ITT Goulds Pumps HSUL User manual

Installation, Operation,
and Maintenance Manual
HSUL

Table of Contents
HSUL Installation, Operation, and Maintenance Manual 1
Table of Contents
Introduction ............................................................................................................................. 2
Inspect the package ................................................................................................................ 2
Inspect the unit ........................................................................................................................ 2
Safety ........................................................................................................................................ 3
Safety terminology and symbols ............................................................................................. 3
Environmental safety .............................................................................................................. 4
User safety .............................................................................................................................. 5
Precautions before work ....................................................................................................... 5
Precautions during work ....................................................................................................... 5
Safety regulations for Ex-approved products in potentially explosive atmospheres ................ 6
Transportation and Storage ................................................................................................... 8
Receive the unit ...................................................................................................................... 8
Unpack the unit ....................................................................................................................... 8
Pump handling ........................................................................................................................ 8
Lifting methods ..................................................................................................................... 8
Pump storage requirements .................................................................................................... 9
Preservation and Storage ..................................................................................................... 10
Installation ............................................................................................................................. 11
Inspect the Pump .................................................................................................................. 11
Install the sump ..................................................................................................................... 11
Install the motor .................................................................................................................... 11
Install the pump ..................................................................................................................... 11
Slide rail system (optional) .................................................................................................... 11
Install the base component assembly ................................................................................. 11
Install the guide bracket / pivot bracket assembly .............................................................. 12
Install the lifting bracket assembly ...................................................................................... 12
Install the slide rail .............................................................................................................. 13
Commissioning, Startup, Operation, and Shutdown ......................................................... 16
Start the pump ...................................................................................................................... 16
Maintenance ........................................................................................................................... 17
Maintenance - O-ring, pump flange to slide rail base flange ................................................. 17
Disassembly .......................................................................................................................... 18
Disassemble the pump ......................................................................................................... 18
Pre-assembly ......................................................................................................................... 20
Pre-assembly inspections ..................................................................................................... 20
Replacement guidelines ........................................................................................................ 20
Reassembly ........................................................................................................................... 21
Reassemble the pump .......................................................................................................... 21
Troubleshooting .................................................................................................................... 23
Troubleshooting .................................................................................................................... 23

Introduction
HSUL Installation, Operation, and Maintenance Manual2
Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product
can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the unit.
Requesting other information
Special versions can be supplied with supplementary instruction leaflets. See the sales
contract for any modifications or special version characteristics. For instructions, situations, or
events that are not considered in this manual or in the sales documents, please contact the
nearest ITT representative.
Always specify the exact product type and identification code when requesting technical
information or spare parts.
Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
If the product has been picked up at a distributor, make a claim directly to the distributor.
Inspect the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
4. Contact your sales representative if anything is out of order.

Safety
HSUL Installation, Operation, and Maintenance Manual 3
Safety WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is over-
pressurized. Take all necessary measures to avoid over-pressurization.
• Operating, installing, or maintaining the unit in any way that is not covered in this manual
could cause death, serious personal injury, or damage to the equipment. This includes any
modification to the equipment or use of parts not provided by ITT. If there is a question
regarding the intended use of the equipment, please contact an ITT representative before
proceeding.
• Do not change the service application without the approval of an authorized ITT
representative.
• Never operate the pump without safety devices installed.
• Never operate the pump with the discharge valve closed.
• Never use heat to disassemble the pump due to the risk of an explosion from trapped
liquid.
• Always lockout power to the driver before performing pump maintenance.
• Never operate any pumping system with a blocked suction and discharge. Operation, even
for a brief period under these conditions, can cause confined pumped fluid to overheat. If
pump becomes plugged, shut down and unplug prior to restarting pump.
• The pump can handle hazardous and toxic fluids. Identify the contents of the pump and
observe proper decontamination procedures in order to eliminate the possible exposure to
any hazardous or toxic fluids. Wear the proper personal protective equipment. Potential
hazards include, but are not limited to, high temperature, flammable, acidic, caustic,
explosive, and other risks. You must handle and dispose of pumped fluid in compliance
with the applicable environmental regulations.
• If the pump/motor is damaged or leaking oil, do not operate as it may cause an electric
shock, fire, explosion, liberation of toxic fumes, physical harm, or environmental damage.
Correct/repair the problem prior to putting back in service.
• Never apply heat to remove an impeller. The use of heat may cause an explosion due to
trapped liquid, resulting in severe physical injury and property damage.
• Read this manual carefully before installing and using the product. Improper use of the
product can cause personal injury and damage to property, and may void the warranty.
Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent these
hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
Hazard levels
Hazard level Indication
DANGER: A hazardous situation which, if not avoided, will
result in death or serious injury

Safety
HSUL Installation, Operation, and Maintenance Manual4
Hazard level Indication
WARNING: A hazardous situation which, if not avoided, could result in death or serious injury
CAUTION: A hazardous situation which, if not avoided, could result in minor or moderate injury
NOTICE: • A potential situation which, if not avoided,
could result in undesirable conditions
• A practice not related to personal injury
Hazard categories Hazard categories can either fall under hazard levels or let specific symbols replace the
ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary hazard
levels and may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard
Environmental safety
The work area Always keep the station clean to avoid and/or discover emissions.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable environmental
regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
WARNING:
Do NOT send the product to the manufacturer if it has been contaminated by any nuclear
radiation. Inform ITT so that accurate actions can take place.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Recycling guidelines
Always follow local laws and regulations regarding recycling.

Safety
HSUL Installation, Operation, and Maintenance Manual 5
User safety
General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Safety equipment Use safety equipment according to the company regulations. Use this safety equipment within
the work area:
• Helmet
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other sections of this manual.
Electrical connections
Electrical connections must be made by certified electricians in compliance with all internation-
al, national, state, and local regulations. For more information about requirements, see sections
dealing specifically with electrical connections.
Precautions before work
Observe these safety precautions before you work with the product or are in connection with
the product:
• Provide a suitable barrier around the work area, for example, a guard rail.
• Make sure that all safety guards are in place and secure.
• Allow all system and pump components to cool before you handle them.
• Make sure that you have a clear path of retreat.
• Make sure that the product cannot roll or fall over and injure people or damage property.
• Make sure that the lifting equipment is in good condition.
• Use a lifting harness, a safety line, and a breathing device as required.
• Make sure that the product is thoroughly clean.
• Make sure that there are no poisonous gases within the work area.
• Make sure that you have quick access to a first-aid kit.
• Disconnect and lock out power before servicing.
• Check the explosion risk before you weld or use electric hand tools.
Precautions during work
Observe these safety precautions when you work with the product or are in connection with the
product:
• Never work alone.

Safety
HSUL Installation, Operation, and Maintenance Manual6
• Always wear protective clothing and hand protection.
• Stay clear of suspended loads.
• Always lift the product by its lifting device.
• Beware of the risk of a sudden start if the product is used with an automatic level control.
• Beware of the starting jerk, which can be powerful.
• Rinse the components in water after you disassemble the pump.
Hazardous liquids
The product is designed for use in liquids that can be hazardous to your health. Observe these
rules when you work with the product:
• Make sure that all personnel who work with biologically hazardous liquids are vaccinated
against diseases to which they may be exposed.
• Observe strict personal cleanliness.
• A small amount of liquid will be present in certain areas like the seal chamber.
Wash the skin and eyes
1. Follow these procedures for chemicals or hazardous fluids that have come into contact with
your eyes or your skin:
Condition Action
Chemicals or hazardous
fluids in eyes 1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least
15 minutes.
3. Seek medical attention.
Chemicals or hazardous
fluids on skin 1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
Safety regulations for Ex-approved products in potentially
explosive atmospheres
Guidelines for compliance
WARNING:
This manual clearly identifies accepted methods for disassembling units. These methods
must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion and
injury. Never apply heat to impellers, propellers, or their retaining devices to aid in their removal
unless explicitly stated in this manual.
If there are any questions regarding these requirements, the intended use, or if the equipment
requires modification, contact an ITT representative before you proceed.
Personnel requirements
ITT disclaims all responsibility for work done by untrained and unauthorized personnel.
These are the personnel requirements for Ex-approved products in potentially explosive
atmospheres:
• All work on the product must be carried out by certified electricians and ITT-authorized
mechanics. Special rules apply to installations in explosive atmospheres.
• All users must know about the risks of electric current and the chemical and physical
characteristics of the gas and/or vapor present in hazardous areas.
• Any maintenance for Ex-approved products must conform to international and national
standards (for example IEC/EN 60079-17).

Safety
HSUL Installation, Operation, and Maintenance Manual 7
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in
potentially explosive atmospheres:
• Only use the product in accordance with the approved motor data stated on the
nameplates.
• The Ex-approved product must never run dry during normal operation. Dry running during
service and inspection is only permitted outside the classified area.
• Before you start working with the product, make sure that the product and the control panel
are isolated from the power supply and the control circuit, so they cannot be energized.
• Do not open the product while it is energized or in an explosive gas atmosphere.
• Make sure that thermal contacts are connected to a protection circuit according to the
approval classification of the product.
• Intrinsically safe circuits are normally required for the automatic level-control system by the
level regulator if mounted in zone 0.
• The yield stress of fasteners must be in accordance with the approval drawing and the
product specification.
• Do not modify the equipment without approval from an authorized ITT representative.
• Only use parts that have been provided by an authorized ITT representative.
Equipment for monitoring
For additional safety, use condition-monitoring devices. Condition-monitoring devices include
but are not limited to these devices:
• Pressure gauges
• Flow meters
• Level indicators
• Motor load readings
• Temperature detectors
• Bearing monitors
• Leak detectors
• PumpSmart control system

Transportation and Storage
HSUL Installation, Operation, and Maintenance Manual8
Transportation and Storage
Receive the unit
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
4. Pump should be placed in upright position only.
Unpack the unit
1. Remove packing materials from the unit.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the unit to determine if any parts have been damaged or are missing.
3. Contact your ITT representative if anything is out of order.
4. Pump should be placed in upright position only.
Pump handling
WARNING:
• Make sure that the unit cannot roll or fall over and injure people or damage property.
• These pumps might use carbon or ceramic silicon carbide components. Do not drop the
pump or subject it to shock loads as this can damage the internal ceramic components.
NOTICE:
Use a forklift truck or an overhead crane with sufficient capacity to move the pallet with the
pump unit on top. Failure to do so can result in equipment damage.
Lifting methods
WARNING:
• All lifting must be done in compliance with all applicable regulations/standards.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and
wear steel-toed shoes at all times.
Use the supplied lifting lugs and suitable slings in order to lift the entire pump to a vertical
position and lower the unit into the sump. Then use the lifting lugs on the motor and a suitable
sling, or optional slide rail system to hoist the motor into position. Use a tag line attached to the
casing end in order to prevent the pump from swinging.