ITT GOULDS PUMPS 3996 Installation, Operation And Maintenance Instructions
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ITT GOULDS PUMPS 3996 Installation, Operation And Maintenance Instructions

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Maintenance Instructions
3996

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  • Page 1 Installation, Operation and Maintenance Instructions 3996...

  • Page 3: Table Of Contents

    Table of Contents Table of Contents 1 Introduction and Safety ............................ 3 1.1 Introduction..............................3 1.1.1 Requesting other information ......................3 1.2 Safety ................................ 3 1.2.1 Safety terminology and symbols ..................... 4 1.2.2 Environmental safety........................5 1.2.3 User safety ............................5 1.2.4 Ex-approved products ........................
  • Page 4 Table of Contents 5 Preventive Maintenance ..........................29 5.1 General Comments ..........................29 5.2 Maintenance Schedule..........................29 5.2.1 Routine Maintenance ........................29 5.2.2 Routine Inspections........................29 5.2.3 3 Month Inspections ........................29 5.2.4 Annual Inspections........................29 5.2.5 Inspection Intervals ........................30 5.3 Lubrication...............................

  • Page 5: Introduction And Safety

    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.

  • Page 6: Safety Terminology And Symbols

    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...

  • Page 7: Environmental Safety

    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.
  • Page 8 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. •...

  • Page 9: Ex-Approved Products

    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.

  • Page 10: Product Warranty

    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: •...

  • Page 11: Atex Considerations And Intended Use

    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.
  • Page 12 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.

  • Page 13: General Information

    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.

  • Page 14: Handling Techniques

    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.
  • Page 15 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...

  • Page 16: Nameplate Information

    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.
  • Page 17 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:...

  • Page 18: Installation

    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.

  • Page 19: Suction Piping

    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.

  • Page 20: Discharge Piping

    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.

  • Page 21: Shaft Alignment

    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"...
  • Page 22 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...

  • Page 23: Operation

    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.
  • Page 24 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.
  • Page 25 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).
  • Page 26 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...
  • Page 27 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.

  • Page 28: Start-Up Precautions

    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.

  • Page 29: Operation

    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.

  • Page 30: Operating Under Freezing Conditions

    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.

  • Page 31: Preventive Maintenance

    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.

  • Page 32: Inspection Intervals

    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.
  • Page 33 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.

  • Page 34: Pure Oil Mist Lubricated Bearings (Optional)

    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.

  • Page 35: Stuffing Box

    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.

  • Page 36: Dynamic Seal

    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.

  • Page 37: Impeller Clearance Setting

    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.

  • Page 38: Feeler Gauge Method

    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...

  • Page 39: Vibration

    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.

  • Page 40: Disassembly And Reassembly

    6 Disassembly and Reassembly 6 Disassembly and Reassembly 6.1 Required Tools • Wrenches • Screwdriver • Lifting Sling • Rubber Mallet • Induction Bearing Heater • Bearing Puller • Brass Drift Punch • Snap-Ring Pliers • Torque Wrench with Sockets •...

  • Page 41: Inspection And Replacement

    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.

  • Page 42: Reassembly

    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.
  • Page 43 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.

  • Page 44: Additional Details

    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.

  • Page 45: Engineering Data Construction Details

    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"...

  • Page 46: Sectional View

    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.

  • Page 47: Spare And Repair Parts

    6.9 Spare and Repair Parts 6.9 Spare and Repair Parts Table 11: Item No. Qty / Pump Part Name Casing Impeller w/o RG Ball bearing OB GRS RLF FTG Bearing end cover Shaft assy Deflector Shaft sleeve Bearing housing Bearing locknut Ball bearing 1B SB cover SA Grease fitting...

  • Page 48: Dynamic Seal / Self Draining Covers Options Sectional Views

    6.10 Dynamic Seal / Self Draining Covers Options Sectional Views 6.10 Dynamic Seal / Self Draining Covers Options Sectional Views Dynamic Seal Dynamic Seal ® Packed box CHEKSEAL Item Part Name Mat'l Item Part Name Mat'l Req'd Req'd Gland Stuffing box packing GRAFOIL Repeller/Sleeve Gland...
  • Page 49 6.10 Dynamic Seal / Self Draining Covers Options Sectional Views Dynamic Seal Self Draining Stuffing Box Lip Seal Cover/Seal Chamber Item No. No Part Name Mat'l Req'd Gland Repeller/Sleeve Gasket, CVR, BXPL PTFE Screw, ST, Box, BKPL 316SS 333A Lip Seal Viton Stud, Gland 316SS...

  • Page 50: Bearing Options - Sectional View

    6.11 Bearing Options - Sectional View 6.11 Bearing Options - Sectional View Greased for Life Bearings Pure Oil Mist Item Part Name Mat'l Req'd 112A Ball Bearing OTBD Steel 168A Ball Bearing INBD Steel * Recommended spare parts Duplex Thrust Bearings Grease Lube with Provisions for Pure Oil Mist Item No.
  • Page 51 6.11 Bearing Options - Sectional View Heat Flinger Item No. No. Req'd Part Name Mat'l 123B Heat Flinger Alum * Recommended spare parts 3996 Installation, Operation and Maintenance Instructions...

  • Page 52: Troubleshooting

    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.
  • Page 53 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.
  • Page 54 Visit our website for the latest version of this document and more information: www.gouldspumps.com ITT Goulds Pumps, Inc. 240 Fall Street Seneca Falls, NY 13148 Form IOM.3996.en-US.2020-08 ©2020 ITT Inc. The original instruction is in English. All non-English instructions are translations of the original instruction.

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