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The purpose of this manual is to provide necessary information for: • Installation • Operation • Maintenance
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 installing and using the product.
Save this manual for future reference and keep it readily available.
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 considered 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. Specifications such as weights, dimensions or centers of gravity of the pump, pump unit or subassemblies are described in the supplier's applicable documentation.
• 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. • 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 measures 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. Prohibited 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.
• 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. • 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. • 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. • Running a pump without safety devices exposes operators to risk of serious personal injury or death. Never operate a unit unless appropriate safety devices (guards, etc.) are properly installed.
• 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.
This product contains Carbon Black a chemical known to the State of California to cause cancer. For more information go to www.P65Warnings.ca.gov
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
A hazardous situation which, if not avoided, will result in death or serious injury
A hazardous situation which, if not avoided, could result in death or serious injury
A hazardous situation which, if not avoided, could result in minor or moderate injury
• A potential situation which, if not avoided, could result in undesirable conditions
• A practice not related to personal injury
Electrical hazards are indicated by the following specific symbol:
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
The Ex symbol indicates safety regulations for Ex-approved products when used in atmospheres that are potentially explosive or flammable.
Always keep the station clean to avoid and/or discover emissions.
Move equipment to a safe/non Ex environment for repairs/adjustments or use spark resistant tools and work methods.
Observe these safety regulations regarding waste and emissions: • Appropriately dispose of all waste. • Handle and dispose of the processed liquid 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.
If the product has been contaminated in any way, such as from toxic chemicals or nuclear radiation, do NOT send the product to ITT until it has been properly decontaminated and advise ITT of these conditions before returning.
For electrical installation recycling requirements, consult your local electric utility.
Always follow local laws and regulations regarding recycling.
These safety rules apply: • 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. • Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
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 must be made by certified electricians in compliance with all international, national, state, and local regulations. For more information about requirements, see sections dealing specifically with electrical connections.
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. Personnel 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, enclosing equipment to reduce noise. Local law may provide specific guidance regarding exposure of personnel to noise and when noise exposure reduction is required.
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 potentially unsafe temperature. Do not touch hot surfaces. Allow pumps operating at a high temperature 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 necessary. Local law may provide specific guidance regarding exposure of personnel to unsafe temperatures.
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. • Make sure that you have a clear path of retreat. • 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. • Allow all system and pump components to cool before you handle them. • Make sure that the product has been thoroughly cleaned. • Disconnect and lock out power before you service the pump. • Check the explosion risk before you weld or use electric hand tools.
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 installing 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. • Do not exceed the maximum working pressure of the pump. • Do not open any vent or drain valve or remove any plugs while the system is pressurized. Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump, remove plugs, or disconnect piping.
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.
Follow these procedures for chemicals or hazardous fluids that have come into contact with your eyes or your skin:
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.
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 a ProCast 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 ProCast parts are used. • Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved products.
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
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.
Special care must be taken in potentially explosive environments to ensure that the equipment is properly operated and maintained. Compliance with the essential safety and health requirements has been assured by compliance with the following standards, method of protection Constructional Safety (C): ISO 80079-36 ISO 80079-37
Follow these special handling instructions if you have an Ex-approved unit.
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. • Any maintenance for Ex-approved products must conform to international and national standards (for example, EN 60079-17). ITT disclaims all responsibility for work done by untrained and unauthorized personnel.
These are the product and product handling requirements for Ex-approved products in potentially explosive atmospheres: • Only use the product in accordance with the approved motor data. • The Ex-approved product must never run dry during normal operation. Dry running during service and inspection is only permitted outside the classified area. • Before you start work on the product, make sure that the product and the control panel are isolated from the power supply and the control circuit, so they cannot be energized. • Do not open the product while it is energized or in an explosive gas atmosphere. • Make sure that thermal contacts are connected to a protection circuit according to the approval classification of the product, and that they are in use. • Intrinsically safe circuits are normally required for the automatic level-control system by the level regulator if mounted in zone 0. • The yield stress of fasteners must be in accordance with the approval drawing and the product specification. • Do not modify the equipment without approval from an authorized ITT representative. • Only use parts that are provided by an authorized ITT representative.
The Ex-directives are a specification enforced in Europe and the United Kingdom for electrical and non-electrical equipment installed in those locations. Ex-directives deal with the control of potentially explosive atmospheres and the standards of equipment and protective systems used within these atmospheres. The relevance of the Ex-requirements is not limited to Europe or the UK. You can apply these guidelines to equipment installed in any potentially explosive atmosphere.
Compliance is fulfilled only when you operate the unit within its intended use. Do not change the conditions of the service without the approval of an ITT representative. When you install or maintain explosion proof products, always comply with the directive and applicable standards (for example, IEC/EN 60079-14). 1. Monitoring the pump frame liquid end temperature. 2. Maintaining proper bearing lubrication. 3. Ensuring that the pump is operated in the intended hydraulic range. The Ex 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 https://www.gouldspumps.com/en-US/Tools-and-Resources/Literature/ IOMs/ or from your local ITT Goulds Pumps Sales representative. All pumping unit (pump, seal, coupling, motor and pump accessories) certified for use in an Ex classified environment, are identified by an Ex tag secured to the pump or the baseplate on which it is mounted.
Table 1: Temperature class definitions on page 12 is for the purpose of determining T'x' code for Ex applications with liquid temperatures exceeding 107ºC | 225ºF. 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.
Recommended bearing replacement interval (based on L10 life) = 17,520 hours of operation.
For additional safety, use condition-monitoring devices. Condition-monitoring devices include but are not limited to these devices: • Pressure gauges • Flow meters • Level indicators • Motor load readings • Temperature detectors • Bearing monitors • Leak detectors • PumpSmart control system
• 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 instructions 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. • If equipment is to be installed in a potentially explosive atmosphere and these procedures are not followed, personal injury or equipment damage from an explosion may result. • Particular care must be taken when the electrical power source to the equipment is energized. • Improper impeller adjustment could cause contact between the rotating and stationary parts, resulting in a spark and heat generation. • Lock out driver power to prevent electric shock, accidental start-up and physical injury. • NEVER start pump without proper prime. • Equipment that will operate in a potentially explosive environment must be installed in accordance with the following instructions. • All equipment being installed must be properly grounded to prevent unexpected static electric discharge. This includes ensuring that the PFA lined pumps (Model 3198), ETFE lined pumps (Model 3298, SP3298, V3298, E3198, CV3198), and the non-metallic liquid end pumps (Model NM3196) are pumping fluids that are conductive. If not, a static electric discharge may occur when the pump is drained and disassembled for maintenance purposes.
• All equipment being installed must be properly grounded to prevent unexpected static electric discharge. • When pumping fluids with conductivity less than 1000 ps/m follow IEC TS 60079 32-1 guidelines. • Alignment procedures must be followed to prevent unintended contact of rotating parts. Follow coupling manufacturer’s installation and operation procedures. • When installing in a potentially explosive environment, ensure that the motor and accessories are properly certified. • 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. • The impeller and wear ring clearance setting procedures 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. • Service temperature in an Ex classified environment is limited to the area classification specified on the Ex tag affixed to the pump (reference Table 1 in the Safety section for Ex classifications). • The coupling used in an Ex classified environment must be properly certified. • The coupling guard used in an Ex classified environment must be constructed from a spark-resistant material. • Bearings must be lubricated properly in order to prevent excess heat generation, sparks and premature failure. • The mechanical seal used in an Ex classified environment must be properly certified. • The mechanical seal must have an appropriate seal flush system. Failure to do so will result in excess heat generation and seal failure. • Packed stuffing boxes are not allowed in an Ex classified environment. • Dynamic seals are not allowed in an Ex classified environment. • Pumps must be fully primed at all times during operation. • The preventive maintenance section must be adhered to in order to keep the applicable Ex classification of the equipment. Failure to follow these procedures will void the Ex classification for the equipment. Bearing replacement intervals are given in the specific pump model IOM. • Inspection intervals should be shortened appropriately if the pumpage is abrasive and/or corrosive, or if the environment is classified as potentially explosive. • Throughout this section on bearing lubrication, different pumpage temperatures are listed. If the equipment is Ex certified and the listed temperature exceeds the applicable value shown in Table 1 under SAFETY, then that temperature is not valid. Should this situation occur, please consult with your ITT/Goulds representative. • Cooling systems, such as those for bearing lubrication, mechanical seal systems, etc., where provided, must be operating properly to prevent excess heat generation, sparks and premature failure. • Rotate shaft by hand to ensure it rotates smoothly and there is no rubbing which could lead to excess heat generation, sparks and premature failure. • Flange loads from the piping system, including those from thermal expansion of the piping, must not exceed the limits of the pump. Casing deformation can result in contact with rotating parts which can result in excess heat generation, sparks and premature failure. • Ensure that pump and systems are free of foreign objects before operating and that objects cannot enter the pump during operation. Foreign objects in the pumpage or piping system can cause blockage of flow which can result in excess heat generation, sparks and premature failure.
• Do not insulate or allow the bearing housings to accumulate a dust layer as this can result in excess heat generation, sparks and premature failure. • Check for magnetism on the pump shaft and demagnetize the shaft if there is any detectable magnetism. Magnetism will attract ferritic objects to the impeller, seals and bearings which can result in excess heat generation, sparks and premature failure. • Leakage of process liquid may result in creation of an explosive atmosphere. Ensure the materials of the pump casing, impeller, shaft, sleeves, gaskets and seals are compatible with the process liquid. • Leakage of process liquid may result in creation of an explosive atmosphere. Follow all pump and seal assembly procedures. • A buildup of gases within the pump, sealing system and or process piping system may result in an explosive environment within the pump or process piping system. Ensure process piping system, pump and sealing system are properly vented prior to operation. • Sealing systems that are not self purging or self venting, such as plan 23, require manual venting prior to operation. Failure to do so will result in excess heat generation and seal failure. • Do not apply additional paint or coatings to the pump when in an Ex environment. Static electric discharge can be initiated when contacting or rubbing surfaces with excessive coating thickness. • Potential electrostatic charging hazard. Do not rub, clean, or blast equipment with dry cloth or dry media. • Stray electrical currents may ignite explosive atmospheres. Ensure drives are certified for variable frequency drive operation by the manufacturer. • User shall observe necessity of using a safety device, such as a flame arrestor, to prevent flame entering or leaving the pump sump, tank, or barrel when applicable. • For variable speed motor applications, the electric motor must be specified with shaft grounding and used with a conductive type coupling suitable for the area classification. • In plants or pumps with cathodic corrosion protection, a small current constantly flows through the construction. This is not permissible on the complete pump or partially-assembled machinery without further precautions being taken. ITT should be consulted in this context. • Move equipment to a safe/non Ex environment for repairs/adjustments or use spark resistant tools and work methods.
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