GORMAN-RUPP PUMPS T3A24-B Application guide

OM-01040-OB05

November 21, 1996

THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO

GORMAN-RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.

ECopyright by the Gorman-Rupp Company

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

TSERIESPUMP

MODEL

T3A24 --- B

INCLUDING: /F, /FM

TABLE OF CONTENTS

INTRODUCTION PAGE I --- 1.................................................

SAFETY --- SECTION A PAGE A --- 1...........................................

INSTALLATION --- SE CTION B PAGE B --- 1....................................

Pump Dimensions PAGE B --- 1.....................................................

PREINSTALLATION INSPECTION PAGE B --- 2............................................

POSITIONING PUMP PAGE B --- 2.......................................................

Lifting PAGE B --- 2.................................................................

Mounting PAGE B --- 2.............................................................

Clearance PAGE B --- 2.............................................................

SUCTION AND DISCHARGE PIPING PAGE B --- 2.........................................

Materials PAGE B --- 2..............................................................

Line Configuration PAGE B --- 3......................................................

Connections to Pump PAGE B --- 3..................................................

Gauges PAGE B --- 3...............................................................

SUCTION LINES PAGE B --- 3...........................................................

Fittings PAGE B --- 3...............................................................

Strainers PAGE B --- 3..............................................................

Sealing PAGE B --- 3...............................................................

Suction Lines In Sumps PAGE B --- 3.................................................

Suction Line Positioning PAGE B --- 4................................................

DISCHARGE LINES PAGE B --- 4........................................................

Siphoning PAGE B --- 4.............................................................

Valves PAGE B --- 4................................................................

Bypass Lines PAGE B --- 5..........................................................

AUTOMATIC AIR RELEASE VALVE PAGE B --- 6...........................................

Theory of Operation PAGE B --- 6....................................................

Air Release Valve Installation PAGE B --- 6............................................

ALIGNMENT PAGE B --- 7..............................................................

Coupled Drives PAGE B --- 8........................................................

V-Belt Drives PAGE B --- 8...........................................................

OPE RAT ION --- SE CTION C PAGE C --- 1......................................

PRIMING PAGE C --- 1.................................................................

STARTING PAGE C --- 1................................................................

Rotation PAGE C --- 1..............................................................

OPERATION PAGE C --- 2..............................................................

Lines With a Bypass PAGE C --- 2....................................................

Lines Without a Bypass PAGE C --- 2.................................................

Leakage PAGE C --- 2..............................................................

Liquid Temperature And Overheating PAGE C --- 2.....................................

Strainer Check PAGE C --- 3.........................................................

Pump Vacuum Check PAGE C --- 3..................................................

STOPPING PAGE C --- 3................................................................

Cold Weather Preservation PAGE C --- 3..............................................

BEARING TEMPERATURE CHECK PAGE C --- 3..........................................

TABLE OF CONTENTS

(continued)

TROUBLE SHOOTING --- SE CTION D PAGE D --- 1..............................

PUMP MAINTENANCE AND REPAIR --- SECTION E PAGE E --- 1................

PERFORMANCE CURVE PAGE E --- 1...................................................

PARTS LISTS:

Pump Model T3A24 --- B PAGE E --- 3.................................................

44163---217 Repair Rotating Assembly PAGE E --- 5....................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E --- 6.........................

Back Cover And Wear Plate Removal PAGE E --- 6.....................................

Suction Check Valve Removal PAGE E --- 6...........................................

Rotating Assembly Removal PAGE E --- 6.............................................

Impeller Removal PAGE E --- 7......................................................

Seal Removal PAGE E --- 8..........................................................

Shaft and Bearing Removal and Disassembly PAGE E --- 8.............................

Shaft and Bearing Reassembly and Installation PAGE E --- 9............................

Seal Installation PAGE E --- 10........................................................

Impeller Installation PAGE E --- 11.....................................................

Rotating Assembly Installation PAGE E --- 12...........................................

Suction Check Valve Installation PAGE E --- 12.........................................

Back Cover Installation PAGE E --- 13.................................................

PRESSURE RELIEF VALVE MAINTENANCE PAGE E --- 13..................................

Final Pump Assembly PAGE E --- 13..................................................

LUBRICATION PAGE E --- 13.............................................................

Seal Assembly PAGE E --- 13.........................................................

Bearings PAGE E --- 13..............................................................

Power Source PAGE E --- 14.........................................................

TSERIES OM--01040

PAGE I -- 1INTRODUCTION

INTRODUCTION

This Installation, Operation, and Maintenance

manual is designed to help you achieve the best

performance and longest life from your Gorman-

Rupp pump.

This pump is a T Series, semi-open impeller, self-

priming centrifugal model with a suction check

valve. The pump is designed for handling abrasive

liquids containing large entrained solids, mud or

slurries. The basic material of construction is gray

iron, with stainless steel impeller, wear plate and

impeller shaft.

If there are any questions regarding the pump or its application which are not covered in this manual or in

other literature accompanying this unit, please contact your Gorman-Rupp distributor, or write:

The Gorman-Rupp Company or Gorman-Rupp of Canada Limited

P.O. Box 1217 70 Burwell Road

Mansfield, Ohio 44901--1217 St. Thomas, Ontario N5P 3R7

Forinformationortechnicalassistanceonthepowersource,contactthepowersourcemanufacturer’slocal

dealer or representative.

The following are used to alert maintenance personnel to procedures which require special attention, to

those which could damage equipment, and to those which could be dangerous to personnel:

Immediate hazards whichWILL result in

severe personal injury or death. These

instructions describe the procedure re-

quired and the injury which will result

from failure to follow the procedure.

Hazards or unsafe practices which

COULD result in severe personal injury

or death. These instructions describe

the procedure required and the injury

which could result from failure to follow

the procedure.

HazardsorunsafepracticeswhichCOULD

result in minor personal injury or product

or property damage. These instructions

describe the requirements and the possi-

ble damage which couldresult from failure

to follow the procedure.

NOTE

Instructions to aid in installation, operation, and

maintenance or which clarify a procedure.

TSERIES OM--1040

PAGE A -- 1SAFETY

SAFETY --- SECTION A

These warnings apply to T Series basic

pumps. Gorman-Rupp has no control

over or particular knowledge of the

power source which will be used. Refer

to the manual accompanying the power

source before attempting to begin

operation.

Beforeattemptingtoopenorservicethe

pump:

1. Familiarize yourself with this man-

ual.

2. Disconnect or lock out the power

sourcetoensurethatthe pumpwill

remain inoperative.

3. Allow the pump to completely cool

if overheated.

4. Check the temperature before

opening any covers, plates, or

plugs.

5. Close the suction and discharge

valves.

6. Vent the pump slowly and cau-

tiously.

7. Drain the pump.

This pump is designed to handle abra-

sive liquids containing large entrained

solids, mud or slurries. Do not attempt

to pump volatile, corrosive or flam-

mable liquids which may damage the

pumporendanger personnelasaresult

of pump failure.

After the pump has been positioned,

make certain that the pump and all pip-

ing connections are tight, properly sup-

ported and secure before operation.

Do not operate the pump without the

guards in place over the rotating parts.

Exposed rotating parts can catch cloth-

ing, fingers, or tools, causing severe in-

jury to personnel.

Do not remove plates, covers, gauges,

pipe plugs, or fittings from an over-

heatedpump. Vapor pressure within the

pump can cause parts being disen-

gaged to be ejected with great force. Al-

low the pump to cool before servicing.

Do not operate the pump against a

closed discharge valve for long periods

oftime.Ifoperatedagainstacloseddis-

charge valve, pump components will

deteriorate, and the liquid could come

to a boil, build pressure, and cause the

pump casing to rupture or explode.

Use lifting and moving equipment in

good repair and with adequate capacity

to prevent injuries to personnel or dam-

age to equipment. Suction and dis-

charge hoses and piping must be re-

moved from the pump before lifting.

OM--01040TSERIES

PAGE B -- 1INSTALLATION

INSTALLATION --- SECTION B

Review all SAFETY information in Section A.

Since pump installations are seldom identical, this

section offers only general recommendations and

practices required to inspect, position, and ar-

range the pump and piping.

Most of the information pertains to a standard

static lift application where the pump is posi-

tioned above the free levelof liquid to bepumped.

If installedinafloodedsuctionapplicationwhere

the liquid is supplied to the pump under pressure,

some of the information such as mounting, line

configuration, and priming must be tailored to the

specific application. Since the pressure supplied

to the pump is critical to performance and safety,

be sure to limit the incoming pressure to 50% of

the maximum permissible operating pressure as

shown on the pump performance curve.

For furtherassistance,contact yourGorman-Rupp

distributor or the Gorman-Rupp Company.

Pump Dimensions

SeeFigure1fortheapproximatephysicaldimen-

sionsofthispump.

OUTLINE DRAWING

NOTE: OPTIONAL ASA OR DIN STANDARD SUCTION & DISCHARGE SPOOL FLANGES AVAILABLE

Figure 1. Pump Model T3A24-B

OM--01040 TSERIES

PAGE B -- 2 INSTALLATION

PREINSTALLATION INSPECTION

The pump assemblywas inspectedand tested be-

fore shipment from the factory. Before installation,

inspect the pump for damage which may haveoc-

curred during shipment. Check as follows:

a. Inspectthepumpforcracks, dents,damaged

threads, and other obvious damage.

b. Check for and tighten loose attaching hard-

ware. Since gaskets tend to shrink after dry-

ing, check for loose hardware at mating sur-

faces.

c. Carefully read allwarnings and cautions con-

tained in this manual or affixed to the pump,

and perform all duties indicated. Note the di-

rection of rotation indicated on the pump.

Check that the pump shaft rotates counter-

clockwise when facing the impeller.

Only operate this pump in the direction in-

dicated by the arrow on the pump body

and on the accompanying decal. Refer to

ROTATION in OPERATION,SectionC.

d. Check levels and lubricate as necessary. Re-

fer to LUBRICATION in the MAINTENANCE

AND REPAIR section of this manual and per-

form duties as instructed.

e.Ifthepumpandpowersourcehavebeen

stored for more than 12 months, some of the

components or lubricants may have ex-

ceeded their maximum shelf life. These must

be inspected or replaced to ensure maxi-

mum pump service.

If the maximum shelf life has been exceeded, or if

anything appears to be abnormal, contact your

Gorman-Rupp distributor or the factory to deter-

minethe repairor updating policy. Donotputthe

pump into service until appropriate action has

been taken.

POSITIONING PUMP

Lifting

Use lifting equipment with a capacity of at least

2,000 pounds (907,2 kg). This pump weighs ap-

proximately400 pounds (181,4 kg), not including

the weight of accessories and base. Customer in-

stalled equipment such as suction and discharge

piping must be removed before attempting to lift.

Thepumpassemblycanbeseriously

damagedifthecablesorchainsusedtolift

andmovetheunitareimproperlywrapped

around the pump.

Mounting

Locatethepumpinanaccessibleplaceascloseas

practical tothe liquid being pumped. Level mount-

ing is essential for proper operation.

The pump may have to be supported or shimmed

to provide for level operation or to eliminate vibra-

tion.

Clearance

When positioning the pump, allow a minimum

clearance of 18 inches (457 mm) in front of the

backcover topermit removalofthecoverandeasy

access to the pump interior.

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in-

creased suction lift, discharge elevation, and fric-

tion losses. See the performance curve and oper-

ating range shown on Page E-1 to be sure your

overall application allows pump to operate within

thesafeoperationrange.

Materials

Either pipe or hose maybe used for suction and

discharge lines; however, the materials must be

OM--01040TSERIES

PAGE B -- 3INSTALLATION

compatiblewiththeliquidbeingpumped.Ifhoseis

used insuction lines, it must be the rigid-wall, rein-

forced type to prevent collapseunder suction.Us-

ing piping couplings in suction lines is not recom-

mended.

Line Configuration

Keep suction and discharge lines as straight as

possible to minimize friction losses. Make mini-

mum use of elbows and fittings, which substan-

tiallyincreasefriction loss.Ifelbowsarenecessary,

use the long-radius type to minimize friction loss.

Connections to Pump

Before tightening a connecting flange, align it ex-

actly with the pump port. Never pulla pipe line into

place by tightening the flange bolts and/or cou-

plings.

Lines near the pump must be independently sup-

ported to avoid strain on the pump which could

cause excessive vibration, decreased bearing life,

and increased shaft and seal wear. If hose-type

linesareused, theyshouldhaveadequatesupport

to secure them when filled with liquid and under

pressure.

Gauges

Most pumps are drilled and tapped for installing

discharge pressure and vacuum suction gauges.

If these gauges are desired for pumps that arenot

tapped, drill and tap the suction and discharge

lines not less than 18 inches (457,2 mm) from the

suction and discharge ports and install the lines.

Installation closer tothe pump may result in erratic

readings.

SUCTION LINES

Toavoidairpocketswhichcouldaffect pumpprim-

ing, the suction line must be as short and direct as

possible.Whenoperationinvolvesasuctionlift,the

line must always slope upward to the pump from

the source of the liquid being pumped; if the line

slopes down to the pump at any point along the

suction run, air pockets will be created.

Fittings

Suction lines should bethe same size as the pump

inlet. If reducers are used in suction lines, they

should be the eccentric type, and should be in-

stalled withthe flatpart ofthe reducers uppermost

to avoid creating air pockets. Valves are not nor-

mally used in suction lines, but if a valve is used,

install it with the stem horizontal to avoid air pock-

ets.

Strainers

If a strainer is furnished with the pump, be certain

touseit;anysphericalsolidswhichpassthrougha

strainer furnished with the pump will also pass

through the pump itself.

If a strainer is not furnished with the pump, but is

installed by the pump user, make certain that the

total area of the openings in the strainer is at least

three or four times the cross section of the suction

line, and that the openings will not permit passage

of solids larger than the solids handling capability

of the pump.

This pump is designed to handle up to 2-1/2 inch

(63,5 mm) diameter spherical solids.

Sealing

Since even a slight leak will affect priming, head,

and capacity, especially when operating with a

high suction lift, allconnections in the suction line

should be sealed with pipe dope to ensure an air-

tight seal. Follow the sealant manufacturer’s rec-

ommendations when selecting and applying the

pipe dope. The pipe dope should be compatible

with the liquid being pumped.

Suction Lines In Sumps

If a single suction line is installed in a sump, it

should be positioned away from the wall of the

sump at a distance equal to1 1/2 times the diame-

ter of the suction line.

If there is a liquid flow from an open pipe into the

sump, the flow should be kept away from the suc-

tion inlet because the inflow will carry air downinto

the sump, and air entering the suction line will re-

duce pump efficiency.

OM--01040 TSERIES

PAGE B -- 4 INSTALLATION

If it is necessary to position inflow close to the suc-

tioninlet, installa bafflebetween the inflow and the

suction inlet at a distance 1 1/2 times the diameter

of the suction pipe. The baffle will allow entrained

air to escape from the liquid before it is drawn into

the suction inlet.

If two suction lines are installed in a single sump,

theflowpathsmayinteract,reducingtheefficiency

of one or both pumps. To avoid this, position the

suction inlets so that they are separated by a dis-

tance equal to at least 3 times the diameter of the

suction pipe.

Suction Line Positioning

The depth of submergence of the suction line is

critical to efficient pump operation. Figure 2 shows

recommended minimum submergence vs. veloc-

ity.

NOTE

The pipe submergence required may be reduced

by installing a standard pipe increaser fitting at the

end of thesuction line. The larger opening size will

reduce the inlet velocity. Calculate the required

submergence using the following formula based

on the increased opening size (area or diameter).

Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity

DISCHARGE LINES

Siphoning

Do not terminate the discharge line at a level lower

than that of the liquid being pumped unless a si-

phon breaker is used in the line. Otherwise, a si-

phoning action causing damage to the pump

could result.

Valves

If a throttling valve is desired in the discharge line,

useavalveaslargeasthelargestpipetominimize

friction losses. Never install a throttling valve in a

suction line.

Withhighdischargeheads,itisrecommendedthat

a throttling valve and a system check valve be in-

stalled in the discharge line to protect the pump

OM--01040TSERIES

PAGE B -- 5INSTALLATION

from excessive shock pressure and reverse rota-

tion when it is stopped.

If the application involves a high discharge

head, gradually close the discharge

throttling valve before stopping the pump.

Bypass Lines

Self-priming pumps are not air compressors. Dur-

ing the priming cycle, air from the suction line must

be vented to atmosphere on the discharge side. If

the discharge line is open, this air will be vented

through the discharge. However, if a check valve

has been installed in the discharge line, the dis-

chargesideofthepumpmustbeopenedtoatmos-

phericpressurethrougha bypasslineinstalledbe-

tween the pump discharge and the check valve. A

self-priming centrifugal pump will not prime if

there is sufficient static liquid head to hold the dis-

charge check valve closed.

NOTE

The bypass line should be sized so that it does not

affect pump discharge capacity; however, the by-

pass line should be at least 1 inch (25,4 mm) in di-

ameter to minimize the chance of plugging.

Inlow discharge head applications (less than 30

feet or 9 meters), it is recommended that the by-

pass line be run back to the wet well, and located 6

inches below the water level or cut-off point of the

low level pump. In some installations, this bypass

line may be terminated with a six-to-eight foot

length of1 1/4 inch I.D.smooth-borehose;airand

liquid vented during the priming process will then

agitate the hose and break up any solids, grease,

or other substances likely to cause clogging.

A bypass line that is returned to a wet well

must be secured against being drawninto

the pump suction inlet.

It is also recommended that pipe unions be in-

stalled at each 90_elbow in a bypass line to ease

disassembly and maintenance.

In high discharge head applications (more than

30 feet), an excessive amount of liquid may be by-

passed and forced back to the wet well under the

full working pressure of the pump; this willreduce

overallpumpingefficiency. Therefore,itisrecom-

mended that a Gorman-Rupp Automatic Air Re-

lease Valve be installed in the bypass line.

Gorman-Rupp Automatic Air Release Valves are

reliable, and require minimum maintenance. See

AUTOMATIC AIRRELEASE VALVEin this section

for installation and theory of operation of the Auto-

matic Air Release Valve. Consult your Gorman-

Rupp distributor, or contact the Gorman-Rupp

CompanyforselectionofanAutomaticAirRelease

Valve to fit your application.

Iftheinstallationinvolvesafloodedsuctionsuchas

abelow-groundliftstation.Apipeunionandmanu-

alshut-offvalve maybe installedin thebleed lineto

allowserviceofthevalvewithoutshuttingdownthe

station, and to eliminate the possibility of flooding.

If a manual shut-off valve is installed anywhere in

theair release piping, it must beafull-openingball

type valve to prevent plugging by solids.

If a manual shut-off valve is installed in a by-

pass line, it must not be left closed during oper-

ation. A closed manual shut-off valve may

cause a pump which has lost prime to continue

tooperatewithoutreachingprime,causingdan-

gerous overheating and possible explosive

rupture of the pump casing. Personnel could be

severely injured.

Allow an over-heated pump to com-

pletely cool before servicing.Do not re-

move plates, covers, gauges, orfittings

from an over-heated pump. Liquid with-

in the pump can reach boiling tempera-

tures, and vapor pressure within the

pump can cause parts being disen-

gaged to be ejected with greatforce. Af-

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