Goulds Pumps CWX Manual

Installation, Operation and
Maintenance Instructions
CWX

Table of Contents
1 Introduction and Safety ....................................................................................................................................4
1.1 Important Safety Notice.............................................................................................................................4
1.2 Safety Warnings ........................................................................................................................................4
1.3 Safety ........................................................................................................................................................ 5
1.4 General precautions .................................................................................................................................. 5
1.5 Parts .......................................................................................................................................................... 8
2 Introduction........................................................................................................................................................9
2.1 Introduction................................................................................................................................................ 9
2.2 Pump identification .................................................................................................................................... 9
3 Installation........................................................................................................................................................10
3.1 Receiving pump....................................................................................................................................... 10
3.2 Temporary storage .................................................................................................................................. 10
3.3 Location...................................................................................................................................................10
3.4 Foundation .............................................................................................................................................. 10
3.5 Setting and aligning baseplate ................................................................................................................ 11
3.6 Grouting................................................................................................................................................... 12
3.7 Universal joint spacer coupling................................................................................................................ 13
3.8 Universal Joint Coupling Lubrication ....................................................................................................... 14
3.9 Replacing Coupling Parts........................................................................................................................14
3.10 Floating Shaft Spacer Coupling............................................................................................................. 14
3.11 V-Belt Drive............................................................................................................................................15
3.12 Doweling................................................................................................................................................ 15
3.13 Suction and discharge piping ................................................................................................................ 15
3.14 Suction Piping ....................................................................................................................................... 15
3.15 Valves in Suction Piping ........................................................................................................................16
3.16 Discharge Piping ................................................................................................................................... 17
3.17 Valves In Discharge Piping....................................................................................................................17
3.18 Pressure Gages .................................................................................................................................... 17
3.19 External Liquid Piping (C-011)...............................................................................................................17
3.20 Stuffing box (C-011) .............................................................................................................................. 18
3.21 General.................................................................................................................................................. 18
3.22 Stuffing Box Operating Pressure...........................................................................................................18
3.23 Flushing and Lubrication Water............................................................................................................. 18
3.24 Packing.................................................................................................................................................. 20
3.25 Dynamic seal (C-022)............................................................................................................................ 20
4 Operation..........................................................................................................................................................21
4.1 Pre-start checks ...................................................................................................................................... 21
4.2 Priming .................................................................................................................................................... 21
4.3 Starting .................................................................................................................................................... 21
4.4 Operating checks .................................................................................................................................... 22
4.5 Shutdown ................................................................................................................................................ 22
4.6 Freezing protection.................................................................................................................................. 22
4.7 Field tests ................................................................................................................................................ 23
4.8 Performance Curve and Guarantee ........................................................................................................ 23
4.9 Gage Datum ............................................................................................................................................ 23
Table of Contents
CWX Installation, Operation and Maintenance Instructions 1

4.10 Head Measurement...............................................................................................................................23
4.11 Total Head .............................................................................................................................................23
4.12 Suction lift..............................................................................................................................................23
4.13 Positive Suction Head ........................................................................................................................... 24
4.14 Velocity head .........................................................................................................................................24
4.15 Volume Measurement ...........................................................................................................................24
4.16 Horsepower ........................................................................................................................................... 24
4.17 Pump Efficiency..................................................................................................................................... 24
4.18 Trouble shooting.................................................................................................................................... 24
4.19 Lubrication.............................................................................................................................................27
4.20 Oil Lubrication ....................................................................................................................................... 27
4.21 Oil Reservoir.......................................................................................................................................... 27
4.22 Grease Lubrication ................................................................................................................................ 28
4.23 Bearing Lubrication Notes ..................................................................................................................... 28
4.24 Bearing Seal Lubrication ....................................................................................................................... 29
4.25 Coupling lubrication...............................................................................................................................29
4.26 Universal Joint Coupling........................................................................................................................ 29
5 Maintenance..................................................................................................................................................... 30
5.1 General.................................................................................................................................................... 30
5.2 Periodic inspection .................................................................................................................................. 30
5.3 Maintenance after flooded condition ....................................................................................................... 30
5.4 Disassembly ............................................................................................................................................ 31
5.5 Pump Style C-011 ...................................................................................................................................31
5.6 Rotating Element.....................................................................................................................................31
5.7 Frame ...................................................................................................................................................... 32
5.8 Cleaning .................................................................................................................................................. 33
5.9 Inspection ................................................................................................................................................ 33
5.10 Repair and replacement ........................................................................................................................ 34
5.11 Reassembly........................................................................................................................................... 35
5.12 Frame .................................................................................................................................................... 35
5.13 Stuffing Box ........................................................................................................................................... 37
5.14 Rotating Element...................................................................................................................................37
5.15 Pump ..................................................................................................................................................... 38
5.16 Standard C-011 Design .........................................................................................................................38
5.17 Shimming Procedure.............................................................................................................................38
5.18 Impeller Adjustment............................................................................................................................... 39
5.19 Pump run-in (packing adjustment) ........................................................................................................ 39
5.20 Fiber Packing Adjustment .................................................................................................................... 39
5.21 Metallic Packing Adjustment ................................................................................................................. 40
5.22 Dynamic seal CWR-C-022 .................................................................................................................... 40
5.23 General.................................................................................................................................................. 41
5.24 Purpose ................................................................................................................................................. 41
5.25 Construction .......................................................................................................................................... 42
5.26 Static Seal Adjustment .......................................................................................................................... 42
5.27 Dynamic Seal Inspection and Maintenance .......................................................................................... 42
5.28 Dynamic Seal Disassembly...................................................................................................................43
5.29 Rotating Element Assembly .................................................................................................................. 43
5.30 Assembling to the Pump ....................................................................................................................... 43
5.31 Replacement parts ................................................................................................................................ 43
Table of Contents
2 CWX Installation, Operation and Maintenance Instructions

5.32 Variable Drive Requirements.................................................................................................................44
6 CW and CWR Pump-Style C-011 .................................................................................................................... 45
6.1 CW and CWR pump-style C-011.............................................................................................................45
7 Parts List C-011 Pump .................................................................................................................................... 46
7.1 Parts list C-011 pump .............................................................................................................................. 46
8 CWX Pump - Style C-011.................................................................................................................................47
8.1 CWX pump-style C-011........................................................................................................................... 47
9 Parts List C-011 Pump .................................................................................................................................... 48
9.1 Parts list C-011 pump .............................................................................................................................. 48
10 CWR Pump - Style C-022 ..............................................................................................................................49
10.1 CWR pump-style C-022 ........................................................................................................................ 49
11 Parts List C-022 Pump .................................................................................................................................. 50
11.1 Parts list C-022 pump ............................................................................................................................ 50
Table of Contents
CWX Installation, Operation and Maintenance Instructions 3

1 Introduction and Safety
1.1 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 man-
ual will minimize your risk of injury.
ITT Goulds pumps will provide safe, trouble-free service when properly installed, maintained, and operat-
ed.
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 guide-
lines outlined in this Pump Safety Manual and the Instruction, Operation, and Maintenance (IOM) man-
ual. Current manuals are available at https://www.gouldspumps.com/en-US/Tools-and-Resources/Litera-
ture/ 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 https://www.gouldspumps.com
1.2 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 con-
tents of the pump and eliminate the possibility of exposure, particularly if hazardous and/or tox-
ic. Potential hazards include, but are not limited to, high temperature, flammable, acidic, caus-
tic, explosive, and other risks.
1 Introduction and Safety
4 CWX Installation, Operation and Maintenance Instructions

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 for-
bidden. 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 http://www.gouldspumps.com/literature.
1.3 Safety
Definitions
Throughout this manual the words Warning, Caution, and Electrical are used to indicate where special
operator attention is required.
Observe all Cautions and Warnings highlighted in the 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:
WARNING:
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 in-
jury.
1.4 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 equip-
ment.
Table 1: General Precautions
WARNING NEVER APPLY HEAT TO REMOVE IMPELLER. It may explode due to trap-
ped liquid.
1.3 Safety
CWX Installation, Operation and Maintenance Instructions 5

WARNING NEVER use heat to disassemble pump due to risk of explosion from tapped
liquid.
WARNING NEVER operate pump without coupling guard correctly installed.
WARNING NEVER run pump below recommended minimum flow when dry, or without
prime.
WARNING ALWAYS lock out power to the 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.
WARNING 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
WARNING Receiving:
Assembled pumping units and their components are heavy. Failure to properly
lift and support equipment can result in serious physical injury and/or equip-
ment damage. Lift equipment only at specifically identified lifting points or as
instructed in the current IOM. Current manuals are available at www.gould-
spumps.com/literature_ioms.html or from your local ITT Goulds Pumps sales
representative. Note: Lifting devices (eyebolts, slings, spreaders, etc.) must
be rated, selected, and used for the entire load being lifted.
WARNING Alignment:
Shaft alignment procedures must be followed to prevent catastrophic failure of
drive components or unintended contact of rotating parts. Follow coupling
manufacturer's coupling installation and operation procedures.
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.
CAUTION 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 misalign-
ment between pump and driver. Pipe strain will adversely effect the operation
of the pump resulting in physical injury and damage to the equipment.
WARNING Flanged Connections:
Use only fasteners of the proper size and material.
WARNING Replace all corroded fasteners.
WARNING Ensure all fasteners are properly tightened and there are no missing fasten-
ers.
WARNING Startup and Operation:
1.4 General precautions
6 CWX Installation, Operation and Maintenance Instructions

When installing in a potentially explosive environment, please ensure that the
motor is properly certified.
WARNING Operating pump in reverse rotation may result in contact of metal parts, heat
generation, and breach of containment.
WARNING Lock out driver power to prevent accidental start-up and physical injury.
WARNING 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.
WARNING 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.
WARNING Never operate a pump without coupling guard properly installed. Personal in-
jury will occur if pump is run without coupling guard.
WARNING Make sure to properly lubricate the bearings. Failure to do so may result in ex-
cess heat generation, sparks, and / or premature failure.
CAUTION 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.
WARNING Never attempt to replace packing until the driver is properly locked out and the
coupling spacer is removed.
WARNING DO NOT operate pump below minimum rated flows or with suction and/or dis-
charge valve closed. These conditions may create an explosive hazard due to
vaporization of pumpage and can quickly lead to pump failure and physical in-
jury.
WARNING Ensure pump is isolated from system and pressure is relieved before disas-
sembling pump, removing plugs, opening vent or drain valves, or disconnect-
ing 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 decon-
tamination procedures. Proper personal protective equipment should be worn.
Precautions must be taken to prevent physical injury. Pumpage must be han-
dled and disposed of in conformance with applicable environmental regula-
tions.
WARNING Operator must be aware of pumpage and safety precautions to prevent physi-
cal 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 pre-
vent physical injury.
CAUTION If pump is a Model NM3171, NM3196, 3198, 3298, V3298, SP3298, 4150,
4550, or 3107, there may be a risk of static electric discharge from plastic
parts that are not properly grounded. If pumped fluid is non-conductive, pump
should be drained and flushed with a conductive fluid under conditions that
will not allow for a spark to be released to the atmosphere.
WARNING Never apply heat to remove an impeller. The use of heat may cause an explo-
sion due to trapped fluid, resulting in severe physical injury and property dam-
age.
1.4 General precautions
CWX Installation, Operation and Maintenance Instructions 7

CAUTION Wear heavy work gloves when handling impellers as sharp edges may cause
physical injury.
CAUTION Wear insulated gloves when using a bearing heater. Bearings will get hot and
can cause physical injury.
WARNING Noise:
Sound pressure levels may exceed 80 dbA in operating process plants. Clear
visual warnings or other indicators should be available to those entering an
area with unsafe noise levels. Personnel should wear appropriate hearing pro-
tection when working on or around any equipment, including pumps. Consider
limiting personnel’s exposure time to noise or, where possible, enclosing
equipment to reduce noise. Local law may provide specific guidance regard-
ing exposure of personnel to noise and when noise exposure reduction is re-
quired.
WARNING Temperature:
Equipment and piping surfaces may exceed 130ºF (54ºC) in operating proc-
ess plants. Clear visual warnings or other indicators should alert personnel to
surfaces that may reach a potentially unsafe temperature. Do not touch hot
surfaces. Allow pumps operating at a high temperature to cool sufficiently be-
fore performing maintenance. If touching a hot surface cannot be avoided,
personnel should wear appropriate gloves, clothing, and other protective gear
as necessary. Local law may provide specific guidance regarding exposure of
personnel to unsafe temperatures.
1.5 Parts
The use of genuine Goulds parts will provide the safest and most
reliable operation of your pump. ITT Goulds Pumps ISO certifica-
tion and quality control procedures ensure the parts are manufac-
tured to the highest quality and safety levels.
Please contact your local Goulds representative for details on
genuine Goulds parts.
1.5 Parts
8 CWX Installation, Operation and Maintenance Instructions

2 Introduction
2.1 Introduction
This manual is furnished to acquaint you with the easiest and most practical way to install, operate, and
maintain this pump. Keep it handy for future reference. Additional information can be obtained from the
nearest ITT A-C Pump Sales Office. The Standards of the Hydraulic Institute are an excellent source for
more detailed advice on the subject of installation, operation and maintenance.
Equipment cannot operate well without proper care. To keep the unit at top efficiency, correct procedures
for installing and maintenance must be followed. The ITT A-C Pump Service Organization can help in-
stall this equipment correctly, so that maximum machine life can be attained with a minimum of down-
time.
A-C Servicemen are experienced, factory trained erection superintendents, and offer prompt, efficient
service and reasonable rates. Costly errors such as poor grouting, incorrect alignment, pipe stresses
transmitted to the casings, and improperly cleaned piping are frequently found and corrected by these
servicemen, thus saving costly repair and additional delays. The servicemen can be obtained through
the nearest ITT A-C Pump Sales Office. This office will also help with spare parts orders and problems
requiring special attention.
2.2 Pump identification
1. The new CW Pump Standard is designated style C-011. It combines the best features of both the
CW-11 and CW-12 designs.
2. The C-011 Pump has internal pressure relief vanes cast integral in the impeller to reduce stuffing
box pressure. Flush water is piped to the center of the stuffing box. A split seal cage delivers the
water, sealing the packing from entrance of abrasive particles. Lower stuffing box pressure re-
sults in longer shaft sleeve and packing life.
3. The new CWR pump standard designation is style C-011. It is the same design as the CW except
that the impeller is radially ribbed on both the front and back shroud wall. This is recommended
for highly abrasive slurries. The impeller ribs cut down on recirculation of slurry through the wear
plate clearance, reducing wear.
4. The dynamic seal, style C-022, is used when seal water dilution of the product cannot be permit-
ted. This design employs a combination static seal and second impeller to eliminate the conven-
tional stuffing box. Seal water in the amount of 1/4-1/2 GPM is all that is required.
The CW, CWR, and CWX are designated by the pump identification (Nameplate).
The Pump Nameplate contains the following information:
• Serial Number
• Size
• Type
• Impeller Diameter
• G.P.M.
• Head (Ft.)
• R.P.M.
Permanent records for this pump are kept by the serial number; therefore, the serial number must be
used with all correspondence and spare-parts orders.
Maintenance instructions in this manual are based upon the Model F6 frame.
2 Introduction
CWX Installation, Operation and Maintenance Instructions 9

3 Installation
3.1 Receiving pump
1. Check pump for shortage and damage immediately after arrival. Prompt reporting to the carrier's
agent, with notations made on the freight bill, will expedite satisfactory adjustment by the carrier.
2. Unload and handle the unit by lifting equally at four or more points on the baseplate if it is base
mounted. Do not lift on the driver or pump.
3. Pumps with drivers are normally shipped from the factory mounted on a baseplate and painted with
primer and one finish coat.
4. Shafts are not in alignment when unit is shipped; alignment must be established during installation.
The factory has determined that proper and correct alignment can only be made by accepted erec-
tion practices.
3.2 Temporary storage
If the pump is not to be installed and operated soon after arrival, store it in a clean, dry place having
slow, moderate change in ambient temperature. Rotate the shaft periodically to coat the bearings with
lubricant and to retard oxidation and corrosion.
3.3 Location
1. The pump should be installed as near the suction supply as possible, with the shortest and most
direct suction pipe practical. The total dynamic suction lift (static lift plus friction losses in suction
line) should not exceed the limits for which the pump was sold.
2. The pump must be primed before starting. Whenever possible, the pump should be located be-
low pumping level to facilitate priming and assure a steady flow of liquid. This condition provides
a positive suction head on the pump. Suction tank should contain at least sufficient liquid to equal
the rated capacity of the pump in GPM.
3. When installing pump, consider the location of it in relation to the system to assure that sufficient
Net Positive Suction Head (NPSH) at pump suction is provided. Available NPSH must always
equal or exceed the required NPSH of the pump.
3.4 Foundation
1. A substantial foundation and footing should be built to suit local conditions. It should form a rigid
support to maintain alignment. It is advisable to isolate the foundation from adjacent cement work
to prevent vibrations from being transmitted to the pump.
2. The foundation should be poured without interruption to within 1/2 to 1-1/2 inch of the finished
height. The top surface of the foundation should be well scored and grooved before the concrete
sets; this provides a bonding surface for the grout. Foundation bolts should be set in concrete as
shown in Figure 3. A 4-inch long tube around the bolts at the top of the concrete will allow some
flexibility in bolt alignment to match the holes in the baseplate. Figure 2 also shows a bolt and
large washer as an alternate method of anchoring foundation bolts. Allow enough bolt length for
grout, shims, lower baseplate flange, nuts and washers. The foundation should be allowed to
cure for several days before the baseplate is shimmed and grouted.
3 Installation
10 CWX Installation, Operation and Maintenance Instructions

Figure 1: Foundation
Figure 2: Setting baseplate and grouting
3. The pump should be placed with sufficient accessibility for inspection and maintenance. A clear
space with ample head room should be allowed for the use of an overhead crane or hoist suffi-
ciently strong to lift the unit.
NOTICE:
Al low sufficient space to be able to dismantle pump without disturbing the pump inlet and dis-
charge piping.
4. Select a dry place above the floor level wherever possible. Take care to prevent pump from freez-
ing during cold weather when not in operation. Should the possibility of freezing exist during a
shut-down period, the pump should be completely drained, and all passages and pockets where
liquid might collect should be blown out with compressed air.
5. Make sure there is a suitable power source available for the pump driver. If motor driven, electri-
cal characteristics should be identical to those shown on motor data plate.
6. The pump rotation is clockwise viewing the drive (or coupling) end.
3.5 Setting and aligning baseplate
1. Any baseplate may be slightly sprung in shipment or unloading, or be distorted by an uneven sup-
port on the foundation or uneven tightening of the foundation bolts. Incorrect piping installation may
3.5 Setting and aligning baseplate
CWX Installation, Operation and Maintenance Instructions 11

also impose a strain or pull on the pump, bowing the baseplate, causing misalignment. Align cou-
pling according to procedure under 3.7 Universal joint spacer coupling on page 13.
2. The foundation surface will support the pump and driver with shims and plates under the baseplate
at the foundation bolts. The foundation should be smooth and level at these points to distribute the
load evenly on the shims. A thin metal plate leveled in a puddle of mortar or grout is often the easi-
est way to achieve this level and smooth surface. Use thick shims wherever possible to reduce the
number of shims used. (See Figure 3.)
3. Leveling bolts made of cap screws and nuts are very useful when leveling large base plates, but
they should not replace blocks and shims for supporting the load.
4. Adjust shims under baseplate until pump and driver shafts are level and the space between the
baseplate and foundation is from 1/2 to 1-1/2 inch maximum. Check the coupling for alignment at
this point.
NOTICE:
Tighten the foundation bolts securely and check to assure that final alignment can be establish-
ed.
3.6 Grouting
Grout compensates for unevenness in the foundation and base and distributes the weight of the unit uni-
formly over the foundation, It also prevents the unit from shifting after mounting and alignment. It is es-
sential that the unit be expertly grouted by use of non-shrinking grout. The mix required varies with the
type of unit to be grouted, location and amount of grout. Grout the unit as follows:
1. Build a form of plywood or thin planking around the foundation to contain the grout. Support ade-
quately to prevent deformation.
2. Soak top of concrete pad thoroughly with water before grouting. Remove all surface water before
pouring.
3. Pour the grout through the openings in the baseplate. While pouring, tamp liberally in order to fill
all cavities and prevent air pockets. The grout thickness under baseplate must be a minimum of 1
inch. In order to prevent baseplate from shifting, fill under baseplate at least 4 inches in from all
four edges. Take care that grout will not interfere with pump or driving unit mounting bolts to allow
shifting as necessary.
NOTICE:
If pouring and tamping the grout will trap air in some places, temporarily place small diameter
tubes (thick-walled rubber hose) to provide venting. Remove the tubes after grout has filled the
cavity, before pouring the remainder.
If not certain as to the proper grout material to use, a non-shrinking grout such as "Embeco MB
423" by Masters Builders, Cleveland, Ohio or equivalent is recommended. Follow grout manufac-
turer's instructions.
CAUTION:
Keep water content to a minimum to avoid shrinkage.
4. After the grout has thoroughly hardened, retighten the foundation bolts, if they have become
loose.
5. Check the alignment after the foundation bolts are tightened.
6. Approximately 14 days after the grout has been poured or when the grout has thoroughly dried,
apply an oil base paint to the exposed edges of the grout to prevent air and moisture from com-
ing in contact with the grout.
3.6 Grouting
12 CWX Installation, Operation and Maintenance Instructions

3.7 Universal joint spacer coupling
This coupling is furnished standard on all horizontal direct driver units.
1. With this coupling, alignment difficulties are reduced, as it is made to operate at a slight angle,
and actually operates more efficiently in this manner.
2. Do not line up coupling perfectly. Alignment should be within 1/8 to 1/4 inch, which is accurate
enough. Ordinarily, after baseplate is permanently installed and leveled with foundation bolts
firmly tightened, this coupling does not require further alignment. However, it is advisable to
check the coupling to see that the limits as stated above are not exceeded.
3. The coupling is a precision made unit that will give trouble-free service if properly installed and
operated. Coupling installation is made easier by following the procedures outlined below.
4. Couplings are normally shipped factory unassembled. Before check for proper motor rotation
couple within alignment limits above.
5. When pump, base, coupling, coupling guard, but no motor is furnished, the complete unit cannot
be assembled, but the coupling is completely assembled and fastened to the base. The pump
half coupling and motor half are bored for their respective shafts.
6. After motor is located and bolted to the base, the coupling should be installed. It is not necessary
to completely disassemble coupling hubs from universal joint when installing. Disassemble one
hub (either pump or motor hub) from universal joint assembly by removing the four cap screws
holding the hub to the cross and bearing assembly. Attach this hub to its shaft by sliding it all the
way on.
Table 2: Universal joint spacer adjustments
Coupling
No. A B C E F H J K
Bore Limits (in.)
Min Max
3C 7-1/2 1-3/16 1-3/16 6-7/8 1-3/4 13-3/8 1-1/2 9-7/8 5/8 2-3/8
5C 11-1/2 5/16 5/16 8-3/4 2-1/2 17-1/8 1-11/16 12-1/8 1-1/16 2-7/8
7C 11-1/2 3/8 3/8 11 3 18-1/4 5/8 12-1/4 1-11/16 3-7/8
8C 11-1/2 0 0 9-3/4 3-1/2 18-1/2 7/8 11-1/2 1-11/16 3-7/8
8C 17-1/2 1/2 1-3/4 14-1/2 3-1/2 26-3/4 2-5/8 19-3/4 - -
9C 17-1/2 0 0 13 5 27-1/2 2-1/4 17-1/2 2-1/16 4-7/8
7. Assemble remaining hub with universal joint assembly attached to the shaft in the same manner.
Length of universal joint assembly can be adjusted by turning lubricant retainer and sliding spline
stub shaft into slip yoke. After both hubs are assembled on shafts, with adjustment mentioned
above, lengthen universal joint assembly until the male fits on the cross and bearing assembly
are fitted tightly into female fits on coupling hub. Replace four cap screws bolting two pieces to-
gether. Insert safety wire thru cap screw heads in pairs.
3.7 Universal joint spacer coupling
CWX Installation, Operation and Maintenance Instructions 13

8. Finally tighten two set screws in each hub over keyway, which fasten hubs to shafts. Check to
see that alignment is within 1/8 to 1/4 inch. Unit is then ready to operate.
3.8 Universal Joint Coupling Lubrication
These couplings are equipped with Alemite Zerk fittings at each point requiring lubrication. The cross of
each joint is drilled so that the lubricant is distributed to the four roller bearings from the Alemite Zerk
fitting in the cross, or the fitting in the bearing. The slip yoke is lubricated by means of a fitting in the slip
yoke.
1. A high grade semi-fluid lubricant, such as recommended in the partial list of approved lubricants
should be used for this coupling.
2. The joints should be lubricated every 500 hours of operation. The universal joint has been lubri-
cated at the factory, therefore, it is not necessary to lubricate it for the first 500 hours.
3.9 Replacing Coupling Parts
The cross and bearing assembly is subject to wear and should be replaced if it becomes worn. To do this
disassemble universal joint assembly, including the two cross and bearing assemblies and turn down the
lock plate tabs holding the cap screws in place. Remove the four cap screws (4 per yoke) and take off
complete cross and bearing assembly. This assembly may be ordered from the factory ready to instain-
stall on coupling. Reassemble cross and bearing assemblies to universal joint and reassemble this to
coupling hubs in the manner previously outlined.
3.10 Floating Shaft Spacer Coupling
The following alignment procedure is recommended where precise alignment is necessary or desirable.
Other simpler methods may be used depending on how critical the results must be held. Some couplings
and services may be more critical than others and judgment must be used.
Figure 3: Checking coupling alignment
1. Remove center section of coupling so that there is no connection between driving and driven shaft.
2. Mount dial indicators as shown in Figure 4.
3. Scribe index lines to serve as reference points in taking indicator readings.
4. Turn both shafts through a complete revolution, keeping index lines matched with each other. Make
several tries, noting the indicator readings.
3.8 Universal Joint Coupling Lubrication
14 CWX Installation, Operation and Maintenance Instructions

5. It is easier to first correct for angular misalignment, which is made by moving the driver so that the
shaft is tilted up or down and left or right from its original position until the required reading is
obtained on the angular alignment dial indicator.
6. Correction of parallel misalignment is then made by moving the driver parallel in a direction indicat-
ed by the parallel dial indicator. Note that it is easier to first move the driver horizontally to get the
best possible reading in this plane and then move the driver vertically. Repeat this procedure until
the desired reading is obtained.
3.11 V-Belt Drive
Pump and drive sheaves must be parallel and in line. Use a straight edge against sheave faces to as-
sure alignment. Adjust belt to proper tension for best result.
3.12 Doweling
Dowel the pump and driving unit as follows:
1. Check the alignment after the unit has been in operation approximately one week. Correct if neces-
sary.
2. Through opposite pump feet drill through and into the base. Holes must be a diameter of 1/64 inch
less than dowel pin. Clean out the chips.
3. Ream the holes in feet and base to the proper diameter for the pins (light push fit). Clean out the
chips.
4. Insert pins to be approximately flush with pump feet.
3.13 Suction and discharge piping
When installing the pump piping, be sure to observe the following precautions:
1. Both the suction and discharge piping should be independently supported near the pump and
properly aligned so that no strain is transmitted to the pump when the flange bolts are tightened.
Use pipe hangers or other supports at necessary intervals to provide supports.
2. It is usually advisable to increase the size of both suction and discharge pipes at the pump con-
nections to decrease the loss of head from friction.
3. Install piping as straight as possible, avoiding unnecessary bends. Where necessary, use long
radius or 90° fittings to decrease friction losses.
4. Make sure that all piping joints are airtight.
5. Where flanged joints are used, assure that inside diameters match properly.
6. Remove burrs and sharp edges when making up joints.
7. Do not "spring" piping when making any connections.
8. Provide for pipe expansion when hot fluids are to be pumped. The use of expansion joints is not
recommended.
CAUTION:
Bolt torque must not exceed 125 ft. lbs. on flanges. Hard iron is brittle and an over-torque could
crack casing.
3.14 Suction Piping
When installing the suction piping, observe the following precautions (see Figure 5).
3.11 V-Belt Drive
CWX Installation, Operation and Maintenance Instructions 15

Figure 4: Suction piping installation
1. The sizing and installation of the suction piping is extremely important. It must be selected and in-
stalled so that pressure losses are minimized and sufficient liquid will flow into the pump when start-
ed and operated. Many NPSH (Net Positive Suction Head) problems can be directly attributed to
improper suction piping systems.
2. Suction piping should be short in length, as direct as possible, and never smaller in diameter than
the pump suction opening. If the suction pipe is short, the pipe diameter can be the same size as
the suction opening. If longer suction pipe is required, pipes should be one or two sizes larger than
the opening depending on piping length.
3. The suction pipe should slope upward to the pump nozzle. A horizontal suction line must have a
gradual rise to the pump. Any high point in the pipe will become filled with air and thus prevent prop-
er operation of the pump. When reducing the piping to the suction opening diameter use an eccen-
tric reducer with the eccentric side down to avoid air pockets.
NOTICE:
Never use a straight taper reducer in a horizontal suction pipe as it tends to form an air pocket
in the top of the reducer and the pipe
3.15 Valves in Suction Piping
When installing valves in the suction piping, observe the following precautions:
1. If the pump is operating under static suction lift conditions, a foot valve may be installed in the
suction line to avoid the necessity of priming it each time the pump is started. This valve should
be of the flapper type, rather than the multiple spring type, sized to avoid excessive friction in the
suction line. (Under all other conditions a check valve, if used, should be installed in the dis-
charge line). (Refer to 3.17 Valves In Discharge Piping on page 17)
2.
When foot valves are used, or where there are other possibilities of "liquid hammer", close the
discharge valve before shutting down the pump.
3.15 Valves in Suction Piping
16 CWX Installation, Operation and Maintenance Instructions

3. Where two or more pumps are connected to the same suction line, install gate valves so that any
pump can be isolated from the line. Install gate valves with stems horizontal to avoid air pockets,
Globe valves should not be used, particularly where NPSH is critical.
4. Valves in the suction line should be used only to isolate the pump for maintenance purposes and
should always be installed in positions to avoid air pockets. By no means use a suction valve to
throttle liquid flow into pump.
3.16 Discharge Piping
For plain liquid service, if the discharge piping is short, the pipe diameter can be the same as the dis-
charge opening. If the piping is long, pipe diameter should be one or two sizes larger than the discharge
opening. On long horizontal runs it is desirable to maintain as even a grade as possible. Avoid high
spots, such as loops, which will collect air and throttle the system or lead to erratic pumping. For slurries
it is suggested to consult technical advise on correct pipe sizing. Each application may require consider-
ation to provide proper line velocity to prevent settling out. Selection of size of discharge line is important
in order to keep velocities up to prevent slurries from settling out.
3.17 Valves In Discharge Piping
A check valve and gate valve should be installed in the discharge. The check valve, placed between
pump and gate valve, protects the pump from excessive pressure, and prevents liquid from running back
through the pump in case of power failure. The gate valve is used in priming and starting, and when
shutting the pump down.
3.18 Pressure Gages
Properly sized pressure gages can be installed in both the suction and discharge pipe sections adjacent
to the pump. The gages will enable the operator to easily observe the operation of the pump, and also
determine if the pump is operating in conformance with the performance curve. For slurry service gages
should be of the protected type. If cavitation, vapor binding or other unstable operation should occur,
widely fluctuating discharge pressure will be noted.
NOTICE:
The standard pump has no drain or vent taps,
3.19 External Liquid Piping (C-011)
1. The liquid being pumped usually contains solids or is otherwise not compatible with seal materi-
als, and an outside supply of liquid must be furnished. Injection liquid (from an outside source) is
always required when the following conditions prevail:
1. Liquid being pumped contains dirt, grit, or other impurities.
2. Temperature of the liquid being pumped is below 32°F or above 180ºF. Consult the facto-
ry for recommendations.
3. Liquid being pumped has non-lubricating properties.
2. Install valves in this piping to regulate liquid flow and pressure to the seals. For packed type
seals, the seal liquid pressure should be regulated to be 5-10 psi more than the pump suction
pressure. Refer to 3.22 Stuffing Box Operating Pressure on page 18 and 3.23 Flushing and Lu-
brication Water on page 18.
3.16 Discharge Piping
CWX Installation, Operation and Maintenance Instructions 17

3.20 Stuffing box (C-011)
3.21 General
It is absolutely essential with any packed stuffing box to keep contaminants in the pumped liquid from
entering the packing space. These contaminants will cause severe abrasion or corrosion of the shaft
sleeve, rapid packing deterioration, and can even plug the stuffing box flushing and lubrication system.
The stuffing box must be supplied at all times with a source of clean, clear water to flush and lubricate
the packing. The most important consideration is to establish the minimum flushing pressure that will
eliminate contaminants from the packing. If this pressure is too low, dirty liquid may be forced into the
stuffing box. If the pressure is too high, excessive packing wear will result, and extreme heat developed
in the shaft will cause higher bearing temperatures. The most desirable condition, therefore, is to use the
lowest possible flushing pressure which the operating conditions will permit.
3.22 Stuffing Box Operating Pressure
The actual stuffing box operating pressure may be obtained by installing a pressure gage on one test
connection located on the stuffing box cover. Gage readings should be taken with the pump running un-
der various head and capacity conditions. The pressure of the flushing or lubrication water can then be
set at a value 5 to 10 psi above the maximum expected stuffing box operating pressure. Even under the
best conditions, a properly packed stuffing box should be watched closely. If pressure conditions change
slightly, there will be a resultant change in packing "seating" which should be compensated by a change
in gland adjustment.
3.23 Flushing and Lubrication Water
A recommended method to minimize error in regulating flushing water is the "Controlled Pressure Sys-
tem" as shown in Figure 6. Most important is the pressure reducing valve which may be adjusted to a
value slightly exceeding the stuffing box operating pressure. A flow indicating device is advisable that will
serve to indicate a failing of the bottom packing rings, allowing leakage into pump, If this becomes exces-
sive, the flow indicator will show it. The gland may be adjusted to a slow drip. The "out" connection from
the stuffing box should be closed with this system.
3.20 Stuffing box (C-011)
18 CWX Installation, Operation and Maintenance Instructions