Goulds Pumps 3196 i-FRAME Installation, Operation And Maintenance Manual
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Goulds Pumps 3196 i-FRAME Installation, Operation And Maintenance Manual

Severe duty process pump
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Installation, Operation,
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Model 3196 i-FRAME

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Summary of Contents for Goulds Pumps 3196 i-FRAME

  • Page 1 Installation, Operation, and Maintenance Manual Model 3196 i-FRAME...

  • Page 3: Table Of Contents

    Pump-to-driver alignment instructions ................34 C-face adapter ........................37 Grout the baseplate ......................37 Piping checklists ........................39 General piping checklist ..................... 39 Suction-piping checklist ...................... 40 Discharge piping checklist ....................42 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 4 Remove the frame adapter (MTi, LTi, XLT-i, i17) ..............82 Remove the inboard labyrinth oil seal ................... 83 Disassemble the power end (STi, MTi) ................. 83 Disassemble the power end (STi and MTi with duplex bearings) .......... 85 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 5 Assembly troubleshooting ....................141 ® i-ALERT Condition Monitor troubleshooting ..............141 Parts Listings and Cross-Sectionals ................. 142 Parts list ..........................142 Certification: CE or CE ATEX ..................... 151 Certificates of conformance ....................151 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 6 Table of Contents Other Relevant Documentation or Manuals ..............157 Local ITT Contacts ......................158 Regional offices ........................158 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 7: Introduction And Safety

    ITT representative. Always specify the exact product type and identification code when requesting technical information or spare parts. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 8: Safety

    • Personal accidents and health problems • Damage to the product • Product malfunction Hazard levels Hazard level Indication A hazardous situation which, if not avoided, will result in death or serious injury DANGER: Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 9: Environmental Safety

    If the product has been contaminated in any way, such as from toxic chemicals or nuclear radiation, do NOT send the product to ITT unless it has been properly decontaminated. Electrical installation For electrical installation recycling requirements, consult your local electric utility. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 10: User Safety

    Failure to observe the instructions contained in this manual could result in personal injury and property damage, and may void the warranty. Read this manual carefully before installing and using the product. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 11: Ex-Approved Products

    Product and product handling requirements 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. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 12: Product Approval Standards

    • Temperature Class: T4 (for ambients up to 100ºC) • ATEX Marking: Ex II 1 G CSA certification Intrinsically safe for: • Class I, Div. 1, Groups A, B, C, D • Class II, Div. 1, Groups E, F, G Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 13: Product Warranty

    • Material damages • Economic losses Warranty claim 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. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 14: Transportation And Storage

    A bare pump with lifting handles Lift the pump by the handles. A base-mounted pump Use slings under the pump casing and the drive unit, or under the base rails. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 15 Do not use this method to lift a Polyshield ANSI Combo with the pump and motor mounted. These items are not designed to handle the heavy weight of the Polyshield system. Doing so may result in equipment damage. Figure 3: Example of a proper lifting method Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 16 Securing at the frame adapter will prevent slipping of the strap and possible equipment damage. Figure 5: Example of a proper lifting method with a strap secured around the frame adapter Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 17: Storage Guidelines

    Table 2: Situations when the pump is or is not frostproof Situation Condition Operating The pump is frostproof. Immersed in a liquid The pump is frostproof. Lifted out of a liquid into a temperature below The impeller might freeze. freezing Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 18: Product Description

    Ensure that the code classifications on the pump are compatible with the specific environment in which the equipment is to be installed. If they are not compatible, do not operate the equipment and contact an ITT representative before proceeding. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 19: Part Description 3196

    The threads are sealed from the pumped liquid by a PTFE O-ring for the 3196. Cover Standard • Stuffing Box cover designed for packing or a mechanical seal • BigBore or TaperBore® PLUS seal chambers designed for improved performance of mechanical seals Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 20: General Description I-Alert Condition Monitor

    ("Software") in binary executable form in the normal operation of the i-ALERT condition monitor for monitoring the condition of an Goulds Pump Inc. model. Title, ownership rights, and intellectual property rights in and to the Software remain in ITT or its third-party Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 21 This table shows the average condition monitor battery life under normal and alarm-mode operating conditions. Condition monitor operational state Battery life Normal operating and environmental conditions Three to five years Alarm mode One year Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 22: Nameplate Information

    ANSI standard designation MAT L. CONST. Material of which the pump is constructed SER. NO. Serial number of the pump MAX DSGN PSI @ Maximum pressure at 100ºF according to the pump design 100ºF Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 23 Outboard bearing designation BRG. I. B. Inboard bearing designation Serial number of the pump LUBE Lubricant, oil or grease ATEX nameplate Figure 12: ATEX nameplate Nameplate field Explanation Group 2 Category 2 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 24 Ensure that the code classifications on the pump are compatible with the specific environment in which the equipment is to be installed. If they are not compatible, do not operate the equipment and contact an ITT representative before proceeding. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 25: Installation

    If the pump location is overhead, under- Consider a consultation with a noise specialist. take special precautions to reduce pos- sible noise transmission. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 26: Foundation Requirements

    Prepare the baseplate for mounting 1. Remove all the attached equipment from the baseplate. 2. Clean the underside of the baseplate completely. 3. If applicable, coat the underside of the baseplate with an epoxy primer. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 27: Install The Baseplate Using Shims Or Wedges

    • A maximum difference of 3.2 mm | 0.125 in. lengthwise • A maximum difference of 1.5 mm | 0.059 in. across You can use the baseplate-leveling worksheet when you take the readings. 6. Hand-tighten the nuts for the foundation. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 28: Install The Baseplate Using Jackscrews

    Failure to do so can result in equipment damage or decreased performance. a) Put one machinist's level lengthwise on one of the two pads. b) Put the other machinist's level across the ends of the two pads. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 29 7. Check that the driver's mounting pads are level and adjust the jackscrews and the foundation bolts if necessary. The correct level measurement is a maximum of 0.0167 mm/m | 0.002 in./ft . Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 30: Install The Baseplate Using Spring Mounting

    When the baseplate is level, tighten the top adjusting nuts so that the top springs are not loose in their followers. 8. Fasten the lower and upper jam nuts on each spring assembly. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 31: Install The Baseplate Using Stilt Mounting

    Adjust the height and level the baseplate by moving the lower adjusting nuts. c) When the baseplate is level, tighten the top adjusting nuts. 8. Fasten the lower and upper jam nuts on each stilt. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 32 1. Mounting plate 2. Mounting nut 3. Stilt bolt 4. Foundation cups 5. Washer 6. Upper adjustment nut 7. Mounting washer 8. Mounting bolt Figure 21: Example of an installed stilt assembly Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 33: Baseplate-Leveling Worksheet

    Installation Baseplate-leveling worksheet Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 34: Install The Pump, Driver, And Coupling

    Final alignment (hot alignment) checks When After the first run This ensures correct alignment when both the pump and the driver are at operating temperature. Periodically This follows the plant operating procedures. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 35: Permitted Indicator Values For Alignment Checks

    This makes it possible to move the driver before you make alignment corrections. when you make alignment corrections. Check the alignment again after any mechanical adjustments. This corrects any misalignments that an adjustment may have caused. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 36: Attach The Dial Indicators For Alignment

    • Add shims in order to raise the feet of the driver at the other end. Figure 23: Side view of an incorrect vertical alignment 4. Repeat the previous steps until the permitted reading value is achieved. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 37 Figure 25: Side view of an incorrect vertical alignment 4. Repeat the previous steps until the permitted reading value is achieved. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 38 2. Rotate the indicators to the bottom-center position (6 o’clock). 3. Record the indicator readings. 4. Make corrections according to the separate instructions for angular and parallel alignment until you obtain the permitted reading values. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 39: C-Face Adapter

    If high reliability (with shaft alignments of less than 0.05mm | 0.002 in.) is required for the pump, use a foot-mounted drive unit on a precision-machined baseplate and perform a conventional alignment. Grout the baseplate Required equipment: Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 40 6. Fill the remainder of the baseplate with grout, and allow the grout to set for at least 48 hours. 1. Baseplate 2. Grout 3. Foundation 4. Dam 5. Bolt Figure 29: Fill remainder of baseplate with grout 7. Tighten the foundation bolts. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 41: Piping Checklists

    If the pump handles liquids at This helps to prevent misalignment due to linear expan- elevated temperatures, make sion of the piping. sure that the expansion loops and joints are properly installed. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 42: Suction-Piping Checklist

    See the Example sections for illustrations. Install an eccentric reducer between the pump inlet and the suction piping. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 43 Make sure that the suction piping is This prevents air from entering the pump through adequately submerged below the sur- a suction vortex. face of the liquid source. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 44: Discharge Piping Checklist

    • Inspection and maintenance of the pump • Reduce risk of pumpage vaporization and vapor locking at low flow rates for low specific gravity liquids. See Example: Discharge piping equipment for illustrations. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 45 1. Check valve (incorrect position) 1. Bypass line 2. The isolation valve should not be positioned 2. Shut-off valve between the check valve and the pump. 3. Check valve 4. Discharge isolation valve Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 46: Commissioning, Startup, Operation, And Shutdown

    • Bring variable-speed drivers to the rated speed as quickly as possible. • Run a new or rebuilt pump at a speed that provides enough flow to flush and cool the close-running surfaces of the stuffing-box bushing. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 47: Remove The Coupling Guard

    3. Remove the nut, bolt, and washers from the driver half of the coupling guard. 4. Remove the driver-side end plate. 5. Remove the driver half of the coupling guard: a) Slightly spread the bottom apart. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 48 7. Remove the pump half of the coupling guard: a) Slightly spread the bottom apart. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 49: Check The Rotation - Frame Mounted

    6. Lock out power to the driver. Impeller-clearance check The impeller-clearance check ensures the following: • The pump turns freely. • The pump operates at optimal efficiency for long equipment life and low energy consumption. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 50: Impeller Clearances (3196 And Ht 3196)

    • Electrical connections must be made by certified electricians in compliance with all international, national, state, and local rules. • Refer to driver/coupling/gear manufacturer's installation and operation manuals (IOM) for specific instructions and recommendations. 1. Remove the coupling guard. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 51: Set The Impeller Clearance - Feeler Gauge Method (All Except Cv 3196)

    • Refer to driver/coupling/gear manufacturer's installation and operation manuals (IOM) for specific instructions and recommendations. 1. Lock out the driver power and remove the coupling guard. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 52: Couple The Pump And Driver

    Couplings must have proper certification to be used in an ATEX classified environment. Use the instructions from the coupling manufacturer in order to lubricate and install the coupling. Refer to driver/coupling/gear manufacturers IOM for specific instructions and recommenda- tions. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 53: Install The Coupling Guard

    If the pump size is... Then... STi, MTi, LTi Align the pump-side end plate to the bearing frame. You do not need to adjust the impeller. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 54 Place the coupling guard half over the pump-side end plate. 1. Annular groove 2. Pump-side end plate 3. Driver 4. Pump half of the coupling guard Figure 34: Guard half installation Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 55 1. Nut 2. Washer 3. Bolt Figure 36: Secure coupling guard half to end plate 5. Put the driver half of the coupling guard in place: a) Slightly spread the bottom apart. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 56 8. Use a bolt, a nut, and two washers to secure the coupling guard half to the end plate. Hand- tighten only. The hole is located on the driver-side of the coupling guard half. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 57: Bearing Lubrication

    Pumps are shipped without oil. You must lubricate oil-lubricated bearings at the job site. Grease-lubricated bearings are lubricated at the factory. The bearing manufacturer fills greased-for-life bearings with grease and seals them at the factory. You do not need to lubricate or seal these bearings. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 58 Fill the bearing frame with oil until the oil level reaches the middle of the sight glass (319). The correct volume of oil required for each size of bearing frame can be found in the ‘Oil Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 59: Shaft-Sealing Options

    Connection of sealing liquid for mechanical seals Seal lubrication is required Seal faces must have liquid film between them for proper lubrication. Locate the taps using the illustrations shipped with the seal. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 60: Packed Stuffing Box Option

    Dynamic seals are not allowed in an ATEX-classified environment. The dynamic seal consists of two parts: • Repeller seal • Secondary seal (one of the following): • Graphite packing • Elastomenic face seal Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 61: Set An Elastomeric Face Seal

    2. Open the air vents on the suction and discharge piping until the pumped fluid flows out. 3. Close the air vents. 1. Discharge isolation valve 2. Check valve 3. Suction isolation valve Figure 41: Suction supply above pump Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 62: Prime The Pump With The Suction Supply Below The Pump

    5. Check valve Figure 42: Pump priming with suction supply below pump This illustration is an example of priming the pump with a foot valve using a bypass around the check valve: Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 63: Other Methods Of Priming The Pump

    Before you start the pump, you must perform these tasks: • Open the suction valve. • Open any recirculation or cooling lines. 1. Fully close or partially open the discharge valve, depending on system conditions. 2. Start the driver. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 64: Activate The I-Alert Condition Monitor

    1. Displays a series of red LEDs followed by a solid green LED. 2. Collects eight samples that are spaced one second apart. 3. Averages these readings to establish the baseline vibration level. 4. Flashes a green LED after approximately twelve seconds. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 65: I-Alert ® Condition Monitor Routine Operation

    • The pumped fluid exceeds the rated flow rate. • Make sure to operate the pump at or near the rated conditions. Failure to do so can result in pump damage from cavitation or recirculation. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 66: Shut Down The Pump

    This should take 10-15 seconds if the condition monitor is in normal operating mode and approximately five seconds if the condition monitor is in alarm mode. 2. Remove the magnet. If the deactivation is successful, solid red LEDs will be displayed. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 67: Reset The I-Alert Condition Monitor

    1. Touch a magnet to the condition monitor over the ITT logo to turn the power on.The condition monitor begins to establish a new baseline vibration level. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 68: Make The Final Alignment Of The Pump And Driver

    See Remove the coupling guard in the Maintenance chapter. 4. Check the alignment while the unit is still hot. See Pump-to-driver alignment in the Installation chapter. 5. Reinstall the coupling guard. 6. Restart the pump and driver. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 69: Maintenance

    • Check the pump power. If the pump performance does not satisfy your process requirements, and the process requirements have not changed, then perform these steps: 1. Disassemble the pump. 2. Inspect it. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 70: Bearing Maintenance

    Use ISO viscosity grade 100 with bearing-frame cooling or finned-tube oil cooler. The finned-tube oil cooler is standard with the HT 3196 model and optional for all other models. Pumped-fluid temperatures exceed 177°C | 350°F Use synthetic lubrication. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 71: Regrease The Grease-Lubricated Bearings

    4. Make sure that the frame seals are seated in the bearing housing. If they are not, press them in place with the drains located at the bottom. 5. Reinstall the grease-relief plugs. 6. Wipe off any excess grease. 7. Recheck the alignment. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 72: Lubricate The Bearings After A Shutdown Period

    The mechanical seal used in an Ex-classified environment must be properly certified. CAUTION: Running a mechanical seal dry, even for a few seconds, can cause seal failure and physical injury. Never operate the pump without liquid supplied to the mechanical seal. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 73: Packed Stuffing-Box Maintenance

    NOTICE: Never over-tighten packing to the point where less than one drop per second is observed. Over-tightening can cause excessive wear and power consumption during opera- tion. If you cannot tighten the packing to obtain less than the specified leakage rate, then replace the packing. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 74: Dynamic-Seal 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. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 75: Tools Required

    Do not reinstall the plug or close the drain valve until the reassembly is complete. 2. Remove the coupling guard. Remove the coupling 1. Disconnect the coupling. 2. Remove the C-face adapter. 3. Remove the coupling-guard pump end-plate. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 76: Remove The Back Pull-Out Assembly

    2. Does your pump use a C-face adapter? • If Yes: Place one sling from the hoist through the frame adapter (108) or frame (228A) for the STi and a second sling from the hoist through the C-face adapter. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 77 7. Mark and remove the shims from under the frame foot and save them for reassembly. 8. Remove and discard the casing gasket. You will insert a new casing gasket during reassembly. 9. Remove the jackscrews. 10. Clean all gasket surfaces. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 78: Remove The Coupling Hub

    1. Slide the shaft wrench (A05107A or A01676A) over the shaft (122) and key. 2. Rotate the impeller (101) clockwise (viewed from the impeller end of the shaft) and raise the wrench off of the work surface. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 79: Remove The Impeller (Xlt-I, And I17)

    CAUTION: Risk of physical injury from sharp edges. Wear heavy work gloves when handling impellers. Clamp the frame foot (241) to the workbench when you use this method to remove the impeller. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 80 If the impeller cannot be removed by the previous methods, cut the shaft between the gland and the frame, remove the impeller, stuffing-box cover, gland, sleeve, and shaft end as a unit. Do not apply heat. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 81: Seal-Chamber Cover Removal

    Be careful with the mechanical seal. Carbon or ceramic components are brittle and easily broken. 5. Remove the rotary portion of the seal from the sleeve by loosening the setscrews and sliding it off the sleeve. Refer to the mechanical-seal instructions for more information. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 82: Remove The Stuffing-Box Cover (3196, Cv 3196, Ht 3196, Lf 3196, 3796)

    Remove the stuffing-box cover (3196, CV 3196, HT 3196, LF 3196, 3796) 1. Remove the gland nuts (355) and the gland (107). 2. Remove the stuffing-box-cover nuts (370H). 3. Remove the stuffing-box cover (184). Figure 55: Stuffing box cover removal Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 83: Remove The Dynamic Seal

    5. Remove the packing (106) and lantern ring (105) from the stuffing-box cover (184). A lantern ring does not come with self-lubricating graphite packing. Figure 58: Packing and lantern ring removal Remove the dynamic seal 1. Remove the stud nuts (370H). Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 84: Remove The Frame Adapter (Mti, Lti, Xlt-I, I17)

    The 3198 frame adapter is not interchangeable with the adapter of any other model. 1. Remove the dowel pins (469B) and the bolts (370B). 2. Remove the frame adapter (108). 3. Remove and discard the gasket (360D). Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 85: Remove The Inboard Labyrinth Oil Seal

    1. Remove the clamp screws (370C) and back off the jam nuts (423). 2. Tighten the jack screws (370D) evenly to move the bearing housing (134) out of the bearing frame (228A). Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 86 7. Remove the bearing housing (134) and bearings (112A and 168A) from the shaft (122). Figure 64: Bearing housing and bearings removal 8. Remove the bearing locknut (136) and bearing lock washer (382). 9. Remove the inboard bearing (168A). 10. Remove the outboard bearing (112A). Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 87: Disassemble The Power End (Sti And Mti With Duplex Bearings)

    2. Tighten the jack screws (370D) evenly to move the bearing housing (134) out of the bearing frame (228A). 3. Remove the shaft assembly from the bearing frame (228A). Figure 66: Shaft assembly removal Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 88 Figure 68: Bearing housing and bearing removal 8. Remove the inboard bearing (168A). Figure 69: Inboard bearing removal 9. Remove the bearing locknut (136) and bearing lockwasher (382). 10. Remove the outboard bearings (112A). Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 89: Disassemble The Power End (Lti)

    Figure 71: Shaft assembly removal 4. Remove the jack screws (370D) with the nuts (423). 5. Remove the clamp-ring screws (236A) and separate the clamp ring (253B) from the bearing housing (134). Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 90 Use force only on the inner race when pressing bearings from the shaft. Failure to do so may result in equipment damage. NOTICE: Do not reuse bearings if removed from shaft. Doing so may result in equipment damage. Replace the bearings before reassembly. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 91: Disassemble The Power End (Xlt-I And I17)

    3. Tighten the jack screws (370D) evenly to move the bearing housing (134) out of the bearing frame (228A). 4. Remove the shaft assembly from the bearing frame (228A). 5. Remove the jack screws (370D), the nuts (423), and the bearing housing O-ring. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 92 11. Remove the bearing locknut (136), the bearing lockwasher (382), and the outboard bearing (112A). NOTICE: Use force only on the inner race when pressing bearings from the shaft. Failure to do so may result in equipment damage. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 93: Disassemble The Power End (Xlt-I And I17 With Duplex Bearings)

    4. Remove the shaft assembly from the bearing frame (228A). 5. Remove the jack screws (370D) and the nuts (423). 6. Remove the bearing housing O-ring (496) and the inboard bearing (168A). Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 94: Disassemble The Bearing Frame

    Do not reuse bearings if removed from shaft. Doing so may result in equipment damage. Replace the bearings before reassembly. Disassemble the bearing frame 1. Remove these plugs from the bearing frame (228A). • oil-fill plug (113A) Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 95: Guidelines For I-Alert Condition Monitor Disposal

    1. Loosen the motor-mounting bolts and remove the motor. Table 12: Required number of motor-mounting bolts This table shows the number of motor-mounting bolts. Pump frame Motor frame Number of bolts Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 96: Pre-Assembly Inspections

    • Pitting that is greater than 3.2 mm | 1/8 in. deep • Irregularities in the casing-gasket seat surface Casing areas to inspect The arrows point to the areas to inspect for wear on the casing: Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 97 Figure 78: Areas to inspect for wear on the 3196 impeller. Frame adapter check and replacement • Replace the frame adapter if it has cracks or excessive corrosion damage. • Make sure the gasket surface is clean. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 98: Shaft And Sleeve Replacement Guidelines

    Table 13: Shaft runout tolerances for sleeve fit and coupling fit Sleeve fit in millimeters | inches Coupling fit in millimeters | inches With sleeve 0.025 | 0.001 0.025 | 0.001 Without sleeve 0.051 | 0.002 0.025 | 0.001 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 99: Bearing-Frame Inspection

    If any bores are outside the measurements in the Bearing fits and tolerances table, replace the bearing frame. Surface inspection locations This figure shows the areas to inspect for wear on the bearing frame outside surface. Figure 81: Outside surface inspection locations Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 100: C-Face Adapter Inspection

    Replace the seal chamber and stuffing box cover if pitting or wear exceeds this measurement. • Inspect the machined surfaces and mating faces noted in the figures. These images point to the areas to inspect: Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 101 Maintenance Figure 84: BigBore chamber Figure 85: Stuffing box cover Figure 86: Dynamic-seal backplate Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 102: Bearings Inspection

    Ensure that the snap-ring groove is not cracked. Clear all grooves and holes. XLT-i and i17 Clean the gasket surface. Inspection locations The following images point to the areas to inspect on the bearing housing. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 103 Maintenance Figure 88: STi and MTi bearing housing Figure 89: LTi bearing housing Figure 90: XLT-i and i17 bearing housing Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 104: Bearing Fits And Tolerances

    Install the oil-drain plug (408A). c) Install the sight glass (319). d) Install the sight oiler plug (408J). e) Install the plug for the oil-cooler inlet (408L). Install the plug for the oil-cooler outlet (408M). Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 105 Make sure that the flat side of the ring is towards the bearing. 7. Coat the inner surfaces of the bearings with lubricant. 8. Put the inboard bearing (168) onto the shaft (122). Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 106 Install the shaft assembly into the bearing frame (228). Make sure that the shaft rotates freely. d) Install the clamp bolts (370C) in the bearing housing (134) and tighten by hand. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 107: Assemble The Rotating Element And The Bearing Frame (Sti And Mti With Duplex Bearings)

    Install the plug for the oil-cooler inlet (408L). Install the plug for the oil-cooler outlet (408M). g) Install four oil-mist connection plugs (408H). Or: Install two grease fittings (193) and two grease-relief plugs (113). Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 108 4. Thread the locknut (136) onto the shaft (122) and tighten it until it is snug. 5. Bend the tangs of the lockwasher into the slots of the locknut. 6. Place the bearing-clamp ring (253B) onto the shaft (122). Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 109 Place the bearing-clamp ring (253B) onto the shaft (122). b) Fasten the clamp-ring bolts (236A) crosswise. See the specified torque values. Make sure that the shaft rotates freely. c) Install a new O-ring (496). Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 110: Assemble The Rotating Element And The Bearing Frame (Lti)

    Failure to use this method may result in equipment damage. 1. Prepare the bearing frame (228) as follows (see the illustration): a) Install the oil-fill plug (113A). b) Install the oil-drain plug (408A). Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 111 Lightly coat the bearing seating with a thin film of oil. c) Remove the bearings (112) from their packaging. d) Wipe the preservative from the bearing (112) bore and outer diameter. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 112 11. Prepare the shaft for assembly as follows (see the illustration): a) Fasten the clamp-ring bolts (236A) crosswise. See the specified torque values. Make sure that the shaft rotates freely. b) Install a new O-ring (496). Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 113: Assemble The Rotating Element And The Bearing Frame (Xlt-I And I17)

    Lifting and handling heavy equipment or components poses a crush hazard. Use caution during lifting and handling and wear appropriate Personal Protective Equipment (PPE, such as steel-toed shoes, gloves, etc.) at all times. Seek assistance if necessary. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 114 Remove the bearing locknut (136) after the bearing (112) cools. 3. Put the lockwasher (382) onto the shaft (122). 4. Thread the locknut (136) onto the shaft (122) and tighten it until it is snug. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 115 Coat the inner surfaces of the bearings with lubricant. b) Put the inboard bearing (168) onto the shaft (122). The regreasable bearing has a single shield. Make sure that the bearing is installed with the shield away from the impeller. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 116: Assemble The Rotating Element And The Bearing Frame (Xlt-I And I17 With Duplex Bearings)

    Lifting and handling heavy equipment or components poses a crush hazard. Use caution during lifting and handling and wear appropriate Personal Protective Equipment (PPE, such as steel-toed shoes, gloves, etc.) at all times. Seek assistance if necessary. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 117 The duplex bearings are mounted back-to-back. Make sure that the orientation of the bearings are correct. a) Inspect the shaft (122) to ensure that it is clean, dimensionally correct, and is free of nicks and burrs. Figure 106: Shaft inspection Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 118 Put the bearing housing (134) onto the shaft. Do not use force. 7. Fasten the gasket (360C) and the end cover (109A) with the bolts (371C). See the specified torque values. Make sure that the shaft rotates freely. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 119 Install the clamp bolts (370C) in the bearing housing (134) and tighten by hand. e) Install the jack bolts (370D) with the locknuts (423) in the bearing housing (134) and tighten by hand. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 120: Assemble The Frame

    0.048 | 0.0019 0.025 | 0.0010 0.033 | 0.0013 0.023 | 0.0009 MTi millimeters | inches 0.053 | 0.0021 0.030 | 0.0012 Not applicable 0.025 | 0.0010 LTi millimeters | inches 0.038 | 0.0015 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 121 Remove the impeller and shaft sleeve. Figure 108: Remove impeller and shaft sleeve 4. Check the frame-face run-out by rotating the shaft so that the indicator measures the fit for 360º. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 122 Figure 110: Align bolt holes and dowel locations c) Install the dowel pins (469B) and bolts (370B). Tighten the bolts in a criss-cross pattern according to the specifications in the bolt torque values table. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 123: Inpro Labyrinth Oil Seal Description

    Since there is no metal-to-metal contact, there are no friction or wear concerns. NOTICE: The labyrinth seal is a one-piece design. Do not attempt to separate the rotor from the stator. Doing so will damage the seal. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 124: Assemble The Inpro Labyrinth Oil Seal

    1. Mount the pump and the motor-coupling hubs if they are not already mounted. 2. Slide the C-face adapter over the pump shaft and mount it against the bearing-frame flange using four bolts. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 125: Shaft Sealing

    2. Place the repeller (262) in the backplate (444) with the sleeve side up. 3. Place a gasket (264) on the backplate (444) and align the holes in the gasket with the holes in the backplate. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 126: Seal The Shaft With A Packed Stuffing Box

    Pumps are shipped without the packing, lantern ring, or split gland installed. These parts are included with the box of fittings shipped with each pump and must be installed before startup. 1. Carefully clean the stuffing-box bore. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 127: Seal The Shaft With A Cartridge Mechanical Seal

    Refer to the Impeller clearance setting topic for more information. 6. Tighten the setscrews in the seal locking ring in order to secure the seal to the shaft. 7. Remove the centering clips from the seal. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 128: Seal The Shaft With A Conventional Inside-Component Mechanical Seal

    Figure 120: Check seal-chamber cover runout Rotate the indicator through 360º. If the total indicator reading is greater than 0.13 mm | 0.005 inches, determine the cause and correct the issue before you proceed. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 129: Seal The Shaft With A Conventional Outside-Component Mechanical Seal

    Running a mechanical seal dry, even for a few seconds, can cause seal failure and physical injury. Never operate the pump without liquid supplied to the mechanical seal. 1. Assemble the seal chamber. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 130 Figure 123: Check seal-chamber cover runout Rotate the indicator through 360 degrees. If the total indicator reading is greater than 0.13 mm | 0.005 in., determine the cause and correct the issue before you proceed. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 131 8. Install the gland, with the stationary seat and gland gaskets installed, on the seal chamber. 9. Reinstall the seal chamber. 10. Complete the reassembly of the pump. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 132: Install The Impeller

    (clockwise, viewed from the impeller end of shaft). b) Apply a few sharp raps to tighten the impeller (101). Figure 125: Tighten the impeller 3. Loosen the clamp bolts (370C) and the jack bolts (370D). Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 133: Attach The I-Alert Condition Monitor To The Pump

    For more information on how to set the impeller clearances, refer to the Impeller-clearance checks and Impeller-clearance setting sections in Commissioning, Startup, Operation, and Shutdown. ® Attach the i-ALERT Condition Monitor to the pump Tools required: • 5/32 inch hex wrench Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 134: Post-Assembly Checks

    Personal Protective Equipment (PPE, such as steel-toed shoes, gloves, etc.) at all times. Seek assistance if necessary. 1. Clean the casing fit and install the casing gasket (351) on the seal chamber and stuffing- box cover. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 135 2. Loosen the clamping bolts (370C) and jack bolts (370D) on the bearing housing. Figure 129: Loosen clamp bolts and jack bolts on bearing housing 3. Install the back pull-out assembly in the casing. Figure 130: Install back pull-out assembly Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 136 Determine the cause and correct the problem before you proceed. 8. Adjust the impeller clearance. Refer to the Impeller clearance setting section for more information. 9. Replace the auxiliary piping. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 137: Bolt Torque Values

    80 | 59 96 | 71 145 | 107 156 | 115 235 | 173 153 | 113 230 | 170 191 | 141 287 | 212 447 | 330 671 | 495 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 138: Shaft-End Play

    • Inboard labyrinth-seal stationary O-ring (497J) • Lantern ring half (105) (packed stuffing box) • Stuffing box packing (106) (packed stuffing box) • Packing gland (107) (packed stuffing box) • Impeller gasket (428D) (XLT-i and i17 only) Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 139: 3196 Interchangeability

    (NLGI 1 or 3 with NLGI 2) or with different thickeners. For example, never mix a lithium-based grease with a polyurea based grease. If it is necessary to change the grease type or consistency, remove the rotor and old grease from the housing before regreasing. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 140: Convert From Greased-For-Life Or Regreaseable To Oil-Lubricated Bearings

    3309 7309 6311 Not applicable 7310 XLT-i, i17 6313 3313 7313 4. Remove the grease fittings (193) to prevent accidental greasing. Two plugs (408H) are required to replace the two grease fittings. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 141: Conversion From Flood-Oil To Pure-Oil Mist

    Conversion from flood-oil to pure-oil mist Consult your local ITT representative for further information on this topic. Convert from flood oil to regreaseable Consult your local ITT representative for further information on this topic. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 142: Troubleshooting

    Readjust the packing. If the packing is worn, then replace the packing. Rotating parts are rubbing against each other. Check the parts that are wearing for proper clearances. The impeller clearance is too tight. Adjust the impeller clearance. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 143: Alignment Troubleshooting

    The baseline is bad. Check the temperature and vi- vibration are at acceptable levels. bration levels and reset the con- dition monitor. The unit is malfunctioning. Consult your ITT representative for a warranty replacement. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 144: Parts Listings And Cross-Sectionals

    Stud—Stuffing Box Cover-to-Adapter 2228 370Y Bolt—Cap Casing to Support – – 2210* 371C 6 *** Cap Screw-End Cover to Bearing 2210 Housing Bearing Lockwasher Steel Mechanical Seal Material varies Coupling Key 2210 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 145 2229 Shaft Sleeve 2232 2150 2155 2248 2247 Bearing Housing 1001 Bearing Locknut Steel 168A Radial Bearing Single row ball Seal Chamber/Stuffing Box Cover 1209 1119 1601 1215 1217 Grease Fitting Steel Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 146 Viton 497G 1 O-Ring—Outboard Labyrinth Stator Viton 497H 1 O-Ring—Inboard Labyrinth Rotor Viton 497J O-Ring—Inboard Labyrinth Stator Viton 497L O-Ring Internal (inboard) Viton 497N 1 O-Ring Internal (outboard) Viton Adapter Ring 1013 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 147 Retaining Ring Steel **** Bolt—Adapter to Case 2228 370B 4 Bolt—Frame-to-Adapter 2210 370C ** Clamp Bolt —Bearing Housing 2210 370D **l Jack Bolt—Bearing Housing 2210 370F 2 Bolt—Frame Foot to Frame 2210 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 148 4 for 6 in. STi 8 for 8 in. STi and MTi 16 for 13 in. MTi, LTi , XLT-I 24 for 15 in. XLT-I 12 for 10 in. MTi, LTi , i17 Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 149 A434Gr4140 4140 Steel 2239 A193 Gr. B7 Alloy B-2 2247 B335 (N10665) Alloy C-276 2248 B574 (N10276) GMP-2000 6929 PFA Lined Steel 6944 PFA Lined 316SS 6947 PFA Lined Ductile 9639 Iron Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 150 Parts Listings and Cross-Sectionals Figure 134: 3196 cross-sectional drawing Figure 135: STi bearing-frame exploded view Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 151 Parts Listings and Cross-Sectionals Figure 136: MTi bearing-frame exploded view Figure 137: LTi bearing-frame exploded view Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 152 Parts Listings and Cross-Sectionals Figure 138: XLT-i bearing-frame exploded view The finned-tube oil cooler is standard on HT 3196 and optional on all other models. Figure 139: Finned-tube oil cooler exploded view Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 153: Certification: Ce Or Ce Atex

    Certification: CE or CE ATEX Certification: CE or CE ATEX Certificates of conformance CSA Certificate Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 154 Certification: CE or CE ATEX Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 155 Certification: CE or CE ATEX ATEX notification Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 156 Certification: CE or CE ATEX IECEx Certificate of Conformity Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 157 Certification: CE or CE ATEX Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 158 Certification: CE or CE ATEX Chinese Certificate of Conformity Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 159: Other Relevant Documentation Or Manuals

    Other Relevant Documentation or Manuals Other Relevant Documentation or Manuals For additional documentation For any other relevant documentation or manuals, contact your ITT representative. Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...

  • Page 160: Local Itt Contacts

    Camino La Colina # 1448 Condominio Industrial El Rosal Huechuraba Santiago 8580000 Chile Middle East and Africa ITT - Goulds Pumps +30 210-677-0770 +30 210-677-5642 Achileos Kyrou 4 Neo Psychiko 115 25 Athens Greece Model 3196 i-FRAME Installation, Operation, and Maintenance Manual...
  • Page 162 Visit our website for the latest version of this document and more information: http://www.gouldspumps.com 240 Fall Street Seneca Falls, NY 13148 Form IOM.3196.i-FRAME.en-US.2017-03 © 2017 ITT Corporation The original instruction is in English. All non-English instructions are translations of the original instruction.

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