Installation, Operation and Maintenance Instructions

Model 3355

FOREWORD
This manual provides instructions for the Installation, Operation, and Maintenance of the Goulds Model 3355. 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 is not 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 visiting our website at www.gouldspumps.com, contacting your local Goulds representative, or by calling 1-800-446-8537.

THIS MANUAL EXPLAINS

n Proper Installation n Start-up Procedures n Operation Procedures n Routine Maintenance n Pump Overhaul n Troubleshooting n Ordering Spare or Repair Parts

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TABLE OF CONTENTS
PAGE SECTION

SAFETY

1 2 3 4 5 6 7 8

GENERAL INFORMATION

13

INSTALLATION

19

OPERATION

23

PREVENTIVE MAINTENANCE

29

DISASSEMBLY & REASSEMBLY

47

SPARE PARTS

49

APPENDIX

49 51 53

I. Maximum Allowable Nozzleloads II. Recommended Minimum Flow / Acceptable Lubricants III.Torque Values

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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 safety warnings is mandatory to ensure personnel, property, and/or the environment will not be harmed. Adherence to these warnings alone, however, is not sufficient it is anticipated that the end user will also comply with industry and corporate safety standards. Identifying and eliminating unsafe installation, operating and maintenance practices is the responsibility of all individuals involved in the installation, operation, and maintenance of industrial equipment. Please take the time to review and understand the safe installation, operation, and maintenance guidelines outlined in this Pump Safety Manual and the Instruction, Operation, and Maintenance (IOM) manual. Current manuals are available at www.gouldspumps.com/literature_ioms.html or by contacting your nearest Goulds Pumps sales representative. These manuals must be read and understood before installation and start-up. For additional information, contact your nearest Goulds Pumps sales representative or visit our Web site at www.gouldspumps.com.

S-1

SAFETY WARNINGS
Specific to pumping equipment, significant risks bear reinforcement above and beyond normal safety precautions. WARNING A pump is a pressure vessel with rotating parts that can be hazardous. Any pressure vessel can explode, rupture, or discharge its contents if sufficiently over pressurized causing death, personal injury, property damage, and/or damage to the environment. All necessary measures must be taken to ensure over pressurization does not occur. WARNING Operation of any pumping system with a blocked suction and discharge must be avoided in all cases. Operation, even for a brief period under these conditions, can cause superheating of enclosed pumpage and result in a violent explosion. All necessary measures must be taken by the end user to ensure this condition is avoided. WARNING The pump may handle hazardous and/or toxic fluids. Care must be taken to identify the contents of the pump and eliminate the possibility of exposure, particularly if hazardous and/or toxic. Potential hazards include, but are not limited to, high temperature, flammable, acidic, caustic, explosive, and other risks. WARNING Pumping equipment Instruction, Operation, and Maintenance manuals clearly identify accepted methods 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. ITT Goulds Pumps will not accept responsibility for physical injury, damage, or delays caused by a failure to observe the instructions for installation, operation, and maintenance contained in this Pump Safety Manual or the current IOM available at www.gouldspumps.com/literature.

S-2

SAFETY
DEFINITIONS
Throughout this manual the words WARNING, CAUTION, ELECTRICAL, and ATEX are used to indicate where special operator attention is required. Observe all Cautions and Warnings highlighted in this Pump Safety Manual and the IOM provided with your equipment.

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Example: Pump shall never be operated without coupling guard installed correctly. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Example: Throttling flow from the suction side may cause cavitation and pump damage. ELECTRICAL HAZARD Indicates the possibility of electrical risks if directions are not followed. Example: Lock out driver power to prevent electric shock, accidental start-up, and physical injury.

When installed in potentially explosive atmospheres, the instructions that follow the Ex symbol must be followed. Personal injury and/or equipment damage may occur 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 representative before proceeding. Example: Improper impeller adjustment could cause contact between the rotating and stationary parts, resulting in a spark and heat generation.

S-3

GENERAL PRECAUTIONS
WARNING A pump is a pressure vessel with rotating parts that can be hazardous. Hazardous fluids may be contained by the pump including high temperature, flammable, acidic, caustic, explosive, and other risks. Operators and maintenance personnel must realize this and follow safety measures. Personal injuries will result if procedures outlined in this manual are not followed. ITT Goulds Pumps will not accept responsibility for physical injury, damage or delays caused by a failure to observe the instructions in this manual and the IOM provided with your equipment.

General Precautions
WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING NEVER APPLY HEAT TO REMOVE IMPELLER. It may explode due to trapped liquid. NEVER use heat to disassemble pump due to risk of explosion from tapped liquid. NEVER operate pump without coupling guard correctly installed. NEVER run pump below recommended minimum flow when dry, or without prime. ALWAYS lock out power to the driver before performing pump maintenance. NEVER operate pump without safety devices installed. NEVER operate pump with discharge valve closed. NEVER operate pump with suction valve closed. DO NOT change service application without approval of an authorized ITT Goulds Pumps representative. Safety Apparel: Insulated work gloves when handling hot bearings or using bearing heater Heavy work gloves when handling parts with sharp edges, especially impellers Safety glasses (with side shields) for eye protection Steel-toed shoes for foot protection when handling parts, heavy tools, etc. Other personal protective equipment to protect against hazardous/toxic fluids Receiving: Assembled pumping units and their components are heavy. Failure to properly lift and support equipment can result in serious physical injury and/or equipment damage. Lift equipment only at specifically identified lifting points or as instructed in the current IOM. Current manuals are available at www.gouldspumps.com/literature_ioms.html or from your local ITT Goulds Pumps sales representative. Note: Lifting devices (eyebolts, slings, spreaders, etc.) must be rated, selected, and used for the entire load being lifted. Alignment: Shaft alignment procedures must be followed to prevent catastrophic failure of drive components or unintended contact of rotating parts. Follow coupling manufacturers coupling installation and operation procedures.

WARNING

WARNING

WARNING

S-4

General Precautions
WARNING Before beginning any alignment procedure, make sure driver power is locked out. Failure to lock out driver power will result in serious physical injury. Piping: Never draw piping into place by forcing at the flanged connections of the pump. This may impose dangerous strains on the unit and cause misalignment between pump and driver. Pipe strain will adversely effect the operation of the pump resulting in physical injury and damage to the equipment. Flanged Connections: Use only fasteners of the proper size and material. Replace all corroded fasteners. Ensure all fasteners are properly tightened and there are no missing fasteners. Startup and Operation: When installing in a potentially explosive environment, please ensure that the motor is properly certified. Operating pump in reverse rotation may result in contact of metal parts, heat generation, and breach of containment. Lock out driver power to prevent accidental start-up and physical injury. The impeller clearance setting procedure must be followed. Improperly setting the clearance or not following any of the proper procedures can result in sparks, unexpected heat generation and equipment damage. If using a cartridge mechanical seal, the centering clips must be installed and set screws loosened prior to setting impeller clearance. Failure to do so could result in sparks, heat generation, and mechanical seal damage. The coupling used in an ATEX classified environment must be properly certified and must be constructed from a non-sparking material. Never operate a pump without coupling guard properly installed. Personal injury will occur if pump is run without coupling guard. Make sure to properly lubricate the bearings. Failure to do so may result in excess heat generation, sparks, and / or premature failure. The mechanical seal used in an ATEX classified environment must be properly certified. Prior to start up, ensure all points of potential leakage of process fluid to the work environment are closed. Never operate the pump without liquid supplied to mechanical seal. Running a mechanical seal dry, even for a few seconds, can cause seal damage and must be avoided. Physical injury can occur if mechanical seal fails. Never attempt to replace packing until the driver is properly locked out and the coupling spacer is removed. Dynamic seals are not allowed in an ATEX classified environment. 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.

CAUTION

WARNING WARNING WARNING

WARNING

WARNING WARNING WARNING

WARNING WARNING WARNING WARNING CAUTION

CAUTION WARNING WARNING WARNING

S-5

General Precautions
WARNING Ensure pump is isolated from system and pressure is relieved before disassembling pump, removing plugs, opening vent or drain valves, or disconnecting piping. 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. The pump may handle hazardous and/or toxic fluids. Observe proper decontamination procedures. Proper personal protective equipment should be worn. Precautions must be taken to prevent physical injury. Pumpage must be handled and disposed of in conformance with applicable environmental regulations. Operator must be aware of pumpage and safety precautions to prevent physical injury. Lock out driver power to prevent accidental startup and physical injury. Allow all system and pump components to cool before handling them to prevent physical injury. If pump is a Model NM3171, NM3196, 3198, 3298, V3298, SP3298, 4150, 4550, or 3107, there may be a risk of static electric discharge from plastic parts that are not properly grounded. If pumped fluid is non-conductive, pump should be drained and flushed with a conductive fluid under conditions that will not allow for a spark to be released to the atmosphere. Never apply heat to remove an impeller. The use of heat may cause an explosion due to trapped fluid, resulting in severe physical injury and property damage. Wear heavy work gloves when handling impellers as sharp edges may cause physical injury. Wear insulated gloves when using a bearing heater. Bearings will get hot and can cause physical injury.

WARNING

WARNING

WARNING WARNING CAUTION

CAUTION

WARNING CAUTION CAUTION

S-6

ATEX CONSIDERATIONS and INTENDED USE

Special care must be taken in potentially explosive environments to ensure that the equipment is properly maintained. This includes but is not limited to: 1. 2. 3. Monitoring the pump frame and liquid end temperature. Maintaining proper bearing lubrication. Ensuring that the pump is operated in the intended hydraulic range.

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

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

The CE and the Ex designate the ATEX compliance. The code directly below these symbols reads as follows:
II 2 G/D T4 = = = = Group 2 Category 2 Gas and Dust present Temperature class, can be T1 to T6 (see Table 1)

Table 1
Code T1 T2 T3 T4 T5 T6 Max permissible surface temperature o F (oC) 842 (450) 572 (300) 392 (200) 275 (135) 212 (100) 185 (85) Max permissible liquid temperature o F (oC) 700 (372) 530 (277) 350 (177) 235 (113) Option not available Option not available

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

S-7

PARTS
The use of genuine Goulds parts will provide the safest and most reliable operation of your pump. ITT Goulds Pumps ISO certification and quality control procedures ensure the parts are manufactured to the highest quality and safety levels. Please contact your local Goulds representative for details on genuine Goulds parts.

S-8

GENERAL INFORMATION
PUMP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 NAMEPLATE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 10 RECEIVING THE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Storage Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

PUMP DESCRIPTION
The Goulds Model 3355 is a radially-split, segmented casing, multi-stage pump designed with modular components. These identical components can be assembled to produce pumps of varying number of stages, hydraulics, materials, and configurations to meet specific requirements. Its multiple nozzle configurations allow the 3355 to adapt to multiple piping installations. Multiple hydraulics for each pump size optimize efficiency across a vast range of applications. RS - Radial Suction configuration (Fig. 1) features radial suction and discharge nozzles. Each nozzle can be positioned either vertically or horizontally at 90 to either side. This design consists of two robust bearing housings with traditional bearings and mechanical seals on each end of the pump. ES - End Suction configuration (Fig. 2) features an end suction nozzle in conjunction with a radial discharge nozzle. The radial discharge nozzle can be positioned either vertically or horizontally at 90 to either side. The suction end of the pump utilizes a product-lubricated bearing elminating the need for a second bearing housing and mechanical seal.

Fig. 1

Fig. 2

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NAMEPLATE INFORMATION
Every pump has a Goulds nameplate that provides information about the pump. The tag is located on the bearing frame. Bearing Frame Tag (Fig. 3) - provides information about the pumps hydraulic characteristics. Note the format of the pump size: Discharge x Suction - Nominal maximum Impeller Diameter in inches. When ordering spare parts you will need to identify pump model, size, serial number, and the item number of required parts. Information can be taken from the bearing frame tag. Item numbers can be found in this manual.

Fig. 3

10

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RECEIVING THE PUMP

Inspect the pump as soon as it is 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.

HANDLING
Pump and components are heavy. Failure to properly lift and support equipment could result in serious physical injury or damage to pumps. Steel toed shoes must be worn at all times. Use care when moving pumps. Lifting equipment must be able to adequately support the entire assembly. Refer to Fig. 4 for example of proper lifting techniques.

! s

WARNING

STORAGE REQUIREMENTS
Short Term: (Less than 6 months) Goulds normal packaging procedure is designed to protect the pump during shipping. Upon receipt, store in a covered and dry location. Long Term: (More than 6 months) Preservative treatment of bearings and 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. 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 not treated at the factory. This service can be supplied by contacting your local Goulds sales representative.

Fig. 4

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11

12

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INSTALLATION
BASEPLATE INSPECTION. . . . . . . SITE / FOUNDATION . . . . . . . . . . LEVEL BASEPLATE . . . . . . . . . . ALIGNMENT . . . . . . . . . . . . . . . Alignmnet Checks . . . . . . . . . . . Alignment Criteria . . . . . . . . . . . ALIGNMENT TROUBLESHOOTING . GROUT BASEPLATE . . . . . . . . . . Alignment Check . . . . . . . . . . . . PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 13 14 14 14 14 15 15 15 16

BASEPLATE INSPECTION
1. 2. Remove all equipment. Completely clean the underside of baseplate. It is sometimes necessary to coat the underside of the baseplate with an epoxy primer. This may have been purchased as an option.

SITE / FOUNDATION
A pump should be located near the supply of liquid and have adequate space for operation, maintenance, and inspection. Baseplate mounted pumps are normally grouted on a concrete foundation, which has been poured on a solid footing. The foundation must be able to absorb any vibration and to form a permanent, rigid support for the pumping unit. The location and size of the foundation bolts are shown on the outline assembly drawing, provided with the pump data package. 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, dirt, oil, chips, water, etc. and remove any contaminants. Do not use oil-based cleaners as grout will not bond to it. Prepare the foundation in accordance with the grout manufacturers recommendations. Fig. 6 Fig. 5

2.

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13

LEVEL BASEPLATE
1. Place two sets of wedges or shims on the foundation, one set on each side of every foundation bolt. The wedges should extend .75 in. (20mm) to 1.50 in. (40mm) above foundation, to allow for adequate grouting. This will provide even support for the baseplate once it is grouted. Remove water and/or debris from anchor bolt holes/sleeves prior to grouting. If the sleeve type bolts are being used, fill the sleeves with packing or rags to prevent grout from entering. 3. 4. Carefully lower baseplate onto foundation bolts. Level 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. Hand tighten the bolts.

2.

5.

ALIGNMENT
Before beginning any alignment procedure, make sure driver power is locked out. Failure to lock out driver power will result in serious physical injury. The points at which alignment is checked and adjusted are: Initial Alignment is done prior to operation when the pump and the driver are at ambient temperature. Final Alignment is done after operation when the pump and driver are at operating temperature. Alignment is achieved by adding or removing shims from under the feet of the driver and shifting equipment horizontally as needed. NOTE: Proper alignment is the responsibility of the installer and user of the unit. Accurate alignment of the equipment must be attained.

! s

WARNING

Final Alignment (Hot Alignment) After First Run - To obtain correct alignment when both pump and driver are at operating temperature. Thereafter, alignment should be checked periodically in accordance with plant operating procedures. NOTE: Alignment check must be made if process temperature changes, piping changes and or pump service is performed.

ALIGNMENT CRITERIA
Good alignment is achieved when the dial indicator readings as specified in the alignment procedure are: .002 in. (.05 mm) Total Indicated Reading (T.I.R.) or less when the pump and driver are at operating temperature (Final Alignment) .0005 in. per inch of dial indicator separation for the reverse dial indicator or laser method when the pump and driver are at operating temperature (Final Alignment).

ALIGNMENT CHECKS
Initial Alignment (Cold Alignment) Before Grouting Baseplate - To ensure alignment can be obtained. After Grouting Baseplate - To ensure no changes have occurred during grouting process. After Connecting Piping - To ensure pipe strains havent altered alignment. If changes have occurred, alter piping to remove pipe strains on pump flanges.

14

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ALIGNMENT TROUBLESHOOTING
Table 1
Problem
Cannot obtain horizontal (Side-to-Side) alignment, angular or parallel

Problem Cause
Driver feet bolt bound.

Remedy
Loosen pump hold down bolts and slide pump and driver until horizontal alignment is achieved. Determine which corner(s) of the baseplate are high or low and remove or add shims at the appropriate corner(s) and realign.

Baseplate not leveled properly, probably twisted.

GROUT BASEPLATE
1. Clean areas of baseplate that will contact grout. Do not use oil-based cleaners because grout will not bond to it. Refer to grout manufacturers instructions. Build dam around foundation. Thoroughly wet foundation (Fig. 7). 4. 5. Allow grout to set. Fill remainder of baseplate with grout. Remove air as before (Fig. 8).

2.

Fig. 8 6. Fig. 7 3. Pour grout through grout hole in baseplate, up to level of dam. Remove air bubbles from grout as it is poured by puddling, using a vibrator, or pumping the grout into place. Non-shrink grout is recommended. 7. Allow grout to set at least 48 hours. Tighten foundation bolts.

ALIGNMENT CHECK
Re-check alignment before continuing, using methods previously described.

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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. 6. 7. Carefully clean all pipe parts, valves and fittings, and pump branches prior to assembly. Additionally, a vent line makes it easier to de-aerate the pump before start-up (Fig. 9).

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. 2. 3. All piping must be supported independently of, and line up naturally with, the pump flanges. Piping runs should be as short as possible to minimize friction losses. DO NOT connect piping to pump until grout has hardened and pump and driver hold-down bolts have been tightened. It is 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. The piping should be arranged to allow pump flushing prior to removal of the unit on services handling corrosive liquids. 2.

! s

WARNING

SUCTION PIPING
NPSHA must always exceed NPSHR as shown on Goulds performance curves received with order. Reference Hydraulic Institute for NPSH and pipe friction values needed to evaluate suction piping. Properly 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. 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.

! s

WARNING

4.

5.

Fig. 9

16

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3.

Reducers should be eccentric at the pump suction flange with sloping side down and horizontal side at the top.

DISCHARGE PIPING
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 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. Increasers, if used, should be placed between pump and check valves. Cushioning devices should be used to protect the pump from surges and water hammer if quickclosing valves are installed in system. For operation at low flow or to insure liquid will always be flowing through the pump, a bypass line should be installed. If a bypass line is not used, it is recommended that precautions be taken to insure that the pump will not run dry or below minimum flow (see Appendix II).

! s
4. 5.

CAUTION

Pump must never be throttled on suction side. Suction strainers, when used, must have a net free area of at least three times the suction pipe area. Separate suction lines are recommended when more than one pump is operating from the same source of supply. 2. 3.

Suction Head / Flooded Suction Conditions 1. An isolation 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. Keep suction pipe free from air pockets. Piping should be level or slope gradually downward from the source of supply. No portion of the piping should extend below pump suction flange. The size of entrance from supply should be one or two sizes larger than the suction pipe. The suction pipe must be adequately submerged below the liquid surface to prevent vortices and air entrainment at the supply. 4.

2. 3. 4. 5. 6.

FINAL PIPING CHECK

After connecting the piping to pump: 1. Rotate shaft several times by hand 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.

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18

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OPERATION
PREPARATION FOR START-UP . . Checking Rotation . . . . . . . . . . Couple Pump and Driver . . . . . . . Lubricating Bearings . . . . . . . . . Priming Pump . . . . . . . . . . . . STARTING PUMP . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . General Considerations. . . . . . . . Operating at Reduced Capacity . . . Operating Under Freezing Conditions SHUTDOWN . . . . . . . . . . . . . . FINAL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 19 19 19 19 20 20 20 20 21 21 21

PREPARATION FOR START-UP

CHECKING ROTATION ! s CAUTION
Serious damage may result if pump is run in the wrong rotation. 1. Lock out power to driver. 2. Install coupling guard.

Never operate a pump without coupling guard properly installed. Personal injury may occur if pump is run without coupling guard.

! s

WARNING

Lock out driver power to prevent accidental start-up and physical injury. 2. Make sure coupling hubs are securely fastened to shafts. NOTE: Pump is shipped with coupling spacer removed. 3. 4. Unlock driver power. Make sure everyone is clear. Jog driver just long enough to determine direction of rotation. Rotation must correspond to arrow on pump. Lock out power to driver.

! s

WARNING

LUBRICATING BEARINGS
Grease Lubrication: Pumps are shipped with grease. See Preventive Maintenance section for lubrication recommendations.

! s

CAUTION

Operation of the unit without proper lubrication will cause bearing failure, and pump seizure.

PRIMING PUMP
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. Suction Supply Above Pump 1. Slowly open the suction valve. 2. 3. Open air vents on the suction and discharge piping and on the seal covers until water flows out. Close the vent valves.

5.

COUPLE PUMP AND DRIVER

Lock out driver power to prevent accidental rotation and physical injury. 1. Install and lubricate coupling per manufacturers instructions.

! s

WARNING

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! s

CAUTION

START-UP PRECAUTIONS
1. All equipment and personal safety related devices and controls must be installed and operating properly. A start-up strainer should be used 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, uncouple the unit and refer to driver manufacturers instructions for assistance. Pumpage temperatures in excess of 93 C (200 F) will require warm-up of pump prior to operation. Circulate a small amount of pumpage through the pump until the casing temperature is within 38 C (100 F) of the pumpage temperature and evenly heated. NOTE: Warm-up rate should not exceed 1.4 C (2.5 F) per minute.

Failure to properly prime the pump may cause damage. Properly vent suction and discharge piping and seal chambers.

2.

Suction Supply Below Pump

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. 1. 2. 3. Close discharge valve and open air vents in casing and the seal covers. Open valve in outside supply line until only liquid escapes from vent valves. Close the vent valves and then the outside supply line. 5.

3. 4.

Other Methods of Priming:

1. 2. Priming by Ejector Priming by Automatic Priming Pump

STARTING PUMP
1. 2. 3. Make sure suction valve and any recirculation or cooling lines are open. Fully close or partially open discharge valve as dictated by system conditions. Start Driver. 4. Slowly open discharge valve until the desired flow is obtained.

! s

CAUTION

! s

CAUTION

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

Immediately observe pressure gauges. If discharge pressure is not quickly attained - stop driver, reprime and attempt to restart.

OPERATION
GENERAL CONSIDERATIONS
Always vary capacity with regulating valve in the discharge line. NEVER throttle flow from the suction side. Driver may overload if the pumpage specific gravity (density) is greater than originally assumed, or the rated flow rate is exceeded. Always operate the pump at or near the rated conditions to prevent damage resulting from cavitation or recirculation.

20

3355 IOM 5/08

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: Increased vibration levels - Affects bearings, seal chamber, and mechanical seal. Increased radial loads - Stresses on shaft and bearings. Heat build up - Vaporization causing rotating parts to score or seize. 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.

! s

WARNING

1. 2.

Slowly close discharge valve.

Shut down and lock driver to prevent accidental rotation.

SHUTDOWN ! s

WARNING

When handling hazardous and/or toxic fluids, proper personal protective equipment should be worn. If pump is being drained, precautions must be taken to prevent physical injury. Pumpage must be handled and disposed of in conformance with applicable environmental regulations.

FINAL ALIGNMENT
1. Run the unit under actual operating conditions for a sufficient length of time to bring the pump and driver and associated system up to operating temperature. Remove coupling guard. 3. 4. Check alignment while unit is still hot per alignment procedure in the Installation Section. Reinstall coupling guard.

2.

3355 IOM 5/08

21

22

3355 IOM 5/08

PREVENTIVE MAINTENANCE
GENERAL COMMENTS . . . . . . . MAINTENANCE SCHEDULE . . . . MAINTENANCE OF BEARINGS . . Grease Lubricated Bearings . . . . . MAINTENANCE OF SHAFT SEALS TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 23 23 23 24 25

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
Bearing lubrication Seal monitoring Vibration analysis Discharge pressure Temperature monitoring

3 MONTH INSPECTIONS
Check the foundation and the hold-down bolts for tightness. Check the shaft alignment. Realign if required.

ANNUAL INSPECTIONS
Check the pump capacity, pressure and power. If pump 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.

ROUTINE INSPECTIONS
Check for unusual noise, vibration and bearing temperatures Inspect pump and piping for leaks Check seal chamber leakage Mechanical Seal: Should be no leakage.

MAINTENANCE OF BEARINGS
GREASE LUBRICATED BEARINGS
Grease lubricated bearings are pre-lubricated at the factory. Most pumps have Sunoco 2EP grease. Other acceptable greases are listed in Table 2. Bearing types are listed in Table 3. Suggested lubrication intervals are listed in Table 4. Regrease Procedure: NOTE: When regreasing, there is danger of impurities entering the bearing housing. The grease container, the greasing device, and fittings must be clean. 1. 2. Wipe dirt from grease fittings. Fill both grease cavities through fittings with recommended grease quantities per Table 4.

3355 IOM 5/08

23

Table 2 Lubricating Grease Requirements

Some acceptable grease lubricants:
NGLI Consistency Mobil Exxon Sunoco SKF 2 Mobilux EP2 Unirex N2 Multipurpose 2EP LGMT 2

Table 4 Interval of Re-Lubrication / Grease Quantity

Grease Qty
Suction Side (oz)
0.25 0.30 0.40 0.55

Interval of Re-Lubrication at
3550 2950 2200 1750 1450 rpm rpm rpm rpm rpm Operating Hours
3800 4300 5500 3500 4000 5000 3300 3800 4500 2500 3300 4300 6000 6500 5500 6000 5000 5500 4800 5000

Pump Size
1.5x2.5-7 2.5x4-8 4x5-10 5x6-11

Discharge Side (oz)

0.40 0.50 0.75 1.10

Table 3 Bearing Types (Ball Bearings) ! s CAUTION

Grease Lubrication Bearing Type Suction Side Only Discharge Side RS RS & ES
6306-C3 6307-C3 6308-C3 6310-C3 5306 A 5307 A C3 2x 7308 BECBM 2x 7310 BECBM Never insulate bearing housing.

NOTE: The bearing temperature usually rises after regreasing due to an excess supply of grease. Temperatures will return to normal after pump has run and purged the excess from the bearings, usually two to four hours.

Pump Size
1.5x2.5-7 2.5x4-8 4x5-10 5x6-11

! s

CAUTION

Never mix greases of different consistency (NGLI 1 or 3 with NGLI 2) or different thickener. For example, never mix a lithium base grease with a polyurea base grease.

NOTE: If it is necessary to change grease type or consistency, the bearings must be removed and the old grease removed.

MAINTENANCE OF SHAFT SEALS

MECHANICAL SEALS
When mechanical seals are furnished, a manufacturers reference drawing is supplied with the data package. This drawing should be kept for future use when performing maintenance. The life 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 it is, however, not possible to give definite indications as to its life. Never operate the pump without liquid supplied to mechanical seal. Running a mechanical seal dry, even for a few seconds, can cause seal damage and must be avoided. Physical injury may occur if mechanical seal fails. Internal flush is standard on the 3355.

! s

WARNING

24

3355 IOM 5/08

TROUBLESHOOTING
Problem
Flow rate too low Flow rate stops after a time Head too low Head too high Drive mechanism overloaded Pump not running quietly Pump casing warms up during operation Temperature in the shaft sealing area too high Temperature at the bearing too high Pump leaking Leakage at shaft seal

Probable Cause and Remedy

1, 4, 6, 7, 8, 9, 10, 11, 13, 14, 15 8, 10, 11, 14, 15 2, 4, 6, 7, 8, 9, 10, 11, 13, 14, 15, 31, 34 3, 5, 30, 34 2, 3, 5, 15, 16, 25, 27, 29, 31 7, 10, 14, 22, 23, 24, 25, 29, 30, 31, 33 8, 10, 14, 30 16, 17, 18, 20 1, 2, 3, 14, 22, 23, 24, 25, 26, 29, 30, 31, 32 25, 28 16, 18, 19, 20, 21, 22, 25

Explanations of probable causes and remedies are found in Table 5.

3355 IOM 5/08

25

Table 5 Explanations of Code Number for Cause and Method of Repair

1 Back-pressure too high open discharge valve further reduce resistance in discharge pipe (e.g. clean filter if necessary) use larger impeller (note available motor power) Back-pressure too low, discharge pressure too low throttle discharge valve Speed too high reduce speed compare speed of motor with specified pump speed (rating plate) when adjusting speed (frequency transformer) check reference value setting Speed too low increase speed (check available motor power) compare speed of motor with specified pump speed (rating plate) when adjusting speed (frequency transformer) check reference value settings Impeller diameter too large use smaller impeller Impeller diameter too small use larger impeller (check available motor power) Pump and/or pipes not completely filled with liquid fill vent Pump or suction/intake pipe blocked clean Air pocket in pipeline vent improve course of pipe NPSH of system too low increase liquid level increase suction pressure reduce resistance in the intake/suction pipe (change course and pipe size, open shutoff valves, clean filters) Air being sucked in increase liquid level check if suction pipe is vacuum-tight provide valves / fittings in suction pipe with water seal Air being sucked in through shaft sealing clean sealing pipe increase sealing pressure replace shaft seal Direction of rotation is wrong change motor rotation Inner components suffering from wear replace worn parts Density and/or viscosity of liquid handled is too high seek assistance Shaft seal worn replace mechanical seal check sealing, flushing and cooling pipe (pressure) avoid dry running Lines and roughness on shaft or shaft sleeve replace parts

5 6 7 8 9

10

11

12

13 14 15

16

17

26

3355 IOM 5/08

18

19

20 21 22 23

24

25

26 27 28 29 30

Deposits on mechanical seal clean replace mechanical seal if necessary if necessary provide additional rinsing or quench Impeller out of balance remove blocks/deposits replace if broken or unevenly worn check shafts to ensure that they are running true Coupling not aligned align pump unit Coupling distance too small change Forces in pipeline too high (pump unit under strain) change (support pipes, use compensators, etc.) is foundation plate/frame properly cast in place? Too much, too little or the wrong type of lubricant change Electricity supply not right check voltage of all phases (2-phase running) check cable connections check fuses Sealing insufficient tighten screws replace mechanical seal Bearing damaged replace check lubricant and bearing space for pollutants (rinse oil area) Discharge pressure too low increase minimum amount carried (open control valves, bypass) Discharge pressure too high reduce amount carried (throttle control valve) Hydraulic Thrust Balance insufficient clean relief holes in impeller replace worn parts (impeller, wear rings) System-related vibration (resonance) seek assistance

3355 IOM 5/08

27

28

3355 IOM 5/08

DISASSEMBLY & REASSEMBLY

REQUIRED TOOLS . . . DISASSEMBLY. . . . . . Replacing Ball Bearings Replacing Shaft Seal . . Repairs . . . . . . . . . REASSEMBLY . . . . . . CROSS SECTIONALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 . . 29 . . 30 . . 31 . . 33 . . 37 40-48

REQUIRED TOOLS
Wrenches Screwdriver Lifting Sling Rubber Mallet Induction Bearing Heater Bearing Puller Spanner Wrench Torque Wrench with Sockets Dial Indicator Micrometer Cleaning Agents Feeler Gauges

DISASSEMBLY
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.

! s

WARNING

1.

Shut off all valves controlling flow to and from pump.

Operator must be aware of pumpage and safety precautions to prevent physical injury. 2. Drain liquid from piping, flush pump if necessary.

! s

WARNING

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

! s

WARNING

Allow all system and pump components to cool before handling them to prevent physical injury. 3. 4. Disconnect all auxiliary piping and tubing. Remove coupling guard. Disconnect coupling. Unbolt the pump from the piping system and baseplate.

! s

WARNING

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

5. 6.

Lock out power supply to driver motor to prevent accidental startup and physical injury.

! s

WARNING

3355 IOM 5/08

29

REPLACING BALL BEARINGS

This section describes how to replace ball bearings. Clean and check condition of all parts that have been removed. When in doubt, components should be replaced. Wearing parts (ball bearings) and seals must always be replaced. If parts or half-open pumps are to be stored for any length of time, they must be protected from dirt and corrosion. 5. 6. 7.

This area must remain clear for excess grease that may be purged from the bearing as it runs, and for the grease that is added during re-lubrication. Fit bearing bracket (228C) and screw on lightly for the time being. Screw the bearing cover (119) to the bearing bracket (228C). Grease the contact surface of the thrower (248) and bring the thrower or heat flinger (123B) into position on the spacer sleeve (157) whichever is applicable. NOTE: The thrower sits in a groove on the spacer sleeve while the heat flinger blades should be positioned approximately from the bearing cover studs (356C). 8. 9. Align the surfaces of the pump feet (place pump on an even surface). Tighten nuts (425) firmly (see Appendix III for torque)

SUCTION END BALL BEARINGS (112)

See relevant sectional drawing. Disassembly 1. Remove heat flinger guards (499) if applicable. 2. Place the pump in a horizontal position, raise the suction casing (100F) with wooden blocks so that the feet of the bearing bracket (228C) are exposed by approximately . Move back the thrower (248) or heat flinger (123B) if applicable. Unscrew nuts (425) and nuts (427H); pull the bearing cover (119) off the bearing bracket (228C). Remove bearing bracket (228C) (tapping the bearing flange lightly in an axial direction facilitates removal). Unscrew shaft nut (136A) (spanner wrench). The shaft nut has a securing device to prevent it from coming loose.

10. Rotate shaft (122) to see that it runs smoothly. 11. Replace flinger guards (499) if applicable.

3. 4. 5.

DISCHARGE END BALL BEARING (409)

See relevant sectional drawing. Disassembly 1. 2. 3. Remove coupling halves. Remove flinger guards (499) if applicable. Place the pump in a horizontal position, raise the discharge casing (100D) with wooden blocks so that the feet of the bearing bracket (228C) are exposed by approximately . Move back the thrower (248) or heat flinger (123B) if applicable. Unscrew nuts (425) and nuts (427H); pull the bearing cover (119) off the bearing bracket (228C).

6.

s !
7. 8.

CAUTION
4.

NOTE: This shaft nut (136A) should never be reused. Remove ball bearings (112) with the bearing puller. Check the shaft surface for damage. Grind away any burs. 5.

Assembly 1. Clean and lubricate the fitting surfaces between the bearing bracket (228C) and suction casing (110F). 2. 3. 4. Preheat new bearing (112) (max. 230F) and slide onto the shaft (122). Tighten the new shaft nut (136A) while the bearing is still hot, then turn back a turn. Fill approximately 60% of the space in the ball bearing (112) with grease (when the bearing has cooled down). Grease should not be added to the bearing housing or cover cavities around bearing.

30

3355 IOM 5/08

6.

Remove bearing bracket (228C) (tapping the bearing flange lightly in an axial direction facilitates removal).

3. 4.

Tighten the shaft nut (136A) while the bearing is still hot. Fill approximately 60% of the space in the ball bearings (409) with grease (when the bearing has cooled down). Grease should not be added to the bearing housing or cover cavities around bearing. This area must remain clear for excess grease that may be purged from the bearing as it runs, and for the grease that is added during re-lubrication. Fit bearing bracket (228C) and screw on lightly for the time being. Screw the bearing cover (119) to the bearing bracket (228C). Grease the contact surface of the thrower (248) and bring the thrower or heat flinger (123B) into position on the spacer sleeve (157), whichever is applicable. NOTE: The thrower sits in a groove on the spacer sleeve while the heat flinger blades should be positioned approximately from the bearing cover studs (356C).

s !

CAUTION

After the bearing bracket (228C) has been removed the shaft can be moved freely in an axial direction (approx. 1/8). Standard shaft seals can absorb this adjustment without their function being impaired. In the case of special shaft seals, please follow the Operating Instructions of the seal. 7. Unscrew shaft nut (136A) (spanner wrench). The shaft nut has a securing device to prevent it from coming loose.

5. 6. 7.

s !
8. 9.

CAUTION

The shaft nut (136A) should never be reused. Remove ball bearings (409) with the bearing puller. Check the shaft surface for damage. Grind away any furrows. 8. 9.

Assembly 1. 2. Clean and lubricate the fitting surfaces between the bearing bracket (228C) and discharge casing (110D). Preheat the new bearing (409) (max. 230F) and slide onto the shaft (122). Variants: Sizes 1.5x2.5-7 and 2.5x4-8: Roller bearing (409) double row angular ball bearings (single bearing). Sizes 4x5-10 and 5x6-11: Roller bearing (409) paired angular ball bearings in back-to-back arrangement (Fig. 10).

Align the surfaces of the pump feet (place pump on an even surface). Tighten nuts (425) firmly (see Appendix III for torque)

10. Rotate shaft (122) to see that it runs smoothly. 11. Mount coupling half (may preheat to max. 230F).

REPLACING SHAFT SEAL

This section describes how to replace the shaft seal. Clean and check condition of all parts that have been removed. In case of doubt, components should be replaced. Wearing parts (ball bearings) and seals must always be replaced. If parts or disassembled pumps are to be stored for any length of time, they must be protected from dirt and corrosion. Mechanical seals are located on the suction side (RS configuration) and discharge side (RS and ES configurations).

Fig. 10 Paired angular ball bearings in back-to-back arrangement

Shaft sleeves (104 & 126) and the mechanical seals (383S and 383) are separate components. The parts must be marked so that they can be mounted in the same position.

3355 IOM 5/08

31

Disassembly
1. 2. Dismantle pump on the appropriate side as described in Replacing Ball Bearings. Remove bearing cover (119), spacer sleeve (157) and thrower (248) or heat flinger (123B) if applicable. Remove shaft sleeve key (401). Remove seal cover (184). Pre-treat fitting surface between the seal cover and the casing with compatible lubricant. Slide off shaft sleeve (104 and 126) and pull out O-ring (412F). Press out the seat ring of the mechanical seal (383 and 383S) from the seal cover (184) using even pressure. Slide the rotating unit of the mechanical seal off the shaft sleeve (104 & 126). If the mechanical seal has set screws these must first be removed. Clean and check all parts for wear. Mechanical seals must always be replaced.

6.

Insert the O-ring (412H) in the casing and secure with silicon grease. If possible, the O-ring should be touching the outer diameter (the O-ring can be enlarged slightly by pulling). Carefully mount the seal cover (184), using caution that the pin is in the correct direction (445E), (groove in bearing bracket). Insert shaft sleeve key (401) and slide on the spacer sleeve (157). Pump spacer sleeve must be assembled in the following direction (Figs. 11 & 12).

7.

3. 4.

8.

5. 6.

157

401

7.

8.

Fig. 11 1.5x2.5-7, 2.5x4-8, 4x5-10

Assembly

s !
1.

CAUTION
157 401

Placing the pump in a vertical position is required for assembly. Always use a lubricant when mounting mechanical seals. Do not use mineral grease or oil if you are not absolutely certain that it is compatible with the O-ring material. Insert the seat ring of the mechanical seal (383 & 383S) in the seal cover (184). Slide the rotating unit of the mechanical seal (383 & 383S) onto the shaft sleeve (104 and 126) and secure with set screw (if required). Slide on the O-ring (412F) and apply lubricating agent (e.g. silicon grease) using a brush. Lubricate the shaft sleeve (104 and 126) on the I.D. so that the O-ring groove remains clean (start approximately inside). Fig. 12 5x6-11 9 Screw the bearing cover (119) to the bearing bracket (228C).

2.

3. 4.

10. Grease the contact surface of the thrower (248) and bring the thrower or heat flinger (123B) into position on the spacer sleeve (157) whichever is applicable. NOTE: The thrower sits in a groove on the spacer sleeve while the heat flinger blades should be positioned approximately from the bearing cover studs (356C). 11. For further assembly work see Replacing Ball Bearings.

s !
5.

CAUTION

Standard O-rings made of EP rubber are not resistant to mineral oil or greases. Slide on the shaft sleeve (104 and 126). When sliding on the shaft sleeve, make sure that the O-ring can slide easily into the groove.

32

3355 IOM 5/08

REPAIRS PUMP DISASSEMBLY

ES Configuration (End Suction) See relevant sectional drawing. If the whole pump is to be dismantled for maintenance work, the pump should be placed in a vertical position (suction nozzle facing upwards). A workbench with a hole (approximately larger than the shaft) is very helpful in such cases. Sizes 1.5x2.5-7 and 2.5x4-8 can be placed on the coupling guard adapter (234A). Stand sizes 4x5-10 and 5x6-11 vertically with an additional support. A hoist or a second person is required for dismantling sizes 4x5-10 and 5x6-11.

11. Unscrew shaft nut (136A) (spanner wrench). The shaft nut has a securing device to prevent it from coming loose.

s !

CAUTION

The shaft nut (136A) should never be reused.

12. Remove ball bearings (112) with the bearing puller. 13. Remove spacer sleeve (157), bearing cover (119) and thrower (248) or heat flinger (123B) if applicable; remove shaft sleeve key (401). 14. Removing the shaft seal: See Replacing the Shaft Seal. 15. Clean all parts. If the pump is to be reassembled at a later date, carefully store all parts and protect from corrosion. RS Configuration (Radial Suction) See relevant sectional drawing. If the whole pump is to be dismantled for maintenance work, the pump should be placed in a vertical position (suction casing facing upwards). A workbench with a hole (approximately larger than the shaft) is very helpful in such cases. Sizes 1.5x2.5-7 and 2.5x4-8 can be placed on the coupling guard adapter (234A). Stand sizes 4x5-10 and 5x6-11 vertically with an additional support. A hoist or a second person is required for dismantling sizes 4x5-10 and 5x6-11.

Secure the pump so that it cannot fall over. NOTE: This description does not include dismantling the mechanical seal. Read the instructions for Replacing the Shaft Seal before dismantling the pump. 1. 2. 3. 4. 5. 6. 7. Loosen nuts (357F) and remove tie rod (356S). Remove suction casing (100F) and remove O-ring (412K). Loosen impeller nuts (304); remove washer (199). Dismantle impeller (101) and diffuser (150); remove impeller key (178). Mark all parts for reassembly. Remove intermediate bearing housing (134C) and bearing sleeve (310). Dismantle pump in stages down to the discharge casing. Invert the remaining portion of the pump. NOTE: Bearing bracket (228C) faces upward.

! s

WARNING

Secure the pump so that it cannot fall over. NOTE: This description does not include dismantling the mechanical seal. Read the instructions for Replacing the Shaft Seal before dismantling the pump in order to carry out any necessary preparations in good time. 1. Slide back the thrower (248) or heat flinger (123B) if applicable. Unscrew nuts (425) and nuts (427H), pull the bearing cover (119) off the bearing bracket (228C). Remove bearing bracket (228C) (lightly tapping the bearing bracket facilitates removal). Unscrew shaft nut (136A) (spanner wrench). The shaft nut has a securing device to prevent it from coming loose.

! s

WARNING

Axially secure shaft (122) (use a support so that it cannot slip). 8. 9. Move back thrower (248) or heat flinger (123B) if applicable. Unscrew nuts (425) and nuts (427H), pull the bearing cover (119) off the bearing bracket (228C).

! s

WARNING

2. 3. 4.

10. Remove bearing bracket (228C) (lightly tapping the bearing bracket facilitates removal).

3355 IOM 5/08

33

s !
6. 7. 8. 9.

CAUTION

REPAIRS
Clean all parts and check for wear. In case of excessive wear, parts must be replaced. This is a practical opportunity to renew parts such as O-rings, ball bearings, and shaft seals.

The shaft nut (136A) should never be reused. Remove ball bearings (112) with the bearing puller. Remove spacer disc (297A) and spacer sleeve (157). For removal of the shaft seal see: Replacing Shaft Seal. Loosen nuts (357F) and remove tie rods (356S).

10. Remove suction casing (100F) and remove O-ring (412K). Remove sleeve (310). 11. Remove impeller (101) and diffuser (150); remove impeller key (178E). Mark all parts for reassembly. 12. Remove interstage casing (100G). 13. Dismantle pump in stages down to the discharge casing (100D). 14. Invert the remaining portion of the pump. NOTE: Bearing bracket (228C) faces upward.

Axially secure shaft (122) (use a support so that it cannot slip). 15. Move back thrower (248) or heat flinger (123B) if applicable. 16. Unscrew nuts (425) and nuts (427H), pull the bearing cover (119) off the bearing bracket (228C). 17. Remove bearing bracket (228C) (lightly tapping the bearing bracket facilitates removal). 18. Unscrew shaft nut (136A) (spanner wrench). The shaft nut has a securing device to prevent it from coming loose.

! s

WARNING

s !

CAUTION

The shaft nut (136A) should never be reused.

19. Remove roller bearings (112) with the gear puller. 20. Remove spacer sleeve (157), bearing cover (119) and thrower (248) and/or heat flinger (123B) if applicable; remove shaft sleeve key (401). 21. Removing the shaft seal: See Replacing the Shaft Seal. 22. Clean all parts. If the pump is to be reassembled at a later date, carefully store all parts and protect from corrosion.

34

3355 IOM 5/08

Wearing parts and dimensions:

Fig. 13

Fig. 14

3355 IOM 5/08

35

Pump Size

Gap New

Gap New

Gap New

Gap New

Gap New

Nominal Diameter

Nominal Diameter

Nominal Diameter

Nominal Diameter

Nominal Diameter

Max. Permissible Gap

Max. Permissible Gap

Max. Permissible Gap

Max. Permissible Gap

Max. Permissible Gap

Nominal Diameter

Gap New

Min 1.496 1.772 2.047 2.559 SS SS SS 0.006 0.008 0.020 6.693 0.006 0.008 0.020 6.693 0.006 0.008 0.006 0.008 0.020 5.315 0.006 0.008 0.020 5.315 0.006 0.008 0.006 0.008 0.020 4.134 0.006 0.008 0.020 4.134 0.006 0.008 0.020 0.020 0.020 0.006 0.008 0.020 3.346 0.006 0.008 0.020 3.346 0.006 0.008 0.020

Max

Min

Max

Min

Max

Min

Max 1.575 1.772 2.047 2.441

Min 0.004 0.004 0.006 0.008 SS

Max 0.006 0.006 0.008 0.010 0.020 0.022 0.022 0.024 1.378 1.575 1.772 2.362

Min 0.002 0.002 0.002 0.003

Max 0.003 0.003 0.003 0.004 0.005 0.005 0.005 0.006

1.5x2.5-7

1.575

0.004

0.006

0.020

2.5x4-8

1.850

0.006

0.008

0.022

4x5-10

2.165

0.006

0.008

0.022

5x6-11

2.559

0.008

0.010

0.024

Materials

SS

Pump Size

Gap New

Gap New

Gap New

Gap New

Nominal Diameter

Nominal Diameter

Nominal Diameter

Nominal Diameter

Max. Permissible Gap

Max. Permissible Gap

Max. Permissible Gap

Max. Permissible Gap

Nominal Diameter

Gap New

Min 1.496 1.772 2.047 2.559 0.012 0.014 0.020 6.693 0.012 0.014 0.020 5.315 0.012 0.014 0.020 4.134 0.012 0.012 0.012 0.012 0.014 0.020 3.346 0.012

Max

Min

Max

Min

Max 0.014 0.014 0.014 0.014 0.020 0.020 0.020 0.020 3.346 4.134 5.315 6.693

Min 0.012 0.012 0.012 0.012

Max 0.014 0.014 0.014 0.014 0.020 0.020 0.020 0.020 1.575 1.772 2.047 2.441

Min 0.010 0.010 0.012 0.012

Max 0.012 0.012 0.014 0.014 0.020 0.022 0.022 0.024

Table 6 Gap Width (Reference Figs. 13 & 14)

1.5x2.5-7

1.575

0.010

0.012

0.020

2.5x4-8

1.850

0.012

0.014

0.022

4x5-10

2.165

0.012

0.014

0.022

5x6-11

2.559

0.014

0.016

0.024

3355 IOM 5/08

* All dimensions in inches * AI = All Iron; SF = Stainless Fitted; SS = Stainless Steel

Max. Permissible Gap

Max. Permissible Gap

36
Area B Gap between impeller hub and diffuser Gap between impeller and casings AI, SF AI, SF AI, SF Gap between impeller and diffuser Gap between shaft and discharge casing AI, SF Area C Area D Area E Area F Gap between bearing sleeve and bearing bushing AI, SF, SS

Area A

Gap between sleeve and suction casing

Materials

AI, SF

REASSEMBLY
PRELIMINARY WORK
Assembling a pump consisting of new parts requires preliminary work. Therefore, some of the following points might already have been carried out when the pump is reassembled. Always use the relevant sectional drawing. 1. 2. 3. Clean all components and remove any rust. Suction casing (100F) (only for RS): Screw in and secure throttling element (252) In addition, a bore with approximately 0.16 diameter must be provided to ventilate the sealing chamber. This bore must always be located in the top position. Therefore, depending on the location of the nozzle of the suction casing, use one of the three cast depressions for this drilled hole. Screw in stud bolts (356A). Discharge casing (100D): Screw in and secure throttling element (252) (use correct bore). Screw in stud bolts (356A). Seal cover (184): Hammer in pin (445E). Bearing bracket (228C): Screw in stud bolts (356C). Bearing cover (119): Screw in lubricating nipple (193B). 1. 2. Fig. 15 Paired angular ball bearings in back-to-back arrangement Tighten the shaft nut (136A) while the bearing is still hot. Fill approximately 60% of the space in the ball bearing (409) with grease (when the bearing has cooled down). Grease should not be added to the bearing housing or cover cavities around bearing. This area must remain clear for excess grease that may be purged from the bearing as it runs, and for the grease that is added during re-lubrication. Mount bearing bracket (228C), and at the same time insert the seal cover (184). Screw bearing cover (119) to bearing bracket (228C). Grease the contact surface of the thrower if applicable on the bearing cover (119). Mount heat flinger (123B) if applicable with heat flinger blades facing and approximately from the bearing cover studs (356C). Bring the thrower (248) into position (groove in the spacer sleeve (157)) if applicable. Lay discharge casing (100D) horizontally so that the shaft can be inserted (122). Place pre-mounted unit on the discharge casing (100D) and tighten nuts (425) (See Appendix III for torque). Variants: Sizes 1.5x2.5-7 & 2.5x4-8: ball bearing (409) double row angular ball bearings (single bearing). Sizes 4x5-10 & 5x6-11: ball bearing (409) paired angular ball bearings in back-to-back arrangement (Fig. 15).

4. 5. 6. 7. 8 9.

10. Intermediate bearing housing (134C): Press in bearing bushing (197A) (only for ES). Type ES (End Suction) See relevant sectional drawing. All parts must be cleaned and free of grease. 1. Clamp the shaft in a vertical position (122) (use soft protective wedges), with coupling end pointing upwards. Other assembly work depends on the type of shaft seal. See Replace Shaft Seal. 4. 5. 6.

3.

2.

s !
3.

CAUTION
7. 8. 9.

Proceed carefully in order to avoid damage to the mechanical seal (383). Preheat the new bearing (409) (max. 230F) and slide onto the shaft (122).

10. Rotate shaft (122) to see that it turns smoothly.

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11. The pump must be inverted for further assembly work (free shaft pointing upwards vertically). 12. Lubricate shaft (122), making sure that lubricant is compatible with shaft o-ring material. 13. Check position of the impeller: Insert diffuser (150L), slide impeller (101) until impact.

Type RS (Radial Suction) See relevant sectional drawing. All parts must be cleaned and free of grease. 1. Clamp the shaft in a vertical position (122) (use soft protective wedges), with coupling end pointing upwards. Other assembly work depends on the type of shaft seal, see Replacing Shaft Seal.

s !

CAUTION

2.

If a pump is assembled with new impellers, the first and last stages are always provided with full diameter impellers. If only one impeller is available with the full diameter, it must be used as the first stage. 3.

s !

CAUTION

Proceed carefully in order to avoid damage to the mechanical seal (383). Preheat the new bearing (409) (max. 230F) and slide onto the shaft (122).

NOTE: Assembly work always starts with the final stage. 14. Remove impeller and diffuser once more, insert O-ring (497D), re-insert diffuser (150L/150). 15. Insert key (178 or 178E) for the impeller that is to be mounted. 16. Mount impeller (101) [as the O-ring (497D) presses on the diffuser (150L/150) the setting will not be correct at first]. 17. Generously grease O-ring (412K) with silicon grease and stage casing (100G). Do not twist O-ring. 18. Place stage casing (100G) on level and force down sharply. Hit with a plastic hammer until it impacts. 19. Assemble pump down to the intermediate bearing housing (134C). 20. Slide on bearing sleeve (310); lubricate bearing surface. 21. Mount intermediate bearing housing (134C) with bearing bushing (197A) as for stage casing. 22. Mount first stage of the pump, secure impeller (101) with washer (199) and nuts (304). 23. Tighten first nut (304) securely, then turn back by turn and secure with counter nut. 24. Mount suction casing (100F) with O-ring (412K); assemble tie rod (356S) and nuts (357F) together slightly. 25. Align bearing surface of pump feet (place pump on a flat surface). 26. Tighten nuts (357F), see table in Appendix III for torque. 27 Rotate shaft (122) to see that it turns smoothly.

Variants: Sizes 1.5x2.5-7 & 2.5x4-8: roller bearing (409) double row angular ball bearings (single bearing). Sizes 4x5-10 & 5x6-11: roller bearing (409) paired angular ball bearings in back-to-back arrangement (Fig. 16).

Fig. 16

Paired angular ball bearings in back-to-back arrangement 4. 5. Tighten the shaft nut (136A) while the bearing is still hot. Fill approximately 60% of the space in the ball bearing (409) with grease (when the bearing has cooled down). Grease should not be added to the bearing housing or cover cavities around bearing. This area must remain clear for excess grease that may be purged from the bearing as it runs, and for the grease that is added during re-lubrication. Mount bearing bracket (228C), and at the same time insert the seal cover (184). Screw bearing cover (119) to bearing bracket (228C).

6. 7.

38

3355 IOM 5/08

8. 9.

Grease the contact surface of the thrower if applicable on the bearing cover (119). Mount heat flinger (123B) if applicable with heat flinger blades facing and approximately from the bearing cover studs (356C).

23. Slide on sleeve (310) and mount suction casing (100F) with O-ring (312F). Make sure that the lines are in the correct position. 24. Further assembly work depends on the type of the shaft seal. See Replacing Shaft Seal. 25. Assemble bearings according to Replacing Ball Bearings.

10. Bring the thrower (248) into position [groove in the spacer sleeve (157)] if applicable. 11. Lay discharge casing (100D) horizontally so that the shaft can be inserted (122). 12. Place pre-mounted unit on the discharge casing (100D) and tighten nuts (425) (see Appendix III for torque). 13. Rotate shaft (122) to see that it runs smoothly. 14. The pump must be inverted for further assembly work (free shaft pointing upwards vertically). 15. Lubricate shaft (122), making sure that lubricant is compatible with shaft O-ring material. 16. Check position of the impeller: Insert diffuser (150L), slide impeller (101) until impact.

s !

CAUTION

If a pump is assembled with new impellers, the first and last stages are always provided with full diameter impellers. If only one impeller is available with the full diameter, it must be used as the first stage.

6
NOTE: Assembly work always starts with the final stage. 17. Remove impeller and diffuser once more, insert O-ring (497D), re-insert diffuser (150L/150). 18. Insert key (178 or 178E) for the impeller that is to be mounted. 19. Mount impeller (101) [as the O-ring (497D) presses on the diffuser (150L/150) the setting will not be correct at first]. 20. Generously grease O-ring (412K) with silicon grease and stage casing (100G). Do not twist O-ring. 21. Place stage casing (100G) on level and force down sharply. Hit with a plastic hammer until it impacts. 22. Assemble pump down to the suction casing (100F).

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Model 3355 RS All Iron Cross Sectional

40

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Model 3355 RS All Iron w/SS Impeller Construction Cross Sectional

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Model 3355 RS Stainless Steel Construction Cross Sectional

42

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Model 3355 ES All Iron Construction Cross Sectional

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Model 3355 ES All Iron w/SS Impeller Construction Cross Sectional

44

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Model 3355 ES Stainless Steel Construction Cross Sectional

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Model 3355 RS (CCW Rotation) All Iron Construction Cross Sectional

46

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Model 3355 RS (CCW Rotation) All Iron w/ SS Impeller Construction Cross Sectional

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Model 3355 RS (CCW Rotation) Stainless Steel Construction Cross Sectional

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SPARE AND REPAIR PARTS

RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . . APPENDIX I MAXIMUM ALLOWABLE NOZZLE LOADS . APPENDIX II 3355 MINIMUM FLOW / LUBRICANTS . . . . APPENDIX III TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 51 53 55

SPARE PARTS
Spare parts should be selected to last for two-years continuous operation. If no other guidelines are applicable, we recommend that you stock the number of parts listed below. NOTE: To ensure optimum availability, we recommend that suitable quantities of spare parts be held in stock.

RECOMMENDED SPARE PARTS

2 Spare part Impeller Diffuser Wear Ring-Casing Shaft With Key and Shaft Screws/Nuts Bearing (Ball Bearing) Bearing Shaft Nut (2x for RS Model) Shaft Sleeve O-Rings for Pump Casing Sets Other O-Ring Sets Mechanical Seal (Sets for RS Model) i=no. of stages i i/2 2i 1 1 2 2 4 4 2 Number Of Pumps (incl. Stand-by Pumps) 3 4 5 6/7 8/9 Number Of Spare Parts i i 2i 2i 3i i/2 i/2 i i 3i/2 2i 2i 4i 4i 6i 1 1 3 2 6 6 3 2 2 4 2 8 8 4 2 2 5 3 8 8 5 2 2 6 3 9 9 6 3 3 8 4 12 10 7 10/more 30% 15% 30% 30% 30% 90% 50% 150% 100% 90%

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50

3355 IOM 5/08

APPENDIX I
MAXIMUM ALLOWABLE NOZZLE LOADS
Direction of Forces Fx = force along the x - axis Fy = force along the y - axis Fz = force along the z - axis Direction of Moments Mx = moment around the x - axis My = moment around the y - axis Mz = moment around the z - axis

Fig. 17 Nozzle loads for suction flange and discharge flange are separate. All stated permissible forces and moments must not be exceeded.

Fig. 18

8
Nozzle Configuration Vertical nozzle perpendicular to the shaft (Fig. 17, 18). Horizontal nozzle perpendicular to the shaft (Fig. 17, 18). Horizontal nozzle parallel to the shaft (Fig. 18) Flange Diameter (in) 1.5 2.5 4 5 6 1.5 2.5 4 5 6 2.5 4 5 6 FORCES (lbf) Fx 74 126 202 254 303 74 126 202 254 303 139 227 281 337 Fy 67 115 182 227 274 85 139 227 281 337 126 202 254 303 Fz 85 139 227 281 337 67 115 182 227 274 115 182 227 274 F 133 220 355 443 531 133 220 355 443 531 220 416 443 531 Mx 207 258 325 420 516 207 258 325 420 516 258 325 420 516 MOMENTS (ft-lbs) My 103 148 192 258 325 103 148 192 258 325 148 192 258 325 Mz 140 192 243 325 398 140 192 243 325 398 192 243 325 398 M 273 354 450 590 730 273 354 450 590 730 354 450 590 730

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52

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APPENDIX II
Recommended Minimum Flow / Acceptable Lubricants
Recommended Minimum Flow
50 HERTZ 3600 RPM 1800 RPM 3000 RPM 1500 RPM QMIN Q-BEP QMIN Q-BEP QMIN Q-BEP QMIN Q-BEP OPERATION FULL DIA. OPERATION FULL DIA. OPERATION FULL DIA. OPERATION FULL DIA. (GPM) (GPM) (GPM) (GPM) (GPM) (GPM) (GPM) (GPM) 33 33 53 70 106 154 374 589 117 176 300 400 600 925 1100 1470 11 11 26 37 53 75 185 286 60 87 145 210 310 412 595 735 26 26 40 57 88 128 308 485 98 147 247 324 500 725 1015 1235 9 9 22 30 44 62 155 238 50 70 120 167 245 360 480 635 60 HERTZ

SIZE 1.5X2.5-7A 1.5X2.5-7B 2.5X4-8A 2.5X4-8B 4X5-10A 4X5-10B 5X6-11A 5X6-11B

s !

CAUTION

Recommended Minimum Flow is intended for brief periodic operation. It is not to be used as a design point. Extended operation at minimum flow may cause pump damage.

Acceptable Grease Lubricants

NGLI Consistency Mobil Exxon Sunoco SKF 2 Mobilux EP2 Unirex N2 Mutipurpose 2EP LGMT 2

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54

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APPENDIX III
TORQUE VALUES
Pump Size
1.5x2.5-7 2.5x4-8 4x5-10 5x6-11

Hexagonal nut

Quality

Screw

ft-lbs

ft-lbs

ft-lbs

Pos Thread joint Tie bolt 356S

Pos 357F

min.

Thread dry Lubricated 142

Thread dry Lubricated 1-8UNC 325 295

Thread dry Lubricated 1-8UNC 244 222

dry 1352 8UNC

Thread Lubricated 320

8.8 3/4-11UNC 190

Bearing bracket (228C) with suction cas356A ing (100F) or discharge casing (100D)

425

8.8

8 x M12

31

28

8 x M12 42

38

8 x M16 71

64

8x M20

112

ft-lbs
99

Size

Size

Size

Size

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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

Visit our website at www.gouldspumps.com

Form No. I-3355 5/08

2006 Goulds Pumps, Incorporated a subsidiary of ITT Corporation