Goulds Pumps 3996 Manual

Model 3996

Lenntech

info@lenntech.com Tel. +31-152-610-900

www.lenntech.com Fax. +31-152-616-289

info@lenntech.com Tel. +31-152-610-900

www.lenntech.com Fax. +31-152-616-289

Lenntech

Installation, Operation and Maintenance Instructions

FOREWORD

This manual provides instructions for the Installation, Operation, and Maintenance of the Goulds Model 3996 pump. This manual covers

the standard product plus common options that are available. For special options, supplemental instructions are supplied. This manual

must be read and understood before installation and start-up.

The design, materials, and workmanship incorporated in the construction of Goulds pumps makes them capable of giving trouble-free

service. The life and satisfactory service of any mechanical unit, however, is enhanced and extended by correct application, proper

installation, periodic inspection, condition monitoring and careful maintenance. This instruction manual was prepared to assist operators in

understanding the construction and the correct methods of installing, operating, and maintaining these pumps.

Goulds shall not be liable for physical injury, damage or delays caused by a failure to observe the instructions for Installation,

Operation, and Maintenance contained in this manual.

Warranty is valid only when genuine Goulds parts are used.

Use of the equipment on a service other than stated in the order will nullify the warranty, unless written approval is obtained in advance

from Goulds Pumps.

Supervision by an authorized Goulds representative is recommended to assure proper installation.

Additional manuals can be obtained by contacting your local Goulds representative or by calling 1-800-446-8537.

THIS MANUAL EXPLAINS

nProper Installation

nStart-up Procedures

nOperation Procedures

nRoutine Maintenance

nPump Overhaul

nTrouble Shooting

nOrdering Spare or Repair Parts

3996 IOM 9/2010 5

TABLE OF CONTENTS

9 SAFETY

13 GENERAL INFORMATION

17 INSTALLATION

21 OPERATION

27 PREVENTATIVE MAINTENANCE

33 DISASSEMBLY/REASSEMBLY

45 TROUBLESHOOTING

3996 IOM 9/2010 7

S-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

manual will minimize your risk of injury.

ITT Goulds pumps will provide safe, trouble-free service when properly installed, maintained, and

operated.

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 guidelines

outlined in this Pump Safety Manual and the Instruction, Operation, and Maintenance (IOM) manual.

Current manuals are available at www.gouldspumps.com/literature_ioms.html 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

www.gouldspumps.com.

S-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 contents of the pump

and eliminate the possibility of exposure, particularly if hazardous and/or toxic. Potential hazards include, but

are not limited to, high temperature, flammable, acidic, caustic, explosive, and other risks.

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 forbidden. 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 www.gouldspumps.com/literature.

S-3

SAFETY

DEFINITIONS

Throughout this manual the words WARNING, CAUTION, ELECTRICAL, and ATEX are used to indicate

where special operator attention is required.

Observe all Cautions and Warnings highlighted in this 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

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 injury.

When installed in potentially explosive atmospheres, the instructions that follow the Ex symbol must be

followed. Personal injury and/or equipment damage may occur if these instructions are not followed. If there

is any question regarding these requirements or if the equipment is to be modified, please contact an ITT

Goulds Pumps representative before proceeding.

Example: Improper impeller adjustment could cause contact between the rotating and stationary

parts, resulting in a spark and heat generation.

S-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

equipment.

General Precautions

WARNING NEVER APPLY HEAT TO REMOVE IMPELLER. The use of heat may cause an

explosion due to trapped fluid, resulting in severe physical injury and property damage.

WARNING NEVER use heat to disassemble pump due to risk of explosion from trapped 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 equipment damage. Lift

equipment only at specifically identified lifting points or as instructed in the current IOM.

Current manuals are available at www.gouldspumps.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.

S-5

General Precautions

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 misalignment 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 fasteners.

WARNING

Startup and Operation:

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



The coupling used in an ATEX classified environment must be properly certified and

must be constructed from a non-sparking material.

WARNING Never operate a pump without coupling guard properly installed. Personal injury will

occur if pump is run without coupling guard.

WARNING



Make sure to properly lubricate the bearings. Failure to do so may result in excess heat

generation, sparks, and / or premature failure.

CAUTION



The mechanical seal used in an ATEX classified environment must be properly certified.

Prior to start up, ensure all points of potential leakage of process fluid to the work

environment are closed.

S-6

General Precautions

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

Dynamic seals are not allowed in an ATEX classified environment.

WARNING



DO NOT operate pump below minimum rated flows or with suction and/or discharge

valve closed. These conditions may create an explosive hazard due to vaporization of

pumpage and can quickly lead to pump failure and physical injury.

WARNING Ensure pump is isolated from system and pressure is relieved before disassembling pump,

removing plugs, opening vent or drain valves, or disconnecting 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 decontamination

procedures. Proper personal protective equipment should be worn. Precautions must be

taken to prevent physical injury. Pumpage must be handled and disposed of in

conformance with applicable environmental regulations.

WARNING Operator must be aware of pumpage and safety precautions to prevent physical 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 prevent 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.

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.

S-7

ATEX CONSIDERATIONS and INTENDED USE

Special care must be taken in potentially explosive environments to ensure that the equipment is properly

maintained. This includes but is not limited to:

1. Monitoring the pump frame and liquid end temperature.

2. Maintaining proper bearing lubrication.

3. Ensuring that the pump is operated in the intended hydraulic range.

The ATEX conformance is only applicable when the pump unit is operated within its intended use. Operating,

installing or maintaining the pump unit in any way that is not covered in the Instruction, Operation, and

Maintenance manual (IOM) can cause serious personal injury or damage to the equipment. This includes any

modification to the equipment or use of parts not provided by ITT Goulds Pumps. If there is any question

regarding the intended use of the equipment, please contact an ITT Goulds representative before proceeding.

Current IOMs are available at www.gouldspumps.com/literature_ioms.html or from your local ITT Goulds

Pumps Sales representative.

All pumping unit (pump, seal, coupling, motor and pump accessories) certified for use in an ATEX classified

environment, are identified by an ATEX tag secured to the pump or the baseplate on which it is mounted. A

typical tag would look like this:

The CE and the Ex designate the ATEX compliance. The code directly below these symbols reads as follows:

II = Group 2

2 = Category 2

G/D = Gas and Dust present

T4 = Temperature class, can be T1 to T6 (see Table 1)

Table 1

Code

Max permissible

surface temperature

oF (oC)

Max permissible

liquid temperature

oF (oC)

T1 842 (450) 700 (372)

T2 572 (300) 530 (277)

T3 392 (200) 350 (177)

T4 275 (135) 235 (113)

T5 212 (100) Option not available

T6 185 (85) Option not available

The code classification marked on the equipment must be in accordance with the specified area where the

equipment will be installed. If it is not, do not operate the equipment and contact your ITT Goulds Pumps sales

representative before proceeding.

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