pull-out assembly ................................................................................................ 56

6.5.4 Post-assembly checks ..................................................................................................................56

6.5.5 Assembly references.....................................................................................................................57

6.6 Shaft seal maintenance...........................................................................................................................57

6.6.1 Mechanical-seal maintenance.......................................................................................................57

6.6.2 Packed stuffing-box maintenance ................................................................................................. 58

7 Troubleshooting ..............................................................................................................................................59

7.1 Operation troubleshooting .......................................................................................................................59

7.2 Alignment troubleshooting.......................................................................................................................59

7.3 Assembly troubleshooting .......................................................................................................................59

8 Parts Listings and Cross-Sectionals.............................................................................................................60

8.1 Parts list...................................................................................................................................................60

9 Certification......................................................................................................................................................62

10 Other Relevant Documentation or Manuals................................................................................................ 63

11 Local ITT Contacts ........................................................................................................................................64

11.1 Regional offices .....................................................................................................................................64

Model ICP i-FRAME Installation, Operation, and Maintenance 3

4

1 Introduction and Safety

1 Introduction and Safety

1.1 Introduction

Purpose of this manual

The purpose of this manual is to provide necessary information for:

• Installation

• Operation

• Maintenance

CAUTION:

Failure to observe the instructions contained in this manual could result in personal injury and/or property damage, and may void the warranty. Read this manual carefully before installing and using the product.

NOTICE:

Save this manual for future reference and keep it readily available.

1.1.1 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 serial number when requesting technical information or spare parts.

1.2 Safety

WARNING:

• Risk of serious personal injury. Applying heat to impellers, propellers, or their retaining devices can cause trapped liquid to rapidly expand and result in a violent explosion. This manual clearly identifies accepted methods for disassembling units. These methods must be adhered to. Never apply heat to aid in their removal unless explicitly stated in this manual.

• The operator must be aware of the pumpage and take appropriate safety precautions to prevent physical injury.

• Risk of serious injury or death. If any pressure-containing device is over-pressurized, it can explode, rupture, or discharge its contents. It is critical to take all necessary measures to avoid over-pressurization.

• Risk of death, serious personal injury, and property damage. Installing, operating, or maintaining the unit using any method not prescribed in this manual is prohibited. Prohibited methods include any modification to the equipment or use of parts not provided by

ITT. If there is any uncertainty regarding the appropriate use of the equipment, please contact an ITT representative before proceeding.

Model ICP i-FRAME Installation, Operation, and Maintenance

1.2 Safety

• If the pump or motor is damaged or leaking, electric shock, fire, explosion, liberation of toxic fumes, physical harm, or environmental damage may result. Do not operate the unit until the problem has been corrected or repaired.

• Risk of serious personal injury or property damage. Dry running may cause rotating parts within the pump to seize to non-moving parts. Do not run dry.

• Risk of death, serious personal injury, and property damage. Heat and pressure buildup can cause explosion, rupture, and discharge of pumpage. Never operate the pump with suction and/or discharge valves closed.

• Running a pump without safety devices exposes operators to risk of serious personal injury or death. Never operate a unit unless appropriate safety devices (guards, etc.) are properly installed. See specific information about safety devices in other sections of this manual.

CAUTION:

• Risk of injury and/or property damage. Operating a pump in an inappropriate application can cause over pressurization, overheating, and/or unstable operation. Do not change the service application without the approval of an authorized ITT representative.

1.2.1 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

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

NOTICE: • 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:

Model ICP i-FRAME Installation, Operation, and Maintenance 5

1.2 Safety

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

1.2.1.1 The Ex symbol

The Ex symbol indicates safety regulations for Ex-approved products when used in atmospheres that are potentially explosive or flammable.

1.2.2 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:

If the product has been contaminated in any way, such as from toxic chemicals or nuclear radiation, do NOT send the product to ITT until it has been properly decontaminated and advise

ITT of these conditions before returning.

Electrical installation

For electrical installation recycling requirements, consult your local electric utility.

1.2.2.1 Recycling guidelines

Always follow local laws and regulations regarding recycling.

1.2.3 User safety

General safety rules

These safety rules apply:

6 Model ICP i-FRAME Installation, Operation, and Maintenance

1.2 Safety

• 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:

• Hardhat

• Safety goggles, preferably with side shields

• Protective shoes

• Protective gloves

• Gas mask

• Hearing protection

• First-aid kit

• Safety devices

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.

Noise

WARNING:

Sound pressure levels may exceed 80 dbA in operating process plants. Clear visual warnings or other indicators should be available to those entering an area with unsafe noise levels. Personnel should wear appropriate hearing protection when working on or around any equipment, including pumps. Consider limiting personnel’s exposure time to noise or, where possible, enclosing equipment to reduce noise. Local law may provide specific guidance regarding exposure of personnel to noise and when noise exposure reduction is required.

Temperature

WARNING:

Equipment and piping surfaces may exceed 130ºF (54ºC) in operating process plants. Clear visual warnings or other indicators should alert personnel to surfaces that may reach a potentially unsafe temperature. Do not touch hot surfaces. Allow pumps operating at a high temperature to cool sufficiently before performing maintenance. If touching a hot surface cannot be avoided, personnel should wear appropriate gloves, clothing, and other protective gear as necessary. Local law may provide specific guidance regarding exposure of personnel to unsafe temperatures.

1.2.3.1 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.

• Make sure that you have a clear path of retreat.

Model ICP i-FRAME Installation, Operation, and Maintenance 7

1.2 Safety

• 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.

• Allow all system and pump components to cool before you handle them.

• Make sure that the product has been thoroughly cleaned.

• Disconnect and lock out power before you service the pump.

• Check the explosion risk before you weld or use electric hand tools.

1.2.3.2 Precautions during work

Observe these safety precautions when you work with the product or are in connection with the product:

CAUTION:

Failure to observe the instructions contained in this manual could result in personal injury and/or property damage, and may void the warranty. Read this manual carefully before installing and using 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.

• Do not exceed the maximum working pressure of the pump.

• Do not open any vent or drain valve or remove any plugs while the system is pressurized. Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump, remove plugs, or disconnect piping.

• Never operate a pump without a properly installed coupling guard.

1.2.4 Hazardous liquids

The product is designed for use in liquids that can be hazardous to your health. Observe these rules when you work with the product:

• Make sure that all personnel who work with biologically hazardous liquids are vaccinated against diseases to which they may be exposed.

• Observe strict personal cleanliness.

• A small amount of liquid will be present in certain areas like the seal chamber.

1.2.5 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

Action

1.

Hold your eyelids apart forcibly with your fingers.

2.

Rinse the eyes with eyewash or running water for at least 15 minutes.

3.

Seek medical attention.

8 Model ICP i-FRAME Installation, Operation, and Maintenance

Condition

Chemicals or hazardous fluids on skin

Action

1.

Remove contaminated clothing.

2.

Wash the skin with soap and water for at least 1 minute.

3.

Seek medical attention, if necessary.

1.2 Safety

1.2.6 Ex-approved products

Follow these special handling instructions if you have an Ex-approved unit.

The coupling guard used in an ATEX classified environment must be properly certified and must be constructed from a spark resistant material.

Personnel requirements

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, the vapor, or both present in hazardous areas.

• Any maintenance for Ex-approved products must conform to international and national standards.

ITT disclaims all responsibility for work done by untrained and unauthorized personnel.

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.

• 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 work on 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, and that they are in use.

• Intrinsically safe circuits are normally required for the automatic level-control system by the level regulator if mounted in zone 0.

• Do not modify the equipment without approval from an authorized ITT representative.

• Only use parts that are provided by an authorized ITT representative.

Model ICP i-FRAME Installation, Operation, and Maintenance 9

1.3 Product approval standards

1.2.6.1 Description of ATEX

The ATEX directives are a specification enforced in Europe for electrical and non-electrical equipment installed in Europe. ATEX deals with the control of potentially explosive atmospheres and the standards of equipment and protective systems used within these atmospheres. The relevance of the ATEX requirements is not limited to Europe. You can apply these guidelines to equipment installed in any potentially explosive atmosphere.

1.2.6.2 Guidelines for compliance

Compliance is fulfilled only when you operate the unit within its intended use. Do not change the conditions of the service without the approval of an ITT representative. When you install or maintain explosion proof products, always comply with the directive and applicable standards (for example, IEC/EN 60079–

14).

1.3 Product approval standards

Regular standards

WARNING:

Use of equipment unsuitable for the environment can pose risks of ignition and/or explosion.

Ensure the pump driver and all other auxiliary components meet the required area classification at the site. If they are not compatible, do not operate the equipment and contact an ITT representative before proceeding.

All standard products are approved according to CSA standards in Canada and UL standards in USA.

The drive unit degree of protection follows IP68 according to standard IEC 60529.

1.4 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

10 Model ICP i-FRAME Installation, Operation, and Maintenance

1.5 ATEX Considerations and Intended Use

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.

1.5 ATEX Considerations and Intended Use

Special care must be taken in potentially explosive environments to ensure that the equipment is properly maintained. This includes but is not limited to:

Description of ATEX

The ATEX directives are a specification enforced in Europe for electrical and non-electrical equipment installed in Europe. ATEX deals with the control of potentially explosive atmospheres and the standards of equipment and protective systems used within these atmospheres. The relevance of the ATEX requirements is not limited to Europe. You can apply these guidelines to equipment installed in any potentially explosive atmosphere.

Guidelines for compliance

Compliance is fulfilled only when you operate the unit within its intended use. Do not change the conditions of the service without the approval of an ITT representative. When you install or maintain explosion proof products, always comply with the directive and applicable standards (for example, IEC/EN

60079-14).

1.

Monitoring the pump frame and liquid end temperature.

2.

Maintaining proper bearing lubrication.

3.

Ensuring that the pump is operated in the intended hydraulic range.

The ATEX conformance is only applicable when the pump unit is operated within its intended use. Operating, installing or maintaining the pump unit in any way that is not covered in the Instruction, Operation, and Maintenance manual (IOM) can cause serious personal injury or damage to the equipment. This includes any modification to the equipment or use of parts not provided by ITT Goulds Pumps. If there is any question regarding the intended use of the equipment, please contact an ITT Goulds representative before proceeding.

Current IOMs are available at https://www.gouldspumps.com/en-US/Tools-and-Resources/Literature/

IOMs/ or from your local ITT Goulds Pumps Sales representative.

All pumping unit (pump, seal, coupling, motor and pump accessories) certified for use in an ATEX classified environment, are identified by an ATEX tag secured to the pump or the baseplate on which it is mounted. A typical tag would look like this:

Model ICP i-FRAME Installation, Operation, and Maintenance 11

1.5 ATEX Considerations and Intended Use

Figure 1: Typical ATEX pump nameplate

The CE and the Ex designate the ATEX compliance. The code below reads as follows:

II - Group – Non Mining Equipment

2G – Category – Category 2 – Gas

Ex – required by ISO 80079 – 36:2016 h – h indicates mechanical equipment

IIB – Gas Group

T1 – T4 – Permitted Maximum Surface Temperature

Gb – Atmosphere + Equipment Protection Level

The code classification marked on the equipment must be in accordance with the specified area where the equipment will be installed. If it is not, do not operate the equipment and contact your ITT Goulds

Pumps sales representative before proceeding.

12 Model ICP i-FRAME Installation, Operation, and Maintenance

2 Transportation and Storage

2 Transportation and Storage

2.1 Inspect the delivery

2.1.1 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.

2.1.2 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.

2.2 Transportation guidelines

2.2.1 Pump handling and lifting

Precautions for moving the pump

Use care when moving pumps. Consult with a lifting and rigging specialist before lifting or moving the pump to avoid possible damage to the pump or injury to personnel.

WARNING:

Dropping, rolling or tipping units, or applying other shock loads, can cause property damage and/or personal injury. Ensure that the unit is properly supported and secure during lifting and handling.

CAUTION:

Risk of injury or equipment damage from use of inadequate lifting devices. Ensure lifting devices (such as chains, straps, forklifts, cranes, etc.) are rated to sufficient capacity.

Keep the pump unit in the same position in which it was shipped from the factory.

Precautions for lifting the pump

WARNING:

• Dropping, rolling or tipping units, or applying other shock loads, can cause property damage and/or personal injury. Ensure that the unit is properly supported and secure during lifting and handling.

• Risk of serious personal injury or equipment damage. Proper lifting practices are critical to safe transport of heavy equipment. Ensure that practices used are in compliance with all applicable regulations and standards.

Model ICP i-FRAME Installation, Operation, and Maintenance 13

2.3 Storage guidelines

• Lifting and handling heavy equipment poses a crush hazard. Use caution during lifting and handling and wear appropriate Personal Protective Equipment (PPE, such as steeltoed shoes, gloves, etc.) at all times. Seek assistance if necessary.

• Safe lifting points are specifically identified in this manual. It is critical to lift the equipment only at these points. Integral lifting eyes or eye bolts on pump and motor components are intended for use in lifting the individual components only.

NOTICE:

• Make sure that the lifting equipment supports the entire assembly and is only used by authorized personnel.

• Do not attach sling ropes to shaft ends.

Lifting the pump

Baseplate-mounted units have lifting points for use with proper lifting devices.

Hoist the pump using a suitable sling under solid points such as the casing, flanges, or frame.

Figure 2: Pump lifting

2.3 Storage guidelines

2.3.1 Long-term storage

If the unit is stored for more than 6 months, these requirements apply:

• Store in a covered and dry location.

• Store the unit free from heat, dirt, and vibrations.

• Rotate the shaft by hand several times at least every three months.

Treat bearing and machined surfaces so that they are well preserved. Refer to the drive unit and coupling manufacturers for their long-term storage procedures.

For questions about possible long-term storage treatment services, please contact your local ITT sales representative.

14 Model ICP i-FRAME Installation, Operation, and Maintenance

3 Product Description

3 Product Description

3.1 General description

The model is a single-stage volute casing pump. Hydraulic design and dimensions comply with ISO

2858/ EN 22858. The technical design complies with ISO 5199/EN 25199. additionally have cooling or heating of the casing cover and/or the volute casing.

Casing

• Heavy-duty, top centerline discharge

• Integral cast feet

• Back pullout design

• Standard 3/8 in. NPT casing drain

• Optional renewable wear ring

Impeller

The impeller is and key driven by the shaft. Standard back vanes or balance holes reduce axial thrust and seal chamber pressures.

Seal chamber

• Wide choice of sealing arrangements for maximum sealing flexibility

• Patented “cyclone” seal chamber for improved lubrication, heat removal, and solids handling

• Confined casing gasket

Power end

• Redesigned i-FRAME large capacity oil sump reduces oil temperature for extended bearing life.

• Heavy-duty cast iron frame gives rigid support to the shaft and bearings for longer service.

• Magnetic drain plug maintains a clean oil environment for extended bearing life.

• Standard hybrid stainless steel/bronze labyrinth oil seals at the pump and coupling end maintain a seal tight, clean operating environment.

Model ICP i-FRAME Installation, Operation, and Maintenance 15

3.2 Nameplate information

• O-ring seal between the frame and adapter for optimized alignment and sealing.

Frame adapter

• Provides safe and accurate alignment for the liquid end to the bearing frame.

• Large access windows make installation and maintenance of seal and auxiliary support systems trouble-free.

Bearings

Heavy-duty ball bearings provide L10 bearing life in excess of 17,500 hours.

The size of the bearing frame is shown in the data sheet and/or order confirmation.

Bearing frame Bearing type

Pump side Drive side

24 i-FRAME 6307 - C3 3307A - C3

32 i-FRAME 6309 - C3 3309A - C3

42 i-FRAME 6311 - C3 3311A - C3

48 i-FRAME 6313 - C3 3313A - C3

Shaft

Rigid shaft designed for less than 0.05 mm shaft deflection. Standard 400 series stainless steel shaft

(1.4021) provides reliable power transmission and corrosion resistance at both the pump and coupling ends.

3.2 Nameplate information

Pump nameplate

16

Figure 3: Pump nameplate

Nameplate Field

S/N

MODEL

SIZE

Explanation

Serial number of the pump

Pump Model

Size of Pump

Model ICP i-FRAME Installation, Operation, and Maintenance

Nameplate Field

STD DIM

HYDRO PRESS

FLOW

RPM

MAX DESIGN WORKING PRESS

HEAD

MATL

IMP DIA

CONT/ITEM NO

MAX DIA

3.2 Nameplate information

Explanation

ANSI Std designation – Not applicable ISO Pumps

Pump Test Pressure in kPag

Rated pump flow in cubic metres per hour

Rated pump speed in revolutions per minute

Maximum Design pressure in kPag at rated temperature in degrees

Centigrade

Rated pump head in metres

Material of which the pump is constructed

Impeller diameter fitted

Contract or tag number

Maximum impeller diameter

Model ICP i-FRAME Installation, Operation, and Maintenance 17

4 Installation

4 Installation

4.1 Pre-installation

Precautions

WARNING:

• When installing in a potentially explosive environment, ensure that the motor is properly certified.

• All equipment being installed must be properly grounded to prevent unexpected discharge. Discharge can cause equipment damage, electric shock, and result in serious injury. Test the ground lead to verify it is connected correctly.

NOTICE:

• Electrical connections must be made by certified electricians in compliance with all international, national, state and local regulations.

• Supervision by an authorized ITT representative is recommended to ensure proper installation. Improper installation may result in equipment damage or decreased performance.

4.1.1 Pump location guidelines

WARNING:

Lifting and handling heavy equipment poses a crush hazard. Use caution during lifting and handling and wear appropriate Personal Protective Equipment (PPE, such as steel-toed shoes, gloves, etc.) at all times. Seek assistance if necessary.

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 swivel 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.

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.

18 Model ICP i-FRAME Installation, Operation, and Maintenance

4.2 Baseplate-mounting procedures

Guideline

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

Acceptable devices:

• Pressure relief valves

• Compression tanks

• Pressure controls

• Temperature controls

• Flow controls

Take into consideration the occurrence of unwanted noise and vibration.

If the system does not include these devices, consult the engineer or architect in charge before you operate the pump.

The best pump location for noise and vibration absorption is on a concrete floor with subsoil underneath.

If the pump location is overhead, undertake special precautions to reduce possible noise transmission.

Consider a consultation with a noise specialist.

4.1.2 Foundation requirements

Requirements

• Provide a flat, substantial concrete foundation in order to prevent strain and distortion when you tighten the foundation bolts.

4.2 Baseplate-mounting procedures

4.2.1 Prepare the baseplate for mounting

1.

Remove all the attached equipment from the baseplate.

2.

Clean the underside of the baseplate completely.

3.

If applicable, coat the underside of the baseplate with an epoxy primer.

Use an epoxy primer only if using an epoxy-based grout.

4.

Remove the rust-proofing coat from the machined mounting pads using an appropriate solvent.

5.

Remove water and debris from the foundation-bolt holes.

4.2.2 Prepare the foundation for mounting

1.

Chip the top of the foundation to a minimum of 25.0 mm | 1.0 in. in order to remove porous or lowstrength concrete.

If you use a pneumatic hammer, make sure that it does not contaminate the surface with oil or other moisture.

NOTICE:

Do not chip the foundation using heavy tools such as jackhammers. This can damage the structural integrity of the foundation.

2.

Remove water or debris from the foundation bolt holes or sleeves.

3.

If the baseplate uses sleeve-type bolts, then fill the sleeves with a non-binding, moldable material.

Seal the sleeves in order to prevent the grout from entering.

4.

Coat the exposed portion of the anchor bolts with a non-bonding compound such as paste wax in order to prevent the grout from adhering to the anchor bolts.

Do not use oils or liquid wax.

5.

If recommended by the grout manufacturer, coat the foundation surface with a compatible primer.

Model ICP i-FRAME Installation, Operation, and Maintenance 19

4.2 Baseplate-mounting procedures

4.2.3 Install the baseplate using shims or wedges

Required tools:

• Two sets of shims or wedges for each foundation bolt

• Two machinist's levels

• Baseplate-leveling worksheet

1.

If you use sleeve-type bolts, fill the bolt sleeves with packing material or rags to prevent grout from entering the bolt holes.

2.

Put the sets of wedges or shims on each side of each foundation bolt.

3.

Lower the baseplate carefully onto the foundation bolts.

4.

Put the machinist's levels across the mounting pads of the driver and the mounting pads of the pump.

NOTICE:

Remove all dirt from the mounting pads in order to ensure that the correct leveling is achieved.

Failure to do so can result in equipment damage or decreased performance.

5.

Level the baseplate both lengthwise and across by adding or removing shims or moving the wedges.

You can use the baseplate-leveling worksheet when you take the readings.

6.

Hand-tighten the nuts for the foundation.

4.2.4 Install the baseplate using jackscrews

Tools required:

• Anti-seize compound

• Jackscrews

• Bar stock

• Two machinist's levels

1.

Apply an anti-seize compound on the jackscrews.

The compound makes it easier to remove the screws after you grout.

2.

Lower the baseplate carefully onto the foundation bolts and perform these steps: a) Cut the plates from the bar stock and chamfer the edges of the plates in order to reduce stress concentrations.

b) Put the plates between the jackscrews and the foundation surface.

c) Use the four jackscrews in the corners in order to raise the baseplate above the foundation.

d) Make sure that the center jackscrews do not touch the foundation surface yet.

20 Model ICP i-FRAME Installation, Operation, and Maintenance

4.2 Baseplate-mounting procedures

3

1

4

2

Item Description

1.

2.

3.

4.

Jackscrew

Baseplate

Foundation

Plate

Figure 4: Jackscrews

3.

Level the driver mounting pads:

NOTICE:

Remove all dirt from the mounting pads in order to ensure that the correct leveling is achieved.

Failure to do so can result in equipment damage or decreased performance.

a) Put one machinist's level lengthwise on one of the two pads.

b) Put the other machinist's level across the ends of the two pads.

c) Level the pads by adjusting the four jackscrews in the corners.

Make sure that the machinist's level readings are as close to zero as possible, both lengthwise and across.

4.

Turn the center jackscrews down so that they rest on their plates on the foundation surface.

5.

Level the pump mounting pads:

NOTICE:

Remove all dirt from the mounting pads in order to ensure that the correct leveling is achieved.

Failure to do so can result in equipment damage or decreased performance.

a) Put one machinist's level lengthwise on one of the two pads.

b) Put the other level across the center of the two pads.

c) Level the pads by adjusting the four jackscrews in the corners.

Make sure that the machinist's level readings are as close to zero as possible, both lengthwise and across.

6.

Hand-tighten the nuts for the foundation bolts.

7.

Check that the driver's mounting pads are level and adjust the jackscrews and the foundation bolts if necessary.

Model ICP i-FRAME Installation, Operation, and Maintenance 21

4.2 Baseplate-mounting procedures

4.2.5 Install the baseplate using spring mounting

NOTICE:

The spring-mounted baseplate is designed only to support piping loads from thermal expansion. Ensure that the suction and discharge piping are supported individually. Failure to do so may result in equipment damage.

The foundation pads are not provided with the baseplate. Make sure that the foundation pads are 316 stainless-steel plates, which have a 16-20 micro-inch surface finish.

Before you start this procedure, make sure that the foundation pads are correctly installed on the foundation/floor (see the manufacturer's instructions).

1.

Put the baseplate on a support above the foundation/floor.

Make sure that there is enough space between the baseplate and the foundation/floor in order to install the spring assemblies.

2.

Install the lower part of the spring assembly: a) Screw the lower jam nut onto the spring stud.

b) Screw the lower adjusting nut onto the spring-stud, on top of the jam nut.

c) Set the lower adjusting nut to the correct height.

The correct height depends on the required distance between the foundation/floor and the baseplate.

d) Put a washer, a follower, a spring, and one more follower onto the lower adjusting nut.

3.

Install the spring assembly on the baseplate: a) Insert the spring assembly into the baseplate's anchorage hole from below.

b) Put a follower, a spring, another follower, and a washer onto the spring stud.

c) Fasten the spring assembly with the upper adjusting nut by hand.

4.

Thread the upper jam nut onto the spring stud by hand.

5.

Repeat steps 2 through 4 for all the spring assemblies.

6.

Lower the baseplate so that the spring assemblies fit into the foundation pads.

7.

Level the baseplate and make the final height adjustments: a) Loosen the upper jam nuts and adjusting nuts.

b) Adjust the height and level the baseplate by moving the lower adjusting nuts.

c) When the baseplate is level, tighten the top adjusting nuts so that the top springs are not loose in their followers.

8.

Fasten the lower and upper jam nuts on each spring assembly.

22 Model ICP i-FRAME Installation, Operation, and Maintenance

4.2 Baseplate-mounting procedures

7

6

1

2

5

3

4

1.

Upper jam nut

2.

Follower

3.

Washer

4.

Foundation pads

5.

Spring

6.

Upper adjusting nut

7.

Spring stud

Figure 5: Example of an installed spring assembly

4.2.6 Install the baseplate using stilt mounting

NOTICE:

The stilt-mounted baseplate is not designed to support static piping loads. Ensure that the suction and discharge piping are supported individually. Failure to do so may result in equipment damage.

1.

Put the baseplate on a support above the foundation/floor.

Make sure that there is enough space between the baseplate and the foundation/floor to install the stilts.

2.

Install the lower part of the stilt assembly: a) Screw the lower jam nut and adjusting nut onto the stilt.

b) Set the lower adjusting nut to the correct height.

The correct height depends on the required distance between the foundation/floor and the baseplate.

c) Put a washer onto the lower adjusting- nut.

3.

Install the stilt assembly on the baseplate: a) Insert the stilt assembly into the baseplate's anchorage hole from below.

b) Put a washer onto the stilt.

c) Fasten the stilt assembly with the upper adjusting nut by hand.

4.

Screw the upper jam nut onto the stilt by hand.

5.

Repeat steps 2 through 4 for all the stilt assemblies.

Model ICP i-FRAME Installation, Operation, and Maintenance 23

4.2 Baseplate-mounting procedures

6.

Lower the baseplate so that the stilts fit into the foundation cups.

7.

Level the baseplate and make the final height adjustments: a) Loosen the upper jam nuts and adjusting nuts.

b) Adjust the height and level the baseplate by moving the lower adjusting nuts.

c) When the baseplate is level, tighten the top adjusting nuts.

8.

Fasten the lower and upper jam nuts on each stilt.

7

8

6

5

1

4

3

2

1.

Mounting plate

2.

Mounting nut

3.

Stilt bolt

4.

Foundation cups

5.

Washer

6.

Upper adjustment nut

7.

Mounting washer

8.

Mounting bolt

Figure 6: Example of an installed stilt assembly

24 Model ICP i-FRAME Installation, Operation, and Maintenance

4.2 Baseplate-mounting procedures

4.2.7 -leveling worksheet

Level measurements

17

5

4

8

15

11

3

2

1

13

14

16

12

9

7

6

10

18

1)____________________

2)____________________

3)____________________

4)____________________

5)____________________

6)____________________

7)____________________

8)____________________

9)____________________

10)___________________

11)___________________

12)___________________

13)___________________

14)___________________

15)___________________

16)___________________

17)___________________

18)___________________

Model ICP i-FRAME Installation, Operation, and Maintenance 25

4.3 Install the pump, driver, and coupling

4.3 Install the pump, driver, and coupling

1.

Mount the driver on the . Use applicable bolts and hand tighten.

2.

Install the coupling.

See the installation instructions from the coupling manufacturer.

4.4 Pump-to-driver alignment

Precautions

WARNING:

• Failure to disconnect and lock out driver power may result in serious physical injury or death. Always disconnect and lock out power to the driver before performing any installation or maintenance tasks.

• Electrical connections must be made by certified electricians in compliance with all international, national, state, and local rules.

• Refer to driver/coupling/gear manufacturer's installation and operation manuals

(IOM) for specific instructions and recommendations.

4.4.1 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 alignment checks

Type of check When it is used

Initial alignment (cold alignment) check

Prior to operation when the pump and the driver are at ambient temperature.

Final alignment (hot alignment) check After operation when the pump and the driver are at operating temperature.

Initial alignment (cold alignment) checks

When

Before you

After you

After you connect the piping

Why

This ensures that alignment can be accomplished.

This ensures that no changes have occurred during the .

This ensures that pipe strains have not altered the alignment.

Final alignment (hot alignment) checks

When

After the first run

Periodically

Why

This ensures correct alignment when both the pump and the driver are at operating temperature.

This follows the plant operating procedures.

4.4.2 Permitted indicator values for alignment checks

26 Model ICP i-FRAME Installation, Operation, and Maintenance

4.4 Pump-to-driver alignment

4.4.2.1 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.

4.4.3 Alignment measurement guidelines

Guideline

Rotate the pump coupling half and the driver coupling half together so that the indicator rods have contact with the same points on the driver coupling half.

Move or shim only the driver in order to make adjustments.

Make sure that the hold-down bolts for the driver are tight when you take indicator measurements.

Make sure that the hold-down bolts for the driver are loose before you make alignment corrections.

Check the alignment again after any mechanical adjustments.

Explanation

This prevents incorrect measurement.

This prevents strain on the piping installations.

This keeps the driver stationary since movement causes incorrect measurement.

This makes it possible to move the driver when you make alignment corrections.

This corrects any misalignments that an adjustment may have caused.

4.4.4 Attach the dial indicators for alignment

You must have two dial indicators in order to complete this procedure.

1.

Attach two dial indicators on the pump coupling half (X): a) Attach one indicator (P) so that the indicator rod comes into contact with the perimeter of the driver coupling half (Y).

This indicator is used to measure parallel misalignment.

b) Attach the other indicator (A) so that the indicator rod comes into contact with the inner end of the driver coupling half.

This indicator is used to measure angular misalignment.

2.

Rotate the pump coupling half (X) in order to check that the indicators are in contact with the driver coupling half (Y) but do not bottom out.

3.

Adjust the indicators if necessary.

4.4.5 Pump-to-driver alignment instructions

4.4.5.1 Perform angular alignment for a vertical correction

1.

Set the angular alignment indicator to zero at the top-center position (12 o’clock) of the driver coupling half (Y).

2.

Rotate the indicator to the bottom-center position (6 o’clock).

3.

Record the indicator reading.

When the reading value is...

Then...

Negative The coupling halves are farther apart at the bottom than at the top. Perform one of these steps:

Add shims in order to raise the feet of the driver at the shaft end.

Remove shims in order to lower the feet of the driver at the other end.

Model ICP i-FRAME Installation, Operation, and Maintenance 27

4.4 Pump-to-driver alignment

When the reading value is...

Positive

Then...

The coupling halves are closer at the bottom than at the top. Perform one of these steps:

Remove shims in order to lower the feet of the driver at the shaft end.

Add shims in order to raise the feet of the driver at the other end.

4.4.5.2 Perform angular alignment for a horizontal correction

1.

Set the angular alignment indicator (A) to zero on left side of the driver coupling half (Y), 90° from the top-center position (9 o’clock).

2.

Rotate the indicator through the top-center position to the right side, 180° from the start position

(3 o’clock).

3.

Record the indicator reading.

When the reading value is...

Negative

Positive

Then...

The coupling halves are farther apart on the right side than the left. Perform one of these steps:

Slide the shaft end of the driver to the left.

Slide the opposite end to the right.

The coupling halves are closer together on the right side than the left. Perform one of these steps:

Slide the shaft end of the driver to the right.

Slide the opposite end to the left.

4.4.5.3 Perform parallel alignment for a vertical correction

Before you start this procedure, make sure that the dial indicators are correctly set up.

A unit is in parallel alignment when the parallel indicator (P) does not vary by more than as measured at four points 90° apart at the operating temperature.

1.

Set the parallel alignment indicator (P) to zero at the top-center position (12 o’clock) of the driver coupling half (Y).

2.

Rotate the indicator to the bottom-center position (6 o’clock).

3.

Record the indicator reading.

When the reading value is...

Then...

Negative

Positive

The pump coupling half (X) is lower than the driver coupling half (Y). Remove shims of a thickness equal to half of the indicator reading value under each driver foot.

The pump coupling half (X) is higher than the driver coupling half (Y). Add shims of a thickness equal to half of the indicator reading value to each driver foot.

4.

Repeat the previous steps until the permitted reading value is achieved.

NOTICE:

The specified permitted reading values are valid only at operating temperature. For cold settings, other values are permitted. The correct tolerances must be used. Failure to do so can result in misalignment. Contact ITT for further information.

28 Model ICP i-FRAME Installation, Operation, and Maintenance

4.5 Grout the baseplate

4.4.5.4 Perform parallel alignment for a horizontal correction

A unit is in parallel alignment when the parallel indicator (P) does not vary by more than as measured at four points 90° apart at the operating temperature.

1.

Set the parallel alignment indicator (P) to zero on the left side of the driver coupling half (Y), 90° from the top-center position (9 o’clock).

2.

Rotate the indicator through the top-center position to the right side, 180° from the start position

(3 o’clock).

3.

Record the indicator reading.

When the reading value is... Then...

Negative The driver coupling half (Y) is to the left of the pump coupling half (X).

Positive The driver coupling half (Y) is to the right of the pump coupling half (X).

4.

Slide the driver carefully in the appropriate direction.

NOTICE:

Make sure to slide the driver evenly. Failure to do so can negatively affect horizontal angular correction.

5.

Repeat the previous steps until the permitted reading value is achieved.

4.4.5.5 Perform complete alignment for a vertical correction

1.

Set the angular and parallel dial indicators to zero at the top-center position (12 o’clock) of the driver coupling half (Y).

2.

Rotate the indicators to the bottom-center position (6 o’clock).

3.

Record the indicator readings.

4.

Make corrections according to the separate instructions for angular and parallel alignment until you obtain the permitted reading values.

4.4.5.6 Perform complete alignment for a horizontal correction

1.

Set the angular and parallel dial indicators to zero at the left side of the driver coupling half (Y), 90° from the top-center position (9 o’clock).

2.

Rotate the indicators through the top-center position to the right side, 180° from the start position

(3 o’clock).

3.

Record the indicator readings.

4.

Make corrections according to the separate instructions for angular and parallel alignment until you obtain the permitted reading values.

4.5 Grout the baseplate

Required equipment:

• Cleaners: Do not use an oil-based cleaner because the grout will not bond to it. See the instructions provided by the grout manufacturer.

1.

Clean all the areas of the baseplate that will come into contact with the grout.

2.

Build a dam around the foundation.

3.

Thoroughly wet the foundation that will come into contact with the grout.

4.

Allow the grout to set.

Model ICP i-FRAME Installation, Operation, and Maintenance 29

4.6 Piping checklists

4.6 Piping checklists

4.6.1 General piping checklist

Precautions

WARNING:

• Risk of serious personal injury or property damage. Fasteners such as bolts and nuts are critical to the safe and reliable operation of the product. Ensure appropriate use of fasteners during installation or reassembly of the unit.

• Use fasteners of the proper size and material only.

• Replace all corroded fasteners.

• Ensure that all fasteners are properly tightened and that there are no missing fasteners.

NOTICE:

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.

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.

4.6.2 Permitted nozzle loads and torques at the pump nozzles

Designing suction and discharge piping

The suction and discharge piping must be designed so that a minimum of forces affect the pump. Do not exceed the force and torque values as shown in the following table. The values are valid for when the pump is operating or when it is idle.

About the data in the table

The data in the following table has the following characteristics:

• The data complies with the Europump Recommendation for pumps according to ISO 5199.

• The data is only valid for static piping loads.

• The values are valid for pump units with standard IC base frames (ungrouted).

• All of the values refer to standard materials EN-GJS400-18LT and 1.4408.

4.6.3 Suction-piping checklist

Suction-piping checks

Check

Check that elbows in general do not have sharp bends.

Explanation/comment

This minimizes the risk of cavitation in the suction inlet of the pump due to turbulence.

Checked

30 Model ICP i-FRAME Installation, Operation, and Maintenance

4.6 Piping checklists

Check

Check that the suction piping is one or two sizes larger than the suction inlet of the pump.

Explanation/comment

The suction piping must never have a smaller diameter than the suction inlet of the pump.

Checked

Install an eccentric reducer between the pump inlet and the suction piping.

Check that the eccentric reducer at the suction flange of the pump has the following properties:

• Sloping side down

• Horizontal side at the top

If more than one pump operates from the same liquid source, check that separate suction-piping lines are used for each pump.

If necessary, make sure that the suction piping includes a drain valve and that it is correctly installed.

Assure adequate insulation is applied for liquids with specific gravity less than 0.60.

This recommendation helps you to achieve a higher pump performance and prevent vapor locking especially with specific gravity of liquid less than 0.60.

To assure sufficient NPSHa.

Liquid source below the pump

Check

Make sure that the suction piping is free from air pockets.

Explanation/comment

This helps to prevent the occurrence of air and cavitation in the pump inlet.

Check that the suction piping slopes upwards from the liquid source to the pump inlet.

If the pump is not self-priming, check that a device for priming the pump is installed.

Use a foot valve with a diameter that is at least equivalent to the diameter of the suction piping.

Checked

Liquid source above the pump

Check

Check that an isolation valve is installed in the suction piping at a distance of at least two times the pipe diameter from the suction inlet.

Explanation/comment

This permits you to close the line during pump inspection and maintenance.

Do not use the isolation valve to throttle the pump.

Throttling can cause these problems:

This helps to prevent the occurrence of air and cavitation in the pump inlet.

• Loss of priming

• Excessive temperatures

• Damage to the pump

• Voiding the warranty

Make sure that the suction piping is free from air pockets.

Check that the piping is level or slopes downward from the liquid source.

Make sure that no part of the suction piping extends below the suction flange of the pump.

Make sure that the suction piping is adequately submerged below the surface of the liquid source.

This prevents air from entering the pump through a suction vortex.

Checked

Model ICP i-FRAME Installation, Operation, and Maintenance 31

4.6 Piping checklists

Correct Incorrect

4.6.4 Discharge piping checklist

Checklist

Check Explanation/comment

The isolation valve is required for:

• Priming

• Regulation of flow

• Inspection and maintenance of the pump

• Reduce risk of pumpage vaporization and vapor locking at low flow rates for low specific gravity liquids.

Checked

See Example: Discharge piping equipment for illustrations.

32 Model ICP i-FRAME Installation, Operation, and Maintenance

Example: Discharge piping equipment

Correct

1

4

2

3

Incorrect

1

2

4.6 Piping checklists

1.

Bypass line

2.

Shut-off valve

3.

Check valve

4.

Discharge isolation valve

1.

Check valve (incorrect position)

2.

The isolation valve should not be positioned between the check valve and the pump.

4.6.5 Bypass-piping considerations

When to use a bypass line

Provide a bypass line for systems that require operation at reduced flows for prolonged periods. Connect a bypass line from the discharge side (before any valves) to the source of suction.

When to install a minimum-flow orifice

You can size and install a minimum-flow orifice in a bypass line in order to prevent bypassing excessive flows. Consult your ITT representative for assistance in sizing a minimum-flow orifice.

When a minimum-flow orifice is unavailable

Consider an automatic recirculation control valve or solenoid-operated valve if a constant bypass (minimum-flow orifice) is not possible.

4.6.6 Auxiliary-piping checklist

Precautions

NOTICE:

Auxiliary cooling and flush systems must be operating properly to prevent excess heat generation, sparks, and/or premature failure. Ensure auxiliary piping is installed as specified on the pump data sheet prior to startup.

Model ICP i-FRAME Installation, Operation, and Maintenance 33

4.6 Piping checklists

4.6.7 Final piping checklist

Check

Check that the shaft rotates smoothly.

Explanation/comment

Rotate the shaft by hand. Make sure there is no rubbing that can lead to excess heat generation or sparks.

If pipe strain exists, then correct the piping.

Checked

34 Model ICP i-FRAME Installation, Operation, and Maintenance

5 Commissioning, Startup, Operation, and Shutdown

5 Commissioning, Startup, Operation, and

Shutdown

5.1 Preparation for startup

WARNING:

• Risk of serious physical injury or death. Exceeding any of the pump operating limits (e.g. pressure, temperature, power, etc.) could result in equipment failure, such as explosion, seizure, or breach of containment. Assure that the system operating conditions are within the capabilities of the pump.

• Risk of death or serious injury. Leaking fluid can cause fire and/or burns. Ensure all openings are sealed prior to filling the pump.

• Breach of containment can cause fire, burns, and other serious injury. Failure to follow these precautions before starting the unit may lead to dangerous operating conditions, equipment failure, and breach of containment.

• Risk of explosion and serious physical injury. Do not operate pump with blocked system piping or with suction or discharge valves closed. This can result in rapid heating and vaporization of pumpage.

• Risk of breach of containment and equipment damage. Ensure the pump operates only between minimum and maximum rated flows. Operation outside of these limits can cause high vibration, mechanical seal and/or shaft failure, and/or loss of prime.

WARNING:

• Risk of death, serious personal injury, and property damage. Heat and pressure buildup can cause explosion, rupture, and discharge of pumpage. Never operate the pump with suction and/or discharge valves closed.

• Running a pump without safety devices exposes operators to risk of serious personal injury or death. Never operate a unit unless appropriate safety devices (guards, etc.) are properly installed.

• Failure to disconnect and lock out driver power may result in serious physical injury or death. Always disconnect and lock out power to the driver before performing any installation or maintenance tasks.

• Electrical connections must be made by certified electricians in compliance with all international, national, state, and local rules.

• Refer to driver/coupling/gear manufacturer's installation and operation manuals

(IOM) for specific instructions and recommendations.

Precautions

WARNING:

The mechanical seal used in an Ex-classified environment must be properly certified.

Model ICP i-FRAME Installation, Operation, and Maintenance 35

5.2 Remove the coupling guard

CAUTION:

When a cartridge mechanical seal is used, ensure that the set screws in the seal locking ring are tightened and that the centering clips have been removed prior to startup. This prevents seal or shaft sleeve damage by ensuring that the seal is properly installed and centered on the sleeve.

NOTICE:

• Verify the driver settings before you start any pump. Refer to the applicable drive equipment IOMs and operating procedures.

NOTICE:

You must follow these precautions before you start the pump:

• Flush and clean the system thoroughly to remove dirt or debris in the pipe system in order to prevent premature failure at initial startup.

5.2 Remove the coupling guard

1.

Slide the driver half of the coupling guard toward the pump.

2.

Remove the driver half of the coupling guard: a) Slightly spread the bottom apart.

b) Lift upwards.

3.

Remove the pump half of the coupling guard: a) Slightly spread the bottom apart.

b) Lift upwards.

5.3 Check the rotation

WARNING:

• Starting the pump in reverse rotation can result in the contact of metal parts, heat generation, and breach of containment. Ensure correct driver settings prior to starting any pump.

• Failure to disconnect and lock out driver power may result in serious physical injury or death. Always disconnect and lock out power to the driver before performing any installation or maintenance tasks.

• Electrical connections must be made by certified electricians in compliance with all international, national, state, and local rules.

• Refer to driver/coupling/gear manufacturer's installation and operation manuals

(IOM) for specific instructions and recommendations.

1.

Lock out power to the driver.

5.4 Couple the pump and driver

36 Model ICP i-FRAME Installation, Operation, and Maintenance

5.5 Install the coupling guard

WARNING:

Failure to disconnect and lock out driver power may result in serious physical injury or death.

Always disconnect and lock out power to the driver before performing any installation or maintenance tasks.

• Electrical connections must be made by certified electricians in compliance with all international, national, state, and local rules.

• Refer to driver/coupling/gear manufacturer's installation and operation manuals (IOM) for specific instructions and recommendations.

5.5 Install the coupling guard

WARNING:

• Running a pump without safety devices exposes operators to risk of serious personal injury or death. Never operate a unit unless appropriate safety devices (guards, etc.) are properly installed.

• Failure to disconnect and lock out driver power may result in serious physical injury or death. Always disconnect and lock out power to the driver before performing any installation or maintenance tasks.

• Electrical connections must be made by certified electricians in compliance with all international, national, state, and local rules.

• Refer to driver/coupling/gear manufacturer's installation and operation manuals

(IOM) for specific instructions and recommendations.

WARNING:

The coupling guard used in an ATEX classified environment must be properly certified and constructed from a spark resistant material.

Required parts:

1.

De-energize the motor, place the motor in a locked-out position, and place a caution tag at the starter that indicates the disconnect.

2.

Put the pump-half of the coupling guard in place: a) Slightly spread the bottom apart.

b) Place the coupling guard half over the pump-side end plate.

Model ICP i-FRAME Installation, Operation, and Maintenance 37

5.5 Install the coupling guard

4

3

1

2

Item Description

1.

Annular groove

2.

3.

4.

Pump-side end plate

Driver

Pump half of the coupling guard

Figure 7: Guard half installation

The annular groove in the coupling guard half must fit around the end plate.

1

2

3

Item Description

1.

2.

2.

Annular groove

End plate (pump end)

Guard half

Figure 8: Annular groove in coupling guard

3.

Use a bolt, a nut, and two washers to secure the coupling guard half to the end plate. Tighten securely.

38 Model ICP i-FRAME Installation, Operation, and Maintenance

5.6 Bearing lubrication

1 2 3

Item Description

1.

Nut

2.

Washer

3.

Bolt

Figure 9: Secure coupling guard half to end plate

4.

Put the driver half of the coupling guard in place: a) Slightly spread the bottom apart.

b) Place the driver half of the coupling guard over the pump half of the coupling guard.

The annular groove in the coupling guard half must face the motor.

5.

Place the driver-side end plate over the motor shaft.

6.

Place the driver-side end plate in the annular groove of the driver-half of the coupling guard.

7.

Use a bolt, a nut, and two washers to secure the coupling guard half to the end plate. Hand-tighten only.

The hole is located on the driver-side of the coupling guard half.

8.

Slide the driver-half of the coupling guard towards the motor so that the coupling guard completely covers the shafts and coupling.

9.

Use a nut, a bolt, and two washers to secure the coupling guard halves together.

10. Tighten all nuts on the guard assembly.

5.6 Bearing lubrication

Pumps are shipped without oil. You must lubricate oil-lubricated bearings at the job site.

Grease-lubricated bearings are lubricated at the factory.

5.6.1 Lubricating oil requirements

Oil quality requirements

Use a high-quality turbine oil with rust and oxidation inhibitors.

Lubricating oil type

Kinematic viscosity at 40°C | 104°F

Flash point (Cleveland)

Setting point (Pourpoint)

Application temperature

(Contact your ITT representative to determine a suitable type of lubrication if ambient temperatures are below

-10°C | 14°F.

175°C | 347°F

-15°C | 5°F

Higher than permitted bearing temperature

Model ICP i-FRAME Installation, Operation, and Maintenance 39

5.6 Bearing lubrication

5.6.2 Lubricate the bearings with oil

WARNING:

Risk of explosive hazard and premature failure from sparks and heat generation.

Ensure bearings are properly lubricated prior to startup.

NOTICE:

The pump is not filled with oil when delivered. Fill with oil before operating the pump.

• Determine which procedure to use in order to fill the bearing frame with oil:

If...

The pump has an oil level sight glass (standard design)

Then...

Use the "Fill the bearing frame with oil" procedure.

The pump has a constant level oiler (optional) Use the "Fill the bearing frame with an optional oiler" procedure.

5.6.2.1 Fill the bearing frame with oil

NOTICE:

Maintain an exact oil level. If the oil level is too high, the bearing temperature can increase. If the oil level is too low, the bearing will not be properly lubricated and could cause operational problems.

1.

Remove the oil filling plug.

2.

Pour oil into the opening.

3.

Fill until the oil level rises to the center of the oil level sight glass.

Figure 10: Oil level sight glass

5.6.2.2 Fill the bearing frame with an optional oiler

NOTICE:

Maintain an exact oil level. If the oil level is too high, the bearing temperature can increase. If the oil level is too low, the bearing will not be properly lubricated and could cause operational problems.

The constant level oiler is supplied loose.

1.

Unscrew the reservoir from the main body (right-threaded) and set aside.

2.

Seal the main body to the bearing frame at the connection for the constant level oiler, using PTFE sealing tape.

3.

Tighten until the threaded boss is in a vertical position.

40 Model ICP i-FRAME Installation, Operation, and Maintenance

5.7 Shaft-sealing options

4.

Remove the oil filling plug near the upper side of the bearing frame.

5.

Fill with oil by pouring into the connection opening until the oil level almost reaches the middle of the oil level sight glass in the main body.

6.

Fill the reservoir using a funnel.

2

1

3

1.

Bearing frame

2.

Oil level sight glass

3.

Main body

Figure 11: Filling bearing frame oiler

7.

Place the O-ring on the reservoir spout.

8.

Place your thumb over the reservoir spout.

9.

Invert the spout and insert it into the internal threaded boss on the main body.

10. Tighten the reservoir.

The oil then flows from the reservoir into the bearing chamber.

11. Repeat steps 6 through 10 until the reservoir remains two-thirds full.

Refill with oil whenever the oil level in the reservoir drops below one-third full.

5.6.3 Lubricating-grease requirements

Precautions

NOTICE:

Avoid equipment damage or decreased performance. Never mix greases of different consistencies (NLGI 1 or 3 with NLGI 2) or with different thickeners. For example, never mix a lithiumbased grease with a polyurea based grease. If it is necessary to change the grease type or consistency, remove the rotor and old grease from the housing before regreasing.

Grease quality requirements

Use a high-quality grease lubricant corresponding to NLGI Grade 2.

Grease lubrication

Consider this information when you lubricate with grease:

• Pumps are delivered from the manufacturer with lubricated bearings and are ready to be used.

• The bearings are filled with lithium-based grease, which is suitable for a temperature range from

-30°C to 90°C | -22°F to 194°F when measured at the surface of the bearing frame.

• Make sure that bearing temperatures, measured at the bearing frame, are no more than 50°C |

122°F above the ambient temperature and never exceed 90°C | 194°F when checked weekly.

5.7 Shaft-sealing options

In most cases, the manufacturer seals the shaft before shipping the pump. If your pump does not have a sealed shaft, see the Shaft-seal maintenance section in the Maintenance chapter.

Model ICP i-FRAME Installation, Operation, and Maintenance 41

5.7 Shaft-sealing options

This model uses these types of shaft seals:

• Cartridge mechanical seal

5.7.1 Mechanical seal options

These are the mechanical seal options for this pump:

• Cartridge mechanical seal

5.7.2 Connection of sealing liquid for mechanical seals

Seal lubrication is required

Seal faces must have liquid film between them for proper lubrication. Locate the taps using the illustrations shipped with the seal.

Seal flushing methods

Table 1: You can use these methods in order to flush or cool the seal:

Method

Product flush

External flush

Description

Run the piping so that the pump pushes the pumped fluid from the casing and injects it into the seal gland. If necessary, an external heat exchanger cools the pumped fluid before it enters the seal gland.

Run the piping so that the pump injects a clean, cool, compatible liquid directly into the seal gland. The pressure of the flushing liquid must be

0.35 to 1.01 kg/cm 2 | 5 to 15 psi greater than the seal chamber pressure. The injection rate must be 2 to 8 lpm | 0.5 to 2 gpm.

Other

5.7.3 Packed stuffing box option

WARNING:

Packed stuffing boxes are not allowed in an ATEX-classified environment.

These parts are included with the pump in the box of fittings. Before you start the pump, you must install the packing, lantern ring, and split gland according to the Packed stuffing box maintenance section in the

Maintenance chapter.

5.7.4 Connection of sealing liquid for a packed stuffing box

NOTICE:

Make sure to lubricate the packing. Failure to do so may result in shortening the life of the packing and the pump.

You must use an external sealing liquid under these conditions:

• The pumped fluid includes abrasive particles.

• The stuffing-box pressure is below atmospheric pressure when the pump is running with a suction lift or when the suction source is in a vacuum. Under these conditions, packing is not cooled and lubricated and air is drawn into pump.

42 Model ICP i-FRAME Installation, Operation, and Maintenance

5.8 Pump priming

Conditions for application of an external liquid

Condition Action

The stuffing box pressure is above atmospheric pressure and the pumped fluid is clean.

The stuffing box pressure is below atmospheric pressure or the pumped fluid is not clean.

Normal gland leaks of 40 to 60 drops per minute is usually sufficient to lubricate and cool the packing. You do not need sealing liquid.

An outside source of clean compatible liquid is required.

An outside source of clean compatible liquid is required.

You must connect the piping to the lantern ring connection with a 40 to 60 drops-per-minute leak rate. The pressure must be 1.01 kg/cm 2

| 15 psi above the stuffing box pressure.

5.8 Pump priming

5.8.1 Prime the pump with the suction supply above the pump

1.

Slowly open the suction isolation valve.

2.

Close the air vents.

5.8.2 Prime the pump with the suction supply below the pump

Use a foot valve and an outside source of liquid in order to prime the pump. The liquid can come from one of these sources:

• A priming pump

• A pressurized discharge line

• Another outside supply

1.

Close the discharge isolation valve.

2.

Open the air vent in the casing.

3.

Open the valve in the outside supply line until only liquid escapes from the vent valves.

4.

Close the vent.

5.

Close the outside supply line.

5.8.3 Other methods of priming the pump

You can also use these methods in order to prime the pump:

• Prime by ejector

• Prime by automatic priming pump

5.9 Start the pump

WARNING:

Risk of equipment damage, seal failure and breach of containment. Ensure all flush and cooling systems are operating correctly prior to starting pump.

NOTICE:

• Risk of equipment damage due to dry operation. Immediately observe the pressure gauges. If discharge pressure is not quickly attained, stop the driver immediately, reprime, and attempt to restart the pump.

Model ICP i-FRAME Installation, Operation, and Maintenance 43

5.10 Pump operation precautions

1.

Fully close the discharge valve, depending on system conditions.

2.

Start the driver.

3.

Slowly open the discharge valve until the pump reaches the desired flow.

4.

Immediately check the pressure gauge to ensure that the pump quickly reaches the correct discharge pressure.

5.

If the pump fails to reach the correct pressure, perform these steps: a) Stop the driver.

b) Restart the driver.

6.

Monitor the pump while it is operating: a) Check the pump for bearing temperature, excessive vibration, and noise.

b) If the pump exceeds normal levels, then shut down the pump immediately and correct the problem.

7.

Repeat steps 5 and 6 until the pump runs properly.

5.10 Pump operation precautions

General considerations

NOTICE:

• 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.

Operation at reduced capacity

WARNING:

• Risk of breach of containment and equipment damage. Excessive vibration levels can cause damage to bearings, stuffing box, seal chamber, and/or mechanical seal. Observe pump for vibration levels, bearing temperature, and excessive noise. If normal levels are exceeded, shut down and resolve.

• Risk of equipment damage and serious physical injury. Heat build-up can cause rotating parts to score or seize. Observe pump for excessive heat build-up. If normal levels are exceeded, shut down and resolve.

NOTICE:

Cavitation can cause damage to the internal surfaces of the pump. Ensure net positive suction head available (NPSH

A

) always exceeds NPSH required (NPSH

3

) as shown on the published performance curve of the pump.

Operation under freezing conditions

NOTICE:

44 Model ICP i-FRAME Installation, Operation, and Maintenance

5.11 Shut down the pump

5.11 Shut down the pump

WARNING:

Precautions must be taken to prevent physical injury. The pump may handle hazardous and/or toxic fluids. Proper personal protective equipment should be worn. Pumpage must be handled and disposed of in conformance with applicable environmental regulations.

1.

Slowly close the discharge valve.

2.

Shut down and lock out the driver to prevent accidental rotation.

5.12 Make the final alignment of the pump and driver

WARNING:

• Failure to disconnect and lock out driver power may result in serious physical injury or death. Always disconnect and lock out power to the driver before performing any installation or maintenance tasks.

• Electrical connections must be made by certified electricians in compliance with all international, national, state, and local rules.

• Refer to driver/coupling/gear manufacturer's installation and operation manuals

(IOM) for specific instructions and recommendations.

You must check the final alignment after the pump and driver are at operating temperature. For initial alignment instructions, see the Installation chapter.

1.

Run the unit under actual operating conditions for enough time to bring the pump, driver, and associated system to operating temperature.

2.

Shut down the pump and the driver.

3.

Remove the coupling guard.

4.

Check the alignment while the unit is still hot.

See Pump-to-driver alignment in the Installation chapter.

5.

Reinstall the coupling guard.

6.

Restart the pump and driver.

Model ICP i-FRAME Installation, Operation, and Maintenance 45

6 Maintenance

6 Maintenance

6.1 Maintenance schedule

Maintenance inspections

A maintenance schedule includes these types of inspections:

• Routine inspections

• Three-month inspections

• Annual inspections

Shorten the inspection intervals appropriately if the pumped fluid is abrasive or corrosive or if the environment is classified as potentially explosive.

Routine inspections

Perform these tasks whenever you check the pump during routine inspections:

• Check for unusual noise vibration, and bearing temperatures.

• Check the pump and piping for leaks.

• Analyze the vibration.*

NOTICE:

*If equipped, temperature and vibration levels can be retrieved by using your i-ALERT monitoring sensor and app.

Three-month inspections

Perform these tasks every three months:

• Check that the foundation and the hold-down bolts are tight.

Annual inspections

Perform these inspections one time each year:

• Check the pump capacity.

• Check the pump pressure.

• Check the pump power.

If the pump performance does not satisfy your process requirements, and the process requirements have not changed, then perform these steps:

1.

Disassemble the pump.

2.

Inspect it.

3.

Replace worn parts.

6.2 Bearing maintenance

46 Model ICP i-FRAME Installation, Operation, and Maintenance

6.2 Bearing maintenance

Bearing lubrication schedule

Type of bearing

Oil-lubricated bearings

First lubrication

Add oil before you install and start the pump.

Change the oil after 200-300 hours of operation, depending on bearing temperature.

Grease-lubricated bearings N/A

Lubrication intervals

See the Oil change schedule table.

Oil change schedule

Oil must be changed at least once a year.

Bearing temperature First oil change Subsequent oil changes

Up to 60°C | 140°F After 300 hours of operation Every 8760 hours of operation

60°C to 80°C | 140°F to 176°F After 300 hours of operation Every 4000 hours of operation

80°C to 100°C | 176°F to 212°F After 200 hours of operation Every 3000 hours of operation

NOTICE:

• Strictly maintain the oil changing schedule if the pump is operating in an potentially explosive environment.

• Change the oil every two years if the pump is left idle.

• Dispose of used oil in accordance with local environmental regulations.

6.2.1 Lubricating oil requirements

Oil quality requirements

Use a high-quality turbine oil with rust and oxidation inhibitors.

Lubricating oil type

Kinematic viscosity at 40°C | 104°F

Flash point (Cleveland)

Setting point (Pourpoint)

Application temperature

(Contact your ITT representative to determine a suitable type of lubrication if ambient temperatures are below

-10°C | 14°F.

175°C | 347°F

-15°C | 5°F

Higher than permitted bearing temperature

6.2.2 Change the oil

1.

Remove the oil drain plug .

2.

Drain the oil.

3.

Flush the pump with fresh oil.

4.

Clean the oil drain plug.

5.

Close the oil drain.

6.

Fill the pump with new oil. See Lubricate the bearings with oil in the Commissioning, Startup, Operation, and Shutdown chapter.

7.

Dispose of used oil in accordance with local environmental regulations.

Model ICP i-FRAME Installation, Operation, and Maintenance 47

6.3 Disassembly

6.2.3 Lubricating-grease requirements

Precautions

NOTICE:

Avoid equipment damage or decreased performance. Never mix greases of different consistencies (NLGI 1 or 3 with NLGI 2) or with different thickeners. For example, never mix a lithiumbased grease with a polyurea based grease. If it is necessary to change the grease type or consistency, remove the rotor and old grease from the housing before regreasing.

Grease quality requirements

Use a high-quality grease lubricant corresponding to NLGI Grade 2.

Grease lubrication

Consider this information when you lubricate with grease:

• Pumps are delivered from the manufacturer with lubricated bearings and are ready to be used.

• The bearings are filled with lithium-based grease, which is suitable for a temperature range from

-30°C to 90°C | -22°F to 194°F when measured at the surface of the bearing frame.

• Make sure that bearing temperatures, measured at the bearing frame, are no more than 50°C |

122°F above the ambient temperature and never exceed 90°C | 194°F when checked weekly.

6.2.4 Regrease the grease-lubricated bearings

NOTICE:

Risk of equipment damage. Ensure that the grease container, the greasing device, and the fittings are clean. Failure to do so can result in impurities entering the bearing housing while regreasing the bearings.

1.

Wipe dirt from the grease fittings.

2.

Fill the grease cavities through the fittings with a recommended grease.

3.

Wipe off any excess grease.

4.

Recheck the alignment.

The bearing temperature usually increases by 5°C to 10°C | 9°F to 18°F 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.

6.3 Disassembly

6.3.1 Disassembly precautions

WARNING:

• Failure to disconnect and lock out driver power may result in serious physical injury or death. Always disconnect and lock out power to the driver before performing any installation or maintenance tasks.

• Electrical connections must be made by certified electricians in compliance with all international, national, state, and local rules.

48 Model ICP i-FRAME Installation, Operation, and Maintenance

6.3 Disassembly

• Refer to driver/coupling/gear manufacturer's installation and operation manuals

(IOM) for specific instructions and recommendations.

• Risk of serious personal injury. Applying heat to impellers, propellers, or their retaining devices can cause trapped liquid to rapidly expand and result in a violent explosion. This manual clearly identifies accepted methods for disassembling units. These methods must be adhered to. Never apply heat to aid in their removal unless explicitly stated in this manual.

• Handling heavy equipment poses a crush hazard. Use caution during handling and wear appropriate Personal Protective Equipment (PPE, such as steel-toed shoes, gloves, etc.) at all times.

• Precautions must be taken to prevent physical injury. The pump may handle hazardous and/or toxic fluids. Proper personal protective equipment should be worn. Pumpage must be handled and disposed of in conformance with applicable environmental regulations.

• Risk of serious physical injury or death from rapid depressurization. Ensure pump is isolated from system and pressure is relieved before disassembling pump, removing plugs, opening vent or drain valves, or disconnecting piping.

• Risk of serious personal injury from exposure to hazardous or toxic liquids. A small amount of liquid will be present in certain areas like the seal chamber upon disassembly.

CAUTION:

• Avoid injury. Worn pump components can have sharp edges. Wear appropriate gloves while handling these parts.

6.3.2 Tools required

In order to disassemble the pump, you need these tools:

• Lifting eyebolt (dependent on pump / motor size)

6.3.3 Drain the pump

6.3.4 Remove the coupling

6.3.5 Remove the back pull-out assembly

WARNING:

Lifting and handling heavy equipment poses a crush hazard. Use caution during lifting and handling and wear appropriate Personal Protective Equipment (PPE, such as steel-toed shoes, gloves, etc.) at all times. Seek assistance if necessary.

1.

Is your bearing frame oil lubricated?

• If No: Proceed to step 2.

• If Yes:

1.

Remove the bearing-frame drain plug (408A) in order to drain oil from the bearing frame.

2.

Replace the plug after the oil is drained.

3.

Remove the oil reservoir, if equipped.

Model ICP i-FRAME Installation, Operation, and Maintenance 49

6.3 Disassembly

Oil analysis should be part of a preventive maintenance program that determines the cause of a failure. Save the oil in a clean container for inspection.

2.

The back pull out assembly consists of all parts except the casing (100). The casing (100) can remain on the foundation and in the piping, if it is not the casing itself, which must be repaired. Drain the casing, by removing the casing drain plug (if equipped).

3.

Does your pump use a C-face adapter?

• If Yes: Place one sling from the hoist through the frame adapter (108) or frame (228A) for the and a second sling from the hoist through the C-face adapter.

• If No: Place a sling from the hoist through the frame adapter (108) or the frame (228A) for the .

4.

Place one sling from the hoist through the frame adapter and a second sling from the hoist to the bearing frame .

5.

Remove the hold-down bolts of the bearing frame foot.

6.

Tighten the jackscrews evenly, using an alternating pattern, in order to remove the back pull-out assembly.

You can use penetrating oil if the adapter to the casing joint is corroded.

7.

Remove the back pull-out assembly from the casing .

Figure 12: Back pullout

8.

Mark and remove the shims from under the frame foot and save them for reassembly.

9.

Remove and discard the casing gasket.

You will insert a new casing gasket during reassembly.

10. Remove the jackscrews.

11. Clean all gasket surfaces.

Clean surfaces prevent the casing gasket from partially adhering to the casing due to binders and adhesives in the gasket material.

6.3.6 Remove the coupling hub

1.

Clamp the frame adapter securely to the workbench.

2.

Remove the coupling hub.

Mark the shaft for relocation of the coupling hub during reassembly.

50 Model ICP i-FRAME Installation, Operation, and Maintenance

6.3 Disassembly

6.3.7 Remove the impeller

WARNING:

• Risk of severe physical injury or death from explosion of trapped liquid. Never use heat to remove parts unless explicitly stated in this manual.

• Risk of serious physical injury or equipment damage. Pump and components are heavy.

Ensure all equipment is properly supported while working. Wear appropriate Personal

Protective Equipment (PPE, such as steel-toed shoes, gloves, etc.) at all times.

CAUTION:

Risk of physical injury from sharp edges. Wear heavy work gloves when handling impellers.

1.

the axial clearance (a) between the impeller and the casing cover .

Figure 13: Back clearance check

2.

Secure the rotor at the end and loosen the impeller nut (right-threaded).

3.

Remove the impeller with two screwdrivers or pry bars.

Figure 14: Impeller removal method

NOTICE:

• Remove shaft guard using a prying tool.

• Be sure to align the pry bars with the impeller vanes in order to prevent damage to the impeller.

4.

Remove the impeller key .

6.3.8 Remove the seal-chamber cover

1.

Remove the gland stud nuts.

2.

Remove the seal-chamber stud nuts.

3.

Remove the seal chamber .

6.3.9 Remove the stuffing-box cover

1.

Remove the gland nuts and the gland .

2.

Remove the stuffing-box-cover nuts.

Model ICP i-FRAME Installation, Operation, and Maintenance 51

6.4 Pre-assembly inspections

3.

Remove the stuffing-box cover .

6.3.10 Disassemble the power end

1.

Loosen and remove the hexagon bolts that hold the frame adapter to the bearing frame.

2.

Remove the frame adapter from the bearing frame .

Figure 15: Bearing frame cross-section

3.

Reach inside the frame and remove the snap ring using the designated snap ring pliers.

Use snap ring pliers according to DIN 5256-C. Refer to this table for the correct size:

Bearing frame size Pliers size Minimum length of pliers

94/C 40 200 mm | 8 in.

94/C 85 250 mm | 10 in.

4.

Remove the shaft , with the radial and thrust bearings and the bearing nut attached, from the bearing frame .

5.

Remove the bearing nut .

The bearing nut is right-hand threaded and is self-locking. It can be reused up to five times, if handled properly.

6.

Use a hydraulic press or bearing puller in order to remove the radial and thrust bearings from the shaft.

6.4 Pre-assembly inspections

Guidelines

Before you assemble the pump parts, make sure you follow these guidelines:

• Inspect the pump parts according to the information in these pre-assembly topics before you reassemble your pump. Replace any part that does not meet the required criteria.

• Make sure that the parts are clean. Clean the pump parts in solvent in order to remove oil, grease, and dirt.

NOTICE:

Protect machined surfaces while cleaning the parts. Failure to do so may result in equipment damage.

6.4.1 Replacement guidelines

Casing check and replacement

WARNING:

Risk of death or serious injury. Leaking fluid can cause fire and/or burns. Inspect and ensure gasket sealing surfaces are not damaged and repair or replace as necessary.

52 Model ICP i-FRAME Installation, Operation, and Maintenance

6.4 Pre-assembly inspections

Gaskets, O-rings, and seats replacement

WARNING:

Risk of death or serious injury. Leaking fluid can cause fire and/or burns. Replace all gaskets and O-rings at each overhaul or disassembly.

WARNING:

Risk of serious personal injury or property damage. Fasteners such as bolts and nuts are critical to the safe and reliable operation of the product. Ensure appropriate use of fasteners during installation or reassembly of the unit.

• Use fasteners of the proper size and material only.

• Replace all corroded fasteners.

• Ensure that all fasteners are properly tightened and that there are no missing fasteners.

6.4.2 Shaft replacement guidelines

6.4.3 Bearing-frame inspection

Checklist

Check the bearing frame for these conditions:

• Visually inspect the bearing frame and frame foot for cracks.

• Check the inside surfaces of the frame for rust, scale, or debris. Remove all loose and foreign material.

• Make sure that all lubrication passages are clear.

• Inspect the inboard-bearing bores.

6.4.4 Seal chamber and stuffing box cover inspection

Checklist

Perform these checks when you inspect the seal chamber and stuffing box cover:

• Make sure that these surfaces are clean:

• Seal chamber and stuffing box cover

• Mounting

• Make sure there is no pitting or wear greater than 3.2 mm | 1/8 in. deep.

Replace the seal chamber and stuffing box cover if pitting or wear exceeds this measurement.

• Inspect the machined surfaces and mating faces noted in the figures.

These images point to the areas to inspect:

6.4.5 Bearings inspection

Condition of bearings

Do not reuse bearings. The condition of the bearings provides useful information on operating conditions in the bearing frame.

Model ICP i-FRAME Installation, Operation, and Maintenance 53

6.5 Reassembly

Checklist

Perform these checks when you inspect the bearings:

• Inspect the bearings for contamination and damage.

• Note any lubricant condition and residue.

• Inspect the ball bearings to see if they are loose, rough, or noisy when you rotate them.

• Investigate any bearing damage to determine the cause. If the cause is not normal wear, correct the issue before you return the pump to service.

6.5 Reassembly

6.5.1 Assemble the rotating element and bearing frame

WARNING:

Lifting and handling heavy equipment poses a crush hazard. Use caution during lifting and handling and wear appropriate Personal Protective Equipment (PPE, such as steel-toed shoes, gloves, etc.) at all times. Seek assistance if necessary.

CAUTION:

Risk of physical injury from hot bearings. Wear insulated gloves when using a bearing heater.

NOTICE:

• Ensure that the pipe threads are clean. Apply thread sealant to the plugs and fittings. Failure to do so may result in oil leaks and equipment damage.

• 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.

1.

Install the bearings: a) Heat the bearings to 100°C | 212°F in an oil bath or with a bearing heater.

b) Clamp the shaft in a bench vise with the thrust bearing surface extending beyond the end of the vise. Use soft jaws to protect the shaft surface.

c) Install the properly-heated thrust bearing onto the shaft.

If necessary, position a tube against the inner ring of the bearing and gently tap the tube with a hammer in order to force the bearing onto the shaft. Hold the outer ring of the bearing in order to prevent vibration damage to the bearing.

d) Apply to the bearing locknut threads on the shaft.

e) Thread the bearing locknut onto the thrust end of the shaft.

The bearing nut is right-hand threaded and is self-locking. It can be reused up to five times, if handled properly.

f) Allow the bearing to cool for 10 minutes and retighten.

Figure 16: Shaft assembly

2.

Install the shaft assembly into the bearing frame: a) Coat the outside of the bearings with oil.

54 Model ICP i-FRAME Installation, Operation, and Maintenance

6.5 Reassembly b) Coat all the internal surfaces of the bearing frame with oil.

c) Turn the bearing frame vertically with the larger open end pointing up.

d) Install the shaft assembly into the bearing frame . Make sure that the shaft rotates freely.

Figure 17: Shaft / bearing frame assembly e) Slide the snap ring onto the shaft. Use the designated snap ring pliers to compress the snap ring and place it into the locking groove in the bearing frame . Make sure that the snap ring is properly seated in the groove by pressing on the snap ring with a flat head screwdriver.

Figure 18: Snap ring detail f) As a recommendation, thread a stud into one of the four threaded bolt holes in the frame adapter , and finger tighten only.

The stud must be between 40 and 50 mm in length. This helps you to align the adapter bolt holes to the frame bolt holes during assembly.

g) Slide the properly heated radial bearing onto the shaft.

The bearing slides easily into place against the shoulder on the shaft h) Place the frame adapter over the radial bearing. Allow the radial bearing to cool for at least 10 minutes.

i) When bearing is cool, gently tap the frame adapter until the radial bearing is properly seated in the frame adapter. Make sure that the bolt holes are aligned.

j) Remove the stud that was used to align frame adapter and frame. Bolt the bearing frame to the frame adapter (334) with the hexagon head bolts .

Make sure to position the bolts in the center of the drilled holes in order to ensure the proper oil settings. Tighten according to the Bolt torque values table.

k) Press the inboard labyrinth oil seal into the Lantern and the outboard labyrinth oil seal into the

Bearing Frame .

that the oil return slot in both seals is positioned in the bottom (6 o'clock) position when the pump is horizontal. Refer to labyrinth seal installation.

6.5.2 Shaft sealing

CAUTION:

Running a mechanical seal dry, even for a few seconds, can cause seal failure and physical injury. Never operate the pump without liquid supplied to the mechanical seal.

Before proceeding with seal installation, complete the ICO assembly worksheet on shim measurement method and installation. Follow Seal the shaft with a cartridge mechanical seal.

6.5.2.1 Seal the shaft with a packed stuffing box

WARNING:

• Packed stuffing boxes are not allowed in an ATEX-classified environment.

WARNING:

Failure to disconnect and lock out driver power may result in serious physical injury. Never attempt to replace the packing until the driver is properly locked out.

Model ICP i-FRAME Installation, Operation, and Maintenance 55

6.5 Reassembly

Pumps are shipped without the packing, lantern ring, or split gland installed. These parts are included with the box of fittings shipped with each pump and must be installed before startup.

1.

Carefully clean the stuffing-box bore.

2.

Twist the packing enough to get it around the shaft.

Packing rings

1

Lantern rings

2

3 4

3

1.

Packing rings

2.

Lantern rings

3.

Correct

4.

Incorrect

Figure 19: Packing rings and lantern rings

3.

Install the gland halves and evenly hand-tighten the nuts .

4

6.5.3 Install the back pull-out assembly

WARNING:

Lifting and handling heavy equipment poses a crush hazard. Use caution during lifting and handling and wear appropriate Personal Protective Equipment (PPE, such as steel-toed shoes, gloves, etc.) at all times. Seek assistance if necessary.

1.

Clean the casing fit and install the casing gasket on the seal chamber and stuffing-box cover.

2.

Install the back pull-out assembly in the casing.

3.

Install and then hand-tighten the casing bolts .

Refer to the bolt torque values for information on how to tighten the casing bolts.

4.

Install and tighten the casing jackscrews.

NOTICE:

Do not overtighten the casing jackscrews. Doing so may result in equipment damage.

5.

Reinstall the shims under the and tighten to the baseplate.

Make sure that you use the proper shim. Mount a dial indicator in order to measure the distance between the top of the frame and the baseplate. Make sure that the distance does not change as you tighten the -foot bolts.

6.

Replace the auxiliary piping.

7.

Reinstall the guard.

6.5.4 Post-assembly checks

Perform these checks after you assemble the pump, then continue with pump startup:

• Rotate the shaft by hand in order to make sure that it rotates easily and smoothly and that there is no rubbing.

• Open the isolation valves and check the pump for leaks.

56 Model ICP i-FRAME Installation, Operation, and Maintenance

6.6 Shaft seal maintenance

6.5.5 Assembly references

6.5.5.1 Bolt torque values

Screw torque values

This table provides the recommended screw torque values.

Location

Casing screws

All other screws

Bolt size Torque for lubricated threads in Nm | lb-ft Torque for dry threads in Nm | lb-ft

M12

M16

M20

M10

M12

M16

35 | 26

105 | 77

210 | 155

40 | 30

60 | 44

150 | 111

50 | 37

150 | 111

305 | 225

50 | 37

90 | 66

220 | 162

Nut torque values

This table provides the recommended nut torque values.

Location Frame size Torque for lubricated threads in Nm | lb-ft Torque for dry threads in Nm | lb-ft

24 35 | 26 45 | 33

Impeller nut

32

42

48

105 | 77

210 | 155

380 | 280

130 | 96

260 | 192

475 | 350

6.5.5.2 Bearing types

Use this table in order to determine the correct bearings for the pump. You can find the size of the bearing frame in the data sheet or the order confirmation.

Bearing frame size Radial bearing Thrust bearing

6307 - C3 3307A - C3

6309 - C3 3309A - C3

6.6 Shaft seal maintenance

6.6.1 Mechanical-seal maintenance

CAUTION:

Running a mechanical seal dry, even for a few seconds, can cause seal failure and physical injury. Never operate the pump without liquid supplied to the mechanical seal.

Cartridge-type mechanical seals

Cartridge-type mechanical seals are commonly used. Cartridge seals are preset by the seal manufacturer and require no field settings. Cartridge seals installed by the user require disengagement of the holding clips prior to operation, allowing the seal to slide into place. If the seal has been installed in the pump by ITT, these clips have already been disengaged.

Model ICP i-FRAME Installation, Operation, and Maintenance 57

6.6 Shaft seal maintenance

Before you start the pump

Check the seal and all flush piping.

6.6.2 Packed stuffing-box maintenance

WARNING:

Packed stuffing boxes are not allowed in an ATEX-classified environment.

WARNING:

Failure to disconnect and lock out driver power may result in serious physical injury. Never attempt to replace the packing until the driver is properly locked out.

Adjustment of gland

Adjust the gland if the leakage rate is greater than or less than the specified rate.

Evenly adjust each of the two gland bolts with a one-quarter (1/4) turn until the desired leakage rate is obtained. Tighten the bolts to decrease the rate. Loosen the bolts to increase the rate.

Tightening of packing

NOTICE:

Never over-tighten packing to the point where less than one drop per second is observed.

Over-tightening can cause excessive wear and power consumption during operation.

If you cannot tighten the packing to obtain less than the specified leakage rate, then replace the packing.

58 Model ICP i-FRAME Installation, Operation, and Maintenance

7 Troubleshooting

7 Troubleshooting

7.1 Operation troubleshooting

7.2 Alignment troubleshooting

Symptom

Horizontal (side-to-side) alignment cannot be obtained (angular or parallel).

Cause

The driver feet are boltbound.

The baseplate is not leveled properly and is probably twisted.

Remedy

Loosen the pump's hold-down bolts, and slide the pump and driver until you achieve horizontal alignment.

1.

Determine which corners of the baseplate are high or low.

2.

Remove or add shims at the appropriate corners.

3.

Realign the pump and driver.

7.3 Assembly troubleshooting

Model ICP i-FRAME Installation, Operation, and Maintenance 59

8 Parts Listings and Cross-Sectionals

8 Parts Listings and Cross-Sectionals

8.1 Parts list

Cross-sectional drawing

60

Parts list and materials of construction

Item Part name

102V Casing

161 Seal chamber / stuffing box cover

183

210

Support foot

Shaft

230 Impeller

320.51 Radial bearing

320.52 Thrust bearing

330 Bearing frame

344

400

Frame adapter

Casing gasket

412.21 O-ring, shaft sleeve and impeller nut

412.41 O-ring, bearing frame

421.41 Oil seal, inboard

421.51 Oil seal, outboard

507 Flinger

524

637

Shaft sleeve

Oil vent

901.11 Casing bolts, hexagon head capscrews

903.51 Drain plug

912.11 Casing drain plug

Ductile iron (NL)

316 SS

(VV)

Ductile iron 316 SS

Ductile iron 316 SS

Cast iron

Pump material

Duplex

(WW)

Alloy 20

(AA)

Duplex SS Alloy 20

Duplex SS Alloy 20

Steel, magnet-tipped

Alloy 20

Hastelloy

(BB/CC)

Hastelloy

Hastelloy

Titanium

(TT)

Titanium

Titanium

316 SS

Carbon steel

Stainless steel (1.4021)

Duplex SS Alloy 20

Single row ball bearing

Hastelloy

Double row, angular contact ball bearing

Cast iron

Ductile iron

Non-asbestos aramid fiber

PTFE

Titanium

316 SS

Viton

Lip seal (buna and steel)

Lip seal (buna and steel)

Noryl 66

Duplex SS (1.4462)

Steel

Alloy 20

Stainless steel (A2)

Hastelloy Titanium

Hastelloy Titanium

Model ICP i-FRAME Installation, Operation, and Maintenance

Item Part name

922 Impeller nut

923.51 Bearing locknut

932.51 Snap ring / circlip

940.31 Impeller key

Parts not shown

Item Part name

236 Inducer (optional)

452

458

Packing gland

Lantern ring

461 Packing

502.11 Wear ring (optional)

642 Oil level sight glass

8.1 Parts list

Ductile iron (NL)

316 SS

(VV)

Duplex SS

Pump material

Duplex

(WW)

Alloy 20

(AA)

Alloy 20

Steel/nylon

Carbon steel

Carbon steel

Hastelloy

(BB/CC)

Titanium

(TT)

Hastelloy Titanium

Ductile iron (NL)

Duplex SS

(1.4462)

316 SS

(VV)

Alloy 20

316 SS (1.4410)

Pump material

Duplex

(WW)

Hastelloy

Alloy 20

(AA)

Titanium

Hastelloy

(BB/CC)

Titanium

(TT)

316 SS

Glass-filled PTFE

PTFE impregnated

Duplex SS Alloy 20

Glass/plastic

Hastelloy Titanium

Model ICP i-FRAME Installation, Operation, and Maintenance 61

9 Certification

9 Certification

62 Model ICP i-FRAME Installation, Operation, and Maintenance

10 Other Relevant Documentation or Manuals

10 Other Relevant Documentation or

Manuals

Model ICP i-FRAME Installation, Operation, and Maintenance 63

11 Local ITT Contacts

11 Local ITT Contacts

11.1 Regional offices

Region

North America

(Headquarters)

Houston office

Los Angeles

Asia Pacific

Asia Pacific

Europe

Latin America

Middle East and Africa

Address

ITT - Goulds Pumps

240 Fall Street

Seneca Falls, NY 13148

USA

12510 Sugar Ridge Boulevard

Stafford, TX 77477

USA

Vertical Products Operation

3951 Capitol Avenue

City of Industry, CA 90601-1734

USA

ITT Fluid Technology Asia Pte Ltd

1 Jalan Kilang Timor

#04-06 Singapore 159303

ITT Goulds Pumps Ltd

35, Oksansandan-ro

Oksan-myeon, Heungdeok-gu,

Cheongju-si, Chungcheongbuk-do

28101, Rep. of KOREA

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

Telephone

+1 315-568-2811

+1 281-504-6300

+1 562-949-2113

+65 627-63693

+82 234444202

+44 1297-639100

+562 544-7000

+30 210-677-0770

Fax

+1 315-568-2418

+1 281-504-6399

+1 562-695-8523

+65 627-63685

+44 1297-630476

+562 544-7001

+30 210-677-5642

64 Model ICP i-FRAME Installation, Operation, and Maintenance

Visit our website for the latest version of this document and more information: http://www.gouldspumps.com

Goulds Pumps

240 Fall Street

Senenca Falls, NY 13148

USA

Form IOM.ICPi-FRAME/ICPIi-FRAME/ICPHi-FRAME/ICPIHi-FRAME.en-US.2021-06

©2021 ITT Organization

The original instruction is in English. All non-English instructions are translations of the original instruction.

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