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Installation, Operation and Maintenance Instructions

Model 3600 API 610 10th Edition (ISO 13709)

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Pump Safety Tips

Safety Apparel:

Insulated work gloves when handling hot bearings orusing bearing heater

Heavy work gloves when handling parts with sharpedges, especially impellers

Safety glasses (with side shields) for eye protection,especially in machine shop areas

Steel-toed shoes for foot protection when handlingparts, heavy tools, etc.

Other personal protective equipment to protectagainst hazardous/toxic fluids

Coupling Guards:

Never operate a pump without a coupling guardproperly installed

Flanged Connections:

Never force piping to make a connection with a pump

Use only fasteners of the proper size and material

Ensure there are no missing fasteners

Beware of corroded or loose fasteners

Operation:

Do not operate pump outside of parameters for whichpump was sold

Do not operate below minimum rated flow, or withsuction/discharge valves closed

Do not open vent or drain valves, or remove plugswhile system is pressurized

Do not operate pump if installed safety devices havebeen disconnected

Maintenance Safety:

Always lock out power

Never use heat to disassemble pump due to risk ofexplosion from trapped liquid

Ensure pump is isolated from system and pressure isrelieved before disassembling pump, removing plugs,or disconnecting piping

Use proper lifting and supporting equipment toprevent serious injury

Observe proper decontamination procedures

Know and follow company safety regulations

Observe all cautions and warnings highlighted in pumpInstallation, Operation and Maintenance Instructions .

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3600 IOM 6/05 3

IMPORTANT SAFETY REMINDER

To: Our Valued Customers

Goulds' pumps will provide safe, trouble-free service when properly installed, maintained, and operated. We have anextensive network of experienced sales and service professionals to assist in maximizing your satisfaction with our products.

Safe installation, operation, and maintenance of Goulds' equipment are an essential end user responsibility. ThisInstruction,Operation, and Maintenance(IOM) manual identifies specific safety risks that must be considered at all times during productlife. Understanding and adhering to these safety warnings is mandatory to ensure personnel, property, and/or the environmentwill not be harmed. Adherence to these warnings alone, however, is not sufficient it is anticipated that the end user will alsocomply 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.

Specific to pumping equipment, two significant risks bear reinforcement above and beyond normal safety precautions.

! WARNING

1 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 is avoided.

! WARNING

2 Pumping equipment Instruction, Operation, and Maintenance manuals clearly identify accepted methods for

disassembling pumping units. These methods must be adhered to. Specifically, applying heat to impellers and/or

impeller retaining devices to aid in their removal is strictly forbidden. Trapped liquid can rapidly expand and result

in a violent explosion and injury.

Please take the time to review and understand the safe installation, operation, and maintenance guidelines outlined in thismanual.

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FOREWORDThis manual provides instructions for the Installation, Operation, and Maintenance of the Goulds Model 3600 High Pressure,High Temperature Process Pump designed to API* Standard 610 10th Edition (ISO13709). This manual covers the standard

product plus common options that are available. For special options, supplemental instructions are supplied. This manualmust be read and understood before installation and maintenance.

The design, materials, and workmanship incorporated in the construction of Goulds pumps make them capable of givinglong, trouble-free service. The life and satisfactory service of any mechanical unit, however, is enhanced and extended bycorrect application, proper installation, periodic inspection, condition monitoring and careful maintenance. This instructionmanual was prepared to assist operators in understanding the construction and the correct methods of installing, operating,and maintaining these pumps.

ITT Industries - Goulds Pumps is not liable for physical injury, damage or delays caused by a failure to observe theinstructions for Installation, Operation, and Maintenance contained in this manual.

NOTE: When pumping unit is installed in a potentially explosive atmosphere, the instructions after the Ex symbolmust be followed. Personal injury and/or equipment damage may occur if these instructions are not followed. Ifthere is any question regarding these requirements or if the equipment is to be modified, please contact a Gouldsrepresentative before proceeding.

Warranty is valid only when genuine ITT Industries - Goulds Pumps parts are used.

Use of the equipment on a service other than stated in the order will nullify the warranty, unless written approval is obtainedin advance from ITT Industries, Goulds Pumps.

Supervision by an authorized ITT Industries - Goulds Pumps representative is recommended to assure proper installation.

Additional manuals can be obtained by contacting your local ITT Industries - Goulds Pumps representative, by calling1-800-446-8537, or visiting our website at www.gouldspumps.com.

THIS MANUAL EXPLAINS

Proper Installation

Start-up Procedures

Operation Procedures

Routine Maintenance

Pump Overhaul

Troubleshooting

Ordering Spare or Repair Parts

4 3600 IOM 6/05

* American Petroleum Institute

1220 L Street, Northwest

Washington, D.C. 20005

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TABLE OF CONTENTSPAGE

7 SAFETY

11 GENERAL INFORMATION

15 INSTALLATION

23 OPERATION

31 PREVENTIVE MAINTENANCE

37 DISASSEMBLY & REASSEMBLY

71 SPARE PARTS

81 APPENDIX

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SECT

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3600 IOM 6/05 7

SAFETYD E F I N I T I O N S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SPECIAL ATEX CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 8ATEX IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

CONDITION MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

DEFINITIONS

This pump has been designed for safe and reliableoperation when properly used and maintained inaccordance with instructions contained in this manual. A

pump is a pressure containing device with rotating partsthat can be hazardous. Operators and maintenance

personnel must realize this and follow safety measures.ITT Industries - Goulds Pumps shall not be liable for

physical injury, damage or delays caused by a failure toobserve the instructions in this manual.

Throughout this manual the words WARNING,CAUTION, ELECTRICAL, ATEX,andNOTEare usedto indicate procedures or situations which require specialoperator attention:

! WARNINGOperating procedure, practice, etc. which, if notcorrectly followed, could result in personal injury orloss of life.

CAUTIONOperating procedure, practice, etc. which, if notfollowed, could result in damage or destruction ofequipment.

If equipment is to be installed in a potentiallyexplosive atmosphere and these procedures are notfollowed, personal injury or equipment damage froman explosion may result.

NOTE: Particular care must be taken when theelectrical power source to the equipment isenergized.

NOTE: Operating procedure, condition, etc. which isessential to observe.

EXAMPLES

! WARNINGPump shall never be operated without coupling guardinstalled correctly.

CAUTIONThrottling flow from the suction side may causecavitation and pump damage.

Improper impeller adjustment could cause contactbetween the rotating and stationary parts, resultingin a spark and heat generation.

Lock out driver power to prevent electric shock,accidental start-up and physical injury.

NOTE: Proper alignment is essential for long pumplife.

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GENERAL PRECAUTIONS

! WARNINGPersonal injuries will result if procedures outlined inthis manual are not followed.

A C NEVER operate pump without coupling guardcorrectly installed.

A D NEVER operate pump beyond the ratedconditions to which the pump was sold.

A D NEVER start pump without proper prime(sufficient liquid in pump casing).

A D NEVER run pump below recommendedminimum flow or when dry.

C B ALWAYS lock out power to the driver beforeperforming pump maintenance.

A C NEVER operate pump without safety devicesinstalled.

A C NEVER operate pump with discharge valveclosed.

A D NEVER operate pump with suction valve closed.

A DO NOT change conditions of service withoutapproval of an authorized Goulds representative.

EXPLOSION PREVENTION

In order to reduce the possibility of accidental explosions in atmospheres containing explosive gasses and/or dust,the instructions under the ATEX symbol must be closely followed. ATEX certification is a directive enforced inEurope for non-electrical and electrical equipment installed in Europe. The usefulness of ATEX requirements is notrestricted to Europe. They are useful guidelines for equipment installed in any potentially explosive environment.

SPECIAL ATEX CONSIDERATIONS

All installation and operation instructions in this manualmust be strictly adhered to. In addition, care must be takento ensure that the equipment is properly maintained. This

includes but is not limited to: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.

ATEX IDENTIFICATION

For a pumping unit (pump, seal, coupling, motor and pumpaccessories) to be certified for use in an ATEX classifiedenvironment, the proper ATEX identification must be

present. The ATEX tag will be secured to the pump or thebaseplate on which it is mounted. A typical tag will looklike this:

The CE and the Ex designate the ATEX compliance.

The code directly below these symbols reads as follows:

II = Group 2

2 = Category 2

G/D = Gas and Dust present

T4 =Temperature class, can be

T1 to T6(see followingTable 1)

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Table 1

Code Max permissiblesurface temperature,

F (C)

Max permissibleliquid temperature,

F (C)

T1 842 (450) 700 (372)

T2 572 (300) 530 (277)

T3 392 (200) 350 (177)

T4 275 (135) 235 (113)

T5 212 (100) Option not available

T6 185 (85) Option not available

The code classification marked on the equipment should bein accordance with the specified area where the equipmentwill be installed. If it is not, please contact yourITT/Goulds representative beforeproceeding.

INTENDED USE

The ATEX conformance is only applicable when the pump

unit is operated within its intended use. All instructionswithin this manual must be followed at all times.Operating, installing or maintaining the pump unit in anyway that is not covered in this manual 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. If there is any question regardingthe intended use of the equipment, please contact anITT/Goulds representative before proceeding.

CONDITION MONITORING

For additional safety precautions, and where notedin this manual, condition monitoring devices shouldbe used. This includes, but is not limited to:

Pressure gauges Flow meters Level indicators Motor load readings Temperature detectors Bearing monitors Leak detectors PumpSmart control system

For assistance in selecting the proper instrumentation andits use, please contact your ITT/Goulds representative.

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GENERAL INFORMATION

PUMP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

NAMEPLATE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

RECEIVING THE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13STORAGE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

PUMP DESCRIPTION

The Model 3600 is a high pressure, multi-stage, betweenthe bearings, horizontal centrifugal pump designed to meetthe rigorous demands of the petroleum and petrochemical

market place. It is in full compliance with API 610 10thEdition (ISO 13709).

The model consists of 7 sizes.

Casing- The casing is near centerline mounted with sidesuction and side discharge nozzles. ANSI class 900 poundraised face serrated flanges with a 125-250 rims finish arestandard. 600 and 1500 pound and ring type joint (RTJ)flanges are available options.

Impeller- The impeller is a fully closed design and is keydriven.

Seal Chamber -The Model 3600 has a seal chamberdesigned in accordance with API 682 2nd Edition criteria.Customer selected cartridge mechanical seals are standard.

Bearing Housings- Ductile iron bearing housings arestandard on non-API services and carbon steel on APIservices. Oil level is viewed through a sight glass.Constant level oilers and labyrinth seals are standard. Nomachining is required to convert the standard ring oil lubeto either purge or pure mist, although pure mist applicationsrequire minor bearing housing modifications. Pressurelubrication is required with hydrodynamic thrust bearings.

Shaft- The heavy duty shaft is designed for cartridgemechanical seals, minimal shaft deflection at the seal faces(.002) when run in the worst case condition (typicallyminimum flow), and a critical speed at least 20% abovedesign operating speed. Fully compliant with API 10thEdition (ISO 13709).

Bearings- Radial loads are carried by a single row, deepgroove ball bearing (standard) or sleeve bearings(optional). The axial thrust load is taken either by a pair ofsingle row angular contact ball bearings mounted back to

back (standard), or a hydrodynamic thrust bearing (used

with sleeve type journal bearings). When ball bearings areused (standard), the outboard bearing (thrust bearing) isshouldered and locked into place, thus enabling it to carry

both radial and axial thrust loads. All fits are precisionmachined to both the shaft and bearing housing to industrystandards. Size 6x8-13 pumps come standard withsleeve/ball bearing arrangement.

Baseplate- The fabricated steel baseplate is designed tosupport the pump, driver and accessories in accordancewith API 10th Edition (ISO 13709) requirements.

Direction of Rotation- Counterclockwise (left hand) asviewed from the driver, looking at the pump shaft. (Checkwith the factory for clockwise rotation.)

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NAMEPLATE INFORMATION

Every pump has a Goulds nameplate that providesinformation about the pump. The nameplate is located onthe pump casing.

When ordering parts, you will need to identify the pumpmodel, size, serial number, and the item number of therequired parts. Information can be taken from the pumpcasing tags. Item numbers can be found later on in thismanual.

12 3600 IOM 6/05

Description Fig. No. Example

Pump Casing Tag- provides informationabout the pumps hydraulic characteristics.

Note the format of the pump size: Dischargex Suction - Nominal maximum ImpellerDiameter in inches. (Example: 2x3-8)

(Figs. 1 & 2).

Fig. 1

English

Fig. 2Metric

ATEX Tag- If applicable, your pump unitmay have the following ATEX tag affixed tothe pump and/or baseplate. See theSafetysection for a description of the symbols andcodes (Fig. 3).

Fig. 3

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Inspect the pump as soon as it is received. Carefully checkthat everything is in good order. Make notes of damaged ormissing items on the receipt and freight bill. File any claimswith the transportation company as soon as possible.

STORAGE REQUIREMENTSShort Term(Less than 6 months)Goulds normal packaging procedure is designed to protect

pump during shipping. Upon receipt, store in a covered anddry location.

Long Term(More than 6 months)Preservative treatment of bearings and machined surfaceswill be required. Rotate shaft several times every 3 months.Refer to driver and coupling manufacturers for their longterm storage procedures. Store in a covered and drylocation.

NOTE: Long term storage treatment may bepurchased with initial pump order.

HANDLING

! WARNINGPump and components are heavy. Failure to properlylift and support equipment could result in seriousphysical injury, or damage to pumps.

Use care when moving pumps. Lifting equipment must beable to adequately support the entire assembly. Hoist bare

pump using suitable slings under the suction flange and

discharge flange (Fig. 4). Baseplate mounted units areprovided with lifting points for use with proper liftingdevices. Refer to (Fig. 5 & 6) for examples of properlifting techniques.

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RECEIVING THE PUMP

Fig. 4

Fig. 5

Fig. 6

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INSTALLATIONSITE/FOUNDATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

BASEPLATE INSTALLATION PROCEDURE. . . . . . . . . . . . . . . . . . . 16

BASEPLATE PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 16FOUNDATION PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . 16

SETTING AND LEVELING BASEPLATE . . . . . . . . . . . . . . . . . . . . 16

ALIGNMENT AND ALIGNMENT CRITERIA. . . . . . . . . . . . . . . . . . . 17

GENERAL CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . 17

ALIGNMENT CRITERIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

ALIGNMENT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 18

BASEPLATE GROUTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . 18

GENERAL PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

ALIGNMENT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SUCTION PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0DISCHARGE PIPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

BYPASS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

AUXILIARY PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

FINAL PIPING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Equipment that will operate in a potentially explosive environment must be installed in accordance with thefollowing instructions.

SITE/FOUNDATION

GENERAL INFORMATIONProcedures for installation described in this section aregeneral in nature. More detailed procedures are describedin various publications including API RecommendedPractice 686/PIP (Process Industry Practices) REIE 686,"Recommended Practices for Machinery Installation andInstallation Design." A pump should be located near thesupply of liquid and have adequate space for operation,maintenance, and inspection. Be sure to allow for crane orhoist service.

Baseplate mounted pumps are normally grouted on aconcrete foundation which has been poured on a solidfooting. The foundation must be able to absorb anyvibration and to form a permanent, rigid support for the

pumping unit.

All equipment being installed must be properlygrounded to prevent unexpected static electricdischarge.

The location and size of foundation bolts are shown on theoutline assembly drawing provided with the pump data

package.

Foundation bolts commonly used are sleeve type(Fig. 6) and J type. If using the sleeve type, the insidediameter of the sleeve should be 2 1/2 - 3 times the boltdiameter. A washer should be placed between the bolt headand the sleeve. Both foundation bolt types permit movementfor final bolt adjustment.

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BASEPLATE INSTALLATION PROCEDUREIndustry standard procedures, such as API RP 686/ PIPREIE 686, and/or the following procedure should befollowed prior to grouting the baseplate. The procedureassumes the installer has a basic knowledge of baseplateand foundation design and installation methods.

BASEPLATE PREPARATION1. Inspect all surfaces of baseplate that will contact grout for

contamination (e.g. - rust, oil, grime, etc.).

2. Thoroughly clean all surfaces of the baseplate that will

contact grout with a cleaner that will not leaveanyresidue.

NOTE: It may be necessary to sandblast the contactsurfaces and coat with a primer compatible with the grout.If sandblasting is necessary, remove all equipment prior tosandblasting.

3. Inspect all machined surfaces for burrs, rust, paint or

any other type of contamination. If necessary, use a

honing stone to remove burrs.

FOUNDATION PREPARATION1. Chip top of foundation a minimum of 25 mm

(1.0 in.) to remove porous or low strength concrete. If

using a pneumatic hammer, assure that it is not

contaminating the surface with oil, moisture, etc.

CAUTIONDo not use heavy tools such as jackhammers, as theycould damage the structural integrity of thefoundation.

2. Remove water and/or debris from foundation bolt

holes/sleeves. If the sleeve type bolts are being used,

fill the sleeves with nonbinding moldable

material and seal to prevent grout from entering.

3. Coat exposed portion of anchor bolts with anon-bonding compound (such as paste wax) to prevent

grout from adhering to anchor bolts.

NOTE: Do not use oils or l iquid wax.

4. If recommended by grout manufacturer, coat

foundation surface with a compatible primer.

SETTING AND LEVELING BASEPLATE1. Lower baseplate carefully onto foundation bolts.

Baseplate will rest on top of foundation on jackscrews

provided on baseplate.

2. Adjust leveling jack screws, located adjacent to the

foundation bolt holes, until the baseplate rests 1-2 in.

(25 - 50 mm) above foundation to allow for adequate

grouting. This will provide even support for the

baseplate once it is grouted.

3. Level baseplate to within .002 in./ft. (0.20 mm/m) of

length or width of the baseplate, respectively, by

adjusting leveling screws. Maximum total variation

from one end or side of the baseplate to the other is

.015 in. (0.38 mm).

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Fig. 7 Fig. 8

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Equipment mounting surfaces should be utilized to

establish level.

4. Coat portions of leveling screws that will contact grout

with a non-bonding (anti-seize) compound (such as

paste wax) to facilitate their removal after grouting.

NOTE: Do not use oils or l iquid wax.

5. Thread nuts on foundation bolts and hand tighten.

ALIGNMENT AND ALIGNMENT CRITERIA

Alignment procedures must be followed to preventunintended contact of rotating parts. Followcoupling manufacturer's installation and operationprocedures.

GENERAL CONSIDERATIONS

! WARNINGBefore beginning any alignment procedure, make suredriver power is locked out. Failure to lock out driverpower will result in serious physical injury.

To remove coupling guard, refer to coupling guardinstallation and disassembly instructions in Appendix II.

The times at which alignment is checked and adjusted are:

Initial Alignment (Cold Alignment)is done prior tooperation when the pump and the driver are at ambient

temperatures.

Before Grouting Baseplate - To ensure alignment can

be obtained.

After Grouting Baseplate - To ensure pipe strains

havent altered alignment. If changes have occurred,

alter piping to remove pipe strains on pump flanges.

Final Alignment (Hot Alignment)is done after operationwhen the pump and driver are at operating temperatures.

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 plant operating procedures.

NOTE: Alignment check must be made if processtemperature changes, piping changes and/or pumpservice is performed.

Alignment is achieved by adding or removing shims fromunder the driver and/or shifting driver horizontally asneeded.

NOTE: Proper alignment is the responsibilityof the installer and user of the unit.

Accurate alignment of the equipment must be attained.Trouble-free operation can be accomplished by achievingalignment within the levels specified in the followingsection.

Three common alignment methods are utilized:

Reverse Dial Indicatormethod is most common.

Lasermethod is similar to reverse dial indicator

method, but uses a laser to obtain the necessary

measurements.

Dial Indicator(rim-and-face) method.

Follow alignment equipment manufacturers procedureswhen utilizing reverse dial indicator or laser methods. Adetailed procedure for alignment using the dial indicator(rim-and-face) method is included as Appendix III.

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Fig. 9

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ALIGNMENT CRITERIAGood alignment is attained when readings as specified in thissection have been achieved with pump and driver at operatingtemperatures (final alignment).

Maximum allowable Total Indicator Reading (T.I.R.) forparallel and angular misalignment is .002 (0.05mm) for allModel 3600 pumps, regardless of the alignment method

used.

Maximum AllowableParallel and Angular Misalignment

SizeMaximum Allowable Misalignment

Parallel Angular

All0.05 mm(.002 in.)

0.03 degrees

[0.125 mm/cm(.0005 in. /in.) ofcoupling face

diameter]

NOTE A: For electric motors, motor shaft initial (cold)parallel vertical alignment setting should be 002-.004 in.(0.05 - 0.10 mm) lower than pump shaft, since thermalexpansion will cause the motor shaft on foot mountedmotors to "grow" up to the pump shaft centerline.

NOTE B: For other drivers (turbines, engines, etc.), followdriver manufacturers recommendations.

ALIGNMENT TROUBLESHOOTING

BASEPLATE GROUTING PROCEDURE

GENERAL PROCEDUREUse of non-shrink epoxy grout is recommended.

NOTE: Grout manufacturers instructions should beconsulted and followed.

The following are general procedures for grouting

baseplates. Additional information may be found in APIStandard 610, 8th Edition, Appendix L, APIRP 686, Chapter 5, and other industry standards.

Baseplate Installation Procedure should be followed priorto grouting baseplate.

1. Build dam (form) around foundation to level of bottom

of baseplate (Fig. 8).

2. Pour grout through grout hole in baseplate, up to level

of dam. Remove air bubbles from grout as it is poured

by puddling or by pumping the grout into place.

3. Strike along top of dam with trowel to give a neat

finished appearance.

4. Allow grout to set.

5. Fill remainder of baseplate with grout, removing air as

before (Fig. 9).

6. Allow grout to set at least 48 hours. Leveling screws

should be removed when grout has hardened.

7. Tighten foundation bolts.

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Problem Probable Cause Remedy

Cannot obtain horizontal (Side-to-Side)alignment, angular or parallel

Driver feet bolt bound.Loosen pump hold down bolts and slide pumpand driver until horizontal alignment isachieved.

Baseplate not leveledproperly, probably twisted.

Determine which corner(s) of the baseplate arehigh or low and adjust leveling screws at theappropriate corner(s) and realign.

Cannot obtain vertical (Top-to-Bottom)alignment, angular or parallel

Baseplate not leveledproperly, probably bowed.

Determine if center of baseplate should be raised orlowered and correct by adjusting leveling screws

equally at the center of the baseplate.

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ALIGNMENT CHECKRe-check alignment before continuing, using criteria

previously stated.

PIPING

Guidelines for piping are given in the Hydraulic InstituteStandards, available from:

Hydraulic Institute30200 Detroit RoadCleveland, OH 44145-1967

and in API RP 686, and must be reviewed prior to pumpinstallation.

! WARNINGNever draw piping into place by forcing at the flangedconnections of the pump. This may impose dangerousstrains on the unit and cause misalignment betweenpump and driver. Pipe strain will adversely affect theoperation of the pump resulting in physical injury anddamage to the equipment.

Flange loads from the piping system, includingthose from thermal expansion of the piping, mustnot exceed the limits of the pump. Casingdeformation can result in contact with rotating parts

which can result in excess heat generation, sparksand premature failure.

1. Piping runs should be as short as possible to minimize

friction losses.

2. It is suggested that expansion loops be properly

designed and installed in suction and/or discharge lines

when handling liquids at elevated temperatures, so

thermal expansion of piping will not draw pump out of

alignment.

3. The piping should be arranged to allow pump flushing

prior to removal of the unit on services handling

hazardous liquids.

4. Carefully clean all pipe parts, valves and fittings, and

pump branches prior to assembly.

5. All piping must be supported independently of, and

line up naturally with, the pump flanges. Table 2

shows piping flange alignment criteria.

Table 2Piping Flange Alignment

Type CriteriaAxial Flange gasket thickness 0.8 mm (.03 in.).

Parallel 0.001 mm/mm (.001 in./in.) of flange diameter

to a maximum of 0.8 mm (.03 in.).

Concentric Flange bolts should easily install by hand.

In no case should loads on the pump flanges

exceed the limits stated in API Standard 610,

10th Edition (ISO 13709).

6. Piping must not be connected to the pump until the

grout has thoroughly hardened and the foundation

bolts, as well as driver and pump hold down bolts,

have been tightened.

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SUCTION PIPING

ACAUTIONNPSHAmust always exceed NPSHRas shown on Gouldsperformance curves received with order. (ReferenceHydraulic Institute for NPSH and pipe friction valuesneeded to evaluate suction piping).

Properly designed and installed suction piping is a necessity fortrouble-free pump operation. Suction piping should be flushedBEFORE connection to the pump.

1. Use of elbows close to the pump suction flange should

be avoided. There should be a minimum of two (2)

pipe diameters of straight pipe [five (5) pipe diameters

is preferred] between the elbow and suction inlet.

Where used, elbows should be long radius.

2. Use suction pipe one (1) or two (2) sizes larger than

the pump suction, with a reducer at the suction flange.

Suction piping should never be of smaller diameter

than the pump suction.

3. Reducers, if used, should be eccentric and located at

the pump suction flange with sloping side down.

! !! CAUTIONPump must never be throttled on suction side.

4. A suction screen should be installed prior to initial

start-up and when suction system has been opened for

work. The screen should be of the cone type with a net

area equal to at least three (3) times the cross sectional

area of the suction pipe. The mesh of the screen

should be sized to prevent particles larger than 1.6 mm(1/16 in.) from entering the pump and should be

installed in a spool piece to allow removal for cleaning.

The screen should remain in the system until periodic

inspection shows system is clean.

5. Separate suction lines are recommended when more

than one pump is operating from the same source of

supply.

Suction Lift Conditions

1. Suction pipe must be free from air pockets.

2. Suction piping must slope upwards to pump.

3. All joints must be air tight.

4. A means of priming the pump must be provided.

Suction Head/Flooded Suction Conditions

1. An isolation valve should be installed in the suction

line at least two (2) pipe diameters from the pump

suction to permit closing of the line for pump

inspection and maintenance.

2. Keep suction pipe free from air pockets.

3. Piping should be level or slope gradually downward

from the source of supply.

4. No portion of the piping should extend below pump

suction flange.

5. The size of entrance from supply should be one (1) or

two (2) sizes larger than the suction pipe.

6. The suction pipe must be adequately submerged belowthe liquid surface to prevent vortices and air

entrainment at the supply.

DISCHARGE PIPINGProperly designed and installed discharge piping is anecessity for trouble-free pump operation. Discharge

piping should be flushed BEFORE connection tothe pump.

1. Isolation and check valves should be installed in

discharge line. Locate the check valve between

isolation valve and pump; this will permit inspection of

the check valve. The isolation valve is required forpriming, regulation of flow, and for inspection and

maintenance of 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 system.

BYPASS PIPINGSystems that require operation at reduced flows forprolonged periods should be provided with a bypass lineconnected from the discharge side (before any valves) tothe source of suction.

A minimum flow orifice can be sized and installed inbypass line to preclude bypassing excessive flows. Consultnearest sales office or factory for assistance in sizingorifice.

An automatic recirculation control valve and/or solenoidoperated valve should be considered if a constant bypass(i.e. orifice) is not possible.

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AUXILIARY PIPING

The mechanical seal must have an appropriate sealflush system. Failure to do so will result in excessheat generation and seal failure.

Cooling systems such as those for bearinglubrication, mechanical seal systems, etc., whereprovided, must be operating properly to preventexcess heat generation, sparks and prematurefailure.

Sealing systems that are not self purging or selfventing, such as plan 23, require manual ventingprior to operation. Failure to do so will result inexcess heat generation and seal failure.

Auxiliary piping may be required for bearing cooling, sealchamber cover cooling, mechanical seal flush or otherspecial features supplied with the pump. Consult pumpdata sheet for specific auxiliary piping recommendations.

If bearing cooling and/or seal chamber cover cooling is required,follow guidelines listed below.

1. Flows of 4 l/min. (1 GPM) will generally satisfy

cooling requirements for each component. If both

bearing and seal chamber cover cooling are provided, a

minimum flow of 8 l/min. (2 GPM) will be necessary.

2. Cooling water pressure should not exceed

7.0 kg/cm2 (100 psig).

FINAL PIPING CHECKAfter connecting the piping to pump:

Rotate shaft by hand to ensure it rotates smoothlyand there is no rubbing which could lead to excessheat generation and or sparks.

Check alignment, per alignment criteria outlinedpreviously, to determine if pipe strain has affectedalignment. If pipe strain exists, correct piping.

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OPERATIONPREPARATION FOR START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . 23

CHECKING ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

COUPLING PUMP AND DRIVER. . . . . . . . . . . . . . . . . . . . . . . . . 23

LUBRICATING BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24SHAFT SEALING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

START-UP PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

STARTING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

O P E R A T I O N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 7

GENERAL CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . 27

OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

OPERATING AT REDUCED CAPACITY. . . . . . . . . . . . . . . . . . . . . 27

OPERATING UNDER FREEZING CONDITIONS . . . . . . . . . . . . . . . . 28

SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

FINAL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28DOWELING PUMP CASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

COLD SERVICE APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . 29

HOT SERVICE APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 29

PREPARATION FOR START-UP

When installing in a potentially explosiveenvironment, ensure that the motor is properlycertified.

CHECKING ROTATION

CAUTIONSerious damage may result if pump is run in the wrongrotation.

NOTE: Pump is shipped with coupling spacerremoved.

1. Lock out power to driver. Remove coupling spacer if

installed.

! WARNINGLock out driver power to prevent accidental start-upand physical injury.

2. Make sure coupling hub is securely fastened to the

driver shaft. (This is a good time to check pump hub

also.)

3. Unlock driver power.

! WARNINGDo NOT jog a coupled pump.

4. Make sure everyone is clear. Jog driver just long

enough to determine direction of rotation. Rotation

must correspond to arrow on bearing housing.

5. Lock out power to driver before proceeding with

coupling spacer installation.

COUPLING PUMP AND DRIVER

! WARNINGLock out driver power to prevent accidental rotationand physical injury.

The coupling used in an ATEX classifiedenvironment must be properly certified.1. Check the gap between the coupling hubs against the

dimensions shown on the elevation drawing or as

stamped on the coupling hub. For any necessary

adjustment, move the driver not the pump.

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Motors with sleeve bearings may be manufactured

with or inch end movement (float) in the motor

rotor. For limited end-float arrangement, the gap

between the coupling halves must be set in a different

manner. If specific directions are not indicated in the

motor instructions, the following is applicable.

NOTE: If the driver is mounted at Goulds, the sett ing

for the coupling will already have been determined.

a. Slide the rotor towards the outboard end of the

motor as far as it will go and mark the shaft at the

motor frame (Fig. 13).

b. Slide the motor rotor towards the inboard end

of the motor as far as it will go and mark the shaft

again. The distance between marks should be

either or inch if the motor is arranged for

limited end-float travel.

c. Scribe a third mark on the shaft half way between

scribe marks made in (a.) and (b.) above.

d. Clamp the rotor in place.

e. Move the motor as a unit towards the pump

until the end of the motor shaft is the correctcoupling spacer distance from pump shaft.

2. Install and lubricate coupling per manufacturers

instructions.

3. Check angular and parallel alignment of coupling

halves using a dial indicator and a feeler gauge.

SeeAlignment and Alignment Criteria in

OperationSection.

The coupling guard used in an ATEX classifiedenvironment must be constructed from anon-sparking material.

4. Install coupling guard. Refer to coupling guard

installation instructions inAppendix II.

! WARNINGNever operate a pump without coupling guard properlyinstalled. Refer toAppendix IIfor coupling guardinstallation instructions. Personal injury will occur ifpump is run without coupling guard.

LUBRICATING BEARINGS

Bearings must be lubricated properly in order toprevent excess heat generation, sparks andpremature failure.

Ring Oil Lubrication

Ring oil lubricated ball bearings are standard on Model3600 units. Sleeve/ball bearings are optional. Bearinghousings are supplied with constant level oilers and sightglasses.

CAUTIONThe bearings are NOT lubricated at the factory. (SeeMaintenance of Bearings inPreventive MaintenanceSection.)

Assure that oil rings are properly located as described inDisassembly & Reassemblysection.

NOTE: See Preventive Maintenance section forlubrication recommendations.

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Pure or Purge Oil Mist Lubrication

Pure or purge oil mist are optional features for the Model3600 pump. Follow oil mist generator manufacturersinstructions. The inlet and drain connections (drainconnection required for pure mist only) are located on thetop and bottom, respectively, of the bearing housing. (See

Appendix Ifor conversion from ring oil bearings to purgeor pure mist bearings.)

NOTE: SeePreventive Maintenancesection forlubrication recommendations.

! WARNINGOperation of the unit without proper lubrication willcause bearing failure and pump seizure.

SHAFT SEALING

The mechanical seal used in an ATEX classifiedenvironment must be properly certified.Mechanical Seal Option

Pumps may be shipped with or without mechanical sealsinstalled. The seal used with this model is the cartridgetype. Cartridge seals are preset at the seal manufacturersfacility and require no field settings. Cartridge sealsinstalled by the user require disengagement of the holdingclips prior to operation, allowing the seal to slide into place.If the seal has been installed in the pump by Goulds, theseclips have already been disengaged. For other types ofmechanical seals, refer to the seal manufacturersinstructions for installation and setting.

Packing Option

Although rarely provided, packed 3600 pumps will besupplied with specific instructions.


Cooling systems such as those for bearinglubrication, mechanical seal systems, etc., whereprovided, must be operating properly to preventexcess heat generation, sparks and prematurefailure.


Connection of Sealing Liquid

For satisfactory operation, there must be a liquid filmbetween seal faces to lubricate them. Refer to sealmanufacturers drawing for location of taps. Some methodswhich may be used to flush/cool the seal are:

Product Flushing - In this arrangement, the pumpage

is piped from the casing (and cooled in an external

heat exchanger when required) then injected into sealchamber.

External Flush - A clean, cool compatible liquid is

injected from an outside source directly into seal

chamber. Flushing liquid must be at a pressure 20 to

25 psi (1.4-1.76 kg/cm 2) greater than seal chamber

pressure. Injection rate should generally be 2 GPM

(8 LPM) although the mechanical seal instructions

indicate proper amounts for given applications.

Other methods may be used which make use of

multiple gland connections. Refer to documentation

supplied with the pump, mechanical seal reference

drawing, and piping diagrams.

PRIMING PUMP

Pumps must be fully primed at all times duringoperation.

!CAUTIONNever start the pump until it has been properly primed.

Figure 14 shows the supply above the pump suction.

1. Slowly open the suction valve.

2. Open air vents on the suction and discharge piping,

casing, seal chamber, and seal piping, if provided, until

all air is vented and only liquid flows out.

3. Close the vents.

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START-UP PRECAUTIONS

CAUTION

Ensure that pump and systems are free of foreignobjects before operating and that objects cannot enterthe pump during operation. Foreign objects in thepumpage or piping system can cause blockage of flow

which can result in excess heat generation, sparks andpremature failure.

NOTE: A build up of gases within the pump, sealingsystem and or process piping system may result in anexplosive environment within the pump or processpiping system. Ensure process piping system, pump andsealing system are properly vented prior to operation.

1. All equipment and personal safety related devices and

controls must be installed and operating properly.

2. To prevent premature pump failure at initial start-up

due to dirt or debris in the pipe system, operate the

pump continuously at full speed and flow for 2 to 3

hours with suction strainers installed.

3. Variable speed drivers should be brought to rated

speed as quickly as possible.

4. Variable speed drivers should not be adjusted

or checked for speed governor or overspeed trip

settings while coupled to the pump at initial start-up.

If settings have not been verified, uncouple the unit

and refer to driver manufacturers instructions for

assistance.

5. Running a new or rebuilt pump at slow speeds may not

provide enough flow to adequately flush and cool the

wear ring and throat bushing close running surfaces.

6. Pumpage temperatures in excess of 200F (93C) will

require warm-up of pump prior to operation. Circulate

a small amount of pumpage (typically through the

casing drain connections on the 3600) until the casing

temperature at all points monitored is within 50F to75F of pumpage temperature. As a guideline, warm

up the pump at a rate of 50F per hour. Average

warming stream rates are based on observations at

various operating sites and are indicated in Table 2for

reference only.

Table 2

Pump

Discharge

Nozzle

Size

Operating Temperature vs

Warming Stream Flow Rate

(GPM) per Pump

200F 450F 700F3 3 4 54-6 4 5 6

STARTING PUMP

1. Make sure suction valve and any recirculation or

cooling lines are open.

2. Fully close or partially open discharge valve as

dictated by system conditions.

3. Start driver.

CAUTIONImmediately observe pressure gauges. If dischargepressure is not quickly attained, stop driver, reprimeand attempt to restart.

4. Slowly open discharge valve until the desired flow

is obtained.

!CAUTION

Observe pump for vibration levels, bearing temperatureand excessive noise. If normal levels are exceeded,shut down and resolve.

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OPERATION

GENERAL CONSIDERATIONS

CAUTION

Always vary capacity with regulating valve in thedischarge line. NEVER throttle flow from thesuction side.

Driver may overload if the pumpage specific gravity(density) is greater than originally assumed, or therated flow rate is exceeded.

Always operate the pump at or near the ratedconditions to prevent damage resulting fromcavitation or recirculation.

OPERATIONAL CHECKS

CAUTIONThe following are minimum operational checks for the

pump only. Consult driver and auxiliary equipmentmanufacturers literature for additional information.

1. For ball bearings and sleeve radial/ball thrust bearing

pumps, remove two oil ring inspection plugs (113B)

and verify that oil rings are turning and are throwing

oil. Replace plugs (See Fig. 15).

2. Check oiler to ensure oil level has remained steady.

3. Visually check oil level in sump via sight windows.

4. Check bearing temperatures using a pyrometer or other

accurate temperature measuring device. Monitor

bearing temperature frequently during initial operation

to determine if a bearing problem exists as well as to

establish normal bearing operating temperature.

5. On units equipped with auxiliary piping, assure that

proper flows have been established and that equipment

is operating properly.

6. Baseline vibration readings should be established to

determine normal running conditions. If it is

determined that the unit is running rough, consult

factory.

7. Monitor all gauges to ensure pump is running at or

near rating and that suction screen (when used) is not

clogged.

OPERATING AT REDUCED CAPACITY

! WARNINGDo NOT operate pump below minimum rated flows orwith discharge valve closed. These conditions maycreate an explosive hazard due to vaporization ofpumpage and can quickly lead to pump failure andphysical injury.

CAUTIONDamage occurs from:

1. Increased vibration levels - Affects bearings, seal

chambers/stuffing boxes, and mechanical seals.

2. Increased radial load - Stresses on shaft and bearings.

3. Heat build up - Vaporization causing rotating parts to

score or seize.

4. Cavitation - Damage to internal surfaces of pump.

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OPERATING UNDER FREEZINGCONDITIONSExposure to freezing conditions while pump is idle couldcause liquid to freeze and damage the pump.

Liquid inside pump should be drained. Liquid insideauxiliary piping, if supplied, should also be drained.

SHUTDOWN

1. Slowly close discharge valve.

2. Shut down and lock out driver to prevent accidental

rotation.

! WARNINGWhen handling hazardous and/or toxic fluids, properpersonal protective equipment is required. If pump isbeing drained, precautions must be taken to preventphysical injury. Pumpage must be handled and

disposed of in conformance with applicableregulations.

FINAL ALIGNMENT

NOTE: Alignment procedures must be followed toprevent unintended contact of rotating parts. Followcoupling manufacturer's installation and operationprocedures.

1. Run the unit under actual operating conditions for asufficient length of time to bring the pump and driver

and associated systems to operating temperature.

2. Shut down the pump and lock out the driver.

! WARNINGLock out driver to prevent accidental startup andphysical injury.

3. Remove coupling guard. Refer to coupling guard

installation and disassembly instructions in

Appendix II.

4. Check alignment while unit is still hot per alignment

criteria in theInstallationsection..

5. Reinstall coupling guard. Refer to coupling guard

installation and disassembly instructions in

Appendix II.

6. Unlock driver power.

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DOWELING PUMP CASING

The pump casing must be doweled to the baseplate pedestalsto positively maintain position. Two (2) separate methodsare used by Goulds, depending on whether the pump is usedin a cold application or a hot application (see below).

Model Stage Length Temperature

F C

3600

4 N/R N/R

5 N/R N/R

6 375 190

7 350 180

8 325 160

9 300 150

10 275 135

11 275 135

12 250 120

13 250 12014 250 120

When the driver is mounted at the factory, the pump isdoweled for both cold and hot applications. The driver isnot doweled to allow for final field alignment. When thedriver is mounted in the field, the pump is not doweled.Therefore, the following procedure, typically done at theGoulds manufacturing factory, must be done in the field.

NOTE: Doweling should only be done after finalalignment has been completed.

MOTOR INSTALLATION

1. Center the pump on its pedestal such that the holddown bolts are centered in the tapped holes of the

pump pedestal.

2. Place the motor on the baseplate with the proper shaft

separation (DBSE = Distance Between Shaft Ends).

3. Tighten down on the pump hold down bolts.

4. After correct motor location has been determined on

the motor pedestals, transfer the location of the motor

onto the pedestals by hole punching the motor pedestal

through the hold down bolt holes in the motor feet.

5. Remove the motor, then drill and tap the punched holeson the motor pedestal.

NOTE: Scribe the motor shims in order to return themto the correct location on the motor pedestal.

6. Set the motor back onto the baseplate with the shims in

the correct location. Tighten hold down bolts.

7. Loosen the pump and motor hold down bolts. Confirm that

the pump and motor are not bolt-bound. This step assures

that the final drilled holes will be correctly located.

NOTE: Pump is not doweled prior to this t ime becausethe pump cannot be moved on its pedestals after it hasbeen doweled.

COLD SERVICE APPLICATIONNOTE: This procedure must done only after the pumpis properly aligned with the driver on the baseplate.

1. Drill two (2) holes, using a 21/64 in. or "Q" size drill

through the pump foot and pump pedestal. Position the

hole between the hold down bolt and the end of the

pump foot at the coupling end on both sides.

CAUTIONIf water cooled pedestals have been provided, do NOTdrill through the baseplate pedestal or leakage ofcooling water will occur.

2. Ream the holes with a Number 7 taper pin reamer to

the proper fit with the taper dowel pins. Pins should

insert to a depth that leaves only the threaded portion

exposed when fully seated.

3. Seat taper pins firmly in holes with hardwood block or

soft faced hammer.

Should it become necessary to remove the dowel pins,tighten the hex nuts provided on the pins. If the pins are notseated deeply enough, a spacer under the hex nut may berequired to lift the pins free when the hex nut is tightened.

!CAUTION

Failure to remove the dowel pins prior to casingremoval may result in casing damage.

HOT SERVICE APPLICATION

Refer to Fig. 16 for Steps 1 through 5.

1. Remove the hold-down bolts from the pump feet

furthest from the coupling.

2. Scribe a mark mid-way between the end of the pump

foot and the hold down bolt hole centerline, paralell

with the pump axis.

3. Re-torque the hold down bolt between the pump footand the pump pedestal.

4. The pump foot and the outside of the pedestal will not

be flush. Mill or grind a spot on the pump pedestal to

make it flush with the pump foot.

5. Drill and ream for a 1.00 inch dowel pin, keeping the

pin flush with the pump foot.

NOTE: Drilling is best accomplished with a magneticbased drill.

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PREVENTIVE MAINTENANCEGENERAL COMMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

ROUTINE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 MONTH INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

ANNUAL INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

MAINTENANCE OF BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 32

RING OIL LUBRICATED BEARINGS . . . . . . . . . . . . . . . . . . . . . . 32

PURE OR PURGE OIL MIST LUBRICATED BEARINGS (OPTIONAL) . . . . 33

MAINTENANCE OF SHAFT SEALS . . . . . . . . . . . . . . . . . . . . . . . . 33

MECHANICAL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

T R O U B L E S H O O T I N G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4

GENERAL COMMENTS

A routine maintenance program can extend the life of your pump. Well maintained equipment will last longer and require

fewer repairs. You should keep maintenance records as this will help pinpoint potential causes of problems.

ThePreventive Maintenancesection must be adhered to in order to keep the applicable ATEX classification of theequipment. Failure to follow these procedures will void the ATEX classification for the equipment.

MAINTENANCE SCHEDULE

ROUTINE MAINTENANCE

Bearing lubrication

Seal monitoring

Vibration analysis

Discharge pressure monitoring

Temperature monitoring

ROUTINE INSPECTIONS

Check for unusual noise, vibration and bearing

temperatures.

Inspect pump and piping for leaks.

Verify there is no seal chamber leakage.

3 MONTH INSPECTIONS

Check foundation and hold down bolts for tightness.

If pump has packing and has been left idle, check

packing. Replace if required.

Oil should be changed at least every 3 months (2000

hours) or more often if there are any adverse

atmospheric conditions or other conditions which

might contaminate or break down the oil. Oil should

also be changed if it is cloudy or contaminated.

Check shaft alignment and realign if required.

ANNUAL INSPECTIONS

Check pump capacity, pressure and power. If pump

performance does not satisfy your process require-

ments, and process requirements have not changed,

pump should be disassembled, inspected, and worn

parts should be replaced. Otherwise, a systeminspection should be done.

Inspection intervals should be shortenedappropriately if the pumpage is abrasive and/orcorrosive, or if the environment is classified aspotentially explosive.

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MAINTENANCE OF BEARINGS

Do not insulate bearing housings as this can resultin excess heat generation, sparks, and prematurefailure.

RING OIL LUBRICATED BEARINGSRing oil lubricated ball bearings are standard on Model3600 pumps.

! WARNINGPumps are shipped without oil. Oil lubricated bearingsmust be lubricated at the job site.

A high quality turbine oil with rust and oxidation inhibitorsshould be used. For the majority of operational conditions,

bearing temperatures will run between 120F (50C) and180F (82C). In this range, an oil of ISO viscosity grade68 at 100F (40C) is recommended. If bearing tempera-

tures exceed 180F (82C) use oil of ISO viscosity grade100.

Bearing temperatures are generally about 20F (11C)higher than the bearing housing outer surface temperature.

Some acceptable oils are:

Exxon Teresstic EP 68

Mobil Mobil DTE 26 300 SSU

@ 100F (38C)

Sunoco Sunvis 968

Royal Purple SYNFILM ISO VG 68Synthetic Lube

For extreme conditions, refer to the factory or a lubricationexpert.

Oil should be changed after 200 hours if bearings are new.Thereafter, change oil every 2000 operating hours or 3months, whichever first occurs.

Ring oil lubricated pumps are supplied with an oiler whichmaintains a constant oil level in the bearing housing. Theoiler must be adjusted to 0" setting to maintain the oillevel in the middle of the sight glass. This is accomplished

by either removing the oiler adjusting stem, or screwing itdown to the bottom. Refer to Fig. 18 and Table 3for

proper setting dimensions.

NOTE: Setting dimension (A) of 0 will beaccomplished by removing and discarding the oileradjusting stem.

Table 3Oiler Adjusting Stem Setting and

Oil Level DimensionsDimension

A (Setting Dimension) 0

B (Oil Level) 316 in. (5 mm)

The oil reservoir in the bearing housing should be filled byfilling the oiler bottle with oil and placing it into the oilerhousing. Several fillings of the oiler bottle will berequired. Do not fill bearing housing oil reservoir throughthe vent or through the oiler housing without using the

bottle.

Oil capacities and oiler information for the various 3600bearing housings are shown in Table 4.

Table 4Bearing Housing Oil Capacities

Size

Bearing HousingCapacity

TricoOiler

No.

Oiler Capacity

Ounces Milliliters Ounces Milliliters

3x4-8B3x6-93x6-10

35 1035

5 8 2374x6-104x6-116x8-11

58 1715

Verify the correct oil level by comparing the oil level in thebottom of the oiler housing with the oil level sight glass onthe bearing housing.

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PURE OR PURGE OIL MISTLUBRICATED BEARINGS(OPTIONAL)

! WARNINGPumps are shipped without oil. Oil mist lubricatedbearings must be lubricated at the job site.

NOTE: Oil mist is recommended for use on ballbearing arrangements only(See Appendix I).

The same oil requirements applicable to ring oil lubricatedbearings also apply to oil mist lubricated bearings.

The steps necessary for oil mist lubrication are as follows:

1. Follow oil mist system suppliers instructions.

2. Connect oil mist supply lines to oil ring inspection

plug connections (Fig. 19) (Note that only one of the

two connection ports in the radial bearing housing is

used [immediately above the single row radial bearing]

while both connections on the thrust housing must beconnected since there are two rows of bearings.)

3. For pure oil mist, connect drain lines to outlet

connections (not required for purge oil mist).

NOTE: See Appendix I for Bearing HousingLubrication Conversion.

MAINTENANCE OF SHAFT SEALS

The mechanical seal used in an ATEX classifiedenvironment must be properly certified.

MECHANICAL SEALSWhen mechanical seals are furnished, a manufacturersreference drawing is supplied with the data package. Thisdrawing should be kept for future use when performingmaintenance and adjusting the seal. The seal drawing willalso specify required flush liquid and attachment points.The seal and all flush piping must be checked and installedas needed prior to starting the pump.

The life of a mechanical seal depends on various factors

such as cleanliness of the liquid handled and its lubricatingproperties. Due to the diversity of operating conditions it is,however, not possible to give definite indications as to itslife.

! WARNINGNEVER operate the pump without liquid supplied tomechanical seal. Running a mechanical seal dry, evenfor a few seconds, can cause seal damage and must beavoided. Physical injury can occur if mechanical sealfails.


Cooling systems such as those for bearinglubrication, mechanical seal systems, etc., whereprovided must be operating properly to preventexcess heat generation, sparks, and prematurefailure.


NOTE: The standard 3600 is supplied with sealchambers designed for cartridge mechanical seals.

3600 IOM 6/05 33

Fig. 19

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TROUBLESHOOTING

34 3600 IOM 6/05


No liquid delivered

Pump not primed.

Check that pump and suction line are full ofliquid.Reprime pump.

Suction line clogged/not filled with liquid Remove obstructions/fill line.

Impeller clogged with foreign material. Back flush pump to clean impeller.

Foot valve or suction pipe opening notsufficiently submerged .

Consult factory for proper depth.Use baffle to eliminate vortices.

Suction lift too high. Reduce suction lift.

Wrong rotative direction. Provide correct rotation

Air or vapor pocket in suction line. Vent suction line.

Available NPSH not sufficient. Increase available NPSH.

Pump not up to rated speed. Increase speed.

System head too high. Decrease system resistance.

Pump not producingrated flow or head.

Air leak thru gasket. Replace gasket.

Air leak thru seal chamber Replace or readjust packing/mechanical seal. Impeller partly clogged. Back flush pump to clean impeller.

Worn wearing rings. Replace defective part as required.

Insufficient suction head.

Ensure that suction line shutoff valve is fullyopen and line is unobstructed and filledwith liquid.Vent line of vapor or air pockets.Increase suction head.

Worn or broken impeller. Inspect and replace if necessary.

Wrong direction of rotation. Change rotation to concur with direction

indicated by arrow on bearing frame.


Pump not up to rated speed. Increase speed.

Pump starts then stopspumping

Improperly primed pump. Reprime pump and maintain full suction line.

Air or vapor pockets in suction line. Rearrange piping to eliminate air pockets.

Air leak in suction line or seal chamber. Repair (plug) leak.

Air or vapor in liquid. Deareate liquid, maintain pressure to prevent

vaporization.


Bearings run hot

Improper alignment. Re-align pump and driv er.

Improper lubrication.

Check lubricant for suitability, quantity, quality,and pressure. Remove dirt and moisture from oiland bearings.

Insufficient cooling liquid. Check cooling system, clean oil cooler.

Bearings too tight. Replace bearings.

Excessive vibration Correct cause of vibration.

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TROUBLESHOOTING

3600 IOM 6/05 35


Pump is noisy orvibrates

Improper pump/dri ver alignment. Align shafts, recheck piping stability.

Partly clogged impeller causing imbalance. Backflush pump to clean impeller, remove

rotating element to inspect if necessary.

Broken or bent impeller or shaft. Replace as required.

Impeller out of balance. Balance impeller.

Foundation not rigid. Assure uniform contact of pump and/or supports

with foundation, confirm bolts are tight.

Worn bearings. Replace.

Suction or discharge piping not anchored orproperly supported.

Anchor per Hydraulic Institute Standardsrecommendations. Check to API Appendix orPiping Loads.

Pump is cavitating. Locate and correct system problem.

Loosen driver or pump hold down bolts Tighten bolts, check level and alignment, and

correct, as required.

Vibration transmitted from drive to pump

Disconnect coupling and run driver at full speed.

If driver vibrates, follow its manufacturersinstructions for corrective action.

Excessive leakage fromstuffing box

Worn mechanical seal parts. Replace wor n parts.

Overheating mechanical seal. Check lubrication and cooling lines.

Shaft sleeve scored. Remachine or replace as required.

Motor requiresexcessive power

Head lower than rating. Pumps too muchliquid.

Consult factory.Install throttle valve.Cut impeller. Confirm system head curve.

Liquid heavier than expected. Check specific gravity and viscosity.

Rotating parts bind. Check internal wearing parts for proper

clearances.

Speed too high. Reduce speed.

Misalignment. Align shafts.

Shaft bent. Correct or replace shaft.

Bearings wear rapidly

Misalignment Re-align pump and driver.

Shaft bent. Correct or replace shaft.

Vibration Correct cause of vibration.

Excessive thrust resulting from mechanicalfailure or wear inside pump.

Check cause of excessive thrust and reduce.

Improper lubrication.

Check lubricant for suitability, quantity, qualityand pressure. Remove dirt and moisture from oiland bearings.

Bearings installed improperly. Re-install bearings confirming correct dimension.

Excessive cooling of bearings Check cooling system, monitor temperature toconfirm cooling rating.

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DISASSEMBLY & REASSEMBLYREQUIRED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

RENEWAL OF WEAR PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 54REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

REQUIRED TOOLS

DISASSEMBLY

! WARNINGPump components are heavy. Proper methods of liftingand securing must be employed to avoid physical injuryand/or equipment damage.

! WARNINGThe Model 3600 may handle hazardous and/or toxicfluids. Trapped or undrained pumpage can causeexplosions when heat is applied. Never apply heat atthe pump site (Fig. 20) for this reason. Heat also candistort machined surfaces. Proper personal protectionis required. Precautions must be taken to preventphysical injury. Pumpage must be handled anddisposed of in conformance with applicableregulations.

NOTE: Before disassembling the pump for overhaul,ensure all replacement parts are available.

! WARNINGLock out power supply to driver to prevent accidentalstartup and physical injury.

3600 IOM 6/05 37

Open end wrenches

Lifting sling

Induction bearing heater

Brass drift punch

Spanner wrench

Allen wrenches

Dial indicator

Micrometers (inside and outside)

Cleaning agents

Feeler gauges

Torque wrench with sockets

Drill

Tap

Spanning type puller

Soft face hammer

Press

Fig. 20

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PREPARATION FOR DISASSEMBLY1. Shut off all valves controlling flow to and from pump.

! WARNINGOperator must be aware of pumpage and safetyprecautions to prevent physical injury.

2. Drain liquid from piping; flush pump if necessary.

3. Disconnect all auxiliary piping, tubing and

equipment that will interfere with removal of head and

rotor.

4. Remove oil drain plugs (408A) (Fig. 21) from the

bottom of bearing housings (134) and drain oil.

Dispose of oil in accordance with applicable

regulations.

5. Remove oiler bottle (251) (Fig. 15) and store in a safe

place.


6. Remove coupling guard (501B). Refer toCoupling

Guard Installation and Disassemblysection in

Appendix II.

7. Unbolt and remove coupling spacer (235B).

Follow coupling manufacturers instructions for

assistance.

8. Remove coupling guard pump endplate (234A).

9. Remove coupling nut (520) from pumps tapered shaft

end. (See pump cross sectional drawing in spare parts

section).

10. Remove pump coupling hub (233).

NOTE: Use a spanner type puller or puller holesprovided in hub to assist removal. Refer tomanufacturers instructions for further assistance.Blue and scribe shaft (122) for relocating couplinghub during reassembly.

NOTE: At this point, pump can be removed frombaseplate.

11. Reposition setting tabs to maintain position ofmechanical seal (refer to manufacturers seal

installation drawing).

NOTE: Both seals should be repositioned at this time.

DISASSEMBLY OF BALL BEARINGPUMPS.

Refer to Fig. 22 for Steps 1-7

RADIAL END1. Unbolt and remove cover bolts (371C) and outboard

end cover (160); loosen inboard end cover (160) and

cap screws (371C).

NOTE: Outboard laby seal (332A) and bearinghousing gasket (360A) will come off with outboardcover (160).

2. Remove dowel pins (469J) between bearing

housing flange and case flange (connection point of

housing to case is referred to as saddle).

3. Unbolt bearing housing from saddle by removing four

nuts (427J).4. Pull studs (371T). Rotate bearing housing in

order to remove the inboard end cover bolts (371C).

5. Remove oil ring (114).

6. Pull bearing housing (134) off shaft. Gasket (360A)

will likely remain on bearing housing.

7. Loosen set screw (388L) on oil ring sleeve (324) and

remove sleeve.

38 3600 IOM 6/05

Fig. 21

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8. Using bearing puller, remove radial bearing (168) from

shaft.

9. Remove the following items: inboard bearing cover

(160); inboard laby seal (333A); inner bearing cover

bolts (371C).

10. Remove seal plate nuts (355) and mechanical

seal (250) (per vendors instructions).

3600 IOM 6/05 39

Fig. 22

Fig. 23

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THRUST END

Refer to Fig. 24 for Steps 12 through 19:

12. Unbolt and remove cover bolts (371C) and outboard

thrust bearing end cover (109A); loosen inboard endcover (160) and cap screws (371C). Bearing housing

gasket (360A) will likely remain on end covers (109A

or 160).

13 Remove dowel pins (469J) between bearing housing

flange and head flange (connection point of housing to

case is referred to as saddle).

14. Unbolt bearing housing from saddle by removing four

nuts (427J).

15. Pull studs (371T). Rotate bearing housing in order to

remove the inboard end cover bolts (371C).

16. Remove oil ring (114).

17. Pull bearing housing (134) off shaft.

18. Remove locknut (136) and lockwasher (382).

19. Remove oil ring sleeve (443B) held in place by the

thrust locknut (136).

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Fig. 24

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Refer to Fig. 25 for Steps 20 through 22

20. Using bearing puller, remove the thrust bearing (112A)

from the shaft (122). The inner race on this inner

duplex bearing will likely remain on the shaft when the

bearing is pulled. Remove this inner race by heat.

! WARNINGThe Model 3600 may handle hazardous and/or toxicfluids. Trapped or undrained pumpage can cause

explosions when heat is applied. Never apply heat atthe pump site (Fig. 20) for this reason. Heat also candistort machined surfaces. Proper personal protectionis required. Precautions must be taken to preventphysical injury. Pumpage must be handled anddisposed of in conformance with applicableregulations.

NOTE: All pumps have a bearing spacer (217).

21. Remove the following items: inboard bearing cover

(160); inboard laby seal (333A); inner bearing cover

bolts (371C).

22. Remove seal plate nuts (355) and mechanical seal(250) (per vendors instructions).

3600 IOM 6/05 41

Fig. 25

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DISASSEMBLY OF SLEEVE/BALLBEARING PUMPS

RADIAL END

Refer to Fig. 26 for Steps 1 thru 3.

1. Remove dowel pins (2) between upper and lower

halves of bearing housing (134).

2. Remove hex screws that connect the upper and lower

halves of the bearing housing.

3. Tighten jackscrews (2) on the bearing housing

horizontal parting flanges to separate the two halves.

4. Remove top half of bearing housing with the upper

half of the sleeve bearing (117) (Fig. 27). (Note that

the bearing is pinned to the bearing housing. Other

figures show this pictorially: Only Fig. 27 calls it out

by name).

5. Remove dowel pins (469J) from the lower half bearinghousing to the case flange (Fig. 28). Loosen and

remove nuts (427J) holding the bearing housing in

place.

6. Rotate the lower half of the sleeve bearing (117)

around the shaft (122) to remove from the lower

housing.

7. Remove the lower half of the bearing housing.

Refer to Fig. 29 for Steps 8 thru 10.

8. Remove the outboard laby (332A).

9. Remove the two (2) oil rings (323).

10. Remove the inboard labyrinth seal (333A).

42 3600 IOM 6/05

Fig. 26

Fig. 27

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3600 IOM 6/05 43

Fig. 29

427J

427J

469J

134

Fig. 28

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THRUST ENDRefer to Fig. 30 for Steps 11 thru 14.

11. Remove the outboard end cover (109A) by removing

the end cover cap screws (371C).

12. Remove the dowel pins between the upper and lower

halves of the bearing housing (134A).

13. Remove the hex head screws connecting the upper and

lower halves of the bearing housing (134A).

14. Tighten jackscrews in order to separate the housing

halves.

15. Remove the top half of the thrust bearing (134A)

housing with the upper half of the sleeve bearing

(117). Note that the bearing is pinned to the housing

(Fig. 31).

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Fig. 30

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Refer to Fig. 32 for Steps 16, 18, and 20 through 24.

16. Remove outboard oil ring (114 - right hand side

of Fig. 32).

Refer to Fig. 33 for Steps 17 and 19.

17. Remove dowel pins ((469J) from the lower half

bearing housing to the case flange. Loosen nuts (427J)

holding the bearing housing in place. The bearinghousing will rest on the studs.

18. Rotate the lower half of the sleeve bearing (117)

around the shaft (122) to remove from the lower

bearing housing.

19. Remove nuts (427J). Remove the lower half of the

bearing housing (134A) using a crane. Remove studs

(371T).

20. Remove the thrust locknut (136) and the lockwasher

(382) from the shaft.

21. Remove oil ring sleeve, thrust (443B).

3600 IOM 6/05 45

Fig. 31

Fig. 32

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22. Using a bearing puller tool, remove the thrust bearing

(112A) from the shaft. The inner race on this inner

duplex bearing will likely remain on the shaft when the

bearing is pulled. Remove this inner race by heat (See

WARNING after Step 20 in Disassembly of Ball

Bearing Pumps) All pumps have a bearing spacer

(217).

23. Remove two oil rings (323) located at sleeve bearing.

24. Remove the labyrinth seals (333A).

For the rarely-supplied sleeve/Kingsburybearing arrangement, refer to the includedsleeve/ball arrangement for sleeve bearingdisassembly. Also see the includedinstructions from Kingsbury for specificinstructions regarding this tilting padhydrodynamic bearing.

DISASSEMBLY OF ROTATINGASSEMBLY FROM CASING


1. Loosen and remove casing nuts (425) and taper pins.

2. Using jacking bolts (provided with pump), loosen

upper half from lower half of casing (100).

! WARNINGDo Not Use Heat (Refer to WARNING in DisassemblySection).

3. Insert eye bolts (not supplied) in pre-drilled threaded

holes in perimeter of upper half. Remove upper half to

work area.

! WARNINGEye bolt is to be used to lift upper half of casing only.It will not support weight of the entire pump.

Refer to Fig. 35 for Steps 4, 6 and 8.

4. Using two slings [one between throttle bushing (129)

and impeller and the other one between first stage

impeller (101) and seal chamber (221)], lift rotating

assembly slightly to remove contact with wear parts.

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Fig. 33

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3600 IOM 6/05 47

Fig. 34

Fig. 35

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Refer to Fig. 36 for Steps 5 and 7.

5. Remove socket head cap screws from center bushing

(155), all stage rings (144) and diaphragm (146) if

supplied. Remove upper half of all components.

Rotate lower half of all components out of lower halfof casing.

6. Lift rotating assembly further to disengage stationary

locks.

7. Remove seal chambers (220, 221), throttle bushing

(129), first stage casing ring (164A) and series casing

ring (164) on opposite side.

8. Lift rotating assembly out of lower half casing.

9. Remove casing studs (356A, 356C, 356K) and casing

gasket (351).

DISASSEMBLY OF ROTATINGELEMENT

Refer to Fig. 37 for Step 1.

1. Remove throttle bushing sleeve (128). First remove

snap ring (361F). Slide sleeve towards center of the

rotor exposing the locating ring (361H). Remove thelocating ring (two halves) and throttle bushing sleeve.

Refer to Fig. 38 for Step 2.

! CAUTIONUse insulated gloves when removing impeller.Impeller will get hot and can cause physical injury.

2. Remove the snap ring (361F) on first stage impeller

(101). Heat impeller to 300 - 400F and slide towards

center or rotor exposing locting ring (361H). Quickly

remove locating ring and impeller. Remove

subsequent casing ring (164).

48 3600 IOM 6/05

Fig. 36

Fig. 37

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Refer to Fig. 39 for Step 3 (6x8-13 pumps only)

! CAUTIONUse insulated glvoes when removing impeller. Impeller

will get hot and can cause physical injury.

3. On 6x8-13 pumps only, the first stage impeller is held

in place by two snap rings (361). Remove both, heat

impeller to 300 - 400F and slide impeller off.

Remove subsequent casing ring (164).

Refer to Fig. 40 for Step 4 (double suction pumps only).

4. For double suction pumps only, repeat Step 1 for

diaphragm sleeve (204).

3600 IOM 6/05 49

Fig. 38

Fig. 39

Fig. 40

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Refer to Fig. 41 for Step 5 (6x8-13 pumps only).

5. On 6x8-13 pumps only, the diaphragm sleeve is held

in place by a shoulder and a snap ring (361). Remove

snap ring and remove sleeve.

6. Repeat step 2 for remaining impellers.

NOTE: Allow shaft to cool to ambient temperaturebefore removing the next impeller

7. Once all impellers are removed, remove center sleeve

(205). Not applicable on 6x8-13 pumps.

INSPECTIONS

Model 3600 parts must be inspected to the followingcriteria before they are reassembled to ensure the pump willrun properly. Any part not meeting the required criteriashould be replaced.

NOTE: Clean parts to remove oil, grease or dirt.Protect machined surfaces against damage duringcleaning.

CASING (100)The casing should be inspected for excessive wear,corrosion or pitting. Areas most susceptible are indicated

by the arrows in Fig. 42. The casing should be repaired orreplaced if it exceed

3600_ATEX-lr

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