Goulds A-C Series User manual

INSTRUCTION MANUAL
AC0921
G&L Pumps Series A-C
ALL HORIZONTAL AND
VERTICAL DRY-PIT PUMPS
Packing Adjustment – Fiber packing should not be tightened to the point of no leak-
age. Without some leakage packing may burn and score shaft or sleeve. With new pack-
ing, gradually take up gland with pump running to control leakage as packing seats. New
metallic packing may smoke during run-in. When seated, metallic packing forms a solid,
bearing-like surface. Adjust gland with pump running, for either type, to provide leakage of
40 to 60 drops per minute. Pipe away all leakage. Never tighten gland with pump is idle.
MECHANICAL SEALS
If pump has mechanical seals, check contract for engineering information as special
provisions may be necessary for pressurization, lubrication, cooling or ushing of seal.
Many seals, however, are ready to run without special attention. Consult nearest A-C Pump
representative if in doubt regarding seal operation.
LUBRICATION
Refer to applicable maintenance manuals for detailed information on lubrication of
driver and pump.
Oil-Lubricated Pumps
1. Maintain oil level as shown by a line in the sight glass or oil level indicator.
2. DO NOT OVER OIL. Over-oiling an cause bearings to run hot.
3. Use approved oil. See maintenance manual. Do not mix oils from different suppliers.
4. Check oil frequently for moisture, dirt or signs of “breakdown”.
In installations with moderate temperature changes, humidity, and dirt, the oil should
be changed after approximately 160 hours of operation. The oil should be inspected at this
time to determine the operating period before the next oil change. Oil change periods may
be increased up to 2000-4000 hours based on an 8000-hour year.
Grease-Lubricated Pumps
1. Examine grease in bearings at regular intervals. Watch for discoloration and con-
tamination which indicate need for ushing and regreasing.
2. Add grease every 3 to 6 months and ush yearly – or more often under adverse
conditions. Use lithium based NLGI-2 grade grease.
3. DO NOT OVER GREASE. Over-greased bearings may show signs of gailing. Under-
greased bearings may show signs of pitting. Bearing balls should roll, not slide.
4. After grease has been added to bearings, remove drain plug (where applicable) on
bottom of bearing housing for half an hour while pump is running.
Coupling Lubrication – check type of coupling used. Many couplings do not require
lubrication.
For additional information, refer to pump and driver maintenance manuals, which are avail-
able upon request.
Starting –
1. Close discharge valve.
2. Open fully all valves in suction line.
3. Turn on seal water to stufng box (for external-injection). If pumped liquid is
dirty or if inleakage of air is to be prevented, this line should always be left open.
4. Prime the pump. If pump does not prime properly, or loses prime during start-
up, shut down and correct condition before repeating procedure.
5. For pump moving high temperature liquids, open warm-up valve to circulate
liquid for preheating. Close valve after pump is warm.
6. Start the pump driver. (Turbines and engines require warming up – consult
manufacturer’s instructions.)
7. When pump is operating at full speed, open discharge valve slowly. Damage
will result from overheating if pump operates with valve closed.
8. Adjust seal-liquid valves per stufng box instructions.
Running – Periodically inspect pump while running, but especially after rst start,
and following repair.
1. Check pump and piping for leaks. Repair immediately.
2. Record pressure gage reading for future reference.
3. Record driver data.
4. Check pump bearing for lubrication and temperature.
5. Check and adjust stufng box for correct operation. Check sealing water lines
and valves.
6. Adjust pump output (capacity) only with discharge valve. DO NOT throttle
suction line.
Shutdown
1. Close discharge valve slowly, unless system is automatically controlled..
2. Shut down driver promptly.
3. Close seal-liquid valves (for packed pumps). (If pumped liquid is dirty or if
inleakage is to be prevented, these external lines should always be left open.)
4. Open drain valves as required.
5. Close suction line valves, to retain prime or to isolate pump.
Freezing Protection – Protect pumps shut down during freezing conditions by
one of the following methods:
1. Drain pump, remove all liquid from the casing.
2. Keep uid moving in pump and insulate or heat the pump to prevent freezing.
Do not use excessive heat – only enough to keep pump from freezing
3. Fill pump completely with antifreeze solution.
CAUTION: IF HEAT IS USED TO KEEP THE PUMP FROM FREEZING, DO NOT LET
THE TEMPERATURE OF THE PUMP OR LIQUID CONTAINED RISE ABOVE 150° F
MAINTENANCE
Operating conditions vary so widely that to recommend one schedule of preven-
tative maintenance for all centrifugal pumps is not possible. Yet some sort of regular
inspection must be planned and followed. We suggest a permanent record be kept of
the periodic inspections and maintenance performed on your pump. This recognition
of maintenance procedure will keep your pump in good working condition, and prevent
costly breakdowns.
One of the best rules to follow in the proper maintenance of your centrifugal pump
is to keep a record of actual operating hours. Then, after a predetermined period of
operation has elapsed, the pump should be given a thorough inspection. The length of
this operating period will vary with different applications, and can only be determined
from experience. New equipment, however, should be examined after a relatively short
period of operation. The next inspection period can be lengthened somewhat. This
system can be followed until a maximum period of operation is reached which should
be considered the operating schedule between inspections.
Periodic Inspection – Each month measure bearing temperature by thermometer.
If hot, inspect for excess lubricant and misalignments. See lubrication instructions.
NOTE: A bearing frame which feels hot to the touch of the hand is not necessarily
running at too high a temperature. Check with an accurate temperature measuring
device to be sure.
Every 6 months check packing, shaft or shaft sleeve for scoring, and alignment of
piping with pump.
Every year remove rotating element to inspect and clean thoroughly. Clean stufng
box passages or external piping. Inspect, clean and check foot valves.
Cleaning – Remove oil, dust, dirt, water, chemicals from exterior of driver and
pump. Refer to applicable driver maintenance manual for cleaning procedures. If neces-
sary, use high pressure clean-out water (up to 80 psi maximum) to ush out any matter
clogging impeller or liquid passage. Be sure suction valve is closed during cleaning.
SAFETY FIRST – BE CAREFUL WHEN WORKING ON ANY OPERATING
MACHINERY. REPLACE COUPLING GUARD BEFORE STARTING PUMP.
RECHECK ROTATION.
G&L Pumps is a trademark of Xylem, Inc. or one of its subsidiaries.
Goulds is a trademark of Goulds Pumps, Inc. and is used under license.
© 2013 Xylem Inc. AC-0921 August 2013
Xylem Inc.
8200 N. Austin Avenue
Morton Grove, Illinois 60053
Phone: [phone]
Fax: [phone]
www.xyleminc.com/brands/gouldswatertechnology

READ BEFORE INSTALLING
AND OPERATING PUMP
Inspection – Check pump for shortage and damage immediately upon arrival. Note
damage or shortage on freight bill (bill of lading); immediately le claim with carrier. Notify
the A-C Pump sales ofce.
Handling – Handle with care. Dropping or jarring can seriously damage or break parts.
WARNING: WHEN UNLOADING HORIZONTAL PUMPS, LIFT EQUALLY AT FOUR OR
MORE POINTS ON THE BASEPLATE. DO NOT LIFT ON THE DRIVER OR PUMP. DO NOT
LIFT BY FLANGES OR BY THE EYEBOLTS FOUND ON THE MOTOR. BE VERY CARE-
FUL NOT TO DAMAGE ANY AUXILIARY PIPING OR CONTROLS WHEN MOVING
PUMPS. FOR FURTHER DETAILS, SEE LIFTING INSTRUCTIONS ATTACHED TO PUMP.
Exterior – Pay particular attention to external hardware, drive motor conduit box (if
drive motor included) and accessories. Touch up abrasions or scratches with approved
paint. By hand, test that shaft rotates freely. Check coupling for damage.
Interior – If external damage is noted, or impeller is damaged (look in ports), or shaft
binds or sticks, disassemble as required to permit internal inspection. Refer to applicable
pump and driver maintenance manuals for procedures.
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 changes in ambient temperature. Route the shaft periodically
to coat the bearings with lubricant and to retard oxidation, corrosion, and to reduce the
possibility of false brinelling of the bearings. Refer to pump instruction book for temporary
storage instructions. For storage of three months or longer, ask for bulletin 52-113-268.
INSTALLATION:
Pump location should provide the following:
1. Proximity as close to suction supply as possible.
2. Shortest and most direct suction pipe practical. Suction lift must not exceed
limit for pump. NPSH available must equal or exceed pump requirement.
3. Suction port below pumping level to provide priming.
4. Plenty of room for inspection and maintenance.
5. Protection from freezing when idle in cold weather.
6. Correct power supply for electric motor driver; ample ventilation for internal
combustion motor driver..
7. If outdoors, protection from elements.
8. Access to water supply when stufng box lubrication or ushing is required.
BASEPLATE SETTING, HORIZONTAL UNITS ONLY:
NOTE: This procedure assumes that a concrete sub-foundation has been prepared
with anchor or hold down studs extending up ready to receive unit.
Initial Alignment:
1. Use blocks and shims under base for support at anchor studs and midway be-
tween studs, to position base approximately 2” above the concrete sub-foundation
with studs extending through holes in the baseplate.
2. Level unit by adding or removing shims under base until pump shaft and anges
are level or plumb.
3. If customer drills the base and mounts his own motor A-C Pump can assume no
responsibility for alignment. If customer mounts his own motor on predrilled base,
the motor must be centered in its mounting holes and remain that way during initial
alignment. Pump should be moved in its mounting holes to align. If the pump and
motor were factory mounted, the motor was centered in its mounting holes and
initial alignment veried at the factory.
4. Draw anchor nuts tight against base, and observe pump and motor shafts or coupling
hubs for alignment. (Temporarily remove coupling guard for checking alignment.)
5. If alignment needs improvement, add shims or wedges at appropriate positions
under base so that re-tightening of anchor nuts will shift shafts into closer align-
ment. Repeat this procedure until proper alignment is reached. For single element
couplings, proper initial alignment is dened as .020” TIR parallel alignment and
.009” TIR per inch of radius (R) angular alignment. For double element couplings,
the initial alignment tolerance is .020” TIR parallel and .006” TIR angular per inch
of radius (R). If the motor has been centered in its mounting holes and proper initial
alignment has been achieved, then nal alignment after grouting will be achievable.
BASEPLATE SETTING, VERTICAL UNITS:
1. For vertical pumps where machined ts have been provided for the drive, proper
alignment has been designed into the unit. Where no locating t is provided for the
drive, the nal alignment procedure must be followed. For vertical pumps with line
shafts, consult line shaft manufacturer’s instructions.
GROUTING PROCEDURES
Grout compensates for uneven foundation, distributes weight of unit, and prevents
shifting. Use an approved, non-shrinking grout (such as Embeco 636 by Master Builders,
Cleveland, Ohio or equivalent) as follows, after setting and leveling unit.
1. Build strong form around the foundation to contain grout.
2. Soak top of concrete thoroughly, then remove surface water.
3. Flow grout to ll cavities and prevent air pockets. Temporarily use air-relief tubing if
necessary, to remove trapped air.
4. Grout should be 1 inch minimum under baseplate and lled-in at least 4 inches
from all four edges.
5. Grout baseplate in completely and allow grout to dry thoroughly before attaching
piping to pump (24 hours is sufcient time with approved grouting procedure.)
FINAL COUPLING ALIGNMENT:
NOTE: A exible coupling will only compensate for small amounts of misalignment.
Permissible misalignment will vary with the make of coupling. The tolerances listed
below are recommended for satisfactory pump operation. Consult coupling manu-
facturer’s data when in doubt.
A. For single element couplings
NOTE: Proper alignment is essential for correct pump operation. This should be per-
formed after baseplate has been properly set and grout has dried thoroughly accord-
ing to instruction. Final alignment should be made by shimming driver only. If align-
ment is critical, it should be made at operating temperatures.
1. Coupling hubs are usually mounted on the shaft, if not, install them at this time.
2. Mount dial indicator on one hub as shown in illustration for parallel alignment. Set
dial to zero.
3. Scribe index lines on coupling halves as shown.
4. Turn both coupling halves so that index lines match. Observe dial reading to see
whether pump or driver needs adjustment. Total indicator reading for one complete
turn should not exceed 0.004 inch.
5. Mount indicator as shown for angular alignment. Set dial to zero.
6. Turn both coupling halves so index lines match. Observe dial reading to see whether
driver needs adjustment. Total indicator reading of 0.004 inch per inch of radius (R)
is satisfactory for angular alignment.
7. Assemble coupling. Tighten all bolts and set screws. It may be necessary to repeat
#2 and #4 for a nal check.
B. For double element oating shaft spacer coupling.
Parallel misalignment for double element or two plane oating shaft coupling should
not exceed 1/16 inch per foot of plane separation. Angular misalignment should be .002”
per inch of radius (R). It is recommended to offset universal joint coupling alignment by
1/8” to 1/4” for best operation. Consult coupling manufacturer’s data if in doubt.
PIPING
Suction and discharge gages are useful to check pump operation and are excellent trouble
indicators. Install gages in lines if pump nozzles do not have gage taps. Observe these
precautions when installing piping.
1. Support piping close to, but independently of pump.
2. Keep piping as straight as possible, with few or no bends and ttings.
3. Remove burrs, sharp edges, ream pipe cuts, and make joints air tight.
4. Do not “spring” pipes to make connection. Strain must not be transmitted to pump.
5. Allow for pump expansion with hot uids. If rubber expansion joints, or exible pipe
connectors are to be used, they should be installed in accordance with the instal-
lation and maintenance section of the Technical Handbook for Rubber Expansion
Joints and Flexible Pipe Connectors, published by the Fluid Sealing Association.
Pipe anchors should be adjustable to avoid undue strains on pump anges.
6. Do not move pump to pipe. This could make nal coupling alignment impossible.
Note that piping should not be connected to pump until unit has been set per instruc-
tions and grouted in.
Suction – Size and install piping to keep pressure loss at minimum and to provide
correct NPSH.
1 Suction piping should be as short and direct as possible.
2. Size must never be smaller than suction port; for long runs, use 1 or 2 sizes larger.
3. Pipe should slope upward to pump, even for horizontal runs.
4. Use eccentric reducer at pump, eccentric side down.
5. Use 45 degree or long sweep 90 degree elbows.
6. Use apper type foot valve, but only when necessary to hold prime. Sudden
closing upon reversal of ow may cause serious damage to pump and other
equipment..
7. Use gate valves only for parallel connection and for isolating pump when shut
down. Stem must be horizontal or slope down. Never use globe valves in suc-
tion line, particularly where NPSH is critical. Never throttle pump by use of
suction valve.
8. Use increasing suction nozzle or “drop-out” pipe section to permit cleaning pump.
Discharge – Some end suction pumps permit discharge port location at a number
of positions. If discharge positions must be changed, consult instruction book. Be sure
there is adequate clearance with selected position for lubrication and service of both
driver and pump.
1. If discharge line is short, size may be same as discharge port; if long, use 1 or
2 sizes larger.
2. For long horizontal runs, keep grade as even as possible, avoid high spots and
loops. Trapped air may throttle ow and can result in erratic pumping.
3. Install check and gate valves in discharge line near to pump. Check valve (if
used) should be installed between pump and gate valve.
Stufng Box – For packed pumps the stufng box must have clean, clear liquid
to ush and lubricate packing. For packed stuff boxes, the seal water quality should be
1000 ppm or better with the maximum particle size being 44 microns. For mechanical
seals, the seal water quality should be 1000 ppm or better with the maximum particle
size being 15 microns. Determine stuff box pressure by using a pressure gauge. Provide
seal water pressure at 5 to 10 psi above maximum box operating pressure. For double
mechanical seals, seal water pressure should be 10 to 20 psi above stuff box pressure.
Consult instruction book or factory.
External Seal Flushing Liquid – If pumped liquid will damage or deteriorate seal
material, suitable clean liquid must be supplied to the seal from an outside source.
Install valves in ushing supply piping to regulate ow and pressure to the box. This is
extremely important and must be given careful, engineered planning. Refer to separate
maintenance manual.
OPERATION
Pre-Start – Before initial start of pump check as follows:
1. With coupling disconnected be sure pump operates in direction indicated by
arrow on pump casing. If electric motor drive is used, check rotation each time
motor leads have been disconnected.
2. Check driver for proper operation.
3. Check suction and discharge piping pressure gages, and all other cooling, drain
lines, etc. for proper operation.
4. Turn rotating element by hand to assure free rotation.
5. Check impeller adjustment. Refer to pump maintenance manual.
6. Check stufng box adjustment, lubrication and piping.
7. Assure that all bearings are properly lubricated. Oil lubricated pumps are
shipped without oil. Fill to line in sight gage with oil of the proper viscosity.
See pump instruction book. Grease lubricated pumps are pre-greased at the
factory. Just prior to starting, add one (1) ounce of lithium based NLGI-2 grade
grease at each bearing. Remove vent plug (where provided) for rst half hour
of operation.
8. Assure that pump is full of liquid (primed).
Priming – If pump is installed with a positive head on the suction, prime by opening
suction valve and allowing liquid to enter casing, at the same time venting all air out of
casing.
If pump is installed with a suction lift, priming must be done by other methods,
such as foot valves, ejectors or by manually lling casing and suction line..
CAUTION: UNDER EITHER CONDITION, THE PUMP MUST BE COMPLETELY
FILLED WITH LIQUID BEFORE STARTING. DO NOT RUN THE PUMP IN
THE HOPE IT WILL PRIME ITSELF. IF THIS CONDITION IS NOT SATISFIED
SERIOUS DAMAGE TO THE PUMP WILL RESULT.