ITT GOULDS PUMPS 3600 i-FRAME User manual

Installation, Operation, and
Maintenance Manual
Model 3600 i-FRAME API610 11th Edition / ISO
13709 2nd Edition to current API BB3 Multi-
Stage, Axially Split

Table of Contents
1 Introduction and Safety ....................................................................................................................................4
1.1 Introduction................................................................................................................................................ 4
1.1.1 Requesting other information ..........................................................................................................4
1.2 Safety ........................................................................................................................................................4
1.2.1 Safety terminology and symbols ..................................................................................................... 5
1.2.2 Environmental safety.......................................................................................................................6
1.2.3 User safety ......................................................................................................................................6
1.2.4 Ex-approved products .....................................................................................................................8
1.2.5 Monitoring equipment......................................................................................................................9
1.3 Product warranty .....................................................................................................................................10
2 Transportation and Storage............................................................................................................................ 11
2.1 Inspect the delivery ................................................................................................................................. 11
2.1.1 Inspect the package ...................................................................................................................... 11
2.1.2 Inspect the unit.............................................................................................................................. 11
2.2 Transportation guidelines ........................................................................................................................ 11
2.2.1 Pump handling and lifting.............................................................................................................. 11
2.3 Storage guidelines................................................................................................................................... 15
2.3.1 Long-term storage.........................................................................................................................15
3 Product Description ........................................................................................................................................17
3.1 General description .................................................................................................................................17
3.2 General description i-ALERT®2 Equipment Condition Monitor...............................................................18
3.3 Nameplate information ............................................................................................................................18
4 Installation........................................................................................................................................................21
4.1 Pre-installation......................................................................................................................................... 21
4.1.1 Pump location guidelines .............................................................................................................. 21
4.1.2 Foundation requirements .............................................................................................................. 22
4.2 Baseplate-mounting procedures ............................................................................................................. 23
4.2.1 Prepare the baseplate for mounting..............................................................................................23
4.2.2 Prepare the foundation for mounting............................................................................................. 24
4.2.3 Install and level the baseplate.......................................................................................................24
4.3 Install the pump, driver, and coupling......................................................................................................25
4.4 Pump-to-driver alignment ........................................................................................................................ 26
4.4.1 Alignment checks ..........................................................................................................................26
4.4.2 Permitted indicator values for alignment checks........................................................................... 27
4.4.3 Alignment measurement guidelines ..............................................................................................27
4.4.4 Attach the dial indicators for alignment ......................................................................................... 27
4.4.5 Perform angular alignment for a vertical correction ......................................................................28
4.4.6 Perform angular alignment for a horizontal correction .................................................................. 28
4.4.7 Perform parallel alignment for a vertical correction....................................................................... 29
4.4.8 Perform parallel alignment for a horizontal correction...................................................................30
4.4.9 Perform complete alignment for a vertical correction.................................................................... 31
4.4.10 Perform complete alignment for a horizontal correction..............................................................31
4.5 Grout the baseplate.................................................................................................................................31
4.6 Piping checklists......................................................................................................................................33
4.6.1 General piping checklist ................................................................................................................33
Table of Contents
Model 3600 i-FRAME API610 11th Edition / ISO 13709 2nd Edition to current API BB3 Multi-Stage, Axially Split Installa-
tion, Operation, and Maintenance Manual
1

4.6.2 Suction-piping checklist.................................................................................................................35
4.6.3 Discharge piping checklist.............................................................................................................37
4.6.4 Bypass-piping considerations .......................................................................................................37
4.6.5 Auxiliary-piping checklist ...............................................................................................................38
4.6.6 Final piping checklist .....................................................................................................................38
5 Commissioning, Startup, Operation, and Shutdown ...................................................................................39
5.1 Preparation for startup............................................................................................................................. 39
5.2 Remove the coupling guard .................................................................................................................... 40
5.3 Check the rotation ...................................................................................................................................41
5.4 Couple the pump and driver .................................................................................................................... 41
5.4.1 Coupling guard assembly..............................................................................................................42
5.5 Bearing lubrication................................................................................................................................... 47
5.5.1 Oil volumes ...................................................................................................................................48
5.5.2 Lubricating-oil requirements..........................................................................................................48
5.5.3 Acceptable oil for lubricating bearings ..........................................................................................49
5.5.4 Lubricate the bearings with oil.......................................................................................................49
5.5.5 Replace the oil filter.......................................................................................................................50
5.5.6 Lubricate the bearings with pure or purge-oil mist (optional) ........................................................ 52
5.5.7 Lubricate the bearings with pressurized lubrication ...................................................................... 54
5.5.8 Thrust Bearing Cooling Fan (Optional) .........................................................................................55
5.5.9 Lubricate the bearings after a shutdown period ............................................................................56
5.6 Shaft sealing with a mechanical seal ...................................................................................................... 57
5.7 Connection of sealing liquid for mechanical seals................................................................................... 57
5.8 Pump priming ..........................................................................................................................................58
5.8.1 Prime the pump with the suction supply above the pump.............................................................58
5.9 Start the pump.........................................................................................................................................59
5.10 i-ALERT®2 Equipment Health Monitor..................................................................................................60
5.11 Pump operation precautions.................................................................................................................. 60
5.12 Shut down the pump ............................................................................................................................. 61
5.13 Deactivate the i-ALERT®2 Equipment Health Monitor..........................................................................61
5.14 Make the final alignment of the pump and driver .................................................................................. 62
5.15 Doweling the pump casing ....................................................................................................................62
5.15.1 Installing the driver ......................................................................................................................63
5.15.2 Doweling for low differential temperature service .......................................................................63
5.15.3 Doweling for high differential temperature service ......................................................................64
6 Maintenance.....................................................................................................................................................68
6.1 Maintenance schedule ............................................................................................................................ 68
6.2 Bearing maintenance .............................................................................................................................. 69
6.3 Mechanical-seal maintenance................................................................................................................. 69
6.4 Disassembly ............................................................................................................................................ 70
6.4.1 Disassembly precautions .............................................................................................................. 70
6.4.2 Tools required................................................................................................................................ 70
6.4.3 Prepare for disassembly ...............................................................................................................71
6.4.4 Disassemble the radial end (ball bearing pumps) .........................................................................72
6.4.5 Disassemble the thrust end (ball bearing pumps).........................................................................73
6.4.6 Disassemble the radial end (sleeve/ball bearing pumps)..............................................................75
6.4.7 Disassemble the thrust end (sleeve/ball bearing pumps) .............................................................77
6.4.8 Disassemble the radial end (sleeve/tilt pumps).............................................................................80
Table of Contents
2 Model 3600 i-FRAME API610 11th Edition / ISO 13709 2nd Edition to current API BB3 Multi-Stage, Axially Split Installa-
tion, Operation, and Maintenance Manual

6.4.9 Disassemble the thrust end (sleeve/tilt pumps) ............................................................................82
6.4.10 Guidelines for i-ALERT®2 Equipment Health Monitor disposal .................................................. 84
6.4.11 Remove the rotating element ...................................................................................................... 84
6.4.12 Disassemble the rotating element...............................................................................................86
6.5 Preassembly inspections......................................................................................................................... 89
6.5.1 Replacement guidelines................................................................................................................89
6.5.2 Shaft replacement guidelines........................................................................................................92
6.5.3 Bearings inspection.......................................................................................................................93
6.5.4 Replace the wear rings .................................................................................................................94
6.5.5 Minimum running clearances ........................................................................................................ 95
6.6 Reassembly............................................................................................................................................. 97
6.6.1 Assemble the rotating element......................................................................................................97
6.6.2 Install the rotating element ..........................................................................................................100
6.6.3 Confirm the seal chamber runout................................................................................................101
6.6.4 Assemble the casing ...................................................................................................................105
6.6.5 Assemble the thrust end (ball bearing pumps)............................................................................107
6.6.6 Assemble the radial end (ball bearing pumps)............................................................................109
6.6.7 Assemble the thrust end (sleeve/ball bearing pumps) ................................................................ 111
6.6.8 Assemble the radial end (sleeve/ball bearing pumps) ................................................................ 115
6.6.9 Assemble the thrust end (sleeve/tilt pumps) ............................................................................... 117
6.6.10 Assemble the radial end (sleeve/tilt pumps) ............................................................................. 119
6.6.11 Attach the i-ALERT®2 Equipment Health Monitor to the pump ................................................ 120
6.6.12 Post-assembly checks ..............................................................................................................121
6.6.13 Assembly references.................................................................................................................121
7 Troubleshooting ............................................................................................................................................126
7.1 Operation troubleshooting ..................................................................................................................... 126
7.2 Alignment troubleshooting..................................................................................................................... 127
7.3 i-ALERT®2 Equipment Health Monitor troubleshooting........................................................................128
8 Parts Listings and Cross-Sectionals...........................................................................................................129
8.1 Parts list................................................................................................................................................. 129
8.2 Cross-sectional diagrams...................................................................................................................... 137
9 Other Relevant Documentation or Manuals................................................................................................143
9.1 For additional documentation ................................................................................................................ 143
10 Local ITT Contacts ......................................................................................................................................144
10.1 Regional offices................................................................................................................................... 144
Table of Contents
Model 3600 i-FRAME API610 11th Edition / ISO 13709 2nd Edition to current API BB3 Multi-Stage, Axially Split Installa-
tion, Operation, and Maintenance Manual
3