ITT Goulds pumps will provide safe, trouble-free service when properly installed, maintained, and operat- 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.
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.
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 equip- ment.
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1.4 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. Fail- ure to lock out driver power will result in serious physical injury.
1.5 ATEX Considerations and Intended Use CAUTION Never operate the pump without liquid supplied to mechanical seal. Running a mechani- cal 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.
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1.5 ATEX Considerations and Intended Use 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.
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 Safety Regulations 2 Safety Regulations 2.1 Explosion Protection On application of units in areas endangered to explosion measures and references in the Filling of Unit and Maintenance sections, must be observed, so that explosion protection is guaranteed. Filling of unit During operation of the pump the system of the suction and pressure pipe and the pump itself must permanently be filled with the pumped liquid.
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2.1 Explosion Protection In Limits of Operation, Flow min. / max., the minimum flow is stated. Longer operating phases with these flows and the named liquids don´t cause additional increase of surface temperature at the pump. Furthermore the references in Start-up, Operation, Shut down of these operating Instructions must be taken into consideration.
2.2 Use acc. to Regulations Electric switches and control devices, instrumentation and accessories must correspond with the valid safety requirements and regulations for explosion protection. 2.2 Use acc. to Regulations Speed, Pressure, Temperature Suitable safety measures must be taken at the plant to ensure that the speed, pressure and tempera- ture of the pump and the shaft sealing do not exceed the limit values given in the data sheet and / or order confirmation.
3 Transportation and Storage 3 Transportation and Storage 3.1 Transportation and Storage 3.1.1 Inspect the delivery 3.1.1.1 Inspect the package Inspect the package for damaged or missing items upon delivery. Note any damaged or missing items on the receipt and freight bill. File a claim with the shipping company if anything is out of order.
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3.1 Transportation and Storage 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. Close the suction and discharge ends of the pump with plugs for transport and storage. Precautions for lifting the pump WARNING: •...
3.1 Transportation and Storage Figure 2: Pump lifting 3.1.3 Storage guidelines 3.1.3.1 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. Length of time in Storage requirements storage...
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3.1 Transportation and Storage Situation Condition Immersed in a liquid The pump is frostproof. Lifted out of a liquid into a temperature below freezing The impeller might freeze. ICB Installation, Operation and Maintenance Instruction...
4 Product Description 4 Product Description 4.1 Product Description 4.1.1 General description ICB pumps are single-stage volute casing pumps in block design. Hydraulic design and dimensions com- ply with ISO 2858/ EN 22858, the technical design complies with ISO 5199/EN 25199. The motors comply with DIN 42677-IM B5.
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4.1 Product Description NOTICE: The mechanical seal used in the standard design is not resistant to mineral oils. NOTICE: For further details about mechanical seals, as well as the dangers of accidents, connected to them refer to Monitoring and Mechanical seals. Shaft sealing Two shaft sealing variants are available.
4.1 Product Description 4.1.2 Nameplate information Pump nameplate Figure 3: Pump nameplate Nameplate Field Explanation Serial number of the pump MODEL Pump Model SIZE Size of Pump STD DIM ANSI Std designation – Not applicable ISO Pumps HYDRO PRESS Pump Test Pressure in kPag FLOW Rated pump flow in cubic metres per hour Rated pump speed in revolutions per minute...
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. 5.1.1 Pump location guidelines WARNING: Safe lifting points are specifically identified in this manual.
5.1 Pre-installation Guideline Explanation/comment Do not install and operate the equipment in closed Acceptable devices: systems unless the system is constructed with • Pressure relief valves properly-sized safety devices and control devices. • Compression tanks • Pressure controls • Temperature controls •...
5.2 Piping checklists J-type bolts Item Description Baseplate Shims or wedges Foundation Bolt Figure 5: J-type bolts 5.2 Piping checklists 5.2.1 General piping checklist Precautions WARNING: • Risk of premature failure. Casing deformation can result in misalignment and contact with rotating parts, causing excess heat generation and sparks.
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5.2 Piping checklists static piping loads. All values for forces and torques refer to standard materials EN-GJS400-18LT and 1.4408. Figure 6: Permitted Nozzle loads and torques at pump Nozzle Suction nozzle Discharge nozzle ∅DN ∅DN Sizes Forces in N Torques in Nm Forces in N Torques in Nm ∑F...
5.2 Piping checklists 5.2.5 Connection of Piping to the Pump NOTICE: The pump must not be used as fixed point for the piping. The permitted piping loads must not be exceeded, refer to . Suction and discharge pipe • The pipes must be of a size and design that liquid can flow freely into the pump and that the pump functions without problems.
5.3 Drive Additional connections Any required sealing, flushing or cooling pipe connections must be installed. Please consult the data sheet to see which pipes, pressures and amounts are necessary. The position and size of connections to the pump are given in the appendix, "Connections". NOTICE: These connections are essential for the function.
6 Commissioning, Startup, Operation, and Shutdown 6 Commissioning, Startup, Operation, and Shutdown 6.1 Commissioning, Startup, Operation, and Shutdown 6.1.1 Preparation for startup WARNING: • Risk of serious physical injury or death. Exceeding any of the pump operating limits (e.g. - pressure, temperature, power, etc.) could result in equipment failure, such as explosion, seizure, or breach of containment.
6.1 Commissioning, Startup, Operation, and Shutdown seal or shaft sleeve damage by ensuring that the seal is properly installed and centered on the sleeve. NOTICE: • Verify the driver settings before you start any pump. Refer to the applicable drive equip- ment IOMs and operating procedures.
6.1 Commissioning, Startup, Operation, and Shutdown 10. Check direction of rotation by switching on and off briefly. It must be the same as the directional arrow on the drive lantern. 6.1.4 Switch on drive Immediately (max. 10 seconds on 50 Hz resp. max. 7 seconds on 60 Hz currency feed) after reach- ing normal operating speed open discharge valve adjust the required operating point.
6.1 Commissioning, Startup, Operation, and Shutdown These flow limits are valid unless other data is available in the curves or data sheets: = 0.1 x Q Short-term operation = 0.3 x Q Continuous operation = 1.2 x Q Continuous operation = Flow in efficiency optimum Permitted number of starts Do not start the pump more than the number of times shown in this chart:...
6.1 Commissioning, Startup, Operation, and Shutdown NOTICE: Cavitation can cause damage to the internal surfaces of the pump. Ensure net positive suction head available (NPSH ) always exceeds NPSH required (NPSH ) as shown on the published performance curve of the pump. Operation under freezing conditions NOTICE: Do not expose an idle pump to freezing conditions.
7 Maintenance 7 Maintenance 7.1 Maintenance 7.1.1 Maintenance schedule Maintenance inspections A maintenance schedule includes these types of inspections: • Routine maintenance • Routine inspections • Three-month inspections • Annual inspections Shorten the inspection intervals appropriately if the pumped fluid is abrasive or corrosive or if the envi- ronment is classified as potentially explosive.
7.1 Maintenance 7.1.2 Mechanical seals NOTICE: Before opening the pump, it is essential that you note Safety Regulations and Dismantling and repair of pump. If the liquid being handled leaks out at the mechanical seal, it is damaged and must be replaced. Replacement of the mechanical seal according to accompanying "Mounting Instructions for Shaft seal- ing".
7.1 Maintenance • Risk of serious personal injury from exposure to hazardous or toxic liquids. A small amount of liquid will be present in certain areas like the seal chamber upon disassembly. CAUTION: • Avoid injury. Worn pump components can have sharp edges. Wear appropriate gloves while handling these parts.
7.1 Maintenance Before disassembly check if required parts are ready. Disassemble the pump only so far, as required for the replacement of the repair part. 7.1.8 Removal and Installation of screen in the motor lantern The guard plates (680) are fixed in the windows of the motor lantern (681). For removing insert a screwdriver about 4 cm into the last row with punches of the guard plate.
7.1 Maintenance 7.1.10 Removal of Impeller CAUTION: A worn impeller and/or pump housing can have very sharp edges. Wear protective gloves. If the impeller has back vanes check the axial clearance "a" between the impeller (230) and casing cover (161) before you continue the dismounting. Refer to sect. 8.7.1. NOTICE: Be sure to locate pry bars under impeller vanes to prevent damage to the impeller.
7.1 Maintenance 7.1.12 Removal of Stub Shaft Loosen screws (920.41) and pull motor with stub shaft (210) out of the motor lantern (341). Loosen radial stub shaft screwing (904.41 and 904.42) (stud bolts) and deduct stub shaft (210) from motor shaft. For support (break loose) you can insert a solid screw driver into the cross boring, press it against the front face of the motor and move both shafts against each other.
7.1 Maintenance Radial clear- min. 0,15 0,17 0,20 0,22 0,25 ances (mm) max. 0,19 0,22 0,24 0,27 0,30 worn 0,78 0,85 0,90 1,05 1,15 Axial 0,8 - 1,2 worn max. 1,7 clearance a (mm) When the wear limits has been reached or exceeded, the worn parts must be replaced. For volute casings (102V) with a wear ring (502.11) and cover casings (161) with a wear ring (502.31) there are the following possibilities to restore the correct clearance: Renew impeller (230) and wear ring.
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7.1 Maintenance After the mounting of the back pull out assembly, and its assembly into the volute casing, turn the shaft and control the free moving of the pump in this way. The shaft sealing will cause slightly resist- ance when turning, but there must not be any contact between metal parts. 7.1.14.2 Mount the stub shaft Insert key in the motor stump.
8 Troubleshooting 8 Troubleshooting 8.1 Troubleshooting 8.1.1 Operation troubleshooting The following notes on causes of faults and how to repair them are intended as an aid to recognising the problem. The manufacturer's Customer Service Department is available to help repair faults that the op- erator cannot or does not want to repair.
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8.1 Troubleshooting Symptom Cause Remedy Inner components suffering from wear Replace worn parts Density and/or viscosity of liquid han- Seek assistance dled is too high Discharge stops after a time Flow too little Increase min. flow (open discharge valve, bypass) Pump or suction/intake pipe blocked Clean Suction height too big / NPSH of sys-...
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8.1 Troubleshooting Symptom Cause Remedy Inner components suffering from wear Replace worn parts Density and/or viscosity of liquid han- Seek assistance dled is too high Head too high Speed too high • Reduce speed • Compare speed of motor with specified pump speed (rating plate) •...
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8.1 Troubleshooting Symptom Cause Remedy System-related vibrations (resonance) Seek assistance Temperature in pump too high Flow too little Increase min. flow (open discharge valve, bypass) Pump and/or pipes not completely fil- • Fill led with liquid • Vent Suction height too big / NPSH of sys- •...
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8.1 Troubleshooting Symptom Cause Remedy • Is foundation plate/frame proper- ly cast in place? ICB Installation, Operation and Maintenance Instruction...
9 Spare parts, Spare pumps 9 Spare parts, Spare pumps 9.1 Spare parts, Spare pumps 9.1.1 Spare parts Spare parts should be selected to last for two-years continuous operation. If no other guidelines are ap- plicable, we recommend that you stock the number of parts listed below (in accordance with VDMA 24296).
9.1 Spare parts, Spare pumps 9.1.2 Stand-by pumps NOTICE: It is essential that a sufficient number of stand- by pumps are kept ready for use in plants where failure of a pump could endanger human life or cause damage to property or high costs. Regular checks should be carried out to ensure that such pumps are always ready for use (see Storage / longer periods of non- operation).
10 Appendix 10 Appendix 10.1 Single mech. seal without shaft sleeve (Design code S1..2) 10.1.1 Safety Instructions NOTICE: Every person, who is responsible for the installation, removal, operation, start-up and mainte- nance of the shaft seal, must also have read and understood the Installation, Operation and Maintenance Instruction of the particular pump and especially General remarks and General, and follow the instructions under any circumstances! For pumps which are designed in conformity with the Directive 94/9/EC (Atex95) for environment en-...
10.1 Single mech. seal without shaft sleeve (Design code S1..2) 161 Casing cover 527 a) Fixing ring 210 Shaft 560 b) Pin 230 Impeller 904.31 a) Set screw 412.21 O-ring 904.32*) Set screw 433 Mech. seal 922 Impeller nut 502.31*) Wear ring 940.31 Key *) optional a) not for all designs...
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10.1 Single mech. seal without shaft sleeve (Design code S1..2) NOTICE: Pay attention to the utmost cleanness! Especially the seal faces must be clean, dry and un- damaged. Don´t apply lubrication on the seal faces of the mechanical seal. • If a lubricant is provided with the replacement mechanical seal, you should use this.
10.2 Single mechanical seal with quench without shaft sleeve (Design code S4..2) 10.2 Single mechanical seal with quench without shaft sleeve (Design code S4..2) 10.2.1 Safety Instructions NOTICE: Every person, who is responsible for the installation, removal, operation, start-up and mainte- nance of the shaft seal, must also have read and understood the Installation, Operation and Maintenance Instruction of the particular pump and especially General remarks and General, and follow the instructions under any circumstances!
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10.2 Single mechanical seal with quench without shaft sleeve (Design code S4..2) Index of parts: 161 Casing cover 502.31*) Wear ring 210 Shaft 527 a) Fixing ring 230 Impeller 542.31 Throttle bush 412.21 O-ring 560 b) Pin 412.32 O-ring 904.31 a) Grub screw 433 Mechanical seal 904.32*) Grub screw 471Q Quench cover...
10.2 Single mechanical seal with quench without shaft sleeve (Design code S4..2) 52,5 3/8-18 47,5 57,5 3/8-18 Subject to technical alterations! 10.2.3 Removal of mechanical seal For that purpose use the appropriate sectional drawing and the enclosed data sheet of the mechanical seal.
10.3 Design: S1...2 Single mech. seal, unbalanced (DIN 24960, l1k / EN 12756, design K, form U), Impeller with back vanes NOTICE: Use only lubricants when you are sure that there can´t occur any dangerous reactions between the pumpage and the lubricant. NOTICE: Make all required parts available, so that assembly can be completed quickly.
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10.3 Design: S1...2 Single mech. seal, unbalanced (DIN 24960, l1k / EN 12756, design K, form U), Impeller with back vanes Table 6: Valid for 40-25-160 65-40-160 80-50-315 125-100-200 40-25-200 65-40-200 100-65-160 125-100-250 40-25-250 65-40-250 100-65-200 150-125-250 50-32-160 65-40-315 100-65-250 200-150-250 50-32-200 80-50-160...
10.5 Design: S4...2 Single mech. seal, unbalanced (DIN 24960, l1k / EN 12756, design K, form U), with quench, Impeller with back vanes Part name: Gasket 412.21 O-ring Mechanical seal 502.11 *) Wear ring 502.31*) Wear ring 527 ** Fixing ring 554.41 Washer 554.42 ***)
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10.5 Design: S4...2 Single mech. seal, unbalanced (DIN 24960, l1k / EN 12756, design K, form U), with quench, Impeller with back vanes Table 8: 40-25-160 65-40-160 80-50-315 125-100-200 40-25-200 65-40-200 100-65-160 125-100-250 40-25-250 65-40-250 100-65-200 150-125-250 50-32-160 65-40-315 100-65-250 200-150-250 50-32-200 80-50-160...
10.6 Design: S4...2 Single mech. seal, unbalanced (DIN 24960, l1k / EN 12756, design K, form U), with quench, Impeller with balancing holes Part name: 183 ***) Support foot 183P **) Pump alignment Stub shaft Impeller Motor lantern Gasket 412.21 O-ring 412.32 O-ring...
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10.6 Design: S4...2 Single mech. seal, unbalanced (DIN 24960, l1k / EN 12756, design K, form U), with quench, Impeller with balancing holes Valid for type Table 9: 100-65-315 125-80-315 125-100-315 125-125-315 Part name: 102V Volute casing Casing cover 183 ***) Support foot 183P **) Pump alignment...
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10.6 Design: S4...2 Single mech. seal, unbalanced (DIN 24960, l1k / EN 12756, design K, form U), with quench, Impeller with balancing holes Part name: Gasket 412.21 O-ring Mechanical seal 471Q Quench cover 502.11 *) Wear ring 502.31*) Wear ring 527 ** Fixing ring 542.31...
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10.6 Design: S4...2 Single mech. seal, unbalanced (DIN 24960, l1k / EN 12756, design K, form U), with quench, Impeller with balancing holes Figure 13: Connections: Code Number Connection Bearing bracket 32, 42, 48 PM1 *) pressure gaging 1/4-18 NPT PM2 *) pressure gaging 1/4-18 NPT...
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10.6 Design: S4...2 Single mech. seal, unbalanced (DIN 24960, l1k / EN 12756, design K, form U), with quench, Impeller with balancing holes For the type of your pump refer to data sheet / order confirmation. See Design coding system. Figure 14: Dimensional drawing Pump ICB 40-25-160 ..
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10.6 Design: S4...2 Single mech. seal, unbalanced (DIN 24960, l1k / EN 12756, design K, form U), with quench, Impeller with balancing holes ICB 125-80-200 ..- ... 13,5 140 ICB 125-80-250 ..- ... 13,5 140 ICB 125-80-315 ..- ... 13,5 140 ICB 125-100-200 ..
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10.6 Design: S4...2 Single mech. seal, unbalanced (DIN 24960, l1k / EN 12756, design K, form U), with quench, Impeller with balancing holes ICB 50-32-250 ..- 132 ICB 50-32-250 ..- 160 ICB 50-32-250 ..- 180 ICB 50-32-250 ..- 200 ICB 50-32-315 ..
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10.6 Design: S4...2 Single mech. seal, unbalanced (DIN 24960, l1k / EN 12756, design K, form U), with quench, Impeller with balancing holes ICB 80-50-200 ..- 90 ICB 80-50-200 ..- 100 ICB 80-50-200 ..- 112 ICB 80-50-200 ..- 132 ICB 80-50-200 ..
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10.6 Design: S4...2 Single mech. seal, unbalanced (DIN 24960, l1k / EN 12756, design K, form U), with quench, Impeller with balancing holes ICB 100-65-315 ..- 200 ICB 125-80-160 ..- 90 ICB 125-80-160 ..- 100 ICB 125-80-160 ..- 112 ICB 125-80-160 ..
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10.6 Design: S4...2 Single mech. seal, unbalanced (DIN 24960, l1k / EN 12756, design K, form U), with quench, Impeller with balancing holes ICB 150-125-250 ..- 200 ICB 150-125-315 ..- 160 ICB 150-125-315 ..- 180 ICB 150-125-315 ..- 200 ICB 200-150-250 ..
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