(@GOULDS PUMPS Installation, Operation and Maintenance Instructions Models 3196 CC CV 3196 CC 3796 CC S ittFOREWORD This manual provides instructions for the Installation, Operation, and Maintenance of the Goulds Models 3196 CC, CV3196 CC, and 3796 CC. This manual covers the standard product plus common options that are available. For special options, supplemental instructions are supplied. This manual must be read and understood before installation and start-up. The design, materials, and workmanship incorporated in the construction of Goulds pumps makes them capable of giving long, 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 physical injury, 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 will nullify the warranty, unless written approval is obtained in advance from Goulds Pumps. ‘Supervision by an authorized Goulds representative is recommended to assure proper installation. Additional manuals can be obtained by contacting your local Goulds representative or by calling 1-800-446-8537. THIS MANUAL EXPLAINS Proper Installation Start-up Procedures Operation Procedures Routine Maintenance Pump Overhaul Trouble Shooting Ordering Spare or Repair Parts 3196 CC IOM - 9/03 33196 CC IOM - 9/03ABLE OF CONTEN PAGE SECTION cd ) Nd lhe 57 eee EU CUR ey 3196 CC IOM - 9/03 53196 CC IOM - 9/03IMPORTANT SAFETY NOTICE To: Our Valued Customers User safety is a major focus in the design of our products. Following the precautions outlined in this ‘manual will minimize your risk of injury. ITT Goulds pumps will provide safe, trouble-free service when properly installed, maintained, and operated, ‘Safe installation, operation, and maintenance of ITT Goulds Pumps equipment are an essential end user responsibility. This Pump Safety Manual identifies specific safety risks that must be considered at all times during product life. Understanding and adhering to these salety warnings is mandatory to ensure personnel, property, and/or the environment will not be harmed. Adherence to these wamings alone, however, is not sufficient — itis anticipated that the end user will also comply with industry and corporate safety standards, Identifying and eliminating wnsafe installation, operating and maintenance practices is the responsibilty 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.comylicerature_joms.html or by contacting ‘your nearest Goulds Pumps sales representative. ‘These manuals must be read and understood before For additional information, contact your nearest Goulds Pumps sales representative or visit our Web site at www gouldspumps.com. S-lSAFETY WARNINGS Specific to pumping equipment, significant risks bear reinforcement above and beyond normal safety precautions AX WARNING. A pump isa pressure vessel with rotating parts that can be hazardous. Any pressure vessel can explode, rupture, or discharge its contenis 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. AS WARNING Operation of any pumping systzm 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 ina violent explosion, All necessary measures must be taken by the end user to ensure this condition is, avoided AX WARNING. The pump may handle hazardous and/or toxie 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 tempercture, flammable, acidic, caustic, explosive, and other risks. AX WARNING: Pumping equipment Instruction, Operation, and Maintenance manuals clearly identify accepted methods for disassembling pumping units. “hese methods must be adhered to, Specifically, applying heat to impellers and/or impeller retaining devics to aid in their removal is 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 1OM available at www. goukdspumps.comlliterature, 8-2SAFETY DEFINITIONS ‘Throughout this manual the words WARNING, CAUTION, ELECTRICAL, and ATEX are used to indicate ‘where special operator attention is required, Observe all Caut your equipment. \s and Warnings highlighted in this Pump Safety Manual and the 1OM provided with AS WARNING Indicates « hazardous situation which, if not avoided, could result in death or serious injury. Example: Pump shall neverbe operated without coupling guard installed correctly. AX cavrion Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Example: Throttling flow ficm the suction side may cause cavitation and pump damage. {\ ELECTRICAL HAZARD Indicates the possiblity of electial risk 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 if 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 represeniative before proceeding. Example: ©) improper impeller adjustment could cause contact between the rotating and stationary parts, resulting ina spark and heat generationGENERAL PRECAUTIONS AN WARNING ‘A pump is 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 measutes. 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. Imay 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 correetly installed. WARNING NEVER fu pun slow eae ini ow whe yor io WARNING | 4\_| ALWAYS lock out power tothe driver before performing pump maintenance. WARNING: NEVER operate pump without safety devices installed, WARNING. NEVER operate pump with discharge valve closed, WARNING NEVER operate pump with suction valve closed WARNING DO NOT change service application without approval of an authorized ITT Goulds Pumps representative Safety Appar: + Insulated work gloves when handling hot bearings or using bearing heater + Heavy work gloves when handling parts with sharp edges, especially WARNING impeilers + Safety glasses (with side shields) for eye protection + Steel-oed shoes for foot protection when handling parts, heavy tools, ete + Other personal protective equipment to protect against hazardous/toxie 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 WARNING instructed in the current IOM. Current manuals are available at www.gouldspumps.comyliterature_ioms.html or from your local ITT Goulds Pumps sales representative, Note: Lifting devices (eyebolts, slings, spreaders, ec.) rnust he rated, selected, and used for the entire load being lite. ‘Alignment: | G& | Shalt alignment procedures must be followed to prevent catastrophic failure of WARNING | © 1 rive components or unintended contact of rotating pars. Follow coupling manufacturer's coupling installation and operation procedures. S4General Precautions ‘Before begining any alignment procedure, make sure diver power is locked oot WARNING | /\ | Pale to feck out diver power wil esl nsrous pict ny. Pipin Never draw piping into place by forcing at he flanged connection othe pump, caution | & | thismay impose atgerous sins onthe unit and eause misalignment between pun and diver Pipe sain will adversely effect the operation ofthe pump Testing in physical injury and damage tothe equipment Flanged Connections: WARNING Use only fasteners of the proper size and material. WARNING Replace all corroded fastener. WARNING Ensure al fisteners are properly tightened and there are no missing fasteners ‘Startup and Operatio warns | | When installing ina potentially explosive environment please ensure tat the moto is properly cetfed ‘Operating pumpin reverse rotation may result n contact of metal pars eat WARNING | © | generation, and breach of containment WARNING | A\ | Lock out driver power to prevent accidental star-up and physica injury The nopeler clearance sting procedure must be followed. improperly sting WARNING | & | the clearance or not following any of the proper procedures can result in sparks, unenpected heat generation and equipment damage. If using a cartridge mechanical seal, the centering clips must be installed and set WarninG | & | screws loosened prior to setting impeller clearance. Flare todo so could result in sparks, beat generation, and mechanical seal damage The coupling wsed in an ATEX classified envionment must be propery oerifed WARNING ® and must be constructed from a non-sparking material. WARNING Never operate a pump without coupling guard properly installed. Personal injury. wll occur pnp is tun without coupling puad Tg | Make sure t propery lubricate the bearings, Failure fo do so may Feu exces WARNING | © | heat generation, park, and/or premature failure “he mechanical seal use in an ATEX classified environment must be propely caution | &@ | ceritied. Porto start up, ensue al points of potential leakage of process fui 0 the work environment ay closed ‘Never operate the pump without Iiguid supplied o mechanical seal: Ruming a AauTion | & | mechanical seal dy, even fra few seconds, can cause seal damage and must be ‘voided. Physical injury can oecur i mechanical sal al, WARNING ‘Never attempt to replace packing unl the diver is properly Tocked out and the coupling spice is removed WARNING | & | Dynamic sas are not allowed in an ATEX casiied environment DO NOT operate pump below minimum ed flows or with suction andlor WaRNine | | cischarge valve closed. These conditions may create an explosive hazard due to veporization of pumpage nnd can quietly lead to pup failure and physical injury S-5General Precautions Ensure punip is isolated from system and pressure s relieved belore 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 ‘wom, Precautions must be taken to prevent physical injury. Pumpage must be ‘handled anc 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 If pump is a Model NMB171, 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 eonditions 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 eause 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 S-6ATEX CONSIDERATIONS and INTENDED USE Special care must be taken in potentially explosive environments fo 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. ‘The ATEX conformance is only applicable when the pump unit is operated within its intended use, Operating, installing or maintaining the pump unit in any way that is not covered in the Instruction, Operation, and Maintenance manual (IOM) can eause 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. Ifthere is any question regarding the intended use of the equipment, please contact an ITT Goulds representative before proceeding. Current OMS are available at www.gouldspumps.convliterature_ioms.hem! 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 itis mounted. A typical tag would look like this: a a Il 2 GD Ta ‘The CE and the Ex designate the ATEX compliance, The code directly below these symbols reads as follows: = Group? 2 = Category 2 GD = Gas and Dust present T4 = Temperature class, can be TI 10 T6 (see Table 1) Table 1 ‘Max permissible Max permissible surface temperature | liquid temperature Code “FCC °F CO) T 842450), 700 (372), 2D 572 G00) 30077 B 392 200), 350077) i 275 (133) 235 (113) 212 (100), ‘Option not available 16 185_(85) ‘Option not available ‘The code classification marked on the equipment must be in accordance withthe specified area where the equipment will be installed. If it isnot, do not operate the equipment and contact your ITT Goulds Pumps sales representative before proceeding. S7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.GENERAL INFORMATION PUMP DESCRIPTION ..... . PARTS COMMONALITY . . . NAMEPLATE INFORMATION. RECEIVING THE PUMP............- Storage Requirements . tee i 12 Handling fee fee fee 12 Ez PUMP DESCRIPTION Mode! Pump Description [Size Groups _[No. of Sizes [This model has five (5) hydraulic pump sizes. It has a casing which is ANSI B73 dimensionally compliant and Mx 5 lopen impeller design. [This model has two (2) pump sizes. MTX 2 It is a horizontal overhung, recessed impeller, centrifugal pump 'specifically designad to handle bulky or fibrous solids, air, gas or ©V3196. CC _|shear sensitive liquids. (| This model has three (3) hydraulic pump sizes. MTX 3 |The 3796 is a horizontal overhung, self priming, open impeller, lcentritugal pump, 3796 ANSI Family Parts Commonality All of Goulds Pumps horizontal ANSI pumps share the same stuffing box covers and seal chambers. The non-metallic units all have unique casings, impellers, and seal chambers. The chart on the following pages demonstrates the parts commonality and the relationship between the model lines. 3196 CC IOM - 9/03 9ele 3196 CC “TT 3796CC = CV 3196 CC 10 Con] ‘The casing i top centetne discharge and self venting. ‘The gasket is fully confned. ANSI fat faced 150 # flanges are standaré. The pump is mounted on the Casing fect as nell asthe motor feet for said support Flange-o-tange dimersions mest ANSI B73. “The casing is top certrinesischarge and selt-ventng Ichas an intograly east priming chamber that allows the ‘pump to evacuate airto prime se. The gasket Is fly Eonfned. An integral foot support is used for maximum Fesistance to misalgrment and distorbon from piping Toads. ANSI class 160 ralsed face serated flanges ae ‘avalible as an option. The casing comes witha provision to accept an immersion heater to Keep the liguidin the priming cnamber rom freezing in outdoor applications, ‘The casing is tangertialdlecharge and has a fully confined gasket. ANSI flat faced 160 # flanges are Standaré. The pumg Is mounted on the casing feat as Well as the motor feet for sols suppor. rg “The impellers fully open and threaded to the shat. Threads are sealed fom the umpage by an O-ring (Teflon). The Impallors tho same as used inthe cofwventional Models 3196 and 3796 wity the exception thas an ant-otation option. “The impellers fully open and recessed {rom the casing, thas curved vanes and is troaded tothe shah. The threads are Seeled trom be pumpage by «Ten Crring. The impeller ise same as used Inthe CV 3196 wit he exception ithas an ant-rotation option. 3196 CC IOM- 9/03gee lg Power Ends ‘The 2196 CC, CV 3199 CC, and 3796 use the ‘same seal chambers, These are also iter- Changeable with tha fallowing other Goulds Models: 2196, cV'9196, HT/2198, and LF 3196, 3196 CC IOM - 9/03 Frame Adapter The rame adapters forthe ‘3408 CC, CV 8196 CC. and 3798 are each machined specially for the pump motor combinations. 1NAMEPLATE INFORMATION Every pump has a Goulds nameplate that provides information about the pump. The nameplate is located on the casing, Pump Casing Tag - provides information about the ump’s hydraulic characteristics. Note the format of ‘the pump size: Discharge x Suction - Nominal maximum Impeller Diameter in inches. (Example: 2x3-8) (Figs. 1 & 2). rr eu [ | see wir Ott wp 0564 Bee OSiboe Fig. 1 (Engish) QULDEFUUES, WE. SENECK FALLS, WADE USK wp 1% i m th sur vir ct ws, OSC Fig.2 tee (Metric) RECEIVING THE PUMP Inspect the pump as soon as itis received. Carefully check that everything is in good order. Make notes of damaged or missing items on the receipt and freight bill. File any claims with the transportation company as soon as possible, STORAGE REQUIREMENTS Short Term: (Less than 6 months) Goulds normal packaging procedure is designed to grotect the pump uring shipping. Upon receipt, store in a covered and «ry location. Long Term: (More than 6 months) Preservative treatment of machined surfaces will be required. Rotate shaft several times every 3 months. Refer to driver and coupling manufacturers for their long term storage procedures. Store in a covered dry location. 12 NOTE: Long term storage treatment can be purchased with the initial pump order or can be applied to pumps already in the field that were. fot treated at the factory. This service can bo Supplied by contacting your local Goulds sales fepresent HANDLING paper cr Faure to to pumps, Steet eee 3196 CC IOM - 9/03Use care when moving pumps. Lifting equipment must be able to adequately support the entire assembly. Hoist bare pump using a suitable sing, Under the suction flange and motor. Baseplate mounted units can also be moved with slings under the pump casing and driver. Refer to Figs. 3-4 for ‘examples of proper lifting techniques. Fig. 3 Fig. 4 3196 CC IOM - 9/03 1314 3196 CC IOM - 9/03INSTALLATION BASEPLATE INSPECTION SITE/FOUNDATION............-- LEVEL BASEPLATE BASEPLATE LEVELING WORKSHEET GROUT BASEPLATE Alignment Check PIPING General Suction Piping Discharge Piping . Final Piping Check BASEPLATE INSPECTION 1. Remove all equipment. baseplate with an epoxy primer. This may have been purchased as an option. 2. Completely clean the underside cf baseplate. Itis sometimes necessary to coat the underside of the 3. Remove the rust preventative solution from the ‘machined pads with an appropriate solution. SITE / FOUNDATION A pump should be located near the supply of liquid any vibration and to form a permanent, rigid support and have adequate space for operation, maintenance, _for the pumping unit and inspection. The location and size of the foundation bolts are Baseplate mounted pumps are normally grouted ona__—_shown on the outline assembly drawing provided with conerete foundation, which has been poured on a the pump data package. solid footing. The foundation must be able to absorb 3196 CC IOM - 9/03 15Foundation bolts commonly used are sleeve type (Fig. 5) and J type (Fig. 6). Both designs permit ‘movement for final bolt adjustment. 1. Inspect foundation for dust, dir, cil, chips, water, ete. and remove any contaminants. Do not use oil-based cleaners as grout will not bond to it. Propare the foundation in accordance with the grout manufacturer's recommendations. Fig. 5 o b a Sit z > % LEVEL BASEPLATE FABRICATED STEEL 1. Place two sets of wedges or shims on the foundation, one set on each side of every foundation bolt (Fig. 7 & 8). The wedges should extend .75 in. (20mm) to 1.80 in, (40mm) above foundation, to allow for adequate grouting. This will provide even support for the baseplate once it is grouted. 2. Remove water and/or debris from anchor bolt holes/sleeves prior to grouting. Ifthe sleeve type bolts are being used, fil the sleeves with packing, or rags to prevent grout from entering Carefully lower baseplate onto foundation botts. Lovel baseplate to within 125 in. (3.2mm) over length of the baseplate and to within .088 in. (1.5mm) over the width of the base by adjusting wedges. A level should be placed across the pump ‘mounting pads and the motor mounting pads. Hand tighten the botts. 16 3196 CC IOM - 9/03BASEPLATE LEVELING WORKSHEET LEVEL MEASUREMENTS oo —_ 00 3 7 5 : 7 | 9 | 5 4 6 | oo o°0 | “> \ ) XY ia foo | MIE i l8hig ll [i2[] 7 oo - oo 3196 CC IOM - 9/03 17GROUT BASEPLATE 1. Clean areas of baseplate that will contact grout. Do not use oil-based cleaners because grout will not bond tot. Refer to grout manufacturers instructions. 2. Build dam around foundation. Thoroughly wet foundation (Fig. 9). GROUT - FOUNDATION seve Fig. 9 8. Pour grout through grout hole in baseplate, up to level of dam. Remove air bubbles from grout as itis poured by puddling, using a vibrator, or pumping the grout into place. Non-shrink grout is recommended, 4. Allow grout to set. Fill remainder of baseplate with grout. Remove air as before (Fig. 10). 6. Allow grout to sot at least 48 hours. 7. Tighten foundation bolts. ALIGNMENT CHECK Re-check alignment before continuing, using methods previously described. PIPING GENERAL Guidelines for piping are given in the “Hydraulic Institute Standards” available from: Hydraulic Institute, 9 Sylvan Way, Parsippany, NJ 07054-3802 and must be reviewed prior to pump installation. ‘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 pump and driver. Pipe ‘strain will adversely effect the operation of the: ‘pump resulting in physical injury and damage to. the equipment, 1. All piping must be supported independently of, and line up naturally with, the pump flanges. 2. Piping runs should be as short as possible to minimize friction losses. 18 3. DO NOT connect piping to pump until grout has hardened and pump and driver hold-down bolts have been tightened. 4. Its suggested that expansion loops or joints, if used, be properly installed in suction and/or discharge lines when handling liquids at elevated temperatures, so linear expansion of piping will ‘not draw pump out of alignment (Fig. 11 & 12) 3196 CC IOM - 9/03L CORRECT gy Fig. 11 INCORRECT Fig. 12 3196 CC IOM - 9/03 5. The piping should be arranged to allow pump flushing prior to removal of the unit on services handling corrosive liquids. 6. Carefully clean all pipe parts, valves and fittings, and pump branches prior to assembly. SUCTION PIPING ‘NPSHa must always exceed NPSHpas shown ‘on Goulds. ice curves received with ‘order. Reference Hydraulic Institute for NPSH ‘and pipe friction values needed to evaluate ‘suction piping. Property installed suction piping is a necessity for trouble-free pump operation. Suction piping should be flushed BEFORE connection to the pump. 1. Use of elbows close to the pump suction flange should be avoided. There should be a minimum of two pipe diameters of straight pipe between the elbow and suction inlet. Where used, elbows should be long radius (Fig. 13). CORRECT Fig. 13 eo Fig. 14 2. Use suction pipe one or two 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. 193. Reducers should be eccentric at the pump suction, flange with sloping side down and horizontal side at the top (Figs. 15. 16, 17). ceoanrme eaela wri TEENIE CENTRIC REDUCER Lone Radius e STRAINER Fig. 17 A CAUTION Pump must never be throttled on suction side. 4. Suction strainers, whon used, mus have a net roo area’ ofa leat tree mes the suction pipe area, 5. Separate suction lines are recomnended when more than one pump is operating from the same. source of supply. Incoraecr PIPING CHECK VALE \ aig pocneT secause Eee eNae REDUCER is NOT seo a9 Because SOeron PIE Goes NO SUOe Guanualty Spako FROM SUPPLY } / Gare vaLvE eee Ne 20 Suction Lift Conditions 1. Suction pipe must be free from alr pockets, 2. Suction piping must slope upwards to pump. 3. Allljoints must be air tight. 4. Armeans of priming the pump must be provided, such as a foot valve, except for the 9796 selt priming pump. Suction Head / Flooded Suction Conditions 1. Anisolation valve should be installed in the suction line at least two pipe diameters from the suction to permit closing of the line for pump inspection and maintenance. 2. Keep suetion pipe free trom 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 or two sizes larger 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. 3196 CC IOM - 9/03DISCHARGE PIPING 1. Isolation and check valves should be installed in discharge line. Locate the check valve between isolation valve and pum. This wil permit inspection of the check valve. The isolation valve is required for priming, 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. FINAL PIPING CHECK After connecting the piping to pump: 1. Rotate shaft several times by hard to be sure that there is no binding and all parts are free. 2. Check alignment, per the alignment procedure outlined previously to determine absence of pipe strain. If pipe strain exists, correct piping. 3196 CC IOM - 9/03 2122 3196 CC IOM - 9/03OPERATION PREPARATION FOR START-UP . Checking Rotation. Shaft Sealing Priming Pump Start-Up Precautions... .. . STARTING PUMP... ...... . OPERATION...........-.- General Considerations... . Operating at Reduced Capacity. Operating Under Freezing Conditions. SHUTDOWN » 28 PREPARATION FOR START-UP CHECKING ROTATION A CAUTION Serious damage may result pump is ran in the wrong rotation, 1. Unlock driver power. 2. Make sure everyone is clear. Jog stiver just long enough to determine direction of rctation. Rotation must correspond to arrow on bearing housing, 3. Correct if necessary. A CAUTION ‘Operation of the unit without proper lubrication will cause bearing failure, and pump seizure. CHECK IMPELLER CLEARANCE See Section 5 for details. SHAFT SEALING Cartridge Mechanical Seals: 1. Slide the cartridge seal onto the shaft or sleeve Until it contacts the inboard labyrinth oil seal 2. Assemble the seal chamber per t1e instructions in Section 6 - Disassembly & Reassembly. Slide the cartridge seal into the seal chamber and secure using the four studs and nuts, 4. Continue the pump reassembly per the instructions in Section 6 - Disassembly & Reassembly. 8196 CC IOM - 9/03 5. Tighten the set screws in the seal locking ring to secure the seal to the shaft 6. Remove the centering clips from the al Conventional Inside Component Mechanical Seal: 1. Assemble the seal chamber per the instructions in Section 6 - Disassembly & Heassembly. 2. Apply bluing to the shaft/sleeve at the face of the seal chamber. 3. Continue the complete rea less the mechanical seal sembly of the pump, 4. Set the impeller clearance per the instructions in Section 5 - Operation, 5. Scribe a line on the blued shaftisleeve at the face of the seal chamber. 6. Remove the casing, impeller, and seal chamber per the instructions in Section 6 - Disassembly & Reassembly. 7. Slide the gland (with the stationary seat and gland, gasket installed) onto the shaft until it contacts the inboard labyrinth oil seal, 23Serie Temperature 3136 Lesa ovata a8 sm wrx | — wun) srxwrxcnx| speuocrxxcrx| —stxurx indies | men [tates | rm | tchos | mm Pines | mm | betes | mm | hes | nm 201 iw cawewryl om | o18 | oom [om | ots | ose | 0's | om | ove | 152 | cow | ome Upto gore) Poors | 01s [ooue [o20| oor [ose | cow [os | oo [1a | oots | oss Upioz00F 2c) o0rs | a1 [oone | 020 | oo1s | 038 | cors | oa | ome | 152 | oois | cas uptozsor tare) [oor [ are [oo | 02s | oor [oar cow [oa | oo [1s | oot | ct Table 1 Impeller Clearances Cold Temperaiure Clearances for Various Service Temperatures, inches (mm) "For Model CV3196, clearance is set from the back of the impeller to the stuffing box cover / seal chamber / backplate. 8 10. " Install the mechanical seal rotary unit per the manufacturer's instructions using the scribed line and the seal reference dimension. Reassemble the seal chamber per the instructions in Section 6 - Disassembly & Reassembly. Slide the gland on the seal chamber studs and secure with the gland nuts. Be sure to tighten the ruts evenly such that the gland is seated on the seal chamber pilot and is perpendicular to the shaft. Complete the reassembly of the pump per the instructions in Section 6 - Dissassembly & Reassemby. Genventional Outside Component Mechanical eal: 1 ‘Assemble the seal chamber per t1e instructions in Section 6 - Disassembly & Reassembly. ‘Apply bluing to the shaftsleeve at the face of the seal chamber. Continue the complete reassembly of the pump, less the mechanical seal. Set the impeller clearance per the instructions in Section 5- Operation. Seribe a line on the blued shatt/sleeve at the face of the seal chamber. Remove the casing, impeller, anc seal chamber per the instructions in Section 6 - Disassembly & Reassembly. Install the mechanical seal rotary unit per the manufacturer's instructions using the scribed line and the seal reference dimension. Be sure to secure the rotary unit in place using the set screws in the locking ring, Install the gland (with the stationary seat and 24 gland gaskets installed) on the seal chamber. 9. Reassemble the seal chamber per the instructions in Section 6 - Disassembly & Reassembly. 10. Complete the reassembly of the pump per the instructions in Section 6 - Disassembly & Reassembly. Connection of Sealing Liquid: For satisfactory operation, there must be a liquid film between seal faves to lubricate them. Reter to the seal manufacturer's drawing for the location of the taps. Some methods ‘which may be used to flush/cool the seal are: a. Product Flushing - In this arrangement, the pumpage is piped from the casing (and cooled in an external heat exchanger, when required) then Injected into seal gland. b. External Flush - A clean, cool compatible liquid is injected from an outside source directly into the seal gland. The flushing liquid must be at a pressure of 5-15 psi (0.95-1.01 kgicm*) greater than the seal chamber pressure. Injection rate should be }4-2 GPM (2-8 LPM). ©. Other methods may be used which make use of ‘multiple gland connections and/or seal chamber connections. Refer to the documentation supplied with the pump, mechanical seal reference drawing, and piping diagrams. Packed Stuffing Box Option: Models 3196 CC and CV 3196 CC pumps are shipped without packing, lantern ring or split gland installed. These are included with the box of fittings shipped with the pump and must be installed before start-up. 3196 CC IOM- 9/03Installation of Packing: 1. Carefully clean stuffing box bore. 2, Twist the packing just enough to getit around the shall (Figs. 18, 19) PACKING RINGS = () CORRE WRONG Fig. 18 ANTERN RINGS 0 QO WRONG Fig. 19 3. Insert packing, staggering the joints in each ring by 90°, 4, The stuffing box arrangement in order of installation is: 2 packing rings, lantern ring (two-piece), then 3 packing rings. A CAUTION Follow instructions to ensure the lantern ring is located at the flushing connection (Fig. 20). ‘Otherwise, no flush will be obtained. LANTERN RING ANTERN RING FLUSH CONNECTION GLAND ANONOGENG?) Fig. 20 5. Install the gland halves and evenly hand tighten the nuts. 8196 CC IOM - 9/03 Connection of Sealing Liquid: If the stuffing box pressure is above atmospheric pressure and the pumpage is clean, normal gland leakage of 40-60 drops per minute is usually sufficient to lubricate and cool the packing and sealing liquid is not required, NOTE: Otherwise, a product flush can be used if. clean pumpage exists. ‘An extemal sealing liquid is required when: 1. Abrasive particles in the pumpage could score shaft sleeve. 2. Stuffing box pressure is below atmospheric pressure due to the pump running with a suction lit, or when the suction source is under a vacuum. Under these conditions, packing will not be cooled and lubricated and air will be drawn into the pump. Ian outside source of clean compatible liquid is required, the pressure should be 15 psi (1.0 kg/cm?) above the suction pressure. The piping should be connected to the lantem ring connection with a 40-60 drops-per-minute leak rate NOTE: Most packing Failure to te pac life of the packing and, PRIMING PUMP. (3196 cc and cv 3196.c¢) Never start the pump until it has been properly primed. Several different methods of priming can be Used, depending upon type of installation and service involved. wires lubrication. ing may shorten the (pump. 25Suction Supply Above Pump 1. Slowly open the suction valve (Fig. 21) DISCHARGE SOLATION VALV CK VALVE SLETION ISOLATION VALVE Fig. 21 2. Open air vents on the suction and discharge piping until water flows out. 3. Close the vent valves. ‘Suction Supply Below Pump (Except 3796) A foot valve and outside source of liquid may be used to prime the pump. Outside source of liquid can come from a priming pump, pressurized discharge line, or other outside supply (Fig. 22 and 23). NOTE: Model 3796 is a self-priming pump and ‘does not require the use of a foot valve in the ‘suction line. Refer to the pump’s performance ‘curve to determine the time required for priming, 1. Close discharge valve and open air vents in casing. 2. Open valve in outside supply line until only liquid escapes from vent valves. 3. Close the vent valves and then the outside supply Tine, 26 PRIMING WITH FOOT VALVE AND OUTSIDE SUPPLY DISCHARGE ISOLATION VALVE _> SHUTOFF VALW FROM OUTSIDE SUPPLY FOOT VALVE Fig. 22 PRIMING WITH FOOT VALVE Via BY-PASS AROUND CHECK VALVE DISCHARGE ‘ATION _—- BY-PASS LINE VES I[_—shuTOFE vaive A CHECK WALYE FOOT VALVE Fig. 23 3196 CC IOM- 9/033796 PRIMING IN A PRESSURIZED SYSTEM BYPASS Line CCENTRIC Fig. 24 ‘Suction Supply Below Pump - 3796 NOTE!) The 3796 16/4 seit-priming pump and does not require manual priming prior to start-up (except for the initial charge). However, ina pressurized system, the pump requires an {air vent or a permanent bypass line in the ‘discharge piping to vent the evaucated alr. Other Methods of Priming: 1. Priming by Ejector. 2. Priming by Automatic Priming Pump. START-UP PRECAUTIONS i All equipment and personal safety related devices and controls must be installed and operating properly. To prevent premature pump failure at initial start-up due to dirt or debris in the pipe system, ensure the pump can be run continuously at full speed and flow for 2 to 3 hours. Variable speed drivers should be brought to rated speed as quickly as possible, 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, tuncouple the unit and refer to driver ‘manufacturer's instructions for assistance. Running a new or rebuilt pump at slow speeds ‘may not provide enough flow to adequately flush ‘and cool the stuffing box bushing’s close running surfaces. Pumpage temperatures in excess of 200° F (93° C) will require warm-up of pump prior to operation. Circulate a small amount of pumpage through the pump until the casing temperature is within 100° F (88° C) of the pumpage temperature and evenly heated NOTE: Warm-up rate should not exceed 1,4°C (25° F) per minute. 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 Diver bey CAUTION observe pressure If ovate ine artladlermptio restart 8196 CC IOM - 9/03 4 Slowly open discharge valve until the desired flow is obtained A CAUTION ‘Observe pump for vibration levels, bearing temperature and excessive noise. if normal levels are exceeded, shut down and resolve, 27OPERATION GENERAL CONSIDERATIONS ‘Aiways vary capacity with regulating valve in the ais- ccharge line. NEVER throttle flow from the suction side. Driver may overtoad if the pumpage specific gravity (density) is greater than originally assumed, or the rated flow rate is exceeded. Always operate the pump at or near the rated conditions to prevent damage resulting from cavitation or recirculation, OPERATING AT REDUCED CAPACITY DO NOT operate pump below minimum rated flows or with suction and/or 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. Damage occurs from: 1. Increased vibration levels - Affects bearings, stuffing box or seal chamber, and mechanical seal. 2. Increased radial loads - Stresses on shaft and bearings. 3. Heat build up - Vaporization causing rotating parts to score or soize. 4. Cavitation - Damage to internal surfaces of pump. OPERATING UNDER FREEZING CONDITIONS Exposure to freezing conditions, while pump is idle, could cause liquid to freeze and damage the pump, Liquid inside pump should be drained. Liquid inside cooling coils, it suppliad, should also be drained. SHUTDOWN 1. Slowly close discharge valve. 2. Shut down and lock driver to prevent accidental rotation 28 When Be worn. itpump is being drait handling hazardous and/or toxic fluids, nal protective ee must be physi to prevent, a ae eee ae ‘Sontonnence with applicable environmental 3196 CC IOM- 9/03PREVENTIVE MAINTENANCE GENERAL COMMENTS. ....... MAINTENANCE SCHEDULE. MAINTENANCE OF SHAFT SEALS ...... . Mechanical Seals. . . Packed Stuffing Box IMPELLER CLEARANCE SETTING Feeler Gauge Method TROUBLESHOOTING 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, this will help pinpoint potential causes of problems. MAINTENANCE SCHEDULE ROUTINE MAINTENANCE © Seal monitoring © Vioration analysis © Discharge pressure © Temperature monitoring ROUTINE INSPECTIONS © Check for unusual noise and vibration. © Inspect pump and piping for leaks. © Check seal chamber/stutfing box leakage. — Mechanical Seal: Should be no leakage. — Packing: Excessive leakage requires adjustment or possible packing replacement. Refer to Section 5 - Operation or packing gland adjustment. 3196 CC IOM - 9/03, 3 MONTH INSPECTIONS ‘© Check the foundation and the hold-down bolts for tightness, ‘© If the pump has been left idle, check the packing Replace if required ANNUAL INSPECTIONS ‘@ Check the pump capacity, pressure and power. If ump performance does not satisfy your process requirements, and the process requirements have not changed, the pump should be disassembled, inspected, and worn parts should be replaced. Otherwise, a system inspection should be done. 29MAINTENANCE OF SHAFT SEALS MECHANICAL SEALS When mechanical seals are furnished, a manufacturer's reference drawing is supplied with the data package. This drawing should be kept for future use when performing maintenance and adjusting the seal, The seal drawing will also spect required flush liquid and attachment points. The seal and all flush piping must be checked and installed as needed prior to starting the pump. ‘The ite of a mechanical seal depends on various factors such as cleanliness of the liquid handled and its lubricating properties. Due to the diversity of operating conditions itis, however, not possible to give definite indications as to its life. Naver operate the pump without liquid supplied fo mechanical sea. Running a mechanical seal dry, even for a few seconds, can cause seal ‘and must be avoided. Physical injury an occur if mechanical seal fails. PACKED STUFFING BOX ‘Lock out driver power to prevent accidental ‘Startup and physical inury. ‘The stuffing box is not packed at the factory and must be packed property before operation of the pump. The packing is furnished in a box of fitings which accompany the pump. The packing used must be suitable for the pumpage. Make sure the stuffing box is clean. Examine shaf-sleeve for wear or scoring, replace if necessary. Starting from the innermost ring, the packing is usually arranged as two packing rings, lantern ring, three packing rings, followed by the split gland. Insert single packing rings by twisting as shown in Fig. 18. Press each ring to ensure proper compression in the stuffing box. Stagger joints 90°. Lightly and evenly tighten the gland. Excessive tightening will result in premature failure of the packing and shaft sleeve. After packing, it must be possible to rotate shaft by hand. Final adjustment of packing gland is made after pump is started. IMPELLER CLEARANCE SETTING Lock out driver power to prevent accidental ‘startup and physical injary. ‘A-change in pump performance may be noted over time by a drop in head or flow or an increase in power required. Performance can usually be renewed by adjusting the impeller clearance. FEELER GAUGE METHOD (all but CV) 1. If shims are already installed, loosen motor lock bolts (3708) and remove shims. 2. Loosen the jacking bolts (370D) and back out about four tums. 3. Begin tightening the motor lock bolts (3708) evenly, drawing the motor (338) towards the pump until the impeller contacts the casing. Turn shaft to ensure contact is made 4, Use a feeler gauge to measure the gap between the motor face and the frame adapter (Fig, 25). 30 3196 CC IOM - 9/03,5. Add to this measurement the impeller clearance required from Table 2. Select four (4) sets of shim(s) (3298) equal to this thickness. NOTE: In some cases, finding an exact match may not be possible. in this case, select the next closest size greater. 6. Loosen the motor locking bolts (3708). Using the jacking bolts (370D) back the motor (338) away from the pump until enough space is available to insert the shim(s) (3298). 7. Insert the shim(s) (3298) around the motor locking bolts (Fig. 28). 8. Loosen the jacking bolts (3700), 9. Tighten the motor (338) locking bolts securely. 10. Check shaft for free turning, FEELER GAUGE METHOD (CV) 1. Loosen the motor locking bolts (370B) 2. Begin tightening the jacking bolts (370D) evenly, pushing the motor (338) away from the pump until the impeller contacts the cover. Turn shaft to ensure contact is made. 3. Use a feeler gauge to measure the gap between the motor (338) face and the frame adapter (See Fig. 27), 4, Subtract from this measurement the impeller Clearance required from Table 2. 5. Select four (4) sets of shim(s) (3298) equal to this thickness. NOTE: in some cases, finding an exact match ‘may fot be possible. in this case, select the ‘next closest size greater.) 6. Loosen the jacking bolts (370D). Tighten motor locking bolts (3708) securely. 7. Check shaft for free turning, 3196 CC IOM - 8/03, Fig. 26 Fig. 27 31Table 2 Impeller Clearances Cold Tempera Clearance for Various Sere Temperature, ches (nm) Le96 vate a8 servo | six wrx | srxwmocrxxcrx | — stewie ence Temperature intes_[ mm | intes |-mm_| ices | mm [ines |r BOW IST Z51965°) dots [oss oor [cas | oos | tse | cos | aos UpioT5°F(9°C) 015 [oa f 0015 | ove | oo | ts2 | aots | o08 Up io 20°F (3°) oors [03s f 001s | cas | ons | 1se_| cots | aos ors [oat f 0016 [oat | oos [ts] oo%6 [oat "For Model CV3196, clearance is set from the back of the impeller to the stuffing box cover / seal chamber / backplate. 32 3196 CC IOM - 9/03TROUBLESHOOTING Problem No liquid delivered. Probable Cause Remedy Pum not primed, Raia pnp cinch pay eos ‘Susion line dogged Remove obstructions. Impeller cogged wih foreign material Back fush pump to clean impel. Wrong cretion of rotation ‘Change rotation to concur wih dretion Indicated by arrow on bearing housing o* pump casing. Foot valve or sucton pipe opening not CConsut factory for xoper depth, Use bal to submerged enounh. eliminate voices ‘Suction lito high. ‘Shorten suction pipe No liquid delivered ($796) Vent ine not connected. Pipe in ventne to expel at. ‘Aileak tu gaat. Replace gasket ‘Airleak iu sting box Repiaoe or reads packingimechanical sea. Impolr party dogged ‘Back fush pump to clean impeller. Pump not producing rated flow or head. | Excessive imoel-o-casng clearance. Adjust impel dearance. Ensure that suction ne shutoff valve i fl Insufcint suction nea. Ee att yopen ‘Worn or broken ingle. Inspect and epiace i necessary. Improperly primed pump. Reprime pump. Pump starts then stops pumping Pump is noisy or vibrates. ‘Ait or vapor pockets in suction ine. Rearrange piping lo eliminate ar pockets ‘Aileakinsueton ine Repair (pg) leak Improger pumplfiveralgament ‘Align shat, Paty clogged impeler causing imbalance Backsush pumo to clean imple. Broken or bent impo or shat. Replace as required, Foundation not ii Tighten bold down ols of pump and motor or adjust its Worn bearings. Replace. ‘Suction or discharge pining not anchored of properly supported “Anchor por Hydraulic Institute Standards Manual rogommendatons Pumpiscavtating, Locate and coect system problem Peeking land impopey asta Then gand ats ‘Suing boximoropery packed Check packing and repack Bx Excessive leakage fom stuting box. [Vor mecrancal stl pars. Replace wom pars. Overeating mechanical ea Check ubicaton and coaig nes Shot sloove sored Renacine or replace as equited Const ate. Install vate, Head ner thanaing. Pups to muchiqu. | Conga. tal seas excessive power igi savor an expected Check speci gray and visensy Motor roa Powe ‘Suiting box packing 0 tight Readjst packing. Replace if wom tat prstid Check interal wearing pats for proper 3196 CC IOM - 9/03, earances, 33,34 3196 CC IOM - 9/03,DISASSEMBLY & REASSEMBL REQUIRED TOOLS . DISASSEMBLY . . - INSPECTIONS. . . - REASSEMBLY . . REQUIRED TOOLS # Wrenches « Dial Indicator ‘© Cleaning Agents 1 Scrowdriver f¢ Torque Wrench with Sockets « Foelor Gauges « iting Sing ‘ Allen Wrenches « Leveling Blocks ‘© Rubber Mallet ‘© Micrometer DISASSEMBLY Ea 4. Shut off all valves controlling flow to and from pump. methods of iting must be em 2 ting ue be employed fo nd 10 avoid physical injury and/or equipment Side tod shoes met bo worn etal ties, ‘Precautions to prevent physical injury. Operator must be aware of pumpage and safety 2. Drain liquid from piping, flush pump if necessary. fds Be [Celene eearnant ‘Allow all gystem and ts to cool ‘Proper personal protective equipment Wall syst pump component should be worn. Precautions must be taken to before handling them to prevent physical injury. prevent physical injury. Pumpage must be i Pandlod ard Glepeced of conformance win —— & D®e0NNectall auxiliary piping and tubing ‘environmental regulations. ‘NOTE: Before disassembling tho pump for ‘overhaul, ensure all replacement parts are available. ee prevent accl 'slartup and physical injury. 3196 CC IOM - 9/03 354, Plage siing from hoist through frame adapter (108) of frame and around bottom of mator (Fig. 28). oy Fig. 28 5. Remove motor foot hold down bolts (Fig. 28). 6. Remove casing bolts (370) (Fig. 28). ‘Never apply heat to remove parts. Use of heat may cause an explosion due to trapped fluid, tesulting in severe physical injury and property damage. 7. Remove back pull-out assembly from casing (100). Tighten jack screws evenly to remove back pull-out assembly. NOTE: i aaa ase woee racine to NOTE: Remove and then mark shims from under motor foot, Save for reassembly. ‘Never remove the back pull-out assembly unassisted, physical Injury can occur. 8. Remove casing gasket (361) and discard, (Replace ‘with new gasket during reassembly.) 9. Remove jack scrows (418). NOTE! Casing gasket (351) may Toning aut binders snc athealves inthe” ‘Geskat aerial Goan ail gasket surfaces. 40. Move back pull-out assembly to clean workbench, 11. Support frame adapter (108) securely to workbench. 36 REMOVAL OF IMPELLER tere eee ee fluid, resi in severe physical vane and property Inpoltors (on) ee ohorp edges may cause Physical injury. STX, MTX, & LTX 1. Remove impeller anti-rotation nut (458) from front of impeller. (This part will need to be replaced for proper sealing) (See Fig. 29). Fig. 29 2. Spray penetrating oll through the plug hole into the cavity at the ond of the shaft. Wait 15 minutes. Rotate the shalt several times while waiting to distribute the oil. 3196 CC IOM - 9/033. Slide wrench over the shaft at location of flats (Fig. 30), — 4, Rotate the impeller clockwise (viewed from the impeller end of the shaft) raising the wrench, 5. Quickly turn the impeller counterclockwise (viewed from the impeller end of the shaft), impacting the wrench handle until the impeller loosens (Fig. 30) 6. Romove impeller O-ring (412A) and discard. Replace with a new o-ring during reassembly (Figs. 31 and 32). ; NOTE: itis recommended thatthe motor foot Fig. 90 to the workbench when using this ae eee REMOVAL OF SEAL CHAMBER COVER (MECHANICAL SEAL) 4. Remove gland stud nuts (355). 2. Remove seal chamber stud nuts (70H). 8. Remove seal chamber (184). (Fig. 83) 3196 CC 3796 CC Fig. 31 4, Remove shatt sleeve (126), if used \ NOTE: Mechanical seal is attached to sleeve cv 3196 cc AIDA Fig. 32 (125). Rotary portion of seal needs to be 2k ‘femoved from sleeve by loosening set screws and sliding it off the sleeve. Refer to ‘Seal instructions, 3196 CC IOM - 9/03 375, Remove gland (250) with stationary seat and O-ring (860) (Fig. 34). NOTE: Be careful not to the stationary portion of the mechanical seal. itis seated in the gland bore, Fig. 34 REMOVAL OF STUFFING BOXCOVER (PACKED BOX) 1, Remove gland stud nuts (355), and gland (107). 2. Remove stuffing box cover stud ruts (370H). 3. Remove stuffing box cover (184). (Fig. 35). Fig. 36 5. Remove packing (106) and lantem ring (105) from stuffing box cover (184) (Fig. 37). No lantern ring is provided with sol-lubricating graphite packing. 4, Remove shaft sloove (126) (Fig. 96). 38 3196 CC IOM - 9/03REMOVE FRAME ADAPTER 1. Remove motor lock bolts (3708) and shims. 2. Carefully, remove frame adapter (108) (Fig. 38). Fig. 38 Frame (108) is heavy. Use, iftir (108) is heavy. Use proper lifting when ing. REMOVE INBOARD LABYRINTH OIL SEAL (333A) 1 Itis an O-ring fit into the bearing frame (228A) for STX, frame adapter (108) for MTX, LTX, XLT-X and X17. Remove O-rings (497H), (4974) if necessary (Fig. 39). NOTE: Labyrinth olf seal O-rings (497H, J) are iad maintenance Kiso can bo i part of 31: INSPECTIONS The pump parts must be inspected to the following criteria before they are reassembled to insure the pump will run properly. Any part not meeting the required criteria should be replaced. NOTE: Clean parts in solvent to remove oil, ‘grease or dirt. Protect machined surfaces ‘Against damage during cleaning. Casing The casing (100) should be inspected for cracks and excessive wear or piting. It should be repaired ‘or replaced if it exceeds the following criteria (Fig. 40, 41 & 42) 1. Localized wear or grooving greater than 1/8 in (32 mm) deep. 2. Pitting greater than 1/8 in. (3.2 mm) deep. 3. Inspect case gasket seat surface for irregularities. 3196 CC IOM - 9/03 3196 Fig. 40 39evates Fig. 41 3196 3796 c 3796 Fig. 42 2 Impeller 1. Inspect impelier (101) vanes for camage. Replace b if grooved deeper that 1/16 in. (1.6 mm) or if worn, evenly more than 1/92 in. (0.8 mm) (Area “a"in Fig. 43), c 2. Inspect pumpout vanes for damage. Replace if wor more than 1/32 in. (0.8 mm). (Area "b” in Fig, 43 & 44) 3. Inspect leading and trailing edges ofthe vanes for cracks, pitting, and erosion or corsion damage. — ol (Area “c” in Fig. 43 & 44) ( cvaies Fig. 44 40 (NOTE: For CV 3196 impeller, the face of the i is cast, not machined. The face runout need not be checked. 3196 CC IOM - 9/03Seal Chamber/Stuffing Box Cover 1. Make sure seal chamber/stuffing box cover (184) gasket surface is clean at adapter face (Figs. 45, 46, 47), 2. Replace if there is any pitting or var greater than 118 in, (3.2 mm) deep. BigBore™ Chamber Fig. 45 184 TaperBore™ PLUS Fig. 46, 3196 CC IOM - 9/03 Frame Adapter 1. Check frame adapter (108) for cracks or excessive corrosion damage. Replace if any of these conditions exist (Fig. 43). 2. Make sure gasket surface is clean. AIREASSEMBLY Refer to Table 3 for torque values while reassembling pump. Table 3 Maximum Torque Values in ft.-Ib. (Nm) for Casing Bolts (370) (Values are in inch-Lbs (Nm) ‘Model HT 3196, Models 3196, CV 3196 LF 3196, 3796 and all Models with 150 Ib. Casing flanges ‘with 300 Ib. Casing flanges. Material Specification Alloy Casing with (3048S) F593 Grade 1 or Ductile tron and Alloy Ductile ron Casing with A | (316SS F593) Grade 2 | Casings with A193 grade 307 Grade B casing bolts casing bolts BY casing bolts Casing Bott Frame [Diameter (in)| Lube Dry Lube Dry Lube Dry esx | im 20 wat) | 9547 (73) 073) | orc) etx Tx 58° 36083) 392 | 7tt@6) | tors) | 115 (186) | 173,235) ux XUTX xi sepe,_| wows | var9n | iain [so ea | aos erp Noiort-Adeoier | — Fae ETE) oer) 3040) = = 1. Insert jacking bolts (3700). 2. Install frame adapter (108) onto motor . Align bolt holes with those on frame (Fig. 48). 3. Install motor locking bolts (370B). Hand tighten bolts with a wrench. A CAUTION Fig. 48 42 ‘To not evertighten at this point! 4. Check adapter fits. Rotate shaft through 360°. If total indicator reading is greater than 0.005 in (0.13 mm), determine the cause and correct before proceeding (Fig. 49). Fig. 49 3196 CC IOM- 9/035. Install inboard tabyrinth oil seal (633A) into adapter (108) / bearing frame (228). It is an O-ring fit. Position the labyrinth seal drain slots at the bottom (6 o'clock) position. (Fig. 50). NOTE: For detailed labyrinth sea! instalation iructions, see Appendix |, Labyri Installation Instructions. A Tw ) s}) NH FZ O. MTXILTX XLT-X, X17 Fig. 50 1. Install seal chamber cover or backplate (184) with nuts (870H) Fig. 51). 8196 CC IOM - 9/03 2. Check seal chamber cover run-out. Rotate Indicator through 360 degrees. If total indicator reading is greater than 0.005 in. (.13 mm), determine cause and correct before proceeding (Fig. 52). Fig. 52 3. Install shatt sleeve (126) if used (Fig. 53 & 54). NOTE: Make sure sleeve is fully seated. Wear a heavy set of work gloves when handling ‘impeller (101) as sharp edges may cause physical injury. 4. STX, MTX, LTX - Install impeller (101) with O-ring (Fig. 53 & 54). 43cv 3196 Fig. 54 5. Put wrench on shaft to stop rotation. When impeller (101) makes firm contact with sleeve (126), turn the wrench counterclockwise (viewed from impeller end of shaft) and slam it down. A few sharp raps will tighten impeller (101) properly Fig. 55). Fig. 85 6. Check impeller (101) runout. Check vane tip to vane tip. If total indicator reading is greater than 0.008 in, (18 mm), determine cause and correct before proceeding (Fig. 56) Fig. 86 44 NOTE: |The face of the CV 3196 CC impeller is ‘not machined. Checking the face runout on the €V.3196 CC impeller is not required, Pumps with Mechanical Seals 7. For pumps with non-cartridge mechanical seals, it is necessary to temporarily install spacer shims (8298) before scribing shaft sleeve. 8. To do this, measure the gap between the face of the seal chamber (184) and the back of the impeller pumpout vanes (101) (Fig. 56).. 9. Take the measurement just attained and subtract 0.030 in. (0.76mm) from it. Select shim(s) equal to or next greater to this number. 10. The goal is to have a gap of "as close to" 0.030 (0.76 mm) as possible between the seal chamber and back of the impeller pumpout vanes. 11. Blue the shaft sleeve (126) or shaft (122) if no sleeve is used. Scribe a mark at gland gasket face of seal chamberistulfing box cover (184). This will be the datum for installation of ‘mechanical seal (Fig. 87) NOTE: if installing a cartridge mechanical seal, the shaft or sleeve does not need to be marked, The seal is self setting. 3196 CC IOM- 9/0312. Remove impellor (101), and shaft sleeve (126) it used (Fig. 58) Fig. 58 13. Remove the seal chamber cover or the backplate Fig. 59). For inside mounted seals: 7. Install stationary seat into gland (107) per seal manufacturer's instructions, 8. Slide gland (107) with stationary seat over shat, Up to adapter face (Fig. 60). 8196 CC IOM - 9/03 9. Install mechanical seal on shaft (122) or shaft sleeve (126) per seal manufacturer's instructions. Install shaft sleeve (126) if used (with seal). NOTE: Anti-galling compound can be applied to the sleeve bore to aid in disassembly. 10. Install seal chamber cover (184) with nuts (370H) (Fig. 61). Wear a heavy set of work gloves when handling ‘may cause 1 11. Install impeller (101) with new O-ring (412A), Put wrench on shaft. When impeller (101) makes firm contact with sleove (126), raise shaft wrench (counterclockwise when viewed from impeller end of shaft) and slam it down (clockwise when viewed from impeller end of shaft). A few sharp raps will tighten impeller (101) properly (Fig. 62). Fig. 62 4512. Install Impeller anti-rotation device (488Y) making sure the O-ring (428D) is in good condition. Replace if needed (Fig. 63). NOTE! |Be'siire to Use! a properly balanced impeller. Nasey Fig. 63 13, Install gland (107) with nuts (355) (Fig. 64). 10. Install the impeller (101) with a now O-ring (412A). Put the wrench and on the shaft. When. the impeller makes firm contact with the sloove, raise the shaft wrench (counterclockwise when viewed from the impaller end of the shaft) and slam it down (clockwise when viewed from the impeller end of the shatt). A few sharp raps will tighten the impoller properly (Fig. 67). Fig. 64 For outside mounted seals: f ~ 7. Install the mechanical seal on the shaft (122) or sleeve, if used (126) per the seal manufacturer's instructions. Install the sleeve with the seal, it used. 8. Slide gland and then stationary seat, with gaskets, on the shaft or sleeve (Fig. 65). a 9. Install the seal chamber or backplate (184) with Fig. 67 hex nuts (370H). Be sure that the gland studs line up with the holes in the gland (Fig. 66) NOTE! Be Sire 1 Use @ properly balanced’ 46 3196 CC IOM- 9/0311, Install Impeller anti-rotation device (488Y) making sure the O-ring (428D) is in good condition. Replace if needed (Fig. 68). NOTE! |Be'siire to Use! a properly balanced impeller. Fig. 68 12. Install the gland (107) with hex nuts (355). Pumps With Packing: 7. Install stuffing box cover (184) with nuts (370H) (Fig 69), 8. Install shalt sleeve (126) (Fig. 70), NOTE: Anti-gailing compound can be applied to ‘disassembly. the sieeve bore to aid in. NOTE: Make sure siéeve is fully seated. Wear a heal impeller (1 set of work gloves when handling 1) as sharp ‘may cause injury. 9. Install impeller (101) with O-ring (412A). Put shaft wrench shaft. When impeller (101) makes firm contact with sleeve (126), raise shaft wrench (counterclockwise when viewed from impeller end of shaft) and slam it down (clockwise when viewed from impeller end of shat), A few sharp raps wil tighten impollor properly (Fig. 71). 8196 CC IOM - 9/03 Fig. 71 10. Install Impeller anti-rotation device (458Y) making ssure the O-ring (428D) is in good condition. Replace if needed (Fig. 72). NOTE! Be Sire 16 Use @ properly balanced’ Fig. 72 NOTE: The face of the CV 3196 impeller is not machined. Checking the face runout on the inaliioe is not required. |. Install packing and gland according to Section 4, Operation. 47ALL MODELS STX, MTX, LTX, XLT-X, X17 Reinstall Back Pull-Out Assembly 3. Install casing bolts (370), finger tight. Casing bolts (870) may be coated with anti-galling compound to aid disassembly. Tighten the casing bolts per Back pull-out assembly ‘more than 50 Table 3 torque values. Install casing jack screws St (418), snug tight (Fig. 72) Injury may occur, 1. Clan casing tt anc instal casing geskct 51) in [_dM CAUTION place on seal chamber/stufing box cover. ‘De not overtighten casing jack screws (478), 2. Install back pull-out assembly in casing (Fig. 73). 4+ Replace shims under motor frame foot and tighten frame foot to baseplate. To insure that the 1 proper shim is used, a cial indicator should be ‘mounted to measure distance between top of frame and baseplate. This distance should not change as frame foot bolting is tightened. ~ 5. Replace auxiliary piping at this time. ~~ | Impeller Adjustment Once the pump has been re-assembled, it is. important to perform the correct impollor adjustment prior to start-up. — 1. Rofer to Section 5 - Impeller Clearance Setting for the proper procedure, Fig. 73 ASSEMBLY TROUBLESHOOTING ‘Symptom Cause Remedy ‘Sleeve wom Replace Excessive shafsleeve runout ‘Sha bent Replace CCorsion Replace Excessive frame adapter runout ‘Adapter to rame gasket nt seated propery, | Reseal ‘Seal chamverstitfing box cover not property| peseat Excossvesealchamberisufing box cover | sealed in fame adapta. runout CCoreson or wear Replace Excessive impeller vane tip runout Bent vanes) Replace impel, 48 3196 CC IOM- 9/03This Page Intentionally Left Blank 8196 CC IOM - 9/03 49MATERIAL CROSS REFERENCE CHART Goulds Pumps Materi Material Code ASTM, DIN Iso is aston 1001 AB.GLASS 20, Ductile ron 1012 A395 6160-40-18 Ductile ron 1013 A586 Gr60-42-10 ‘CDAMCu 4081 |AT44 CDAMCU Monel 1119 As94 GAMNSE-1 3168S 1208 ATA CFM 1808 (G51 (S514) ‘Aly 20 1204 ATAACN-TM 1.4500 31788 1209 AT4sCG-8M 14448 Hastloy C 1215 Aso4 cw6M ‘ODAC 1216 ATAACD4MCU 9.4460 HasleioyB 27 AGO NTH Titanium 1220 B67 Gros Nickel 1601 A494 GrCZ100, Monel 2150, B64 UNS No4d00 Nickel 2155) B60 UNS N02200 Titanium 2156 Bate Gro Carbon Stee! 2210, AN08Ge124 3048S 2008 A276 Type 304 31685 28 A2TE Type 316 oy 20 2030) 73 (NO8020) 31788 2032 ADT. 4150 Stee 2231 A822624160 4140 Stee! 2236 As34Ge6140 ‘Aloy B.2 27 8335 (NO665) ‘Ay C276 28 574 (N0276)| ‘GUP-2000 a8 NA PA Linod Stel aud NA PA Lined 3168S eat? NA PFA Lined Duct ron 9638 NA, Fasteners/Plugs Material Goulds Pumps Material Code ASTM “arbon Sioa 2210 ‘ABDICEE, Stainless Stoo! 2208 Fsaacrt 316 Stainless Stool 2229 50962 50 3196 CC IOM- 9/03PARTS LIST WITH MATERIALS OF CONSTRUCTION 8196 CC IOM - 9/03 ‘Material Code tem Part Description 3168S 100. Casing 1203, 401 Impeter 1203) 108 Frame Adapter 1013 184 ‘Cover. Sting Box (Packed Box) 1203) ‘eaht ‘Chamber Seal (Mechanical Seal) 1203) 250, Gland 1203, 3208 ‘Sh Pack 3215) 333A ‘Seal, Labyrinth (board 2 351 Gasket. Casing 5127, 363, Stud, Gland 2208 | 355, Nut, Gland Stud 2208 367K Nu, Stud Cover to Adapter 2228. 358 lug, Drain - Casing (Optional) 208 358A Plug, Pipe - Flush 2209 2600 Gasket, Gland 5108 370 ‘Seren, H. Cap Adapter o Casing 2028 3708 Screw, HH. Cap-AdapMotor 7228, 3700 ‘crow, HH. Cap-Adapt Motor Jacking 2008 70H, ‘Stud, Cover to Adapter 2208 4128, ‘O-Ring, Impeller 5350 18 ‘Seow, HH. Cap-4dapt.Case-Jackng 2228 49TH ‘O-Ring Seal Rotating 5304 497) (O-Ring Seal Stabonary 5304 549 Nameplate, Data — Nameplate, Logo — Bot Assem. (Ant-Rot 2229, 51Model 3196 Cross Sectional 52 fa) 9G) EHD 3196 CC IOM- 9/03Model CV 3196 Cross Sectional 8196 CC IOM - 9/03 53Model 3796 Cross Sectional aa a FRE bs 7 C7 tk | 3196 CC IOM- 9/03 54SPARE PART RECOMMENDED SPARE PARTS......-.....-0005 APPENDIX | - Labyrinth Seal Installation Instructions . . . . 55 tees 57 When ordering spare parts, always state Goulds Serial No. and indicate part name and item number from relevant sectional drawing. It is imperative for service reliability to have a sufficient stock of readily available spares. RECOMMENDED SPARE PARTS ‘© Impeller (101) Lanter Ring Half (105) (Packed Stutfing Box) © Shaft Sleeve (126), if applicable © Stuffing Box Packing (106) (Packed Stutfing Box), if applicable ‘© Casing Gasket (351) mp ‘© Packing Gland (107) (Packed Stuffing Box), if ‘@ Impeller O-Ring (412A) applicable ‘© Inboard Labyrinth Seal Rotary O-Ring (497H) ‘@ Impeller Gasket (428D) XLT-X & X17 ‘@ Inboard Labyrinth Seal Stationary O-Ring (497) ‘¢ Impeller Anti-Rotation Bolt ‘© Shim Packs (4) 8196 IOM - 9103, 5556 3196 IOM - 9/03,APPENDIX | Labyrinth Seal Installation Instructions Description of Operation The labyrinth oll seal serves two functions. The first being to exclude environmental contamination from the power-end. This is accomplished with a series of tight clearance fits between the stationary and rotor. ‘Any water that manages to enter the seal is eliminated from the seal through a drain slot located at the six o'clock position when installed, On the oil side, a series of oil grooves are present to direct any oil between the shaft and stationary back into the oil sump through a drain slot at the six o'clock position. Viton® O-rings are supplied as standard due to their chemical resistance. The stationary uses an O-ring to fit the labyrinth seal to the housing. The stator uses an O-ring to fit the labyrinth to the housing. The rotor uses an O-ring to seal along the shaft and to serve as the drive. Installation Procedures A CAUTION The Goulds labyrinth oil seal is @ one piece assembly. Do not attempt fo separate the rotor ‘and stator. Damage to the seal may result. 1, Assemble the power end per the instructions in Section 6 - Disassembly & Reassembly. A CAUTION The edges lth Koyway can be shara, allure fo cover the keyway may result ia cut O-ring ned damaged sa 2. Wrap tape around the coupling end of the shaft to cover the key, NOTE: The sinooth surface of electrical tape provides an excellent surface to slide the rotor ‘Oring over. 8196 IOM - 9103, 3. Press the seal over the shaft into the thrust bearing housing or thrust bearing ond cover by hhand until the shoulder of the seal is seated against the housing/cover. NOTE: | An O4ring lubricant is not required, but ‘can be used if desired. If used, be sure the lubricant is compatible with the O-ring material ‘and plant standards. (Once the frame adapter is installed on the motor, press the seal over the shaft into the frame adapter by hand until the shoulder of the seal is seated against the adapter. NOTE:|/An|O:ring lubricant is not required) but an be used if desired. itused be sure the lubricant Is compatible wi ing materia ‘and plant standards. NOTE: |During start-up when the parts of the labyrinth oll seal establish a voluntary running ‘clearance, a small amount of wear is ‘experienced as the parts are in contact. This wear produces a carbon filled Tefion® residue, Visible at the outside diameter of the seal and at the drain slot. This is the result of the two ‘surfaces being smoothed, similar to burnish- ing. A lubricant should not be applied between the faces at installation. Once the running ‘clearance has been established, no further wear is experienced and no decrease in seal performance occurs as a result of the carbon/ Teflon” residue. 57HOW TO ORDER When ordering parts call 1-800-446-8537 or your local Goulds Representative EMERGENCY SERVICE Emergency parts service is available 24 hours/day, 365 days/year... Call 1-800-446-8537 ‘© coprtight 2008 Goulds Pumps, Incoporated Form No, [318600 - 6.08 ‘a subsciay of ITT inauses, Inc.