ITT Goulds Pumps MPAF Instruction manual

(3)GOULDS PUMPS
FOREWORD
This manual provides instructions for the installation, Operation, and Maintenance
of the Goulds Model MPAF.
The design, materials, and workmanship incorporated in the construction of Goulds
pumps makes them capable of giving, trouble-free service. The- life. and
satisfactory service of any mechanical unit, however, is enhanced and extended by
correct application, proper installation, periodic inspection, condition monitoring, and
careful maintenance. This instruction manual was prepared to assist operators in
understanding the construction and the correct methods of installing, operating, and
maintaining these pumps.
Goulds shall not be liable for damage or delays caused by a failure to observe
the instructions for Installation, Operation, and Maintenance, contained in this
manual.
Warranty is valid only when genuine Goulds parts are used.
Use of the equipment on a service other than stated in the order could nullify the
warranty, unless written approval is obtained in advance from Goulds Pumps, Inc.
To assure proper installation, supervision from an authorized manufacturer's
representative is recommended.
Additional manuals can be obtained by contacting your local Goulds representative.
THIS MANUAL EXPLAINS
Proper Installation
Start-up Procedures
Operation Procedures
Routine Maintenance
Pump Overhaul
Trouble Shooting
Ordering Spares or Repair Parts
SAFETY
NAMEPLATE INFORMATION
SECTION | - GENERAL
Page 1
Introduction
I-A Importance of Instructions
|-В Special Warnings
-C Receiving and Inspection — Shortages
-D Preservation and Storage
SECTION Il = INSTALLATION INSTRUCTIONS - AXIAL FLOW PUMPS Page 2 through 13
[I-A Location and Foundation of the Pump
11-B Installing the Pump on the Foundation
li-C Grouting
1-0 Suction and Discharge Piping
HE Installing the Pump and Driver
H-F V-Beit Drive Installation
H-G Coupling Alignment
l-H Factors that may Disturb Alignment
1-1 Stuffing Box - Packing
l-J Stuffing Box - Mechanical Seal
SECTION Hil = AXIAL FLOW PUMP START-UP Page 14/15
lI-A Bearing Lubrication ВЕ
|!-В Shaft Rotation
11-C Checking Rotation
1-0 Stuffing Box Lube Lines
HES Stuffing Box Adjustment
Hi-F Priming
SECTION IV - TYPE "MX" BEARING Page 16 through 20
IV-A Bearing Lubrication
1V-B Oil Level Control
IV-C Normal Bearing Temperature
IV-D Installing a Bearing
IV-E Disassembly of the "MX" Bearing Housing
IV-F Assembly of the "MX" Bearing Housing
SECTION V - MPAF LIQUID END WITH BACK PULLOUT Page21/22/23
V-A Impeller Clearance Adjustment
V-B Disassembly of the Liquid End
V-C Assembly of the Liquid End
SECTION VI - OPERATION AND TROUBLE SHOOTING Page 24/25
Vi-A Performance Check
VI-B Causes of Circulation Loss
VI-C High Horsepower Demand
VI-D Pump Vibration - Rough Noisy Operation
VI-E Water Hammer
VI-F General Considerations
SECTION VII - ORDERING SPARE PARTS Page 26
VI-A Replacement Parts Procedure
APPENDICES —
a! SPRING SUPPORTED SUBBASE (IF NEEDED)
B) INFLATABLE SHAFT SEAL (IF NEEDED)
IMPORTANT SAFETY NOTICE
To: Our Valued Customers
User safety 1s a major focus in the design of our products. Following the precautions outlined in this
manual will minimize your risk of injury.
ITT Goulds pumps will provide safe, trouble-free service when properly installed, maintained, and
operated.
Safe installation, operation, and maintenance of ITT Goulds Pumps equipment are an essential end user
responsibility. This Pump Safety Manual identifies specific safety risks that must be considered at all
times during product life. Understanding and adhering to these safety warnings 1s mandatory to ensure
personnel, property, and/or the environment will not be harmed. Adherence to these warnings alone,
however, is not sufficient — it is anticipated that the end user will also comply with industry and corporate
safety standards. Identifying and eliminating unsafe installation, operating and maintenance practices is
the responsibility of all individuals involved in the installation, operation, and maintenance of industrial
equipment.
Please take the time to review and understand the safe installation, operation, and maintenance guidelines
outlined in this Pump Safety Manual and the Instruction, Operation, and Maintenance (IOM) manual.
Current manuals are available at www.gouldspumps.com/literature ioms.html or by contacting
your nearest Goulds Pumps sales representative.
These manuals must be read and understood before installation and start-up.
For additional information, contact your nearest Goulds Pumps sales representative or visit our Web site at
www.gouldspumps.com.
S-1
SAFETY WARNINGS
Specific to pumping equipment, significant risks bear reinforcement above and beyond normal safety precautions.
A
WARNING
A pump 1s a pressure vessel with rotating parts that can be hazardous. Any pressure vessel can explode,
rupture, or discharge its contents if sufficiently over pressurized causing death, personal injury, property
damage, and/or damage to the environment. All necessary measures must be taken to ensure over
pressurization does not occur.
WARNING
Operation of any pumping system with a blocked suction and discharge must be avoided in all cases.
Operation, even for a brief period under these conditions, can cause superheating of enclosed pumpage and
result in a violent explosion. All necessary measures must be taken by the end user to ensure this condition 1s
avoided.
The pump may handle hazardous and/or toxic fluids. Care must be taken to identify the contents of the pump
and eliminate the possibility of exposure, particularly if hazardous and/or toxic. Potential hazards include, but
are not limited to, high temperature, flammable, acidic, caustic, explosive, and other risks.
- WARNING
Pumping equipment Instruction, Operation, and Maintenance manuals clearly identify accepted methods tor
disassembling pumping units. These methods must be adhered to. Specifically, applying heat to impellers
and/or impeller retaining devices to aid in their removal 1s strictly forbidden. Trapped liquid can rapidly
expand and result in a violent explosion and injury.
ITT Goulds Pumps will not accept responsibility for physical injury, damage, or delays caused by a failure to
observe the instructions for installation, operation, and maintenance contained in this Pump Safety Manual or the
current IOM available at www.gouldspumps.com/literature.
S-2
SAFETY
DEFINITIONS
Throughout this manual the words WARNING, CAUTION, ELECTRICAL, and ATEX are used to indicate
where special operator attention 1s required.
Observe all Cautions and Warnings highlighted in this Pump Safety Manual and the IOM provided with
your equipment.
A
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Example: Pump shall never be operated without coupling guard installed correctly.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Example: Throttling flow from the suction side may cause cavitation and pump damage.
ELECTRICAL HAZARD
Indicates the possibility of electrical risks if directions are not followed.
Example: Lock out driver power to prevent electric shock, accidental start-up, and physical injury.
&
When installed in potentially explosive atmospheres, the instructions that follow the Ex symbol must be
followed. Personal injury and/or equipment damage may occur 1f these instructions are not followed. If there
is any question regarding these requirements or if the equipment is to be modified, please contact an ITT
Goulds Pumps representative before proceeding.
\ . . . .
Example: © Improper impeller adjustment could cause contact between the rotating and stationary
parts, resulting in a spark and heat generation.
GENERAL PRECAUTIONS
A WARNING
A pump 1s a pressure vessel with rotating parts that can be hazardous. Hazardous fluids may be contained by the
pump including high temperature, flammable, acidic, caustic, explosive, and other risks. Operators and
maintenance personnel must realize this and follow safety measures. Personal injuries will result if procedures
outlined in this manual are not followed. ITT Goulds Pumps will not accept responsibility for physical injury,
damage or delays caused by a failure to observe the instructions in this manual and the IOM provided with your
equipment.
General Precautions
WARNING NEVER APPLY HEAT TO REMOVE IMPELLER. It may explode due to
trapped liquid.
WARNING NEVER use heat to disassemble pump due to risk of explosion from tapped liquid.
WARNING NEVER operate pump without coupling guard correctly installed.
NEVER run pump below recommended minimum flow when dry, or without
\ :
WARNING | €y prime.
WARNING A ALWAYS lock out power to the driver before performing pump maintenance.
WARNING NEVER operate pump without safety devices installed.
WARNING ES NEVER operate pump with discharge valve closed.
WARNING | €y | NEVER operate pump with suction valve closed.
WARNING | © DO NOT change service application without approval of an authorized ITT
x
Goulds Pumps representative.
Safety Apparel:
* Insulated work gloves when handling hot bearings or using bearing heater
+ Heavy work gloves when handling parts with sharp edges, especially
WARNING impellers
+ Safety glasses (with side shields) for eye protection
* Steel-toed shoes for foot protection when handling parts, heavy tools, etc.
+ Other personal protective equipment to protect against hazardous/toxic fluids
Receiving:
Assembled pumping units and their components are heavy. Failure to properly lift
and support equipment can result in serious physical injury and/or equipment
damage. Lift equipment only at specifically identified lifting points or as
instructed in the current JOM. Current manuals are available at
www.gouldspumps.com/literature _ioms.html or from your local ITT Goulds
Pumps sales representative. Note: Lifting devices (eyebolts, slings, spreaders, etc.)
must be rated, selected, and used for the entire load being lifted.
WARNING
Alignment:
WARNING | © Shaft alignment procedures must be followed to prevent catastrophic failure of
drive components or unintended contact of rotating parts. Follow coupling
manufacturer’s coupling installation and operation procedures.
S-4
General Precautions
Before beginning any alignment procedure, make sure driver power is locked out.
WARNING A Failure to lock out driver power will result in serious physical injury.
Piping:
Never draw piping into place by forcing at the flanged connections of the pump.
CAUTION | y | This may impose dangerous strains on the unit and cause misalignment between
pump and driver. Pipe strain will adversely effect the operation of the pump
resulting in physical injury and damage to the equipment.
Flanged Connections:
WARNING
Use only fasteners of the proper size and material.
WARNING Replace all corroded fasteners.
WARNING Ensure all fasteners are properly tightened and there are no missing fasteners.
| Startup and Operation:
WARNING | x | When installing in a potentially explosive environment, please ensure that the
motor 1s properly certified.
Operating pump in reverse rotation may result in contact of metal parts, heat
\ :
WARNING | “y generation, and breach of containment.
WARNING A Lock out driver power to prevent accıdental start-up and physical injury.
— | The impeller clearance setting procedure must be followed. Improperly setting
WARNING | x) | the clearance or not following any of the proper procedures can result in sparks,
unexpected heat generation and equipment damage.
| If using a cartridge mechanical seal, the centering clips must be installed and set
WARNING | Ey | screws loosened prior to setting impeller clearance. Failure to do so could result
in sparks, heat generation, and mechanical seal damage.
The coupling used in an ATEX classified environment must be properly certified
\ pling properly
WARNING | “y and must be constructed from a non-sparking material.
WARNING Never operate a pump without coupling guard properly installed. Personal injury
will occur if pump 15 run without coupling guard.
Make sure to properly lubricate the bearings. Failure to do so may result in excess
>
WARNING | & heat generation, sparks, and / or premature failure.
The mechanical seal used in an ATEX classified environment must be properly
CAUTION | €x | certified. Prior to start up, ensure all points of potential leakage of process fluid to
the work environment are closed.
| Never operate the pump without liquid supplied to mechanical seal. Running a
CAUTION E | mechanical seal dry, even for a few seconds, can cause seal damage and must be
avoided. Physical injury can occur 1f mechanical seal fails.
WARNING Never attempt to replace packing until the driver 1s properly locked out and the
coupling spacer 1s removed.
WARNING | €x | Dynamic seals are not allowed in an ATEX classified environment.
| DO NOT operate pump below minimum rated flows or with suction and/or
WARNING | € discharge valve closed. These conditions may create an explosive hazard due to
vaporization of pumpage and can quickly lead to pump failure and physical injury.
S-5
General Precautions
WARNING
Ensure pump 1s isolated from system and pressure is relieved before
disassembling pump, removing plugs, opening vent or drain valves, or
disconnecting piping.
WARNING
Shutdown, Disassembly, and Reassembly:
Pump components can be heavy. Proper methods of lifting must be employed to
avoid physical injury and/or equipment damage. Steel toed shoes must be worn at
all times.
WARNING
The pump may handle hazardous and/or toxic fluids. Observe proper
decontamination procedures. Proper personal protective equipment should be
worn. Precautions must be taken to prevent physical injury. Pumpage must be
handled and disposed of in conformance with applicable environmental
regulations.
WARNING
Operator must be aware of pumpage and safety precautions to prevent physical
injury.
WARNING
Lock out driver power to prevent accidental startup and physical injury.
CAUTION
Allow all system and pump components to cool before handling them to prevent
physical injury.
CAUTION
Ey
If pump is a Model NM3171, NM3196, 3198, 3298, V3298, SP3298, 4150, 4550,
or 3107, there may be a risk of static electric discharge from plastic parts that are
not properly grounded. If pumped fluid is non-conductive, pump should be
drained and flushed with a conductive fluid under conditions that will not allow
for a spark to be released to the atmosphere.
WARNING
Never apply heat to remove an impeller. The use of heat may cause an explosion
due to trapped fluid, resulting in severe physical injury and property damage.
CAUTION
Wear heavy work gloves when handling impellers as sharp edges may cause
physical injury.
CAUTION
Wear insulated gloves when using a bearing heater. Bearings will get hot and can
cause physical injury.
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:
l. Monitoring the pump frame and liquid end temperature.
2. Maintaining proper bearing lubrication.
3. Ensuring that the pump 1s operated in the intended hydraulic range.
The ATEX conformance is only applicable when the pump unit 1s operated within its intended use. Operating,
installing or maintaining the pump unit in any way that 1s 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 www.gouldspumps.com/literature_ioms.html 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:
E C
A
+
The CE and the Ex designate the ATEX compliance. The code directly below these symbols reads as follows:
II = Group2
2 = Category 2
G/D = Gas and Dust present
T4 = Temperature class, can be T1 to T6 (see Table 1)
Table 1
Max permissible Max permissible
surface temperature liquid temperature
Code °F (°C) °F (°C)
T1 842 (450) 700 (372)
T2 572 (300) 530 (277)
T3 392 (200) 350 (177)
T4 275 (135) 235 (113)
TS 212 (100) Option not available
T6 185 (85) Option not available
The code classification marked on the equipment must be in accordance with the specified area where the
equipment will be installed. If it 1s not, do not operate the equipment and contact your I'TT Goulds Pumps sales
representative before proceeding.
S-7
The use of genuine Goulds parts will provide the safest and
most reliable operation of your pump. ITT Goulds Pumps ISO
certification and quality control procedures ensure the parts are
manufactured to the highest quality and safety levels.
Please contact your local Goulds representative for details on
genuine Goulds parts.
S-8
INSTALLATION AND
OPERATING INSTRUCTIONS
SECTION | - GENERAL
INTRODUCTION
This instruction manual is intended to assist
those involved with the installation, operation
and maintenance of Goulds SPD slurry
pumps. It is recommended that this manual
be thoroughly reviewed prior to installing or
performing any work on the pump or motor.
I-A. IMPORTANCE OF INSTRUCTIONS
The design, material, and workmanship
incorporated in the construction of Goulds
pumps makes them capable of giving long,
trouble-free service. The life and satisfactory
service of any mechanical unit, however, is
enhanced and extended by periodic
inspection and careful maintenance. This
Instruction Manual was prepared to assist
operators in understanding the construction
and correct methods of installing, operating,
and maintaining these pumps.
Study thoroughly Sections |, lI, lll, and
carefully follow the instructions for installation
and operation. Sections IV, V, VI, and VII are
answers to trouble and maintenance
questions.
Keep this instruction manual handy for
reference. Further information can be
obtained by contacting the Slurry Pump
Division, East Centre St., Ashland, PA
17921 or your local representative.
|-В. SPECIAL WARNINGS
Goulds’ Slurry Pump Division wiil not be liable
for any damages or delay caused by failure to
comply with the provisions of this instruction
Manual. This pump is not to be operated at
speeds, working pressures, discharge
pressures, or temperatures higher than, nor
used with liquids other than stated in the
original order acknowledgement, without
written permission of the Slurry Pump
Division, Goulds Pumps, Inc.
I-C. RECEIVING AND INSPECTION -
SHORTAGES
Care should be taken when unloading any
Goulds’ pump. If shipment is not delivered in
good order and in accordance with the bill of
lading, note the damage and shortage on
both the receipt and freight bill. MAKE ANY
CLAIMS TO THE TRANSPORTATION
COMPANY PROMPTLY.
Instruction sheets on various components as
well as the Instruction Book for the pump are
included in the shipment. DO NOT
DISCARD.
|-D. PRESERVATION AND STORAGE
Short Term: (Less than 6 months) Gould's
Slurry Pump Division's normal domestic
shipping and storage preparation is suitable
for protecting the pump during shipment in
covered trucks. It also provides protection
during short term covered storage at the
jobsite and for a short period between
installation and start-up. Unless otherwise
specified, it is assumed the pump will be
installed upon delivery. Additional protection
can be provided by request.
One approach to preserve the pump is to
provide special preservatives and wrapping
before shipment. However, after installation,
the protective wrappings will have been
removed. Therefore, application of
preservatives after installation is considered
good practice.
Long Term: (More than 6 months) if the
pump is to be idle and exposed to the
elements for an extended period, either
before or after installation, special
precautions are required. Preservative
treatment of bearings and machined surfaces
will be required. Also, driver and coupling
manufacturers should be contacted for long
term storage procedures. Hand rotation of
the shaft is recommended every 30 days to
prevent damage to the bearings.
— INSTALLATION AND
OPERATING INSTRUCTIONS
SECTION II - INSTALLATION INSTRUCTIONS - AXIAL FLOW PUMPS
This section is a general installation and
operating instruction for the MPAF pumps.
There are specific instructions for the bearing
assembly (SECTION IV) and the liquid end
(SECTION V) which follow this section. For a
pump fumished with an inflatable shaft seal
and/or a spring supported subbase, appendices
are added.
To insure pump performance and operating life,
proper installation and reasonable
maintenance are required. The following
instructions are a guide for installation and
maintenance personnel and the pump
operator. We recommend becoming familiar
with these instructions before the pump is
installed, started, or disassembled for any
reason, to avoid unnecessary lost time and
added expense.
I-A. LOCATION AND FOUNDATION OF THE
PUMP a
Location: For all MPAF pumps, the unit should
be located in a clean, dry area free from
flooding. The area should provide adequate
space for operation, maintenance, inspection
and repair, considering complete disassembly
and handling of equipment. The unit should be
positioned to provide the most efficient pipeline
system.
Foundation: The MPAF pumps covered by
these instructions may be designed to hang in
the piping system, fumished with spring loaded
subbase bolts, or have a subbase designed to
be anchor bolted and grouted to the
foundation.
The foundation must be substantial enough to
absorb any vibration and form a permanent,
rigid support for the pumping unit to the degree
that there will not be any adverse movement or
settling over a long period of time.
Foundations for anchor bolted and grouted
subbases are typically concrete with anchor
bolts cast in to secure the pump.
The most commonly used foundation bolts are
the sleeve-type (Fig 2A) and J type (Fig. 2B).
Both designs permit movement for final bolt
adjustment. Anchor bolts should be located in
ue concrete by a template dimensioned from
~P
the pump installation drawing . The top of the
sleeve- type boit should be temporarily sealed
with waste material to prevent concrete from
entering during the concrete pouring operation.
Spring loaded bolts assure that the pump
remains level, regardless of vertical movement
due to thermal pipe expansion created during
operation. The location and size of the
foundation bolts are shown on the outline
assembly drawing, provided with the pump data
package. For more information on spring
mounted subbases, see APPENDIX (if
applicable).
Fig. 2A Sleeve type foundation bolts.
BASEPLATE
Fig. 28 J-type foundation bolts.
INSTALLATION AND
OPERATING INSTRUCTIONS
II-B. INSTALLING
PUMP
FOUNDATION
ON THE
When the unit is received with the pump and
driver mounted on a subbase, it should be
laced on the foundation and the coupling
alves disconnected. The coupling should not
be reconnected until all realignment
operations have been completed. A
recommended coupling alignment procedure
is included in section I|-G.
For pumps with spring supported subbases,
refer to Appendix A rather than the following
paragraphs, which are for anchor bolted
subbases.
The subbase should be supported on
rectangular metal blocks or on metal wedges
having a slight taper. There should be one
supporting block or wedge on each side of
each foundation bolt. A gap of about 3/4" to
1-1/2" should be allowed between the
subbase and the foundation for grouting.
Adjust the metal supports or wedges until the
shafts of the pump and the driver are level.
Check the coupling faces, as well as the
suction and discharge flanges of the pump, for
horzontal or vertical position by means of a
level. Check also for any internal rubbing in
the pump. Correct, if necessary, by adjusting
the supports or wedges under the subbase as
required. In most cases, factory alignment will
be regained by shimming under the subbase
alone.
Provisions must be made to support the
discharge piping independently from the pump
to prevent excessive loads and maintain
pump-driver alignment.
lI-C. GROUTING
When the alignment is correct, the foundation
bolts should be tightened eveniy, one-haif
tum past hand tight. The unit can then be
grouted to the foundation. The subbase
should be completely filled with grout, and it is
desirable to grout the leveling pieces or
wedges in place. Foundation bolts should not
be fully tightened until the grout has
hardened.
The bolts which secure the pump to the
foundation should be 1/8" - 1/4" less in
diameter than the holes in the pump frame
(size is shown on the certified dimension
drawing).
Level Subbase: The subbase should be level
to within .125 in. (3 mm) over the length of the
base and .0875 in. (1.5 mm) over the width of
the base.
Bases anchored with conventional foundation
bolts use shims on both sides of the anchor
boits to level the base. Spring loaded
foundation boits use a combination of intemal
boit adjustment and shimming to level the
base. If the unit is fumished with a spring
supported subbase, follow the spring
adjustment instructions in Appendix A.
1-0. SUCTION AND DISCHARGE PIPING
Properly installed suction piping is a necessity
for trouble-free pump -operation. Suction
piping should be flushed before connection to
the pump. Short suction and discharge -
pipelines having a minimum of elbows and
fittings result in the least amount of pipe
friction.
General Piping Guidelines:
Guidelines for piping are given in the
"Hydraulic Institute Standards" and must be
reviewed prior to pump installation.
1. All piping must be supported independently
of and line up naturally with, the pump flanges.
NEVER DRAW PIPING INTO PLACE BY FORCING AT
THE FLANGED CONNECTIONS OF THE PUMP. THIS
MAY IMPOSE DANGEROUS STRAINS ON THE UNIT
AND CAUSE MISALIGNMENT BETWEEN THE PUMP
AND DRIVER. PIPE STRAIN WILL ADVERSELY
EFFECT THE RELIABILITY OF THE PUMP.
2. Piping runs should be as short as possible
to minimize friction losses. | |
3. DO NOT connect piping to pump until grout
has been hardened and pump and driver
hold-down bolts have been tightened.
4. It is suggested that expansion loops or
joints be properly installed in suction and/or
a
INSTALLATION AND
OPERATING INSTRUCTIONS
discharge lines when handling liquids at
elevated temperatures, so linear expansion of
piping will not draw the pump out of
alignment.
5. The piping should be arranged to allow for
pump flushing prior to removal of the unit on
services handling corrosive liquids.
6. Carefully clean all pipe parts, valves,
fittings, and pump branches prior to assembly.
Suction Piping:
1. Excessive friction
Ex losses will
cavitation.
cause
2. Use of elbows close to the pump suction
flange should be avoided. There shouid be a
minimum of 2 pipe diameters of straight pipe
between the elbow and suction inlet. Where
used, elbows should be long radius.
3. Use suction piping one or two sizes larger
than the pump suction, with a reducer at the
suction flange. Suction piping should never
be a smaller diameter than the pump suction.
4. The piping should not contain high spots
which could trap air pockets.
5. Reducers, if used, should be eccentric at
the pump suction flange, with the sloping side
down.
6. Flow regulating valves must not be located
on the suction side of the pump. Flow should
never be throttled on the suction side.
7. Suction strainers, when used, must have a
net “free area" of at least three (3) times the
suction pipe area.
8. Separate suction lines are recommended
when more than one pump is operating from
the same source of supply.
Suction Lift Conditions:
1. Suction pipes must be free from air
pockets.
2. Suction piping must slope upwards to
pump.
A
3. All joints must be air tight.
4. A means of priming the pump must be
provided, such as a foot valve.
Suction Head/Flooded Suction Conditions:
1. An isolation valve should be installed in the
suction line to permit closing of the line for
pump inspection and maintenance.
2. Keep suction pipe free from air pockets.
3. Piping should be level or slope gradually
downward from the source of supply.
4. No portion of the piping should extend
below the pump suction flange.
5. The size of entrance from the supply should
be no smaller than the suction pipe.
6. The suction pipe must be adequately
submerged below the liquid surface to prevent
vortices and air entrainment at the supply.
Discharge Piping:
1. Isolation and check vaives should be
installed in the discharge line. Locate the
check valve between the isolation valve and
the pump, this will permit inspection of the
check valve. The isolation valve is required for
priming, regulation of flow, and for inspection
and maintenance of the pump. The check
valve prevents pump or seal damage due to
reverse flow through the pump when the driver
is turned off.
2. Increasers, if used, should be placed
between pump and check valves.
3. Cushioning devices should be used to
protect the pump from surges and water
hammer if quick—closing valves are installed in
the system.
4. Excessive friction losses will resuit in
insufficient flow.
The pumps are not designed to carry loads
imposed by the weight of the pipeline. The
pipe must be supported independently near
the pump to prevent any strain being
transmitted to the pump.
INSTALLATION AND
OPERATING INSTRUCTIONS
Arrangements should be made to keep the
pump from back-spinning severely during
shutdown. On a long discharge line, a
non-siam check valve should be installed.
THIS UNIT MUST NEVER BE USED WITHOUT PRIOR
INSTALLATION OF THE SAFETY GUARDS FOR
ROTATING PARTS AS PRESCRIBED BY O.S.H.A.
OPERTION OF THIS PUMP WITH BOTH THE
SUCTION AND DISCHARGE VALVES CLOSED FOR
EVEN BRIEF PERIODS OF TIME IS AN
UNACCEPTABLE AND DANGEROUS PRACTICE. IT
CAN RAPIDLY LEAD TO A VIOLENT PUMP FAILURE.
N-E. INSTALLING THE PUMP AND DRIVER
1. Piping Connection - Connect the elbow
side (or top) opening to the pipeline. If the
unit is supported with a spring supported
subbase, follow the spring adjustment
instructions in Appendix A.
2. Install the Driver -
INCORRECT ROTATION COULD RESULT IN
CONSIDERABLE DAMAGE TO THE PUMP.
LOCKOUT POWER TO THE DRIVER BEFORE
CHECKING THE MOTOR ROTATION.
a) Check the driver rotation before connecting
the driver to the pump. Pump direction of
rotation is indicated by an arrow on the elbow
or casing.
b) Connect the driver to the pump. If the
pump is driven by belts, align the sheaves
and tighten the belts, using care to avoid
excessive beit tension. See SECTION Il - F
V-Belts for more information on V-belt
installation.
If the pump is driven with universal joint
shafting, the shafts must be parallel within 1°
but oftset to have an angular misalignment of
at least 1° at normal system operating
temperature. For more information, consult
the universal shaft manufacturer.
3. Check Impeller Clearance —
a) Impeiler must not rub when shaft is turned
by hand. If the impeller rubs or aimost rubs,
refer to the liquid end section for corrective
action.
b) It is recommended that the IMPELLER
ALIGNMENT WORKSHEET (on the next
page) be filled out and filed with the pump
maintenance records for future reference.
See SECTION V-A - Impeller Adjustment for
more information on impeller adjustment.
4. Final Piping Connection - Connect the
other pump flange (closest to impeller) to the
system
a) Check the flanges before tightening bolts to
be sure no severe strain will be placed on the
pump when flanges are forced together with
bolts. If necessary, correct the piping.
b) Tum pump shaft by hand to check for
impeller rubbing. Impeller may rub if last
flange connection has placed strain on the
pump.
lI-F. V-BELTS
Well designed and properly installed v-belt
drives are capable of running for years. There
are a few points that should be checked
periodically.
1. Sheave Alignment —~ Alignment must be
maintained for full power transmission,
minimum vibration, and long drive life. A dial
indicator can be used to check runout on the
periphery and face of each sheave. A straight
edge can be used to check the alignment of
the pump and drive sheaves in the vertical
direction. See Fig. 3 page 7.
2. Belt Installation - When installing new
belts, shorten center distance between
sheaves so that beits can be placed on the
sheave without the use of force. Never "roll"
or "pry" the belts into place, as this could
damage the belt cords.
INSTALLATION AND
OPERATING INSTRUCTIONS
AXIAL FLOW PUMP
IMPELLER ALIGNMENT WORKSHEET
3 OR 4 VANE IMPELLER
PUMP SERIAL NO.: DATE:
PUMP SIZE: PUMP ALIGNED BY: _
12 O'CLOCK
VANE |
VANE 2
VANE 3
tVANE 4
9 O°CLOCK 3 O’CLOCK
VANE | VANE |
VANE 2 VANE 2
VANE 3 VANE 3
* МАМЕ 4 «МАМЕ 4
6 O'CLOCK
VANE |
VANE 2
VANE 3
*VANE 4
SUM OF ALL CLEARANCES |
MINIMUM CLEARANCE = X —
NUMBER OF MEASUREMENTS 2
* NOTE: FOR THE THREE VANE IMPELLER, ROTATE AND MEASURE 3 CLEARANCES AT EACH
CLOCK POSITION (ONE CLEARANCE FOR EACH VANE). FOR THE 4 VANE IMPELLER MEASURE
4 CLEARANCES AT EACH CLOCK POSITION.
INSTALLATION AND
OPERATING INSTRUCTIONS
Е ЕЦ
Parallel Misalignment
Angular Misalignment
Perfect Alignment
Fig. 3. V-belt drive alignment.
3. Check Belt Fit — Regardless of the beit
section used, the belt should never be allowed
to bottom in the groove. This will cause the
belts to lose their wedging action and slippage
can occur. Sheaves or beits that permit such
a condition to occur should be changed.
4. Maintain Proper Belt Tension - Proper
tension is essential for long belt life. Improper
tension could cause belt fatigue and/or hot
bearings.
The general method of tensioning belts is
given below, and should satisfy most drive
requirements.
General Method:
STEP 1. Reduce the center distance so that
the belts may be placed over the sheaves and
in the grooves without forcing them over the
sides of the grooves. Arange the belts so
that both belt spans have approximately the
same sag between the sheaves, Apply
tension to the belts by increasing the center
distance until the belts are snug, see Fig. 4.
DO NOT OPERATE THE PUMP WITHOUT THE
PROPER DRIVE GUARD IN PLACE. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN
PERSONAL INJURY TO OPERATING PERSONNEL.
Slight Bow
| Too Loose
Figure 4. V-belt tension positions.
STEP 2. Operate the drive a few minutes to
seat the belts in the sheave grooves.
Observe the operation of the drive under its
highest load condition (usually starting). A
slight bowing of the slack side of the drive
indicates proper tension. If the slack side
remains taut during the peak load, the drive is
too tight. Excessive bowing or slippage
indicates insufficient tension. If the belts
squeal as the motor begins operation or at
some subsequent peak load, they are not tight
enough to deliver the torque demanded by the
drive machine. The drive should be stopped
and the belts tightened.
STEP 3. Check the tension on a new drive
frequently during the first day by observing the
slack side span. After a few days of operation
the belts will seat themseives in the sheave
grooves and it may become necessary to
readjust so that the drive again shows a slight
bow in the slack side.
Other methods of determining proper beit
tension can be obtained from the drive
manufacturer.
5. Use Belt Guards — Belt guards protect
personnel from danger and the drive from
contamination. Inspect periodically to assure
that belts do not rub against guard.
~ INSTALLATION AND
OPERATING INSTRUCTIONS
6. Keep Belts Clean - Dirt and grease
reduce belt life. An occasional wiping with a
dry cloth to remove any build~up of a foreign
material can extend the life of the belt.
Should oil or grease splatter onto the belts,
clean with soap and water.
Belt dressing affects performance only
temporarily and is never recommended.
Maintaining a clean drive is a better practice.
If any questions arise pertaining to the drive
limitations, consuit the manufacturer.
lI-G. COUPLING ALIGNMENT
BEFORE BEGINNING ANY ALIGNMENT
PROCEDURE, MAKE SURE DRIVER POWER IS
LOCKED OUT.
The points at which alignment are checked
and adjusted are:
— Initial Alignment is done prior to
operation when the pump and the driver are
at ambient temperature.
- Final Alignment is done after operation
when the pump and driver are at operating
temperature.
NOTE: PROPER ALIGNMENT IS THE
RESPONSIBILITY OF THE INSTALLER AND USER
OF THE UNIT.
Accurate alignment of the equipment must
be attained. Trouble free operation can be
accomplished by following these procedures.
ALIGNMENT CHECKS
Initial Alignment (Cold Alignment)
— Before Mounting Baseplate - To ensure
alignment can be attained.
— After Mounting Baseplate - To ensure no
changes have occurred during the mounting
process.
— After Connecting Piping ~ To ensure pipe
strains have not altered alignment. If
changes have occurred, alter pining to
remove pipe strains on pump flanges.
-B—
Final Alignment (Hot Alignment)
~ After First Run - To obtain correct alignment
when both pump and driver are at operating
temperature. Thereafter, alignment should be
checked periodically in accordance with piant
operating procedures.
ALIGNMENT CRITERIA
Disconnect coupling halves before proceeding
with the alignment. Check for parallel and
angular alignment with either the Dial indicator
Method or the Straight-Edge Method outlined
below.
The faces and outside diameters of the
coupling halves must be square and
concentric with the bores. Good alignment is
achieved when the dial indicator readings, for
both parallel and angular misalignment, are
.003" (.076mm) Total Indicated Reading
(T.LLR.) or less when the pump and driver are
at operating temperature (Final Alignment).
Fig. 5 provides a picture of what to look for.
pr— | `
| \ ; {| ; |
+ —
| | i |! |
uu =
AD
Anauiar Parallel
Misalignment Misalignment
Perfect
Alignment
у
Fig. £. Coupling alignment positions.
INSTALLATION AND
OPERATING INSTRUCTIONS
SET-UP
1. Mount two dial indicators on one of the
coupling halves (X) so that they contact the
other coupling haif (Y), see Fig. 6.
Y
(MOTOR END)
a p
—
Fig. 6. Dial indicator set-up.
2. Check setting of indicators by rotating
coupling half X to ensure indicators stay in
contact with coupling half Y but do not bottom
out. Adjust indicators accordingly.
MEASUREMENT TECHNIQUES
1. To ensure accuracy of indicator readings,
always rotate both. coupling halves together
so indicators contact the same point on
coupling half Y. This will eliminate any
measurement problems due to runout on
coupling half Y.
2. Take indicator measurements with driver
hold-down bolts tightened. Loosen hoid-
down bolts prior to making alignment
corrections.
3. Take care not to damage indicators when
moving driver during alignment corrections.
Keep this instruction manual handy for
reference. Further information can be
obtained by contacting the Slurry Pump
Division, East Centre St., Ashland, PA 17921
or your local representative.
ALIGNMENT PROCEDURE
A check for both angular and parallel
alignment must be completed and the
necessary adjustments be made to obtain the
003" (.076mm) T.1.R. stated in the alignment
criteria.
Angular and parallel misalignment in the
vertical direction, on MPAF pumps, are
corrected by means of shims under the motor
mounting feet. In the horizontal direction,
alignment is corrected simply by sliding the
motor into the proper location.
After each adjustment, it is necessary to
recheck the alignment of the coupling halves.
Adjustment in one -direction may disturb
adjustments already made in another
direction. It should not be necessary to
adjust the pump in any way.
ANGULAR ALIGNMENT
À Unit is in angular alignment when indicator
A (Angular Indicator), Fig 6, does not vary by
more than .003" (.076mm) as measured at
four points on the coupling periphery 90°
apart at operating temperature. There are
two methods outlined below which are
acceptable to achieve the desired alignment.
METHOD 1 - Dial indicator Method
For the following steps, refer to Fig. 7, pg. 10.
1. Zero indicator A at position 1 of coupling
пай Y. Mark this position on both flanges.
2. Rotate both flanges 180° to position 3.
Observe needle and record reading.
3. Negative Reading — The coupling halves
are further apart at position 3 than position 1.
Positive Reading - The coupling haives are
closer at position 3 than position 1.
4. Correct any misalignment by shimming the
motor under its feet to attain the- proper
alignment.
When using positions 2 and 4 in steps 1 — 3,
correct any misalignment by sliding the motor
back and forth to attain the proper alignment.
INSTALLATION AND
OPERATING INSTRUCTIONS
5. Repeat steps 1-4 substituting position 2 for
position 1 and position 4 for position 3. Use
the same marks made on the coupling from
position 1 and be sure to turn the coupling
halves together.
Figure 7. Directions of viewing coupling
View from front of pump.
METHOD 2 - Feeler Gauge Method
For the following steps refer to Fig. 7.
1. Insert a teeler gauge at position 1 at the
periphery of the couplings. Mark this position
on both flanges.
2. Record the largest gauge size which fits
snugly between the two flanges.
3. Rotate both flanges to position 3 — 180°,
4. Insert a feeler gauge at position 3 at the
periphery of the couplings.
5. Record the largest gauge size which fits
snugly between the two flanges.
6. Calculate the difference between the
readings at positions 1 and 3. The difference
should not be greater than .003" (.076mm).
7. Correct any misalignment by shimming the
motor under its feet to attain the proper
alignment.
-10-
When using positions 2 and 4 in steps 1 - 6,
correct any misalignment by sliding the motor
back and forth to attain the proper alignment.
8. Repeat steps 1-6 substituting positions 2
and 4 for positions 1 and 3 respectively. Use
the same marks made on the coupling from
position 1 and be sure to turn the coupling
alves together.
PARALLEL ALIGNMENT
The unit is in parallel alignment when indicator
P (Parallel Indicator) does not vary by more
than .003" (.076mm) as measured at four
points on the coupling periphery 90° apart at
operating temperature. There are two
methods outlined below which are acceptable
to achieve the desired alignment.
METHOD 1 - Dial Indicator Method
For the following steps, refer to Fig. 7.
1. Zero indicator P at position 1 of coupling
hatf Y. Mark this position on both flanges.
2. Rotate both flanges 180° to position 3.
Observe needle and record reading.
3. Negative Reading - The coupling half Y is
shifted toward position 1.
If the value is greater than .003" (.076mm),
correct the misalignment by eveniy (at equal
amounts on both sides) shimming the motor
higher.
When using positions 2 and 4 in steps | - 2,
correct any misalignment by sliding the motor
eveniy toward position 2.
Positive Reading — The coupling half Y is
shifted toward position 3.
If the value is greater than .003" (.076mm),
correct the misalignment by evenly (at equal
amounts on both sides) shimming the motor
ower.
When using positions 2 and 4 in steps 1 - 2,
correct any misalignment by sliding the motor
evenly toward position 4.
4. Repeat steps 1-3 until indicator P reads
003" (.076mm) or less.
INSTALLATION AND
OPERATING INSTRUCTIONS
5. Once the ideal alignment is reached,
repeat steps 1-4 substituting position 2 for
position 1 and position 4 for position 3.
METHOD 2 - Straight-Edge Method
For the following steps refer to Fig. 7, pg. 10..
1. Place a straight edge across the two
coupling flanges at position 1 and mark the
spot on both flanges.
2. Adjust the motor so that the straight-edge
rests evenly on both flanges (within .003" -
076mm).
3. Rotate both flanges 90° to positions 2 and
repeat steps one and two.
4. The unit will be in parallel alignment when
the straight edge rests evenly (within .003" -
.076mm) on the coupling periphery at both
positions along the periphery.
NOTE: Care must be taken to have the
straight edge parallel to the axis of the shafts
lI-H. FACTORS THAT MAY DISTURB
ALIGNMENT
The unit should be checked periodically for
alignment. If the unit does not stay in line
after being properly installed, the following are
possible causes:
1. Settling or spring of the foundation.
2. Wear of bearings.
3. Pipe strains distorting or shifting the
machine.
4. Spring of the base plate due to heat
created from an adjacent heat source.
5. Shifting of the building structure due to
variable loading or other causes.
6. Loose nuts or bolts on the pump or driver
assembly.
H-1. STUFFING BOX - PACKING
1. Lubrication - In the conventional stuffing
box, packing or mechanical seals are used to
seal the rotating shaft. Generally, a clear
liquid such as water is used to lubricate and
cool the sealing elements. The lubricating
liquid pressure must be 10-15 PSI higher
than the pressure inside the elbow to prevent
pumpage from entering the sealing elements.
The lubricating liquid must be clean and free
of grit. Shaft sleeve scoring, packing
destruction, and mechanical seal face
damage will result from contaminated
lubricant.
The stuffing box may be on the suction or the
discharge side of the impeller, depending on
the direction of flow through the elbow
ordered by the customer. If the pressure
inside the elbow is not known, it should be
measured with a pressure gauge on the
discharge pipe when the pump is operating.
The stuffing box is furnished with two N.P.T.
holes for piping the lubricating liquid. The
lubricating liquid is piped into one of them.
Some users simply plug the other hole. For
additional cooling of the sealing elements, an
outlet pipe with a vaive can be installed to
allow more liquid to flow through the stuffing
box. Double mechanical seals have no
leakage and usually require a lubricant
tlowthrough the stuffing box for cooling. The
lubricant flow should be regulated by the
valve in the outlet pipe rather than by
throttling the flow in the supply pipe.
2. Packing - Original equipment packing is a
suitable grade for the service intended.
3. Packing Procedure —
Refer to Fig. 8, page 12 for the following
instructions.
a) Stuffing box and shaft sleeve must be
clean and free of grit.
b) Form packing over shaft or mandrel of
same diameter. Carefully cut to packing
length. Discard rings cut too short.
c) Pre-form each ring by coiling 1-1/2 turns.
—{1-—
INSTALLATION AND
OPERATING INSTRUCTIONS
VA AAD ADA AA
Fig. 8. Typical stuffing box.
d) To install packing rings, do not pull
straight. Expand the coil as a coil spring,
see Fig SA and 9B for the correct and
incorrect method of installing packing.
e) Expand the first coil as shown and insert
into stuffing box. Tamp packing to
stuffing box shoulder firmly with the gland.
Note where the cut is positioned.
f) Install the second and third coil as
required by assembly drawing, staggerin
the cut 90° to 120°, 9 Sena
g) Insert lantem ring into stuffing box,
carefully noting its proper position on the
assembly drawing. Failure to properly
locate the lantem ring will result in
Fig. 9A. Correct
insufficient packing lubrication. Packing and
shaft sleeve damage may result.
h) After packing and lantem ring are
property installed, insert gland into stuffing
ox. Tighten gland nuts finger tight oniy.
The shaft should turn freely.
i) Turn lubricant supply on, start pump, and
adjust the gland as described in Section
¡N-E Stuffing Box Adjustment.
j) Periodic maintenance is absolutely
required for all packed pumps. Normal shaft
run-out should be under .005" to avoid
pounding of stuffing box packing. With
excessive shaft run-out, shaft straightening
or replacement is necessary.
Fig. 9B. Incorrect.
Fig. 9. Stufiing Box Packing.
-12-
INSTALLATION AND
OPERATING INSTRUCTIONS
4, Stuffing Box Adjustment - See SECTION
INE. Stuffing Box Adjustment.
1-3. STUFFING BOX - MECHANICAL SEAL
Most mechanical seals are installed and
adjusted at the factory. Due to size and
design, some installed mechanical seals are
supplied with shipping retainers. Shipping
retainers hold the sealing faces apart to avoid
damage during transport. Shipping retainers
must be removed before shaft is to be rotated.
Pumps with retained seal faces will be
specifically marked and instructions from the
seal manufacturer for retainer removal will be
provided.
Mechanical seals have a stationary and a
rotating sealing face. Commonly, these
sealing rings are of carbon and ceramic
material, brittle in nature, and easily damaged.
As the sealing rings seat with the operation of
the pump, a compatible wear pattern develops
between the mating surfaces. To disassemble
the mechanical seal after the wear pattern is
established would necessitate the
replacement of the rotating element and
stationary sealing elements. Do not replace
only one component. -
To insure the life and sealing characteristics of
the mechanical seal, lubricating liquid must be
circulated through the stuffing box. Clear,
grit-free liquid is necessary.
Special seal information and replacement seal
elements can be provided by the seal
manufacturer. Goulds strongly recommends
the stocking of replacement sealing elements.
DO NOT MAKE SHAFT ADJUSTMENTS ON
MECHANICAL SEAL INSTALLATIONS WITHOUT
CONSULTING SEAL INSTRUCTIONS AND THE
PUMP ASSEMBLY DRAWING. DAMAGE TO THE
MECHANICAL SEAL MAY RESULT.
-13-
INSTALLATION AND
OPERATING INSTRUCTIONS
SECTION Ill - AXIAL FLOW PUMP START-UP
Before the pump is started, the following
should be checked:
I-A. BEARING LUBRICATION - The
bearings must have adequate lubrication.
Consult SECTION IV - Bearing Lubrication of
this instruction manual for more specific
information.
IMPROPER LUBRICATION COULD RESULT IN
SERIOUS DAMAGE TO THE BEARINGS AND
POSSIBLE PUMP FAILURE.
II-B. SHAFT ROTATION - The pump shaft
must turn without any binding or rubbing. By
manually turning the rotating element, only
the uniform frictional drag of the bearings and
the stuffing box should be sensed. If the shaft
does not turn freely, it should be checked to
determine the cause of binding.
Hi-C. CHECKING ROTATION - The direction
of rotation of the driver must be checked
before it can be coupled with the pump. The
direction of rotation of the pumps is indicated
in a prominent location. For pumps with
impellers threaded on the shaft, reverse
rotation would back the shaft from the impeller
thread. Considerable damage may occur.
SERIOUS DAMAGE MAY RESULT IF THE PUMP IS
RUN IN THE WRONG DIRECTION.
1. Lockout power to the driver.
LOCKOUT DRIVER POWER TO PREVENT
ACCIDENTAL START-UP,
2. Disconnect coupling from the driver or the
beits from the drive. Make sure no parts are
loose.
3. Reinstall drive guard.
4. Unlock driver power.
5. Make sure everyone is clear of the driver.
Jog the driver just long enough to determine
the direction of rotation. Rotation must
correspond to the arrow on the pump.
6. Reinstall driver power.
l11-D. STUFFING BOX LUBE LINES -
Lubricating liquid must be flowing to the
stuffing box before the pump is started. Both
mechanical seals and packing require
lubrication for continued service. See
SECTION И-Н - Stuffing Box for more
information on packing lubrication.
AI-E.STUFFING BOX ADJUSTMENT -
During the first few hours of operation:
1. Gland Adjustment - Adjust the stuffing
box if packing is used. When the pump is first
started, there should be considerable leakage
by the gland to cool the packing. Gradually
tighten the gland nuts one flat at a time while
observing the leakage and the stuffing box
temperature. Packing requires time to “run in"
and extra coolant (leakage) while it is being
‘run in". If the leakage is reduced too quickly,
the packing will overheat and may be
destroyed. The shaft sleeve may also be
damaged.
2. Leakage - The normal leakage for a
properly adjusted stuffing box, depending on
shaft size and speed, varies from a few drops
a second to a small trickie out of the gland.
NI-F. PRIMING - Never install pump until it
has been properly primed
pump starting - make sure suction and
discharge valves are fully open.
INSTALLATION AND
OPERATING INSTRUCTIONS
THIS UNIT MUST NEVER BE USED WITHOUT PRIOR INSTALLATION OF THE SAFETY
GUARDS FOR ROTATING PARTS AS PRESCRIBED BY O.S.H.A.
OPERATION OF THIS PUMP WITH THE DISCHARGE AND/OR SUCTION VALVES CLOSED
FOR EVEN BRIEF PERIODS OF TIME IS AN UNACCEPTABLE AND DANGEROUS PRACTICE.
A GREAT DANGER EXISTS FROM POSSIBLE EXPLOSION.
DO NOT APPLY HEAT TO THE NOSE OF THE IMPELLER. DANGER OF EXPLOSION.
—45-
INSTALLATION AND
OPERATING INSTRUCTIONS
SECTION IV - TYPE "MX" BEARING
The MX bearing uses a pair of angular
contact bearings in the outboard bearing to
carry the combined radial and axial thrust
forces. A single row radial bearing in the
inboard position carries the shaft weight and
counter force from a belt drive system.
This assembly is used with horizontal and
vertical MPAF pumps, with the only change
being the position of the inboard bearing
grease fitting.
The larger MX bearing housings are a split
design to facilitate disassembly and
assembly. This allows using an aiternate
ou
bottom sing half with a larger reservoir
for oil lubrication.
IV-A. BEARING LUBRICATION AND CARE
At the first start-up, place a couple of drops
of oil on the shaft by each lip seal.
Grease Lubrication
If the pump is fumished with grease
lubrication, the bearings were hand packed
with Mobilux #2 grease unless otherwise
specified by the customer. Other suitable
greases are Humble Lidok #2, Texaco Regal
Starfak #2 and Shell Alvania #2. If another
brand is desired, it should be checked with
the supplier for being equivalent to the
above.
The bearings have sufficient grease for at
least 24 hours of operation after start-up.
The bearings will run hotter than normal for
the first few hours until the grease is worked
out of the ball path and the bearings have
"run-in". Adding more grease during this
period may increase the bearing
temperature. After the first re-greasing, a
smail amount of grease should be added at
each fitting every 500 hours of operation.
Oll Lubrication
When the pump is fumished with oil
lubrication, a good grade of oil should be
used to insure long bearing life.
-168-
PUMPS FURNISHED FOR OIL LUBRICATION ARE
SHIPPED WITHOUT OIL ADD OIL UNTIL THE
LEVEL IS UP TO THE OIL LEVEL LINE BEFORE
THE UNIT IS STARTED.
If too much oil is added, there will be
excessive heat generated in the bearings
and there may be leakage from the shaft
seals.
Run pumps for 15 seconds to fill splash
reservoirs in the bearing housing. Check oil
level indicator and add oil accordingly.
Monitor oil level indicator for the first 24
hours of operation and maintain fill level.
If the unit has an external oil lube system, fill
the bearing housing and the reservoir to
satisfy the system requirements. Goulds
recommends a commercial oil such as
Mobil D.T.E. oil BB
Shell Tellus #72
or an equal quality grade oil. However, a
good grade of non-detergent oil of SAE#30
or #40 is usually satisfactory. Consult a
reputable supplier for acceptable substitutes
for the oils mentioned.
For the best resuits, the minimum oil
viscosity should be maintained as follows:
Operating temp. below 150° F - SAE 30
Operating temp. below 160° F — SAE 40
Operating temp. below 180° F - SAE 50
An oil with a higher viscosity than required
will increase the bearing operating
temperature because of the extra viscous
drag, but never to the point where the
viscosity becomes lower than required from
the increased heat generation. |t is therefore
better for the bearings to have an oil that is
too heavy rather than too light.
The oil should be a premium R & O type with
a SAE 30 viscosity, such as Shell Tellus 41
or Exxon Teresstic 65. Detergent
automotive oils are not considered to be
satisfactory for anti-fricion = bearing
INSTALLATION AND
OPERATING INSTRUCTIONS
lubrication. The lubricating oil shouid have a
minimum viscosity of 100 SSU at the bearing
operating temperature.
Change the oil after the first 200 hours of
operation. For normal operating conditions,
change the oil at least four (4) times a year.
If the bearing assembly is exposed to dirty or
moist conditions, the oil shouid be changed
more often.
1V-B. OIL LEVEL CONTROL
If the level of oil in the bearing housing is too
high, excessive heat may be generated due
to churning and there may be leakage from
the shaft seals. If the level is too low,
excessive heat may be generated due to
inadequate lubrication. A liquid level switch
connected to the oil sump can be used to
warn of a dangerous oil level condition.
Observe the oil level requirements shown on
the assembly drawing furnished with the
pump. If excessive heat is experienced
within these levels, consuit the factory. Be
sure that the shaft centerline is horizontal
through the bearing housing.
IV-C. NORMAL BEARING TEMPERATURE
The running temperature for a bearing
assembly depends on many factors such as
speed, bearing loads, ambient air
temperatures, and the condition of the
bearings. Temperatures higher than the
human hand can tolerate are very
satisfactory for good bearing operation and
should not cause any alarm.
For a given speed and loading, the bearing
housing temperature will stabilize at some
temperature, usually below 200° F which wil
be the normal temperature for that
installation. Higher temperatures than this
normal temperature, without any change in
the speed or loading, can mean a lubrication
difficulty or the approach of a bearing failure.
NOTE: TEMPERATURES ABOVE 220° F MAY
REDUCE THE OIL FILM THICKNESS TO A POINT
WHERE THE BEARINGS MAY NOT BE
ADEQUATELY LUBRICATED EVEN THOUGH
THERE IS A SUFFICIENT QUANTITY OF
LUBRICANT.
IV-D. INSTALLING A BEARING
Long bearing life is quite dependent on
careful handling of the bearing when it is out
of the housing and during the installation
procedure, because dirt and rough handling
are prime enemies of precision bearings.
Bearings should be pressed, not "hammered",
into place. If heat is used to facilitate the
installation, a hot oil bath is the best method.
Bearings for grease lubrication should be
hand packed with grease to insure adequate
lubrication at start-up.
— 1 7-
~ INSTALLATION AND
OPERATING INSTRUCTIONS
IV-E. DISASSEMBLY OF THE "MX" BEARING HOUSING
Refer to Fig. 10 for the following instructions.
1. After the liquid has been removed in accordance with the instructions for that section, remove
the cap screws which secure the bearing housing to the hub extender (9833) and separate the.
two components. |
2. Slide excluder (9905) off the impeller end of the shaft.
3. Remove the cap screws securing the retainers (109) and (1198) to the bearing housing. Slide
the retainers off the end of the shaft. The non-split bearing housing uses seal (333) as a
retainer — it is not removed at this time.
4. A) Split Bearing Housing:
Remove the bolts securing the housing halves together. Knock out taper pins, lift off upper
housing half and lift the shaft out of the lower housing half.
B) Solid Bearing Housing:
Carefully slide shaft out of housing.
5. Remove locknut (136) and lockwasher (382). Press bearings (112C) and (168C) off of the
shaft, using force against the bearing inner race. Force on the outer race may damage the
bearing.
—1 8-
INSTALLATION AND
OPERATING INSTRUCTIONS
IV-F. ASSEMBLY OF THE "MX" BEARING HOUSING
1. Clean and inspect all bearing assembly components. Be sure old sealer has been scrapped
from the housing split. The shaft and housing should not have any burrs or rough areas that
could be detrimental to the seals or proper seating of the bearings.
2. Install the bearings (112C) and (168C) an the shaft and secure the thrust bearings with
lockwasher (382) and locknut(136). Make sure the thrust bearings have been oriented according
to the assembly drawing fumished with the pump.
NOTE: IF THE BEARINGS ARE GREASE LUBRICATED, THEY SHOULD BE HAND-PACKED WITH GREASE TO
HAVE EACH BALL PATH FILLED APPROXIMATELY ONE-THIRD FULL OF GREASE.
DO NOT OVERFILL THE BEARINGS.
3. a) Split Bearing Housing:
1) Place the shaft in the bottom housing half.
2) Apply a 1/16" bead of oil resistant silicone sealant slightly inside of the bolt holes
on the mating surface of the lower housing half. DO NOT ALLOW TO DRY!
Immediately lower top half of housing into position, align with taper pins, and
secure together with bolts.
b) Solid Bearing Housing:
Slide shaft, with bearings, into housing. This is usually easier if the housing is
vertical and the shaft is lowered into position. The radial bearing (168C) outer race
may cock as it enters the housing bore, in which case the shaft should be lifted
slightly and another attempt made.
4. Install thrust bearing retainer (109) with sufficient shims to leave a gap of .005"-.008" for
prevention of clamping bearing outer races together. Do this by installing the retainer without
shims, cap screws slightly tightened. Measure the gap between retainer and housing and make
shim about .005" thicker than the measured gap.
5. Install retainer (1198) or seal (333) if the housing is solid.
6. Slide the excluder (9905) into position, close to but not touching the retainer or seal.
7. Check for free rotation of the shaft.
—iQ—
INSTALLATION AND
OPERATING INSTRUCTIONS
332
1198 as 123
8 „N RE
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RON =
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168C A
THRUST
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134
|
TA —
1120 £ —FESN L
AA | EN SEE NOTE “N°
DÁ N
7 —
331
136
0 _ —
109— 389
|
3IA— — LA) NOTE "N": AT ASSEMBLY
+= MEASURE LENGTH "L" AND
| INSTALL NECESSARY SHIMS,
122 [TEM 331, TO MAKE A
x GAP OF .003" TO .006" AT "G"
FIG. 10 THE "MX" BEARING ASSEMBLY
INSTALLATION AND
OPERATING INSTRUCTIONS
SECTION V - MPAF LIQUID END WITH BACK PULLOUT
The MPAF liquid end uses a modified elbow design to allow the back puilout option as illustrated
in this section. Elbows without the back pullout option are a single piece.
The elbow may be fumished with the inflatable shaft seal option, see illustration in Appendix B, if
applicable. A separate section is included with these instructiuons for the inflatable seals when
furnished with the pump.
The MPAF pump with the back pullout option requires a separately machined stuffing box (220).
This is semi~-permanently fastened into place and is not normally removed. If the pump is
furnished for vertical shaft installation, the cavity around the stuffing box, below the drain, is filled
with a suitable grout.
The larger size MPAF pumps may have a plate covering the end of the impeller hub to allow
sealing of the impeller hub cavity.
V-A. IMPELLER CLEARANCE ADJUSTMENT
The impeller requires several thousandths of an inch minimum clearance to prevent rubbing due
to the action of the hydraulic forces when the pump is operating. Many corrosion-resistant
alloys will gall and build up if rubbing occurs, therefore, pumps using these alloys need to be free
from any rubbing.
Clearance adjustment is made by moving the stuffing box cover (184) on the elbow (315A)
and/or by the use of thin shims in one area of the mating surface of these two parts. The pump
was aligned at the factory and taper pinned in the aligned position. Before disturbing this
position, make sure the cap screws fastening the bearing housing to the hub extender and the
extender to the elbow are tight.
NOTE: IMPELLER RUBBING IS OFTEN CAUSED BY PIPE STRAIN. PIPE STRAIN MUST BE
ELIMINATED PRIOR TO IMPELLER ALIGNMENT.
Impeller Alignment — Use the alignment worksheet for the MPAF pump. The measurement
procedure is as follows:
1. Note the number of blades. Mark each 1,2,3 or 1, 2, 3, 4 depending on the number of vanes.
2. Rotate the shaft and measure the gap between each blade and the casing at the 12, 3, 6, and
9 o'clock positions indicated by the worksheet. The value of interest is the largest value of feeler
gage thickness which will slide easily the whole length of the vane tip.
3. Add the measurements for all positions together and divide by the number of measurements.
This will give the average measurement.
4. Divide the average measurement by 2. This will give the minimum clearance.
- 5. If any blade has a clearance in any of the positions which is smaller than the calculated
minimum clearance the prop is not sufficiently centered and should be adjusted.
Example: 3- vane impeller. At 12 o'clock the readings are VANE 1- .040, VANE 2- .041, VANE
3 - .040; at 3 o'clock .050, .051, .050; at 6 o'clock .050, .052, .051: at 9 o'clock .040, .042, .039.
SUM OF READINGS 040+ .041+.040+......
CLEARANCE = A_ LL _ .
AVERAGE CLEARANCE = NUMBER OF RÉADINGS” > 15 0455
MINIMUM CLEARANCE = AVERAGE CLEARANCE _ 0455/, 0028"
—21—
— INSTALLATION AND
OPERATING INSTRUCTIONS
V-B. DISASSEMBLY OF THE LIQUID END
ISOLATE THE PUMP FROM THE PIPING SYSTEM AND DRAIN THE LIQUID IN THE PUMP
PRIOR TO DISMANTLING THE PUMP AND PIPING.
1. Drain the liquid (pumpage) from the elbow (315A). Remove the piping from the impeller end of
the elbow.
2. Remove the impeller (101). The impeller fastening screw (370C) is locked into place with
socket head set screws that have to be removed before the fastening screw is turned. After
screw (370C) is removed, pull impeller off of the shaft.
3. Remove cap screws fastening the bearing housing (134) to the hub extender (9833). Pull the
shaft, with housing, out of the hub assembly.
NOTE: FOR MECHANICAL SEAL EQUIPPED PUMPS, DISASSEMBLY MAY BE REQUIRED
FROM THE STUFFING BOX. REFER TO MECHANICAL SEAL DRAWING.
4. Remove set screw(s) locking the sleeve (126) to the shaft and pull the sieeve off of the shatt.
5 Remove gland (107), packing, and lantern ring (105) from the stuffing box.
6. If required, the stuffing box hub (220) can be removed from the hub disc (184).
V-C. ASSEMBLY OF THE LIQUID END
1. Install the hub (220), if removed, with gasket (211) in the hub disc (184). Secure in place with
three (3) cap screws. Make sure all pipes into the hub are in place and tight.
If the pump is furnished with an inflatable seal, install the seal in hub and secure in place with
seal retainer.
2. Install shaft sleeve, with o-ring (412F), in place and secure with set screws. If a key is used,
be sure it has been installed. Íf pump is fumished with a mechanical seal, refer to the
mechanical seal drawing and install over the sleeve.
3. Slide the shaft assembly into place. Align the housing (134) to the hub extender (9833), using
taper pins and fasten with cap screws.
4. Install the impeller (101) and drive key (178), fastening in place with washer (199A) and cap
screw (370C). Tighten cap screw to have flats next to set screw holes. Install set screws to
prevent cap screws and washers from being able to turn.
5. Тит shaft by hand to check for impeller rubbing. If necessary, correct as described in section
V-A - IMPELLER CLEARANCE ADJUSTMENT.
6. Repack the stuffing box with packing, seal cage, and gland. Do not overtighten the giand.
INSTALLATION AND
OPERATING INSTRUCTIONS
10!
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96
INSTALLATION AND
OPERATING INSTRUCTIONS
SECTION VI - OPERATION AND TROUBLE SHOOTING
Most Axial Flow pumps are in evaporator
circulation service, and since the evaporator
performance and the amount of product
depends on the rate of liquid circulation, care
shouid be taken to maintain these pumps in
good operating condition.
When production drops off, it is usually due to
lower circulation rate. An approximation of
this rate can be made by several methods:
1) Temperature drop across
exchanger
2) Visual inspection of flow in body
3) Testing the circulating pump
the heat
items (1) and (2) above are covered by the
evaporator manufacturer.
VI-A. PERFORMANCE CHECK -
While field conditions preciude absolute
accuracy, a check of pump performance will
give reasonably close resuits. This can be
done by installing a pressure measuring
device at pipe taps located at least one pipe
diameter away from the suction and discharge
flanges of the pump. If gauges are used, the
pressure differential times 2.31 divided by the
specific gravity of the slurry indicates the total
head in feet against which the pump is
actually operating.
Check the pump speed and determine the
flow rate in gallons per minute from the pump
curve. This curve will also give efficiency from
which the horsepower (Hp) requirement can
be determined. A double check is to take
motor ammeter readings, convert to Hp, figure
90% drive efficiency then use it against the
curve to get the GPM. This is only an
approximate check, as the Hp curve on some
applications is rather flat, but is probably
within 7-1/2%. It is important to take and
record these readings when the equipment is
new, so that later readings can be judged on a
relative basis.
—24—
VI-B. CAUSES OF CIRCULATION LOSS -
1. Increase in TDH against which the pump
operates could be caused by:
a) Heat exchanger tubes partially blocked
b) Too many heat exchanger tubes blocked off
с) Improperly sized or partially plugged
strainer
2. Viscosity of slurry is higher than the design
viscosity of the system
3. Pump speed low. V-belt drive may be
slipping and operating pump below design
speed.
4. Pump throttled on suction side. Could be
caused by rubber lining pulling away from the
suction pipe and partially collapsing, by large
solids dropping into suction, or by improperly
sized or plugged strainer in the suction pipe.
S. Pump partially plugged by large solid
jammed between two impeller blades. This
will also cause rough operation with excessive
vibration.
6. Incorrect pump rotation. When changing
motor for any reason or after any electrical
system changes or modifications, always
check motor for correct direction of rotation.
The coupling should be removed for checking
for proper rotation.
7. Worn pump impeller and/or casing. Ona
new pump, clearance between the tip of the
impeller blade and casing is carefully
determined. As this clearance increases,
pump performance decreases.
It is not practical to predict performance at
any given clearance without running a test at
this clearance. On small pumps, this effect is
magnified as the percentage of impeller blade
area lost from wear and corrosion is higher.
INSTALLATION AND
OPERATING INSTRUCTIONS
Other pump conditions and possible causes
are:
VI-C. HIGH HORSEPOWER DEMAND -
1. Increased head or viscosity
2. Pump speed too high
3. Specific gravity of slurry is higher than
normal
4. Packing gland puiled up too tight
5. Impeller rubbing in casing
Vi-D. NOISY ROUGH OPERATION -
1. Throttled suction or plugging
2. Impeller rubbing in casing
3. Loose impeller
4. Broken impeller blade
5. Bearings not properiy lubricated
6. Bent Shaft
7. Impeller out of balance
VI-E. WATER HAMMER
Water hammer is a high pressure surge in a
pipe system created by a rapid change in flow
rate and may result in extensive damage to
the pump and piping. One of the most
common causes is the sudden closing of a
Ном control device. A sudden partial blockage
of the pipe line has the same effect as a
sudden valve closure.
VI-F. GENERAL CONSIDERATIONS
Never vary capacity with regulating valve in
the discharge line. NEVER throttle flow from
the suction side. |
Driver may overload if the pumpage specific
gravity (density) is greater than originally
assumed, or the rated flow rate is exceeded.
DO NOT OPERATE PUMP BELOW MINIMUM RATED
FLOWS OR WITH THE DISCHARGE VALVE CLOSED.
FATE CONDITIONS CAN QUICKLY LEAD TO PUMP
F RE.
Always operate the pump at or near the rated
conditions to prevent damage resuiting from
cavitation or recirculation. Operating at
reduced capacity can cause increased
vibration levels, heat build-up, and cavitation.
Continued operation at these conditions will
then cause premature bearing and/or
mechanical seal failure, stuffing box damage,
and scoring or seizing of rotating parts.
INSTALLATION AND
OPERATING INSTRUCTIONS
SECTION VII - ORDERING SPARE PARTS
VII-A. REPLACEMENT PARTS
PROCEDURE
To insure against possible long and costly
down time periods, especially on critical
services, it is advisable to have spare parts on
hand.
Repair orders will be handled with a minimum
of delay if the following directions are followed:
1. Give model number, size of pump, and
serial number. These can be obtained from
the nameplate on the pump.
2. Write plainly the name and part number of
each part required. These names and
numbers should agree with those on the Bill of
Material.
3. Give the number of parts required.
4. Give complete shipping instructions.
-26—
ITT
IMPAF 5-08 O copyright 2008 Goulds Pumps, Incorporated,
a subsidiary of ITT Corporation
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