ITT Goulds Pumps Trash Hog II User manual

Installation, Operation, and
Maintenance Manual
Model Trash Hog II

Table of Contents
1 Introduction and Safety ....................................................................................................................................3
1.1 Introduction................................................................................................................................................ 3
1.1.1 Requesting other information ..........................................................................................................3
1.1.2 Safety ..............................................................................................................................................3
1.1.3 Product warranty .............................................................................................................................8
2 Transportation and Storage.............................................................................................................................. 9
2.1 Inspect the delivery ................................................................................................................................... 9
2.1.1 Inspect the package ........................................................................................................................9
2.1.2 Inspect the unit................................................................................................................................9
2.2 Transportation guidelines .......................................................................................................................... 9
2.2.1 Precautions .....................................................................................................................................9
2.2.2 Pump handling ................................................................................................................................9
2.2.3 Lifting Methods................................................................................................................................9
2.3 Storage guidelines................................................................................................................................... 11
2.3.1 Storage location ............................................................................................................................ 11
2.3.2 Pump storage requirements.......................................................................................................... 11
2.3.3 Frostproofing .................................................................................................................................12
3 Product Description ........................................................................................................................................13
4 Installation........................................................................................................................................................14
4.1 Pre-installation......................................................................................................................................... 14
4.1.1 Pump location guidelines ..............................................................................................................14
4.1.2 Foundation requirements ..............................................................................................................14
4.1.3 Baseplate-mounting procedures ...................................................................................................14
4.1.4 Grout the baseplate.......................................................................................................................26
4.1.5 Bypass-piping considerations .......................................................................................................26
4.1.6 Suction Piping ...............................................................................................................................26
4.1.7 Discharge Piping ...........................................................................................................................28
4.1.8 Piping checklists............................................................................................................................28
4.2 Air Release Line ...................................................................................................................................... 30
5 Commissioning, Startup, Operation, and Shutdown ...................................................................................31
5.1 Starting .................................................................................................................................................... 31
5.2 Warnings ................................................................................................................................................. 31
5.3 Install the coupling guard ........................................................................................................................ 32
5.4 Lubrication...............................................................................................................................................34
5.5 Impeller Running Clearance....................................................................................................................35
6 Maintenance.....................................................................................................................................................37
6.1 Shaft and Bearing Replacement ............................................................................................................. 37
6.2 Cleaning or Replacing Check Valve ........................................................................................................37
6.3 Cleaning Impeller .................................................................................................................................... 37
6.4 Hydrotest ................................................................................................................................................. 37
6.5 Disassembly ............................................................................................................................................ 38
6.5.1 Disassembly precautions ..............................................................................................................38
6.5.2 Tools required................................................................................................................................38
6.5.3 Drain the pump..............................................................................................................................39
Table of Contents
Model Trash Hog II Installation, Operation, and Maintenance Manual 1

6.5.4 Disassembly.................................................................................................................................. 39
6.6 Preassembly inspections......................................................................................................................... 40
6.6.1 Replacement guidelines................................................................................................................ 40
6.6.2 Bearing-frame inspection ..............................................................................................................41
6.7 Reassembly............................................................................................................................................. 41
6.7.1 Reassembly ..................................................................................................................................41
6.8 Impeller Nut Installation Torque...............................................................................................................41
6.9 Winter Storage ........................................................................................................................................ 41
7 Troubleshooting .............................................................................................................................................. 43
7.1 Troubleshooting Guide ............................................................................................................................ 43
8 Pump Spare Parts List ....................................................................................................................................45
8.1 Trash Hog II Type EL Long Coupled ....................................................................................................... 46
8.2 Pump Spare Parts List ............................................................................................................................ 47
8.3 Trash Hog II Type EL Long Coupled ....................................................................................................... 48
Table of Contents
2 Model Trash Hog II Installation, Operation, and Maintenance Manual

1 Introduction and Safety
1.1 Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
•Installation
• Operation
• Maintenance
CAUTION:
Failure to observe the instructions contained in this manual could result in personal injury
and/or property damage, and may void the warranty. Read this manual carefully before instal-
ling and using the product.
NOTICE:
Save this manual for future reference and keep it readily available.
1.1.1 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 consid-
ered in this manual or in the sales documents, please contact the nearest ITT representative.
Always specify the exact product type and serial number when requesting technical information or spare
parts.
1.1.2 Safety
WARNING:
•The operator must be aware of the pumpage and take appropriate safety precautions to
prevent physical injury.
• Risk of serious injury or death. If any pressure-containing device is over-pressurized, it
can explode, rupture, or discharge its contents. It is critical to take all necessary meas-
ures to avoid over-pressurization.
• Risk of death, serious personal injury, and property damage. Installing, operating, or
maintaining the unit using any method not prescribed in this manual is prohibited. Prohib-
ited methods include any modification to the equipment or use of parts not provided by
ITT. If there is any uncertainty regarding the appropriate use of the equipment, please
contact an ITT representative before proceeding.
• Risk of serious personal injury. Applying heat to impellers, propellers, or their retaining
devices can cause trapped liquid to rapidly expand and result in a violent explosion. This
manual clearly identifies accepted methods for disassembling units. These methods must
be adhered to. Never apply heat to aid in their removal unless explicitly stated in this
manual.
• Risk of serious personal injury or property damage. Dry running may cause rotating parts
within the pump to seize to non-moving parts. Do not run dry.
1 Introduction and Safety
Model Trash Hog II Installation, Operation, and Maintenance Manual 3

• Running a pump without safety devices exposes operators to risk of serious personal in-
jury or death. Never operate a unit unless appropriate safety devices (guards, etc.) are
properly installed. See specific information about safety devices in other sections of this
manual.
• Risk of death, serious personal injury, and property damage. Heat and pressure buildup
can cause explosion, rupture, and discharge of pumpage. Never operate the pump with
suction and/or discharge valves closed.
• Precautions must be taken to prevent physical injury. The pump may handle hazardous
and/or toxic fluids. Proper personal protective equipment should be worn. Pumpage must
be handled and disposed of in conformance with applicable environmental regulations.
• If the pump or motor is damaged or leaking, electric shock, fire, explosion, liberation of
toxic fumes, physical harm, or environmental damage may result. Do not operate the unit
until the problem has been corrected or repaired.
CAUTION:
Risk of injury and/or property damage. Operating a pump in an inappropriate application can
cause over pressurization, overheating, and/or unstable operation. Do not change the service
application without the approval of an authorized ITT representative.
1.1.2.1 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 seri-
ous injury
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 unde-
sirable 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:
1.1 Introduction
4 Model Trash Hog II Installation, Operation, and Maintenance Manual

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
1.1.2.2 Environmental safety
The work area
Always keep the pump station clean to avoid and/or discover emissions.
WARNING:
If the product has been contaminated in any way, such as from toxic chemicals or nuclear radi-
ation, do NOT send the product to ITT until it has been properly decontaminated and advise
ITT of these conditions before returning.
Recycling guidelines
Always recycle according to these guidelines:
1. If the unit or parts are accepted by an authorized recycling company, then follow local recycling
laws and regulations.
2. If the unit or parts are not accepted by an authorized recycling company, then return them to the
nearest ITT representative.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Dispose appropriately of all waste.
• Handle and dispose of the pumped fluid 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.
Reference for electrical installation
For electrical installation requirements, consult your local electric utility.
1.1.2.2.1 Recycling guidelines
Always follow local laws and regulations regarding recycling.
1.1.2.3 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.
1.1 Introduction
Model Trash Hog II Installation, Operation, and Maintenance Manual 5

• 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:
• Hardhat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
Electrical connections
Electrical connections must be made by certified electricians in compliance with all international, nation-
al, state, and local regulations. For more information about requirements, see sections dealing specifical-
ly with electrical connections.
Noise
WARNING:
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. Per-
sonnel should wear appropriate hearing protection when working on or around any equipment,
including pumps. Consider limiting personnel’s exposure time to noise or, where possible, en-
closing equipment to reduce noise. Local law may provide specific guidance regarding expo-
sure of personnel to noise and when noise exposure reduction is required.
Temperature
WARNING:
Equipment and piping surfaces may exceed 130ºF (54ºC) in operating process plants. Clear
visual warnings or other indicators should alert personnel to surfaces that may reach a poten-
tially unsafe temperature. Do not touch hot surfaces. Allow pumps operating at a high tempera-
ture to cool sufficiently before performing maintenance. If touching a hot surface cannot be
avoided, personnel should wear appropriate gloves, clothing, and other protective gear as nec-
essary. Local law may provide specific guidance regarding exposure of personnel to unsafe
temperatures.
1.1.2.4 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.
• Recognize the site emergency exits, eye wash stations, emergency showers and toilets.
• Allow all system and pump components to cool before you handle them.
• Make sure that you have a clear path of retreat.
1.1 Introduction
6 Model Trash Hog II Installation, Operation, and Maintenance Manual

• 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.
1.1.2.5 Precautions during work
Observe these safety precautions when you work with the product or are in connection with the product:
CAUTION:
Failure to observe the instructions contained in this manual could result in personal injury
and/or property damage, and may void the warranty. Read this manual carefully before instal-
ling and using the product.
• Never work alone.
•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.
1.1.2.6 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.
1.1.2.7 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.
1.1 Introduction
Model Trash Hog II Installation, Operation, and Maintenance Manual 7

1.1.3 Product warranty
Coverage
ITT undertakes to remedy faults in products from ITT under these conditions:
•The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an ITT representative within the warranty period.
• The product is used only under the conditions described in this manual.
• The monitoring equipment incorporated in the product is correctly connected and in use.
• All service and repair work is done by ITT-authorized personnel.
• Genuine ITT parts are used.
• Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved prod-
ucts.
Limitations
The warranty does not cover faults caused by these situations:
• Deficient maintenance
• Improper installation
• Modifications or changes to the product and installation made without consulting ITT
• Incorrectly executed repair work
• Normal wear and tear
ITT assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
Warranty claim
ITT products are high-quality products with expected reliable operation and long life. However, should
the need arise for a warranty claim, then contact your ITT representative.
1.1 Introduction
8 Model Trash Hog II Installation, Operation, and Maintenance Manual

2 Transportation and Storage
2.1 Inspect the delivery
2.1.1 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.
2.1.2 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.
2.2 Transportation guidelines
2.2.1 Precautions
WARNING:
•Stay clear of suspended loads.
• Observe accident prevention regulations in force.
2.2.2 Pump handling
WARNING:
Dropping, rolling or tipping units, or applying other shock loads, can cause property damage
and/or personal injury. Ensure that the unit is properly supported and secure during lifting and
handling.
CAUTION:
Risk of injury or equipment damage from use of inadequate lifting devices. Ensure lifting devi-
ces (such as chains, straps, forklifts, cranes, etc.) are rated to sufficient capacity.
2.2.3 Lifting Methods
WARNING:
•All lifting must be done in compliance with all applicable regulations/standards.
2 Transportation and Storage
Model Trash Hog II Installation, Operation, and Maintenance Manual 9

• Safe lifting points are specifically identified in this manual. It is critical to lift the equipment
only at these points. Integral lifting eyes or eye bolts on pump and motor components are
intended for use in lifting the individual components only.
• Lifting and handling heavy equipment poses a crush hazard. Use caution during lifting
and handling and wear appropriate Personal Protective Equipment (PPE, such as steel-
toed shoes, gloves, etc.) at all times. Seek assistance if necessary.
• Do not attach sling ropes to shaft ends.
Table 1: Methods
Pump type Lifting method
A bare pump without lifting
handles
Use a suitable sling attached properly to solid points like the casing, the flanges, or
the frames.
A bare pump with lifting lugs Use a suitable sling attached to the lifting lugs in the casing and bearing cartridge.
A base-mounted pump Use slings under the pump casing and the drive unit, under the base rails, or
through lifting lugs, when provided.
Figure 1: Example of a proper lifting method
2.2 Transportation guidelines
10 Model Trash Hog II Installation, Operation, and Maintenance Manual

Figure 2: Example of a proper lifting method
2.3 Storage guidelines
2.3.1 Storage location
The product must be stored in a covered and dry location free from heat, dirt, and vibrations.
NOTICE:
•Protect the product against humidity, heat sources, and mechanical damage.
• Do not place heavy weights on the packed product.
2.3.2 Pump storage requirements
Storage requirements depend on the amount of time that you store the unit. The normal packaging is
designed only to protect the unit during shipping.
2.3 Storage guidelines
Model Trash Hog II Installation, Operation, and Maintenance Manual 11

Length of time in storage Storage requirements
Upon receipt/short-term (less than six months) • Store in a covered and dry location.
Long-term (more than six months) • Store in a covered and dry location.
•Store the unit free from heat, dirt, and vibrations.
2.3.3 Frostproofing
This table shows to what degree the pump is frostproof:
When the pump is... Then...
Operating The pump is frostproof.
Immersed in a liquid The pump is frostproof.
Lifted out of a liquid into a temperature below freezing The impeller might freeze.
Sitting idle The pump might freeze.
2.3 Storage guidelines
12 Model Trash Hog II Installation, Operation, and Maintenance Manual

3 Product Description
3 Product Description
Model Trash Hog II Installation, Operation, and Maintenance Manual 13

4 Installation
4.1 Pre-installation
Precautions
WARNING:
•When installing in a potentially explosive environment, ensure that the motor is properly
certified.
• All equipment being installed must be properly grounded to prevent unexpected dis-
charge. Discharge can cause equipment damage, electric shock, and result in serious in-
jury. Test the ground lead to verify it is connected correctly.
NOTICE:
•Electrical connections must be made by certified electricians in compliance with all inter-
national, national, state and local regulations.
• Supervision by an authorized ITT representative is recommended to ensure proper instal-
lation. Improper installation may result in equipment damage or decreased performance.
4.1.1 Pump location guidelines
4.1.2 Foundation requirements
Requirements
•Provide a flat, substantial concrete foundation in order to prevent strain and distortion when you
tighten the foundation bolts.
4.1.3 Baseplate-mounting procedures
4.1.3.1 Prepare the baseplate for mounting
1. Remove all the attached equipment from the baseplate.
2. Clean the underside of the baseplate completely.
3. If applicable, coat the underside of the baseplate with an epoxy primer.
Use an epoxy primer only if using an epoxy-based grout.
4. Remove the rust-proofing coat from the machined mounting pads using an appropriate solvent.
5. Remove water and debris from the foundation-bolt holes.
4.1.3.2 Install the baseplate using shims or wedges
Required tools:
• Two sets of shims or wedges for each foundation bolt
• Two machinist's levels
• Baseplate-leveling worksheet
1. If you use sleeve-type bolts, fill the bolt sleeves with packing material or rags to prevent grout from
entering the bolt holes.
4 Installation
14 Model Trash Hog II Installation, Operation, and Maintenance Manual

2. Put the sets of wedges or shims on each side of each foundation bolt.
1
1. Shims or wedges
Figure 3: Top view
1
1. Shims or wedges
Figure 4: Side view
3. Lower the baseplate carefully onto the foundation bolts.
4. Put the machinist's levels across the mounting pads of the driver and the mounting pads of the
pump.
NOTICE:
Remove all dirt from the mounting pads in order to ensure that the correct leveling is achieved.
Failure to do so can result in equipment damage or decreased performance.
5. Level the baseplate both lengthwise and across by adding or removing shims or moving the wedg-
es.
You can use the baseplate-leveling worksheet when you take the readings.
6. Hand-tighten the nuts for the foundation.
4.1.3.3 Install the baseplate using jackscrews
Tools required:
• Anti-seize compound
• Jackscrews
• Bar stock
• Two machinist's levels
1. Apply an anti-seize compound on the jackscrews.
The compound makes it easier to remove the screws after you grout.
2. Lower the baseplate carefully onto the foundation bolts and perform these steps:
a) Cut the plates from the bar stock and chamfer the edges of the plates in order to reduce stress
concentrations.
b) Put the plates between the jackscrews and the foundation surface.
c) Use the four jackscrews in the corners in order to raise the baseplate above the foundation.
d) Make sure that the center jackscrews do not touch the foundation surface yet.
4.1 Pre-installation
Model Trash Hog II Installation, Operation, and Maintenance Manual 15

12
3
4
Item Description
1. Jackscrew
2. Baseplate
3. Foundation
4. Plate
Figure 5: Jackscrews
3. Level the driver mounting pads:
NOTICE:
Remove all dirt from the mounting pads in order to ensure that the correct leveling is achieved.
Failure to do so can result in equipment damage or decreased performance.
a) Put one machinist's level lengthwise on one of the two pads.
b) Put the other machinist's level across the ends of the two pads.
c) Level the pads by adjusting the four jackscrews in the corners.
Make sure that the machinist's level readings are as close to zero as possible, both lengthwise and
across.
4. Turn the center jackscrews down so that they rest on their plates on the foundation surface.
5. Level the pump mounting pads:
NOTICE:
Remove all dirt from the mounting pads in order to ensure that the correct leveling is achieved.
Failure to do so can result in equipment damage or decreased performance.
a) Put one machinist's level lengthwise on one of the two pads.
b) Put the other level across the center of the two pads.
c) Level the pads by adjusting the four jackscrews in the corners.
Make sure that the machinist's level readings are as close to zero as possible, both lengthwise and
across.
6. Hand-tighten the nuts for the foundation bolts.
7. Check that the driver's mounting pads are level and adjust the jackscrews and the foundation bolts
if necessary.
4.1 Pre-installation
16 Model Trash Hog II Installation, Operation, and Maintenance Manual

4.1.3.4 -leveling worksheet
1
2
3
4
5
6
7
89
10
11 12
13
14
15 16
17 18
1)____________________
2)____________________
3)____________________
4)____________________
5)____________________
6)____________________
7)____________________
8)____________________
9)____________________
10)___________________
11)___________________
12)___________________
13)___________________
14)___________________
15)___________________
16)___________________
17)___________________
18)___________________
Level measurements
4.1 Pre-installation
Model Trash Hog II Installation, Operation, and Maintenance Manual 17

4.1.3.5 Install the pump, driver, and coupling
1. Mount the driver on the . Use applicable bolts and hand tighten.
2. Install the coupling.
See the installation instructions from the coupling manufacturer.
4.1.3.6 Alignment checks
When to perform alignment checks
You must perform alignment checks under these circumstances:
• The process temperature changes.
• The piping changes.
• The pump has been serviced.
Types of alignment checks
Type of check When it is used
Initial alignment (cold alignment)
check
Prior to operation when the pump and the driver are at ambient temperature.
Final alignment (hot alignment) check After operation when the pump and the driver are at operating temperature.
Initial alignment (cold alignment) checks
When Why
Before you This ensures that alignment can be accomplished.
After you This ensures that no changes have occurred during the .
After you connect the piping This ensures that pipe strains have not altered the alignment.
Final alignment (hot alignment) checks
When Why
After the first run This ensures correct alignment when both the pump and the driver are at op-
erating temperature.
Periodically This follows the plant operating procedures.
4.1.3.7 Alignment measurement guidelines
Guideline Explanation
Rotate the pump coupling half and the driver coupling half together
so that the indicator rods have contact with the same points on the
driver coupling half.
This prevents incorrect measurement.
Move or shim only the driver in order to make adjustments. This prevents strain on the piping installations.
Make sure that the hold-down bolts for the driver are tight when
you take indicator measurements.
This keeps the driver stationary since move-
ment causes incorrect measurement.
Make sure that the hold-down bolts for the driver are loose before
you make alignment corrections.
This makes it possible to move the driver when
you make alignment corrections.
Check the alignment again after any mechanical adjustments. This corrects any misalignments that an adjust-
ment may have caused.
4.1.3.8 Attach the dial indicators for alignment
You must have two dial indicators in order to complete this procedure.
4.1 Pre-installation
18 Model Trash Hog II Installation, Operation, and Maintenance Manual