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 identification code when requesting technical information or spare parts.
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. 1.2.1 Safety terminology and symbols...
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.
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1.2 Safety • 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. •...
Personnel requirements 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, the vapor, or both present in hazardous areas.
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: •...
Maintenance manual (IOM) can cause serious personal injury or damage to the equipment. This in- cludes 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.
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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.
2 General Information 2 General Information 2.1 Introduction This instruction manual is intended to assist those involved with the installation, operation, and mainte- nance of Goulds Model 3996 pumps. It is recommended that this manual be thoroughly reviewed prior to installing or performing any work on the pump or motor.
2.2 Receiving the Pump 2.1.4 Handling Techniques Care should be used in moving pumps. Where required by size of units, slings should be put under both pump and motor, as shown in 2.2.2 Handling on page 2.2 Receiving the Pump Inspect the pump as soon as it is received.
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2.2 Receiving the Pump Figure 2: Casing Mounted Support Units with drivers mounted are moved with slings under the pump casing and driver. Figure 3: Sling under Pump Casing 3996 Installation, Operation and Maintenance Instructions...
2.3 Nameplate Information Figure 4: Sling under Driver Or with hooks through the holes in the frame mounted support or with slings through the large openings in the casing mounted support. WARNING: Units with drivers mounted can be top heavy. Driver weight could cause the assembled unit to overturn and could result in serious physical injury, or damage to pumps.
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2.3 Nameplate Information Description Example Pump Casing Tag - provides information about the pump's hydraulic characteristics. Note the format of Figure 5: the pump size: Discharge x Suction - Nominal maxi- mum impeller diameter in inches. (Example: 2x3-8) Figure 6: Bearing Frame Tag - provides information on the lu- brication system used Figure 7:...
3 Installation 3 Installation WARNING: When pumping unit is installed in a potentially explosive atmosphere, the instructions after the Ex symbol must be followed. Personal injury and/or equipment damage may occur if these in- structions are not followed. If there is any question regarding these requirements or if the equipment is to be modified, please contact a Goulds representative before proceeding.
3.2 Piping Table 2: Piping Flange Alignment Type Criteria Axial Flange gasket thickness ± 0.8 mm | 0.03 in. Parallel 0.001 mm/mm | 0.001 in./in. of flange diameter to a maximum of 0.8 mm | 0.03 in. Concentric Flange bolts should easily install by hand. Bottom of casing should be supported by a solid foundation or casing feet should be used.
3.3 Discharge Piping Keep suction pipe free from air pockets. Piping should be level or slope gradually downward from the source of supply. No portion of the piping should extend below pump suction flange. The size of entrance from supply should be one (1) or two (2) sizes larger than the suction pipe. The suction pipe must be adequately submerged below the liquid surface to prevent vortices and air entrainment at the supply.
3.5 3996 Shaft Alignment Procedure Model 3196 frame will not give built-in alignment, and normal alignment procedures must be performed. The Model 3196 frame can be identified by the foot and cooling jacket on the side. 3.4.1 Shaft Alignment Many users now require a 0.002" T.I.R. alignment to gain a greater mean time between failure (MTBF). All 3996’s that have been shipped after 1/9/90 have been aligned at the factory to .002"...
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3.5 3996 Shaft Alignment Procedure NOTICE: Tighten coupling bolts and hub set screw onto shaft. Torquing of these components is not done at the factory, yet is required at the site. Please reference the coupling manufacturers instruc- tions for correct torque levels. Table 3: Fastener Size and Recommended Torque Values Fastener Standard Fastner Nominal...
4 Operation 4 Operation 4.1 Preparation for Startup 4.1.1 Checklist WARNING: When installing in a potentially explosive environment, ensure that the motor is properly certi- fied. Checking Rotation CAUTION: Serious damage may result if pump is run in the wrong rotation. Lock out power to driver.
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4.1 Preparation for Startup • See Preventive Maintenance section for lubrication recommendations and connection lo- cations. WARNING: Operation of the unit without proper lubrication will cause bearing failure and pump seizure. Alignment - As described in the Alignment section, alignment is normally built-in and need not be rechecked.
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4.1 Preparation for Startup WARNING: Service temperature in an ATEX classified environment is limited to the area classification specified on the ATEX tag affixed to the pump (reference Fastener Size and Recommended Torque Values in 3.5 3996 Shaft Alignment Procedure on page 19 for ATEX classifications).
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4.1 Preparation for Startup Install and lubricate coupling per manufacturer's instructions. 1. From outside supply 2. Shutoff valve 3. Discharge isolation valve 4. Check valve Figure 10: 3996 Installation, Operation and Maintenance Instructions...
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4.1 Preparation for Startup 1. Discharge isolation valve 2. Check valve 3. By-pass line 4. Shutoff valve Figure 11: Install coupling guard. Refer to Coupling Guard Installation and Disassembly Section Ap- pendix II. WARNING: The coupling guard used in an ATEX classified environment must be constructed from a non- sparking material.
4.2 Start-Up Precautions Close the vents Suction Supply Below Pump A foot valve and outside source of liquid may be used to prime the pump. Outside source of liquid can come from a priming pump, pressurized discharge line, or other supply. Close discharge valve and open air vents in suction and discharge piping, casing, seal chamber and seal piping, if provided.
4.4 Operation NOTICE: Observe pump for vibration levels, bearing temperature and excessive noise. If normal levels are exceeded, shut down and resolve. 4.4 Operation 4.4.1 General Considerations NOTICE: Always vary capacity with regulating valve in the discharge line. NEVER throttle flow from the suction side.
4.6 Operating Under Freezing Conditions Heat build up - Vaporization causing rotating parts to score or seize. Cavitation - Damage to internal surfaces of pump. 4.6 Operating Under Freezing Conditions Exposure to freezing conditions, while pump is idle, could cause liquid to freeze and damage the pump. Liquid inside pump should be drained.
5 Preventive Maintenance 5 Preventive Maintenance 5.1 General Comments A routine maintenance program can extend the life of your pump. Well maintained equipment will last longer and require fewer repairs. You should keep maintenance records, this will help pinpoint potential causes of problems.
5.3 Lubrication 5.2.5 Inspection Intervals Inspection intervals should be shortened appropriately if the pumpage is abrasive and/or corrosive, WARNING: or if the environment is classified as potentially explosive. 5.3 Lubrication Pump bearings are normally grease lubricated and are lubricated at the factory. Regrease at approxi- mately 3-6 month intervals, until grease comes out the oil caps which serve as grease relief fittings.
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5.5 Grease Lubricated Bearings Figure 12: Table 5: Item Description Grease relief plugs Grease fittings Remove two grease relief plugs from side of frame opposite grease fittings. Fill both grease cavities through grease fittings with recommended grease until fresh grease comes out of the relief holes.
5.6 Pure Oil Mist Lubricated Bearings (Optional) 5.6 Pure Oil Mist Lubricated Bearings (Optional) WARNING: Pumps are shipped without oil. Oil mist lubricated bearings must be lubricated at the job site. Follow oil mist system supplier's instructions. Connect oil mist supply lines to upper and center tapped connection. Connect drain line to bottom tapped connection.
5.7 Stuffing Box 5.7 Stuffing Box 5.7.1 Packed Stuffing Box Periodically inspect stuffing box to see that there is sufficient leakage to lubricate the packing and main- tain a cool box. Never draw up packing so that the stuffing box heats, as this will cause damage to both packing and sleeve.
5.11 Dynamic Seal rate, the two gland bolts should be tightened evenly one-quarter (¼) turn each until the desired leakage rate is obtained. NEVER over-tighten packing to the point where less than one drop per minute is ob- served. Over-tightening can cause excessive wear and power consumption during operation. If the pack- ing cannot be tightened to obtain less than two drops per minute, then the packing may need to be re- placed and the packing installation procedures under Operation should be followed.
5.12 Impeller Clearance Setting 360Q 383S 333J Figure 15: Dynamic Seal with Chekseal 5.12 Impeller Clearance Setting 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.
5.14 Feeler Gauge Method Figure 16: Dial Indicator Method Set indicator to zero and back locking bolt (370C) out about one turn. Thread jack bolts (370D) in until they evenly contact the bearing frame. Tighten the jack bolts even- ly (about one flat at a time) backing the bearing housing (134A) away from the bearing frame until the indicator shows the proper clearance per Table 4: Impeller Clearances - Cold Temperature Clearances for Various Service Temperatures on page...
5.15 Vibration Figure 17: * Per Table 4: Impeller Clearances - Cold Temperature Clearances for Various Service Tempera- tures on page 23 5.15 Vibration It is good practice to periodically monitor vibration of the pump. Normally, vibration level will be well be- low accepted standards.
6.3 Inspection and Replacement WARNING: Operator must be aware of pumpage and safety precautions to prevent physical injury. Drain liquid from piping, flush pump if necessary. Remove auxiliary piping. Unbolt and remove spacer member of coupling. Remove the bolts (370) that hold the frame (228) to the casing. Jacking bolts (418) are provided to assist disassembly.
6.4 Reassembly Mechanical Seal (383) – Seal faces, gaskets, and shaft sealing members must be in perfect condi- tion or excessive leakage may result. Replace worn or damaged parts. Ball bearings (112 and 168) – Replace if worn, loose or rough and noisy when rotated. New bear- ings should not be unwrapped until ready for use.
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6.4 Reassembly If unit has mechanical seal (383): The following instructions refer to pumps equipped with mechanical seals, either with or without sleeves. On units with sleeves, the rotary portion of the seal may be mounted on the sleeve, and the seal- sleeve assembly mounted on the shaft as a unit.
6.5 Additional Details Place inboard stationary seat and gaskets into bottom of stuffing box. Place stuffing box cover (184) against frame making sure that studs (370H), align with proper holes in frame. Firmly tighten nuts. Refer to Step 13 for further instructions. 13.
6.6 Engineering Data Construction Details Remove visegrip and refer to Step 9 for further instructions. 6.6 Engineering Data Construction Details Table 9: Power End Power End Model 3996 ST Model 3996 MT Shaft Diam- At Impeller 3/4" (19) 1" (25) eters In Stuffing Box (Less Sleeve) 1 3/8"...
6.8 Sectional view 3996ST 3996MT 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 Pump End x 2-6 x 3-6 x 2-8 x 3-8 x 2-10 x 3-10 3-10 4-10 x 3-13 3-13 4-13 6-13 Max Liquid Temp. (without 250°F (120°C) cooling) Max Liquid Temp.
7 Troubleshooting 7 Troubleshooting 7.1 Troubleshooting Problem Possible Causes and Corrections A. No liquid delivered, not enough liquid delivered, or 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 18, 19, 20. not enough pressure. B.
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7.1 Troubleshooting Cause Remedy 24 Stuffing box not properly packed (insufficient Check packing and repack stuffing box. packing, not properly inserted or run in, packing too tight) 25 Incorrect packing or mechanical seal Consult factory. 26 Damaged mechanical seal Inspect and replace as required. Consult factory. 27 Shaft sleeve scored Remachine or replace as required.
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