API Maxum 610 11 Edition Centrifugal Pump

API Maxum 610 11 Edition Centrifugal Pump
I-401
NOV 2013
Revision 0, ATEX
Inch Units
API Maxum
610 11th Edition Centrifugal Pump
INSTALLATION, OPERATION AND
MAINTENANCE INSTRUCTIONS
Part Number: _______________________________________
Serial Numbers: _____________________________________
These operating instructions contain fundamental information and precautionary notes.
Please read the manual thoroughly prior to installation of unit, electrical connection and
commissioning. It is imperative to comply with all other operating instructions referring to
components of individual units.
This manual shall always be kept close to the unit’s location of operation or directly on the pump set.
API Maxum
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610 11 Edition Centrifugal Pump
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November 2013
EC Declaration of Conformity
MANUFACTURER:
CARVER PUMP COMPANY
2415 PARK AVE.
MUSCATINE, IOWA, USA 52761
PRODUCT DESCRIPTION:
API MAXUM Pump
PART NUMBER:
SERIAL NUMBER:
DATE MANUFACTURED:
APPLICABLE EUROPEAN DIRECTIVES:
Machinery: 2006/42/EC
ATEX:
94/9/EC
APPLICABLE INTERNATIONAL STANDARDS:
Machinery: EN 12100-1, EN 12100-2
ATEX:
EN 1127-1, EN 13463-1, EN 13463-5
NOTIFIED BODY
Det Norske Veritas, ATEX NB 0575 retains a copy of the Technical File
ATEX product marking:
II 2 G c T1
The product described in this Declaration of Conformity complies with the Applicable European Directives and
relevant sections of the Applicable International Standards. The signature on this document authorizes the
distinctive European mark to be applied to the equipment described. A Technical Construction File is available for
inspection by designated bodies
Authorized Signature:
Date:
Important safety information is contained in the installation, operation and service manuals; read and
understand this information prior to installing or using this equipment
This Document applies only to the equipment described above and is invalid if not reproduced in its
entirety
API Maxum
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610 11 Edition Centrifugal Pump
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November 2013
SERVICE RECORD PAGE
Service No. ______________________Model _________________________ Size and Type
Customer Order No. ____________________________ Date Installed
Installation Date
_______________
__________________________________
Location
Application
PUMP RATING
Capacity _____________________________________ Total Head ____________________________________
Suction Pressure ______________________________ Speed (RPM) __________________________________
Liquid pumped ________________________________ Temperature ___________________________________
Specific Gravity
_______________________________ Viscosity ______________________________________
Port Width (inches) _____________________________
PUMP MATERIALS
Casing
_________________________ Impeller _______________________ Shaft _______________________
Gaskets
_____________________________________ Bearing Frame _________________________________
Mechanical Seal/Packing ________________________
MOTOR DATA
Motor
__________________________ Make _________________________ Serial No. ___________________
Type ___________________________ Frame ________________________ AC or DC ___________________
HP _____________________________ RPM _________________________ Volts _______________________
Phase __________________________ Cycles ________________________
API Maxum
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610 11 Edition Centrifugal Pump
I-401
November 2013
NOTES ON INSPECTION AND REPAIRS
INSPECTION DATE
REPAIR TIME
REPAIRS
COST
REMARKS
API Maxum
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610 11 Edition Centrifugal Pump
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November 2013
INSTALLATION, OPERATION AND
MAINTENANCE INSTRUCTIONS
TABLE OF CONTENTS
SECTION/PARAGRAPH
PAGE
I.
GENERAL DESCRIPTION ............................... 1
A. General Information ................................... 1
B. ATEX Directive 2006/42/EC ....................... 1
C. Disclaimer .................................................. 1
D. Personnel Qualification and Training ......... 1
E. Pump Identification..................................... 1
F. Parts Inventory Guide ................................ 2
G. Parts Ordering ............................................ 2
II.
SAFETY ............................................................ 2
A. Safety Precautions ..................................... 2
B. Summary of Safety Marking ....................... 2
C. Products Used in Potentially Explosive
Atmospheres ......................................... 2
D. Scope of Compliance ................................. 2
E. Safety Awareness ...................................... 3
F. Safety Instructions for the Operator/User .. 3
G. Safety Instructions for Maintenance
Inspection and Installation Work ............ 3
H. Non-Compliance with Safety Instructions .. 3
I. Unauthorized Modification and
Manufacture of Spare Parts ................... 3
J. Unauthorized Modes of Operation ............. 4
K. Explosion Protection .................................. 4
III.
EQUIPMENT DESCRIPTION........................... 6
IV.
EFFECTS OF FLUIDS ..................................... 8
A. Net Positive Suction Head (NPSH) ............ 8
B. Changing Pump Speed .............................. 8
C. Effects of Viscosity ..................................... 8
D. Effects of Specific Gravity .......................... 8
V.
TECHNICAL DATA ........................................... 8
VI.
INSPECTION AND STORAGE ........................ 14
A. Inspection ................................................... 14
B. Packing for Return ..................................... 14
C. Storage of Pump ........................................ 14
VII.
INSTALLATION ................................................ 15
A. Location ...................................................... 15
B. Handling ..................................................... 15
SECTION/PARAGRAPH
PAGE
C.
D.
E.
F.
G.
H.
I.
Foundation ................................................. 15
Leveling of Unit .......................................... 16
Grouting ..................................................... 16
Coupling Alignment .................................... 18
Pre-Installation Procedures ....................... 19
Piping ......................................................... 19
Auxiliary Piping Connection
and Gauges ........................................... 19
J. Motor .......................................................... 19
K. Direction of Rotation .................................. 19
VIII. OPERATION .................................................... 20
A. Pre-Start Cautions ..................................... 20
B. Priming ....................................................... 20
C. Starting the Pump ...................................... 21
D. Turbine Applications .................................. 21
E. Minimum/Maximum Flow Calculations ...... 21
F. Operating Checks ...................................... 21
G. Stopping the Pump .................................... 21
H. Indefinite Shutdown ................................... 22
IX.
TROUBLESHOOTING OPERATING
PROBLEMS...................................................... 22
X.
MAINTENANCE ............................................... 24
A. Lubrication of Pump Ball Bearings ............. 24
B. Lubrication of Motor Ball Bearings ............. 25
C. Torque Values ............................................ 25
XI.
SERVICE AND REPAIR ................................... 26
A. Preparations for Disassembly of Pump ..... 26
B. Disassembly of Pump ................................ 27
C. Parts Inspection ......................................... 28
D. Reassembly of Pump ................................. 29
E. Replacement of Wear Ring ........................ 31
F. Motor .......................................................... 32
G. Check Valve ............................................... 32
XII.
PARTS LISTS AND DRAWINGS ..................... 33
API Maxum
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610 11 Edition Centrifugal Pump
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TABLE OF CONTENTS - Continued
LIST OF TABLES
NUMBER
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
TITLE
LIST OF ILLUSTRATIONS
PAGE
Fluid Temperature Limits ........................... 5
Estimated Noise Characteristics ................ 9
Basic Design Features ............................... 11
Key Mechanical Data ................................. 12
Permissible Nozzle Loads ......................... 13
Pumping Unit Troubleshooting .................. 22
Oil Recommendations................................ 25
Ball Bearing Cooling Flow Rates
(100 PSIG Max.) .................................... 25
Recommended Torque Values (ft-lbs) ....... 25
Recommended Equipment ........................ 25
Factory Wear Ring Clearance (Inches) ..... 29
Recommended Spare Parts List ................ 33
Parts List .................................................... 36
NUMBER
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
TITLE
PAGE
Seal Chamber Dimensions .........................10
Sling Position for Moving Pump..................15
Sling Position for Moving Pumping Unit .....15
Grouting and Foundation Bolting ................17
Unit Leveling ...............................................17
Coupling Alignment.....................................18
Constant Level Oiler ...................................25
Inducer ........................................................33
Sectional Assembly – Bare Pump ..............34
Pump with Base ..........................................35
API Maxum
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610 11 Edition Centrifugal Pump
I. GENERAL DESCRIPTION AND
SAFETY PRECAUTIONS.
A. GENERAL INFORMATION.
Carver Pump
Company products are carefully engineered and
manufactured and, if properly installed, maintained, and
operated, should provide maintenance-free operation
and a long service life.
CAUTION
These instructions must always be kept close
to the product's operating location or directly
with the product.
This manual is designed to provide sufficient material to
properly maintain the total pumping unit. The information
presented should improve your knowledge and
understanding of the API Maxum, thus upgrading the
reliability, service life, and quality of pump maintenance.
These operating instructions are intended to facilitate
familiarization with the product and its permitted use to
help satisfy ATEX safety requirements. These operating
instructions do not take into account local regulations;
the operator must ensure that such regulations are
strictly observed by all, including the personnel called in
for installation. Compliance with such laws relating to
the proper installation and safe operation of the pumping
equipment is the responsibility of the equipment owner
and all necessary steps should be taken by the owner to
assure compliance with such laws before operating the
equipment. These instructions are intended to facilitate
familiarization with the product and its permitted use to
help satisfy safety requirements. Always coordinate
repair activity with operations personnel, and follow all
plant safety requirements and applicable safety and
health laws/regulations.
Refer to Figures 9 and 10 to locate the pump parts by
item
number.
Variations
do
exist
between
configurations, not all parts described in the text may be
on your configuration.
CAUTION
These instructions should be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide and in
conjunction with the main user instructions
provided. The equipment must not be put into
service until all the conditions relating to safety
instructions have been met.
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B. ATEX DIRECTIVE 2006/42/EC.
It is a legal
requirement that machinery and equipment put into
service within certain regions of the world shall conform
to the applicable CE Marking Directives for Equipment
for Potentially Explosive Atmospheres (ATEX).
Where applicable the Directive covers important safety
aspects relating to the equipment, its use and the
satisfactory provision of technical documents. Where
applicable this document incorporates information
relevant to these Directives. To establish if the product
itself is CE marked for a Potentially Explosive
Atmosphere check the nameplate and the Certification
provided.
C. DISCLAIMER.
Information in these User
Instructions is believed to be reliable. In spite of all the
efforts of Carver Pump Company to provide sound and
all necessary information the content of this manual may
appear insufficient and is not guaranteed by Carver
Pump Company as to its completeness or accuracy.
D. PERSONNEL QUALIFICATION AND TRAINING.
All personnel involved in the operation, installation,
inspection and maintenance of the unit must be qualified
to carry out the work involved. If the personnel in
question do not already possess the necessary
knowledge and skill, appropriate training and instruction
must be provided. If required the operator may
commission the manufacturer/supplier to provide
applicable training.
Follow instructions in this manual carefully. Factory
warranty applies only when pump operates under
conditions as specified on order acknowledgment, and if
pump is properly installed and maintained as
recommended herein. A copy of this manual should be
available to operating personnel. Additional copies of
this manual are available upon request from Carver
Pump Company and your local distributor. For
comments and/or questions about information provided,
please contact Carver Pump Company or your local
distributor.
E. PUMP IDENTIFICATION. The type of pump, pump
size, operating data, and serial number are all stamped
on the nameplate attached to the pump. Pump
specifications should be recorded upon receipt of the
pumping unit. Record all necessary information on the
pump service record page and inspection and repair
record provided at the front of this manual. This
information must be included in all correspondence
regarding the unit. This will ensure that the correct pump
and/or parts are ordered in a timely manner.
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610 11 Edition Centrifugal Pump
F. PARTS INVENTORY GUIDE.
To avoid
unnecessary delays for maintenance, spare parts
should be readily available, purchase before and keep in
stock, for normal service. Most conditions will be
covered if this manual is followed. For every one to
three pumps, stock one spare set consisting of items
listed in Table 12, Recommended Spare Parts. Part
numbers correspond to Figures 9 and 10.
G. PARTS ORDERING. When ordering replacement
parts, please specify:
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November 2013
used in safety instructions where noncompliance in the hazardous area would cause
the risk of an explosion.
General hazard sign to ISO 7000 - 0434.
The word "Caution" is used to introduce safety
instructions whose non-observance may lead to damage
to the machine and its functions.
Instructions attached directly to the machine, e.g.
•
Serial number of pump (located on nameplate)
•
Part name (located on parts list)
•
Arrow indicating the direction of rotation
•
Quantity of parts needed
•
Markings for fluid connections must always be
complied with and be kept in a perfectly legible
condition at all times.
Carver Pump Company may ship an interchangeable
part that is not identical in appearance or symbol. This is
done only if the part has been improved. Examine parts
carefully upon delivery before questioning factory or
company representative. Never return parts to the
factory without authorization from Carver Pump
Company.
Observe all notes, caution or danger tags attached to
the equipment or included in this manual.
C. PRODUCTS USED IN POTENTIALLY EXPLOSIVE
ATMOSPHERES
If an impeller is ordered, specify diameter across blade
tips. Be sure diameter was NOT trimmed further than
diameter shown on Carver Pump Company records.
Measures are required to:
•
Avoid excess temperature
•
Prevent buildup of explosive mixtures
•
Prevent the generation of sparks
II. SAFETY.
•
Prevent leakages
A. SAFETY PRECAUTIONS. The manual is designed
to provide adequate instructions for the safe and
efficient installation, operation, or maintenance of the
pump. Failure or neglect to properly install, operate, or
maintain the pump may result in personal injury,
property damage, or unnecessary damage to the pump.
This manual must be read and understood both by the
installing personnel and the responsible trained
personnel/operators prior to installation and operation,
and it must always be kept close to the location of the
pumping unit for easy access.
•
Maintain the pump to avoid hazard
If a driver or driver parts are ordered, specify name of
manufacturer and all other data found on the driver
nameplate.
The following instructions for pumps and pump units
when installed in potentially explosive atmospheres
must be followed to help ensure explosion protection.
Both electrical and non-electrical equipment must meet
the requirements of European Directive 2006/42/EC.
D. SCOPE OF COMPLIANCE.
B. SUMMARY OF SAFETY MARKING. The safety
instructions contained in this manual follow specific
ATEX safety marking where non-observance of the
instruction will cause a hazard is specially marked with
the symbol:
Use equipment only in the zone for which
it is appropriate. Always check that the driver,
drive coupling assembly, seal and pump
equipment are suitably rated and/or certified for
the classification of the specific atmosphere in
which they are to be installed.
This symbol indicates explosive
atmosphere marking according to ATEX. It is
Where Carver Pump has supplied only the bare shaft
pump, the Ex rating applies only to the pump. The party
responsible for assembling the pump set shall select the
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API Maxum
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610 11 Edition Centrifugal Pump
coupling, driver, seal and any additional equipment, with
the necessary CE Certificate/Declaration of Conformity
establishing it is suitable for the area in which it is to be
installed.
The output from a variable frequency drive (VFD) can
cause additional heating affects in the motor and so, for
pump sets with a VFD, the ATEX Certification for the
motor must state that it covers the situation where
electrical supply is from the VFD. This is particular
requirement still applies even if the VFD is in a safe
area.
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G. SAFETY INSTRUCTIONS FOR MAINTENANCE,
INSPECTION AND INSTALLATION WORK.
The
operator is responsible for ensuring that all
maintenance, inspection and installation work be
performed by authorized, qualified personnel who are
thoroughly familiar with the manual and pumping unit.
To ensure safe operation the radial and
thrust ball bearings must be replaced at 25000
hours of service or whenever the mechanical
seal is inspected or serviced.
E. SAFETY AWARENESS. It is imperative to comply
with the safety instructions contained in this manual, the
relevant national and international explosion protection
regulations, health and safety regulations and the
operator’s own internal work, operation and safety
regulations.
The pumping unit must have cooled down to ambient
temperature, pump pressure must have been released
and the pump must have been drained before working
on any pumping unit. Work on the pumping unit must be
carried out during shutdown. The shutdown procedure
described in the manual for taking the unit out of service
must be adhered to.
Ex symbol relates to additional
requirements which must be adhered to when
the pump is operated in potentially explosive
atmospheres.
Pumps handling fluids that are hazardous to personnel
must be decontaminated prior to being worked on.
F. SAFETY INSTRUCTIONS FOR THE OPERATOR
/USER.
•
Any hot or cold components that could pose a
hazard must be equipped with a guard by the
operator.
•
Guards which are fitted to prevent accidental
contact with moving parts (e.g. coupling) must
not be removed whilst the unit is operating.
•
Leakages (e.g. at the bearing isolators) of
hazardous fluids (e.g. explosive, toxic, hot) must
be contained so as to avoid any danger to
persons or the environment. Pertinent legal
provisions must be adhered to.
•
Electrical hazards must be eliminated. (In this
respect refer to the relevant safety regulations
applicable to different countries and/or the local
energy supply companies.)
If the pumps/units are located in
potentially explosive atmospheres, it is
imperative to make sure that unauthorized
modes of operation are prevented. Noncompliance may result in the specified
temperature limits being exceeded.
Immediately following completion of the work, all safety
relevant and protective devices must be reinstalled
and/or reactivated. Please observe all instructions set
out in the section on start-up before returning the
pumping unit to service.
H. NON-COMPLIANCE
WITH
SAFETY
INSTRUCTIONS.
Non-compliance with safety
instructions may result in personal injury, property
damage, or unnecessary damage to the pumping unit.
Non-compliance with these safety instructions will also
lead to forfeiture of any and all rights to claims for
damages. Non-compliance, can for example, result in:
•
Failure of important pumping unit functions.
•
Failure of prescribed maintenance and servicing
practices.
•
Hazard to personnel by electrical, mechanical,
and chemical effects as well as explosion.
•
Hazard to the environment due to leakage of
hazardous substances.
I. UNAUTHORIZED
MODIFICATION
AND
MANUFACTURE OF SPARE PARTS. Modifications or
alterations of the pumping unit supplied are only
permitted after consultation with Carver Pump and to the
extent permitted by Carver Pump. Original spare parts
and accessories authorized by Carver Pump ensure
safety. The use of other parts can invalidate any liability
of Carver Pump for consequential damage and/or
warranty.
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610 11 Edition Centrifugal Pump
J. UNAUTHORIZED MODES OF OPERATION. The
warranty relating to operating reliability and safety of the
unit supplied is only valid if the pumping unit is used in
accordance with its designated use as described in the
following sections. The limits stated on the nameplate
must not be exceeded under any circumstances.
K. EXPLOSION PROTECTION. If the pumps/units are
installed in potentially explosive atmospheres, the
measures and instructions given in the following
sections K.1 to K.6 must be adhered to without fail, to
ensure explosion protection.
K.1 Unit Fill.
It is assumed that the system of suction
and discharge lines and thus the wetted pump
internals are completely filled with the fluid to
be handled at all times during pump operation,
so that an explosive atmosphere is prevented.
If the operator cannot warrant this
condition, appropriate monitoring devices must
be used.
CAUTION
In addition, it is imperative to make sure that
the seal chambers, auxiliary systems of the
shaft seal and the heating and cooling systems
are properly filled.
K.2 Marking.
The marking on the pump only refers to
the pump, i.e. the coupling and driver must be
regarded separately. The coupling must have
an EC manufacturer’s declaration. The driver
must be regarded separately.
4
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November 2013
An example of ATEX equipment marking is shown
below. The actual classification of the pump will be
engraved on the nameplate.
II 2 GD c IIC 135 ºC (T4)
Equipment Group
I = Mining
II = Non-mining
Category
2 or M2 = high level protection
3 = normal level of protection
Gas and/or dust
G = Gas
D = Dust
c = Constructional safety
(in accordance with EN13463-5)
Gas Group (Equipment Category 2 only)
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)
Maximum surface temperature (Temperature Class)
(Refer to Section II, Paragraph K.5)
K.3 Checking the Direction of Rotation.
If the explosion hazard also exists during
the installation phase, the direction of rotation
must never be checked by starting up the
unfilled pump unit, even for a short period, to
prevent temperature increases resulting from
contact between rotating and stationary
components.
K.4 Pump Operating Mode.
Make sure that the pump is always started up with the
suction-side shut-off valve fully open and the dischargeside shut-off valve slightly open. However, the pump can
also be started up against a closed swing check valve.
The discharge-side shut-off valve shall be adjusted to
comply with the duty point immediately following the runup process.
API Maxum
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610 11 Edition Centrifugal Pump
Pump operation with the shut-off valves in
the suction and/or discharge pipes closed is not
permitted.
CAUTION
In this condition, there is a risk of the pump
volute taking on high surface temperatures
after a very short time, due to a rapid
temperature rise in the pumped fluid inside the
pump. Additionally, the resulting rapid pressure
build-up inside the pump may cause excessive
stresses on the pump materials or even
bursting.
The minimum flows calculated in Section VIII,
Paragraph E, refer to water and water-like liquids.
Longer operating periods with these liquids and at the
flow rates indicated will not cause an additional increase
in the temperatures on the pump surface. However, if
the physical properties of the fluids handled are different
from water, it is essential to check if an additional heat
build-up may occur and if the minimum flow rate must
therefore be increased.
To check, proceed as described in Section VIII,
Paragraph E.
In addition, the instructions given in Section VIII of this
operating manual must be observed.
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In the ball bearing bracket area, the unit surfaces must
be freely exposed to the atmosphere and the fan inlet
flow must be unimpeded.
In any case, responsibility for compliance
with the specified fluid temperature (operating
temperature) lies with the plant operator. The
maximum
permissible
fluid
temperature
depends on the temperature class to be
complied with.
Table 1 below lists the temperature classes to EN
13463-1 and the resulting theoretical temperature limits
of the fluid handled. In stipulating these temperatures,
any temperature rise in the shaft seal area has already
been taken into account.
Table 1. Fluid Temperature Limits
Temperature class
to EN 13463-1:
Temperature limit of
fluid handled
T5
185 °F (85 °C)
T4
284 °F (120 °C)
T3
365 °F (185 °C)
T2
536 °F (280 °C)
T1
662 °F (350 °C)
CAUTION
Mechanical seals may exceed the
specified temperature limits if run dry. Dry
running may not only result from an
inadequately filled seal chamber, but also from
excessive gas content in the fluid handled.
Pump operation outside its specified operating range
may also result in dry running.
K.5 Temperature Limits.
In normal pump operation, the highest
temperatures are to be expected on the surface
of the pump volute, at the shaft seal and in the
ball bearing areas. The surface temperature at
the pump volute corresponds to the
temperature of the fluid handled.
The permissible operating temperature of the
pump in question is indicated on the data
sheet. If the pump is to be operated at a higher
temperature, the data sheet is missing or if the
pump is part of a pool of pumps, the maximum
permissible operating temperature must be
enquired from the pump manufacturer.
Based on an ambient temperature of 104˚ Fahrenheit
(F) [40˚ Celsius (C)] and proper maintenance and
operation, compliance with temperature class T4 is
warranted in the area of the rolling element ball
bearings. A special design is required for compliance
with temperature class T6 in the ball bearing area. In
such cases, and if ambient temperature exceeds 104˚F
(40˚C), contact the manufacturer.
If the pump is heated, it must be ensured that the
temperature classes stipulated for the plant are
observed.
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610 11 Edition Centrifugal Pump
Pumping liquid over 400˚F (204
˚C) ;
pumps must be equipped with auxiliary cooling.
Pumps of high temperature construction MAY optionally
be provided with cooled ball bearings for a unit
operating in temperature range between 400˚ F and
650˚ F (204˚ C and 343˚ C) . Cooling water is piped
through cavities of the bearing frame and keeps
temperature of the ball bearings within acceptable limits.
Refer to Table 8 for cooling flow rates of water
temperature of 60˚ F (140˚C) for ball bearings.
K.6 Maintenance.
Only a pumping unit which is properly
serviced and maintained in perfect technical
condition will give safe and reliable operation.
This also applies to the reliable function of the thrust and
radial ball bearings whose actual lifetime largely
depends on the operating mode and operating
conditions. Regular checks of the lubricant and the
running noises will prevent the risk of excessive
temperatures as a result of the thrust or radial ball
bearings running hot or defective bearing isolators.
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November 2013
•
Make sure you are NOT grounded while
adjusting electrical equipment or using
measuring equipment.
•
In general, use only one hand when servicing
live electrical equipment.
•
Make sure to de-energize all electrical
equipment before connecting or disconnecting
meters or test leads.
•
For connecting a meter to terminals for
measurement, use a range higher than the
expected voltage.
•
Check to make sure that the frame of the driver
and starter panel are securely grounded before
operating pumping unit or performing any tests
or measurements.
•
If a test meter must be held or adjusted while
voltage is applied, ground case of meter before
starting measurement. Do NOT touch live
equipment while holding the meter. Some
moving vane-type meters should not be
grounded nor held during measurements.
•
Do NOT use test equipment known to be
damaged or in poor condition.
The correct function of the bearing isolators must be
checked regularly. Any auxiliary systems installed must
be monitored, as necessary, to make sure that they
function correctly.
The following specific safety precautions apply to the
pumping unit:
K.7 General Safety Instructions.
III. EQUIPMENT DESCRIPTION.
6
•
Various federal, state, and local laws affect
installation, use, and operation of pumping
equipment. Compliance with such laws relating
to proper installation and safe operation of
pumping equipment is the responsibility of the
equipment owner.
•
Prior to working on pump or driver, ensure all
switches and circuit breakers have been locked
in the open (off) position and tagged, “Out of
Service.”
•
All circuits NOT known to be dead must be
considered live at all times.
•
Do NOT wear loose or torn clothing around
rotating machines.
•
While working near electricity, do NOT use
metal rules, flashlights, metallic pencils, or any
other objects having exposed conducting
material.
•
Do NOT exceed maximum discharge pressure.
The API Maxum is our process pump for handling
hydrocarbons in refining and process industry
applications. It is offered as a centerline mounted unit.
Hydraulic performance extends to 9,000 GPM and 720
feet of head. The design is restricted as noted below.
The Maxum pump unit consists of a pump, base,
coupling, coupling guard and a driver unit. The driver is
usually an electric motor, but can be a steam turbine or
any other power conversion device that can provide the
required horsepower at the proper RPM. Drivers other
than electric motors must be reviewed for compliance
with the applicable directives.
The Maxum pump is supplied with a volute that should
always be mounted solidly on an adequate bedplate. No
shims should be used under the feet of the casing.
The Maxum pump is designed as a back pullout unit.
Therefore it should always be used with a spacer
coupling. The spacer width should permit the entire
rotating assembly to be removed from the casing.
API Maxum
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610 11 Edition Centrifugal Pump
Normally the casing should be left in place on the base
and remain connected to the suction and discharge
piping.
The bare pump consists of following major parts and
options. Refer to Figure 9, the Sectional Assembly and
Figure 10, Pump with Base, drawings for the location of
parts identified by item numbers.
Item 1 - Volute. The volute (1) houses the impeller (2)
and volute wear ring (7) and consists of the suction inlet,
and discharge nozzle. The backhead (11) is held in
place between the volute and the bearing frame (19).
The volute is fastened to the backhead with
volute/adaptor studs (631) and volute hex nuts (616)
with volute/backhead lockwashers (655).
Item 2 - Impeller. Maxum pumps are equipped with
enclosed impellers. The impeller (2) is keyed to the shaft
(6) by the impeller key (32) and is locked in place by the
impeller nut or optional inducer (24) and impeller washer
(28).
Item 6 - Shaft. The shaft (6) of the Maxum pump is
designed for maximum deflection of 0.002 inch at the
face of the mechanical seal (90). The shaft is also
designed to provide stabilization to the rotor system
when pump operates away from the best efficiency
point. A coupling (42) connects the shaft to the driver
shaft (190). The pump coupling key (46) holds the
coupling in place, causing it to rotate with the shaft.
Item 11 - Backhead. The backhead (11) is fastened to
the volute (1) with volute/adaptor studs (631), volute hex
nuts (616), and volute/backhead lockwashers (655). The
backhead houses backhead wear ring (7X). The
backhead is positioned in the volute bore by volute
gasket (73C*) or O-ring (89A*).
The bearing frame (19) is attached to the backhead with
backhead stud (632), backhead hex nut (617) and
adaptor/frame lockwashers (656).
The backhead (11) contains forcing bolts (610) to aid in
loosening the backhead from the volute (1).
Item 16 and 18 – Ball Bearings. A deep-groove
Conrad-type, C3 internal fit radial ball bearing (16) and
light preload, back-to-back mounted thrust ball bearings
(18) are housed in the bearing frame (19). The thrust
ball bearings will be designated as 7000 or 8000 series.
Thrust ball bearings designated in the 7000 series will
be duplex 40° angular contact ball bearings. Thrust ball
bearings designated in the 8000 series will have 40°
and 15° angular contact. The thrust ball bearing is held
in place by the bearing locknut (22) and bearing
lockwasher (69). The ball bearings are oil lubricated.
Either oil bath lubrication or an oil mist system may be
employed.
I-401
November 2013
Item 19 - Bearing Frame. The principal function of the
bearing frame (19) is to carry the loads from the liquid
end of the pump to the base and to transport power from
the power unit to the impeller (2). The bearing frame has
a radial ball bearing (16) located in the front end of the
bearing frame (nearest to the volute) and a pair of
back-to-back mounted angular contact thrust ball
bearings (18) in the rear of the bearing frame. This
bearing frame is designed to be oil lubricated, which can
be accomplished in several ways.
The first method involves the use of a sight glass
constant level oiler (143). The sight glass maintains the
oil level high enough on the higher of the two bearings
so that the bearings themselves provide the motivation
for the oil to be moved through the races of the
bearings.
A second method is to provide an oil flinger (60) which
mounts on the shaft (6) and literally flings the oil
throughout the bearing frame. An oil view gauge
indicator (143) is usually used with this system to make
sure that the oil level within the frame can be observed
and maintained at the proper level.
A third method is the oil mist system. All Maxum pumps
are equipped so that they can be used or can be
converted to oil mist units without any field machining-.
Oil Mist system for ATEX applications
require a user installed system of safety
controls or alarms to insure that the pump is
shut down in event of an oil mist failure.
In addition to the oil lube system, the bearing frame (19)
contains the bearing isolators (47 & 49). The Maxum
pump bearing frame is equipped with a labyrinth oil seal
assembly which becomes a static seal when stopped.
Item 23 - Base. A grout-able base (23) is designed to
provide adequate support for the pump and motor so
pump can be operated without base deflection,
excessive vibration, or resonance. The volute (1) is
attached to the base with stud (634) and hex nut (614).
Grouting of this type of base is required by Carver Pump
Company.
Item 90 – Mechanical Seal. Cartridge mechanical
seals (90) are to be used. Complete cartridge
mechanical seal instructions should be obtained from
the seal manufacturer. The standard seal chamber
dimensions are shown in Figure 1.
7
API Maxum
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610 11 Edition Centrifugal Pump
IV. EFFECTS OF FLUIDS.
Solids in the fluid pumped may cause
internal damage to pump casing and damage
to the seal faces with resulting Hazardous
conditions. Care is to be taken to ensure that
the process fluid is clear of solids and debris.
A. NET POSITIVE SUCTION HEAD (NPSH). Any
liquid, hot or cold, must be pushed into the impeller of
the pump by some absolute pressure, such as the
atmosphere or the vessel pressure from which the pump
takes its action.
The head in feet of liquid necessary to maintain the
required flow into the pump is called the Net Positive
Suction Head (NPSH). This value is measured above
the vapor pressure of the liquid at the pumping
temperature.
NPSH is commonly expressed in two ways: the NPSH
required by the pump, and shown on the pump curve, is
the head needed to cover the losses in the pump
suction and the energy required to enable the liquid to
climb onboard the leading edge of the impeller vane.
The NPSH available is that inherent in the system,
taking into account friction losses in suction piping,
valves, fittings, etc. In all cases, the NPSH available,
measured above vapor pressure, must exceed the
NPSH required in order to push the liquid into the pump.
B. CHANGING PUMP SPEED. Changing the speed of
a centrifugal pump affects the capacity, total head,
NPSH required and the brake horsepower. In general
the capacity will vary in a direct ratio with the speed,
whereas the total head and NPSH required will vary as
the ratio of the speed squared. The brake horsepower
will vary as the ratio of the speed cubed.
C. EFFECTS OF VISCOSITY. The pump is designed
to deliver rated capacity at rated head for a liquid with a
particular viscosity. When pump is handling heavy
viscous liquid, the viscosity of the liquid must allow it to
be pumped easily. The liquid may have to be heated
prior to starting the pump. When contemplating
operation at some viscosity other than that for which the
pump was originally designed, check with Carver Pump
Company.
8
I-401
November 2013
D. EFFECTS OF SPECIFIC GRAVITY. The capacity
and total head in feet of liquid developed by a centrifugal
pump are fixed for every point on the curve and are
always the same for the same speed. Neither capacity
nor total head will be affected by a change in the
specific gravity of the liquid pumped. However, since the
discharge pressure in Pounds per Square Inch (PSI)
and the brake horsepower required driving the pump are
functions of the specific gravity of the liquid, both will be
affected in direct proportion by any change in specific
gravity. Therefore, an increase in specific gravity will
raise the discharge pressure and is dangerous as it
might overload the pump's driver, or exceed the pump
casing allowable pressure.
V. TECHNICAL DATA.
Specifications and operating limits should be recorded
on a Service Record Page; an example is located in the
front matter of this manual. Record the necessary
information upon receipt of the pumping unit.
Estimated Sound Pressure Values.
The sound
pressure values in Table 2 are estimated values as
measured at 1 meter. Noise levels for sizes larger than
200 Horsepower (HP) need considered on a case by
case basis, as larger motors vary greatly in air borne
noise values.
Seal Chamber Dimensions. Standard seal chamber
dimensions are located in Figure 1 and are arranged by
bearing frame number.
Basic Design Features. Basic design features of the
pump are located in Table 3 and are arranged by pump
size.
Key Mechanical Data. Key mechanical data for the
pump is located in Table 4 and is arranged by bearing
frame number.
Permissible Nozzle Loads. The forces and moments
in Table 5 are to be understood as the limit for a single
acting force or moment along the particular coordinate
axes or any resultant of two or more forces and
moment.
API Maxum
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610 11 Edition Centrifugal Pump
I-401
November 2013
Table 2. Estimated Noise Characteristics
Motor
3550 RPM
2950 RPM
1750 RPM
1450 RPM
1150 RPM
HP
kW
Pump
and
Motor
dB[A]
>5
>3.7
82
77
81
78
74
71
75
73
71
69
7.5
5.6
86
81
85
82
78
75
79
77
75
73
10
7.4
86
81
85
82
78
75
79
77
75
73
15
11.2
87
82
86
83
79
76
80
78
76
74
20
14.9
88
83
87
84
80
77
81
79
77
75
25
18.6
88
83
87
84
80
77
81
79
77
75
30
22.4
88
83
87
84
80
77
81
79
77
75
40
29.8
96
91
95
92
88
85
89
87
85
83
50
37.3
96
91
95
92
88
85
89
87
85
83
60
44.7
96
91
95
92
88
85
89
87
85
83
75
55.9
96
91
95
92
88
85
89
87
85
83
100
74.6
96
91
95
92
88
85
89
87
85
83
125
93.2
96
91
95
92
88
85
89
87
85
83
150
111.9
96
91
95
92
88
85
89
87
85
83
Pump
Only
dB[A]
Pump
and
Motor
dB[A]
Pump
Only
dB[A]
Pump
and
Motor
dB[A]
Pump
Only
dB[A]
Pump
and
Motor
dB[A]
Pump
Only
dB[A]
Pump
and
Motor
dB[A]
Pump
Only
dB[A]
The tolerance for these values is ±3 dB[A].
9
API Maxum
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610 11 Edition Centrifugal Pump
Bearing
Frame
Number
Shaft
Diameter
d1
Box Bore
3
I-401
November 2013
d2
Stud
Circle
d3
Max Gland
Diameter
d4
Total
Length
C
Clear
Length
E
Box
Depth
C-E
Stud
Size
(USC)
1.575
3.543
4.921
6.625
6.500
4.000
2.500
1/2” - 13
4
1.968
3.937
5.512
6.625
6.900
4.400
2.500
5/8” - 11
5
2.362
4.725
6.219
7.750
6.900
4.400
2.500
5/8” – 11
6
2.500
5.118
6.693
7.750
6.900
4.400
2.500
5/8” - 11
8
3.543
6.219
8.070
10.875
7.290
4.790
2.500
3/4” - 10
Figure 1. Seal Chamber Dimensions
10
API Maxum
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610 11 Edition Centrifugal Pump
I-401
November 2013
Table 3. Basic Design Features
Pump Size
Bearing
Frame
Max
Speed
(RPM)
1st
Critical
Speed
(RPM)
Discharge
Volute(s)
Casing Design
Shaft Deflection @ 20%
BEP
@ Seal (in.) @ Impeller (in.)
Shaft
Stiffness
L3/D4
WK2 @ Max.
Impeller Dia.
AA- 1½ x 1 x 6
3
3500
13068
Centerline
Single
0.0002
0.0009
183.3
9.500
AB - 2 x 1½ x 6
3
3500
12098
Centerline
Single
0.0006
0.0019
183.3
10.45
AC- 3 x 1½ x 6
3
3500
11317
Centerline
Single
0.0006
0.0021
183.3
11.40
AD - 3 x 2 x 6
3
3500
12098
Centerline
Single
0.0011
0.0036
183.3
10.45
AE - 4 x 3 x 6
3
3500
10122
Centerline
Dual
0.0021
0.0070
183.3
15.20
BA - 1½ x 1 x 8
4
3500
12262
Centerline
Single
0.0003
0.0011
83.6
34.31
BB - 2 x 1½ x 8
4
3500
10754
Centerline
Single
0.0005
0.0017
83.6
41.42
BC - 3 x 1½ x 8
4
3500
11193
Centerline
Single
0.0006
0.0022
83.6
39.05
BD - 3 x 2 x 8
4
3500
11193
Centerline
Single
0.0008
0.0029
83.6
39.05
BE – 4 x 3 x 8
4
3500
10363
Centerline
Dual
0.0004
0.0014
83.6
43.79
BF - 6 x 4 x 8
4
3500
10012
Centerline
Dual
0.0005
0.0017
83.6
46.16
CA – 2 x 1½ x 10
5
3500
13192
Centerline
Single
0.0002
0.0012
42.3
92.29
CB - 3 x 1½ x 10
5
3500
13192
Centerline
Single
0.0002
0.0011
42.3
92.29
CC - 3 x 2 x 10
5
3500
12773
Centerline
Single
0.0004
0.0022
42.3
92.29
CD - 4 x 3 x 10
5
3500
12042
Centerline
Quad
0.0006
0.0032
42.3
108.6
CE - 6 x 4 x 10
5
3500
10429
Centerline
Dual
0.0002
0.0012
42.3
141.3
CF - 6 x 6 x 10
5
1750
8288
Centerline
Dual
0.0002
0.0010
42.3
141.3
CG - 8 x 6 x 10
5
1750
10020
Centerline
Dual
0.0002
0.0012
42.3
152.2
DA - 2 x 1½ x 13
6
3500
11224
Centerline
Single
0.0003
0.0019
35.0
209.6
DB - 3 x 2 x 13
6
3500
8511
Centerline
Single
0.0005
0.0026
35.0
201.8
DC - 4 x 3 x 13
6
3500
9515
Centerline
Quad
0.0009
0.0054
35.0
263.8
DD - 6 x 4 x 13
6
3500
9098
Centerline
Dual
0.0002
0.0013
35.0
287.1
DE - 6 x 6 x 13
6
1750
8306
Centerline
Dual
0.0002
0.0010
35.0
310.3
DF - 8 x 6 x 13
6
1750
7130
Centerline
Dual
0.0003
0.0016
35.0
310.3
DG - 10 x 8 x 13
6
1750
6728
Centerline
Dual
0.0004
0.0023
35.0
418.9
DH – 12 x 10 x 13
6
1750
6215
Centerline
Dual
0.0008
0.0043
35.0
418.9
ED- 6 x 4 x 16
8
1750
8223
Centerline
Dual
0.0001
0.0005
19.5
563.6
EA- 8 x 6 x 16
8
1750
7885
Centerline
Dual
0.0001
0.0011
19.5
647.3
EB - 10 x 8 x 16
8
1750
9053
Centerline
Dual
0.0001
0.0012
19.5
595.9
EE - 12 x 10 x 16
8
1750
7840
Centerline
Dual
0.0001
0.0006
19.5
722.6
EC - 14 x 12 x 16
8
1750
7752
Centerline
Dual
0.0004
0.0035
19.5
849.4
FA - 8 x 6 x 20
8
1750
7478
Centerline
Dual
0.0001
0.0012
19.5
1232.0
FB - 10 x 8 x 20
8
1750
7288
Centerline
Dual
0.0002
0.0018
19.5
1495.0
FC - 12 x 10 x 20
8
1750
6714
Centerline
Dual
0.0003
0.0026
19.5
1859.0
FD - 14 x 12 x 20
8
1750
6075
Centerline
Dual
0.0005
0.0039
19.5
2298.0
11
API Maxum
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610 11 Edition Centrifugal Pump
I-401
November 2013
Table 4. Key Mechanical Data
Bearing Frame
Item
3
Max power (BHP) @ 3500 RPM
@ 1750 RPM
@ 1150 RPM
Bearing type - radial ball bearing
thrust ball bearing
Lubrication method (standard)
L10 bearing life (hrs) - radial
thrust
Radial to thrust ball bearing centerline (in.)
Shaft diameter (in.) @ coupling
@ impeller hub (standard ext.)
@ radial ball bearing
@ thrust ball bearing
@ seal box
Coupling Key – width (in.)
length (in.)
12
150
75
50
6211
7311
5.192
1.375
1.000
2.166
2.166
1.575
0.313
2.625
4
240
120
80
6211
7311
5
6
550
550
275
275
180
180
6213
6213
7313
7313
Oil - ISO Grade 68
50,000
50,000
5.192
8.939
8.939
1.375
2.000
2.000
1.375
1.375
1.875
2.166
2.559
2.559
2.166
2.559
2.559
1.968
2.362
2.500
0.313
0.500
0.500
2.625
2.000
2.000
8
1500
1000
6219
7318
13.198
3.000
2.375
3.741
3.544
3.543
0.750
5.000
API Maxum
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610 11 Edition Centrifugal Pump
I-401
November 2013
Table 5. Permissible Nozzle Loads
Pump Size
AA- 1½ x 1 x 6
AB - 2 x 1½ x 6
AC- 3 x 1½ x 6
AD - 3 x 2 x 6
AE - 4 x 3 x 6
BA - 1½ x 1 x 8
BB - 2 x 1½ x 8
BC - 3 x 1½ x 8
BD - 3 x 2 x 8
BE – 4 x 3 x 8
BF - 6 x 4 x 8
CA – 2 x 1½ x 10
CB - 3 x 1½ x 10
CC - 3 x 2 x 10
CD - 4 x 3 x 10
CE - 6 x 4 x 10
CF - 6 x 6 x 10
CG - 8 x 6 x 10
DA - 2 x 1½ x 13
DB - 3 x 2 x 13
DC - 4 x 3 x 13
DD - 6 x 4 x 13
DE - 6 x 6 x 13
DF - 8 x 6 x 13
DG - 10 x 8 x 13
DH – 12 x 10 x 13
ED- 6 x 4 x 16
EA- 8 x 6 x 16
EB - 10 x 8 x 16
EE - 12 x 10 x 16
EC - 14 x 12 x 16
FA - 8 x 6 x 20
FB - 10 x 8 x 20
FC - 12 x 10 x 20
FD - 14 x 12 x 20
Fx
Fy
Fz
200
200
300
300
400
200
200
300
300
400
700
200
300
300
400
700
700
1100
200
300
400
700
700
1100
1500
1800
700
1100
1500
1800
2000
1100
1500
1800
2000
160
160
240
240
320
160
160
240
240
320
560
160
240
240
320
560
560
850
160
240
320
560
560
850
1200
1500
560
850
1200
1500
1600
850
1200
1500
1600
130
130
200
200
260
130
130
200
200
260
460
130
200
200
260
460
460
700
130
200
260
460
460
700
1000
1200
460
700
1000
1200
1300
700
1000
1200
1300
Suction
Mx
My
340
340
700
700
980
340
340
700
700
980
1700
340
700
700
980
1700
1700
2600
340
700
980
1700
1700
2600
3700
4500
1700
2600
3700
4500
4700
2600
3700
4500
4700
170
170
350
350
500
170
170
350
350
500
870
170
350
350
500
870
870
1,300
170
350
500
870
870
1,300
1800
2200
870
1,300
1800
2200
2300
1,300
1800
2200
2300
Mz
Fx
Fy
Fz
260
260
530
530
740
260
260
530
530
740
1,300
260
530
530
740
1,300
1,300
1,900
260
530
740
1,300
1,300
1,900
2800
3400
1,300
1,900
2800
3400
6300
1,900
2,870
3400
6300
160
160
160
160
240
160
160
160
160
240
320
160
160
160
240
320
560
560
160
160
240
320
560
560
850
1200
320
560
850
1200
1,500
560
850
1200
1,500
130
130
130
130
200
130
130
130
130
200
260
130
130
130
200
260
460
460
130
130
200
260
460
460
700
1000
260
460
700
1000
1200
460
700
1000
1200
200
200
200
200
300
200
200
200
200
300
400
200
200
200
300
400
700
700
200
200
300
400
700
700
1100
1500
400
700
1100
1500
1800
700
1100
1500
1800
Discharge
Mx
My
340
340
340
340
700
340
340
340
340
700
980
340
340
340
700
980
1700
1700
340
340
700
980
1700
1700
2600
3700
980
1700
2600
3700
4500
1700
2600
3700
4500
170
170
170
170
350
170
170
170
170
350
500
170
170
170
350
500
870
870
170
170
350
500
870
870
1,300
1800
500
870
1,300
1800
2200
870
1,300
1800
2200
Mz
200
200
200
200
530
200
200
200
200
530
740
200
200
200
530
740
1300
1300
200
200
530
740
1300
1300
1,900
2800
740
1300
1,900
2800
3400
1300
1,900
2800
3400
M = Moments measured in Foot-Pounds (FT-lbs)
F = Forces measured in Pounds (lbs)
13
API Maxum
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610 11 Edition Centrifugal Pump
VI. INSPECTION AND STORAGE.
A. INSPECTION.
Upon receipt of the shipment,
unpack and inspect the pumping unit and individual
parts to insure none are missing or damaged. Carefully
inspect all boxes and packing material for loose parts
before discarding them. Check to make sure the
shipment complies with the purchase order. Immediately
report any missing parts or damage incurred during
shipment to the factory and to the Transportation
Company and file your “damage and/or lost in shipment”
claim with the carrier.
B. PACKING FOR RETURN. If the pumping unit is
sent back to Carver Pump Company for repair, drain the
unit, and re-seal all flanges and connections that were
covered or plugged. Ship the pump(s) in an assembled
condition to prevent damage to sealing faces of
individual components. A Return Goods Authorization
(RGA) and a Material Safety Data Sheet (MSDS) is
required on all returned pumps. Copies of MSDS
records should be kept and maintained by the customer.
The customer is responsible for cleaning and flushing
the pump before it is returned to the factory. Make sure
to specify the fluid used in the service.
C. STORAGE OF PUMP. If the equipment is not to be
immediately installed and operated, store it in a clean,
dry, well ventilated place, free from vibrations, moisture
and rapid or wide variations in temperature.
NOTE
Storage requirements vary depending on
climatic environment, length of storage and
equipment. For storage periods of three months
or longer, contact manufacturer for specific
instructions. Improper storage could damage
equipment and would result in non-warranty
covered restoration of non-warranty covered
product failures.
When storing the pump up to three months rotate the
shaft for several revolutions at least once per month to
coat the ball bearings with lubricant, retard oxidation and
corrosion, and prevent possible false brinelling.
The motor ball bearings should be prepared for storage
according to the motor manufacturer’s instructions, in
the motor manufacturer’s maintenance manual, which
should come with the motor.
I-401
November 2013
CAUTION
For shipment and long term storage purposes
the pump ball bearing shall be fogged once
every 30 days during storage with a rust
retardant compatible with the oil used in the
system to prevent rusting.
A pump which is made of iron or steel that sits
in extreme heat, high humidity, or full or
partially full water over 30 days will rust and will
most likely seize. If the pump rusts and/or
seizes, a complete overhaul and repair may be
necessary to refurbish the pump.
Consider a unit to be in storage when:
1. It has been delivered to the job site and is
waiting to be installed.
2. It has been installed but operation is delayed
pending completion of construction.
3. There are long (30 days or more) periods
between operating cycles.
4. The plant (or department) is shut down for
periods of longer than 30 days.
Measures to be taken for prolonged shutdown of
installed pumping unit. If the pumping unit remains
installed a periodic check of operation is in order to
make sure that the pump is always ready for instant
start-up and to prevent the formation of deposits within
the pump and the pump intake area. Start up the
pumping unit regularly once a month or once every 3
months for a short time (approximately 5 minutes)
during prolonged shutdown periods. Prior to operation
check run ensure that there is sufficient liquid available
for operating the pump.
Interim Storage (Indoors)/ Preservation. When the
unit is temporarily put into storage, only the wetted low
alloy must be preserved. Commercially available
preservatives can be used for this purpose. Please
observe
the
manufacturer’s
instructions
for
application/removal.
The unit/pump should be stored in a dry room where the
atmospheric humidity is as constant as possible.
If stored outdoors, the unit and crates must be covered
by waterproof material to avoid any contact with
humidity.
Protect all stored goods against humidity, dirt, vermin
and unauthorized access!
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All openings of the assembled unit components are
closed and must only be opened when required during
installation.
All blank parts and surfaces of the pump are oiled or
greased (silicone-free oil and grease) to protect them
against corrosion.
VII. INSTALLATION.
A. LOCATION.
The pump assembly should be
located in an area that will permit periodic inspection
and maintenance. Head room and access should be
provided and all units should be installed in a dry
location with adequate drainage. The discharge piping
should be direct with as few elbows and fittings as
possible.
The pump assembly should be installed as close to the
fluid as possible. A short, direct suction pipe can be
used to keep suction losses at a minimum. If possible,
locate the pump so fluid will flow by gravity to the
suction opening. The discharge piping should be direct
with as few elbows and fittings as possible. The total Net
Positive Suction Head Available (NPSHA), which
includes the suction lift and pipe friction losses, must be
greater than the Net Positive Suction Head Required
(NPSHR) by the pump.
B. HANDLING.
CAUTION
Use a hoist with adequate lifting capacity.
Do not pick up the complete unit by the motor
or the pump shafts or motor lifting eyes.
If the pumping unit slips out of the sling
arrangement, it may cause injury to personnel
and/or damage to the pumping unit.
Moving the unit requires proper preparation and
handling. Always make sure that the pump or the
pumping unit remains in a horizontal position while
being moved and cannot slip out of the transport
suspension arrangement. Use a sling for pumps without
baseplates, refer to Figure 2. To lift a horizontal
mounted unit, a hoist or suitable lifting device should be
attached to each corner of base structure, refer to
Figure 3. The individual motor may be lifted using proper
eyebolts provided by the manufacturer, but these should
not be used to lift the assembled unit.
Figure 2. Sling Position for Moving Pump
Figure 3. Sling Position for Moving Pumping unit
C. FOUNDATION.
Make sure that the concrete
foundation has set firmly before placing the unit on it. Its
surface must be truly horizontal and even. The
foundation bolts must be inserted in the base holes. The
foundation should be 3 to 6 inches wider and longer
than the base, have a level surface, and be of sufficient
mass to prevent vibration and form a permanent rigid
support for the unit. The best foundations are concrete
with anchor bolts of adequate size embedded in the
foundation in pipe sleeves having an inside diameter 21/2 times larger than the bolt diameter. This will allow for
accurate positioning of the unit. Keep the concrete
surface clean, yet rough.
Hydraulic Institute (HI) recommends a foundation
capable of absorbing vibration at least five times the
weight of the pumping unit and to form a permanent,
rigid support for the base plate. Consequently,
maintaining the pump to driver alignment is important for
a flexible coupled unit, refer to Figure 6. A concrete
foundation on a solid base is recommended. Use
foundation bolts of the proper size embedded into the
concrete. A pipe sleeve larger in diameter than the bolt
should be used. This allows movement for final
positioning of the bolts. Refer to Figure 4, Grouting and
Foundation Bolting.
As soon as the pump and driver, mounted on a base, is
placed on the foundation, remove the coupling guard
and disconnect coupling halves. The base should be
supported by the provided jacking screws. Refer to
Figure 5; adjust the leveling screws until provided base
Milled Leveling Pads are true in both the axial and
transverse directions. Verify that the pump and driver
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610 11 Edition Centrifugal Pump
shafts are level. Check coupling faces, as well as,
suction and discharge flanges of the pump for horizontal
or vertical positioning by means of a level. Make
corrections, as necessary, by adjusting the leveling
screws on the base.
D. LEVELING OF UNIT. When the pump is supplied
complete with motor and base, the unit is assembled at
the factory. Lower unit onto foundation, positioning base
structure so anchor bolts are aligned in middle of holes
in base.
The base should be supported on either rectangular
metal blocks with shims or on metal wedges having a
small taper. The support pieces should be placed close
to the foundation bolts. Refer to Figure 4, Grouting and
Foundation Bolting. Place supports directly under the
part of the base, which carries the greatest weight.
Space the supports closely enough to provide uniform
support of the base. Adjust the metal supports or
wedges until the shaft is level. Check suction and
discharge flanges of the pump by means of a level.
Make corrections, as necessary, by adjusting the
supports or wedges under the base.
The base should be supported on metal shims or metal
wedges placed directly beneath the part of the base
supporting the most weight. The shims or wedges
should be spaced close enough to give support and
stability.
Adjust metal supports or wedges until suction and
discharge flanges are level.
CAUTION
Do not attempt to straighten the base by using
the anchor bolts.
E. GROUTING. After the pumping unit has been
leveled and the alignment is correct, grout the unit to the
foundation using a high-grade, non-shrinking grout.
Proceed grouting using the following procedure:
Prepare concrete foundations, anchor bolts and leveling
screws according to individual instructions covering
these items.
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1. Wax forms heavily with at least three coats of
paste wax. Forms must be substantial and well
braced. All corners, joints, bottoms must be
sealed with silicone caulk for water tightness. All
forms should have a 45° chamfer strip installed
to prevent stress risers.
2. Anchor bolt-free length must be wrapped with
duct seal or electricians plastic tape to prevent
grout from contacting the bare metal. Grout
sticking to the anchor bolt will prevent the
elongation necessary to develop the hold-down
force. Failure to do this will result in broken
anchor bolts.
3. Leveling screws must be greased to permit
removal prior to the final torque.
4. Do not use shim packs as a leveling device
unless it is planned to remove them prior to final
torque application.
5. Leveling screw pads should be a minimum of
1/2" thick with minimum diameter of 3". Corners
of pad must be rounded to approximately 1/8"
radius to prevent stress cracking. Set leveling
screws on the chipped concrete surface. Set the
pad with quick set cement or Resin Repair
Compound. With jacking bolt pads secure and
level, set and level base with leveling screws.
6. The underside of the standard factory steel
base plate was painted with epoxy grout primer
and should only require proper cleaning. If the
base must be sandblasted, prepare the contact
faces to SSPC-SP 6 Spec. If base cannot be set
within 24 hours of blasting, the underside must
be coated with a compatible Rust Inhibitive
Primer. Tighten foundation bolts loosely. Allow
the grout to fully cure before firmly tightening the
foundation bolts.
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610 11 Edition Centrifugal Pump
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November 2013
Figure 4. Grouting and Foundation Bolting
Figure 5. Unit Leveling
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F. COUPLING ALIGNMENT. The pump and motor
are connected by a coupling. The base aligns the pump
and motor. No further alignment is necessary unless the
pump or motor were removed from the base or if there
was not a base purchased with the unit then the
following is how to check the coupling alignment. The
coupling should NOT be reconnected until the alignment
has been completed.
NOTE
Refer to coupling manufacturer’s manual for
instructions regarding shaft alignment and
recommended installation limits.
Soft Foot – The equipment must rest flat on its
base. If one or more feet of the pump or motor
are shorter, longer, or angled in some way to
prevent uniform contact (a condition commonly
known as “soft foot”) it must now be corrected.
To improve the life of the coupling, the shafts must be
aligned to minimize deflection of the flexing elements.
Shaft alignment is required in the axial, parallel, and
angular directions, with each of these values not to
exceed the recommended installation limits. Shaft
alignment can be measured using various established
methods, including Laser Alignment, Reverse Dial
Indicator, and Rim and Face.
The motor and pump shafts must be accurately aligned
as any misalignment can cause damage to the coupling,
motor, or pump. When the shafts are in correct
alignment, the coupling hubs will be on a common axis,
concentric with each other, and at the correct distance
apart. If the coupling hubs are misaligned, it is general
practice to adjust the driver to the pump. Insert full
Parallel Offset Misalignment
shims under the feet or supports of the motor and
tighten fastening bolts until correct alignment is
achieved.
1. Move the pump or motor to achieve acceptable
alignment. When properly aligned, the disc
packs will be centered and approximately
parallel to their mating flange faces and the
flexing elements will have little visible waviness
when viewed from the side.
NOTE
Refer to the coupling manufacturer’s manual for
recommended installation limits for Parallel,
Angular, and Axial alignment.
2. The “Parallel Misalignment” value (P) is the
offset between the centers of the hubs, as
shown in Figure 6.
3. When the Parallel Offset is measured by
rotating the hubs in unison with dial indicators
as shown in Figure 6, the Total Indicator
Reading (TIR) should be divided by (2) to
calculate (P).
4. It should be noted that parallel offset measured
on the hub surfaces includes misalignment of
the equipment shafting plus any variation (TIR)
in the hubs. This may be helpful to consider
during problem solving for alignment difficulties.
5. The “Angular Misalignment” value is the
maximum
difference
between
the
measurements X and Y taken at opposite ends
of the hub flanges, as shown in Figure 6.
Parallel Offset (TIR)
Measurement
Figure 6. Coupling Alignment
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Angular Misalignment
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610 11 Edition Centrifugal Pump
G. PRE-INSTALLATION PROCEDURES.
1. Check the pump foundation and confirm the
bolting surface is flat and the bolt pattern is
correct.
2. Slowly lower pump onto the foundation.
3. Rotate the pump by hand. Check for any
mechanical
hesitation,
binding
or
any
acoustically transmitted signals from the pump.
Hand rotation should be smooth and silent.
Install the pump to foundation bolting and
tighten to the system torque values. The pump
should be rotated frequently during the
procedure to tighten down the pumping unit.
4. After the pumping unit has been completely
tightened down to the foundation, confirm that
there is no binding.
5. Connect the piping.
H. PIPING.
All piping should be independently
supported near the pump so that pipe strain will not be
transmitted to the pumping unit.
CAUTION
All piping connections must be made with the
pipe in a freely supported state. Do not apply
vertical or side pressure to align the piping with
the pump flange.
Before connecting suction, discharge, and
auxiliary piping, check to see that the piping is
absolutely clean internally. Any debris in the
piping will be drawn into the pump
passageways and can cause extreme damage.
The internal diameters of the suction and
discharge lines must be equal to the internal
diameters of the pump suction and discharge
nozzles.
The pump is shipped with flange covers to protect flange
faces and to prevent foreign matter from entering the
pump. Flange covers should remain intact until suction
and discharge piping are connected to pump flanges.
Suction lift lines shall be laid with a rising slope toward
the pump and suction headlines with a downward slope
towards the pump.
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November 2013
Never use a straight taper (concentric) reducer in a
horizontal suction line because air pockets may form in
the top of the reducer and the pipe. Use an offset
(eccentric) reducer instead.
It is recommended to install a check valve and closing
valve in discharge line and closing valve in suction line,
depending on the type of plant and pump. The check
valve, between the pump and valve, protects pump from
water hammer and prevents reverse rotation in the
event of power failure. Closing valves are used in
priming, starting, and pump shut down. Pump must
never be throttled by use of a valve in the suction line.
Thermal expansions of the pipeline must be
compensated by appropriate measures so as not to
impose any extra loads on the pump exceeding the
permissible pipeline forces and moments. Refer to Table
5 for permissible forces and moments.
The coupling should be realigned after installing piping
or when hot service units are at the final operating
temperature. Refer to Section VII, Paragraph F for
coupling alignment.
I. AUXILIARY
PIPING
CONNECTIONS
AND
GAUGES. In addition to primary piping connections, the
pump may require other connections such as gauges or
drains. All these lines and gauges should now be
installed. Refer to vendor mechanical seal drawing for
seal line connections to the cartridge mechanical seal.
J. MOTOR. See motor vendor’s manual for motor
information and information on connecting to the power
supply.
CAUTION
Connection to the power supply must be
effected by a trained electrician only. Check
available main voltage against the data on the
motor rating plate and select appropriate startup method.
K. DIRECTION OF ROTATION. Correct pump rotation
is indicated by an arrow on the frame adaptor. The
standard direction of rotation, viewed from the motor
end, is clockwise.
The suction pipe must be air tight and sloped upward to
pump flange to avoid air pockets which will impair pump
operation. The discharge pipe should be as direct as
possible using a minimum number of valves to reduce
pipe friction losses.
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VIII. OPERATION.
A. PRE-START CAUTIONS.
CAUTION
Before activating the pumping unit, check to
make sure there are no personnel working on
the unit. Serious injury or death to personnel
could result if the unit is activated while being
worked on.
1. Before starting or operating the pump, read this
entire manual, especially the following
instructions.
2. Observe all caution or danger tags attached to
the equipment.
CAUTION
Pumps are shipped without oil and should
be filled with oil before starting the pumping
unit. Operation of the unit without proper
lubrication can result in overheating of the ball
bearings, ball bearing failures, pump seizures
and actual breakup of the equipment, exposing
operating personnel to injury.
3. Fill bearing frame with oil (refer to Section X,
Paragraph A and Table 7). Pumps are shipped
with no oil in the bearing frame. If ball bearings
are oil mist lubricated, turn on system, wait for
proper oil quantity and check monitoring
system.
CAUTION
Never run the pump dry. Close running fits
within the pump are liquid lubricated. Dry
running will result in pump seizure or damage.
4. Before starting the pump, fill the volute and
suction line with liquid. The pump may be
primed by using an ejector or vacuum pump.
5. Before starting a mechanical seal pump
equipped with external flush lines, turn on
mechanical seal water, and confirm the
mechanical seal water is at sufficient pressure.
Refer to Table 8 for minimum cooling flow rates.
6. Check final alignment of pump and driver. Both
shafts must turn freely by hand. If necessary,
check coupling alignment.
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7. Jog starter switch on motor to check that the
direction of rotation must agree with the arrow
stamped on the pump frame or base.
8. Before starting the pump, install closed guards
around all exposed rotating parts.
9. If excessive vibration or noise occurs during
operation, shut the pump down and rotate shaft
by hand. If excessive vibration or noise
continues, consult a Carver representative.
10. Before starting the pump, install closed guards
around all exposed rotating parts.
B. PRIMING. Dry running a centrifugal pump can
result in extensive damage and possible seizing. It is,
therefore, imperative that the pump be primed prior to
initial start-up and that prime must be maintained
through subsequent start-stop cycles.
The priming procedure is different for positive and
negative suction head systems. Follow the procedure
listed below.
Positive Suction Head:
1. Open the vent on the highest point on the pump
volute.
2. Open all suction valves.
3. Allow liquid to flow from vent hole until all air
bubbles are vented. Then close the vent.
4. The pump is now primed.
Negative Suction Head:
1. Install an ejector or vacuum pump on the vent at
the highest point on the volute.
2. Close the discharge valve.
3. Open the suction valve.
4. Start the ejector or vacuum pump.
5. Allow liquid to flow until a continuous flow is
exhausted from ejector. Then close the valve to
the vent.
6. The pump is now primed.
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610 11 Edition Centrifugal Pump
C. STARTING THE PUMP.
I-401
November 2013
To=Tf+ΔT
CAUTION
Do NOT operate pumping unit against a closed
discharge system. If pump has any chance of
seeing operation against a closed system, a
bypass system allowing a minimum design flow
should be installed. This bypass will be
satisfactory for short periods of operation. For
extended periods of operation the bypass
should be sized for the minimum continuous
flow required by the pump. Refer to Section
VIII, Paragraph E for minimum/maximum flow
calculation.
1. Confirm pumping unit is ready to start.
Complete Section VIII, Paragraphs A and B.
2. If unit is equipped with mechanical seal cooling
lines, turn on mechanical seal cooling water.
3. Fully open the suction valve.
4. Open discharge valves slightly, about 1 to 1 ½
turns if pump is being started for the first time or
from being turned off for overhaul. Start the
pump.
5. Slowly open discharge valves and adjust
pressure and flow to the appropriate operating
conditions. Refer to pump nameplate and
system operating procedures for design point
condition.
g*H
ΔT =
*(1-η)
c*η
c Specific heat
[J / kg K]
g Acceleration due to gravity
[m/s_]
H Pump head
[m]
T f Temperature of fluid handled
[°C]
T o Temperature of casing surface
[°C]
η Pump efficiency at duty point
[-]
Δ T Temperature difference
[°C]
F. OPERATING CHECKS.
Qmin
=
0.1 x Qopt for short operation
Qmin
=
0.3 x Qopt for continuous operation
Qmax
=
1.1 x Qopt for 2-pole operation
1. Check for undue vibration or noise. If any
occurs and does not stop within a short period
of time, turn off the pump. For determination of
the cause and its remedy refer to
Troubleshooting in Section IX or consult Carver
Pump Company.
2. Check and record flow and pressure readings.
The flow and pressure readings should be
within the operating system guidelines and
similar to number stamped on the pump
nameplate.
3. Check and record ball bearing temperature
according to the following steps, if remote
thermal devise or equal is not installed. Ball
bearing temperature should not exceed 190° F
(87° C).
a. Remove plug (420) on bearing frame
(19) race.
b. Measure and record ball bearing
temperatures under where plug (420)
was located.
c. Reinstall plug (420) on bearing frame
(19) race.
4. Check and record power input to the motor.
Qmax
=
1.25 x Qopt for 4-pole operation
5. Check for leakage at mechanical seals.
Qopt
=
optimum efficiency
D. TURBINE
APPLICATIONS.
For
turbine
applications, consult your local distributor or a
representative from Carver Pump Company.
E. MINIMUM/MAXIMUM
FLOW
CALCULATION.
Unless otherwise specified in the characteristic curves
or on the data sheets, the following applies
G. STOPPING THE PUMP.
The data above refers to water and water-like liquids.
However, if the physical properties of the fluids handled
are different from water, the calculation formula below
must be used to check if an additional heat build-up may
lead to a dangerous temperature increase at the pump
surface. If necessary, the minimum flow must be
increased.
1. If the pump is being stopped for overhaul, slowly
close the discharge valve. Otherwise leave
discharge valves set at condition.
2. Stop the pumping unit in accordance with the
directions on the electrical power supply.
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3. Tagout and lockout power to motor according to
OSHA Standard 1910.147.
4. Close discharge and suction valves and any
auxiliary fluid lines.
5. The pumping unit is now off.
H. INDEFINITE SHUTDOWN.
CAUTION
IX. TROUBLESHOOTING OPERATING
PROBLEMS.
If you have followed the installation and starting
procedures outlined in this manual, the pump should
provide reliable service and long life. However, if
operating problems do occur; significant time and
expense can be saved if you refer to Table 6 to
eliminate the most common causes of those problems.
Immediate action to be taken before proceeding with
corrective actions in Table 6 is to stop the pump, refer to
Section VIII, Paragraph G.
When pump is handling hazardous fluid,
extreme care must be taken to ensure safety of
personnel when attempting to drain pump and
piping before disconnecting the pumping unit.
Suitable protection devices should be used
and/or protective clothing should be worn.
Relubricate ball bearings. Remove volute plug to drain
volute. Drain all piping if there is a possibility of liquid
freezing. Provide pump and driver with a protective
cover.
Table 6. Pumping Unit Troubleshooting
SYMPTOM
Failure to deliver
liquid.
PROBABLE CAUSE
1. Discharge head above shutoff.
2. Check valve stuck or improperly installed.
3. Impeller or suction line clogged.
4. Incomplete priming or venting of pump or
piping.
5. Valves are not fully open.
6. Excessive wear of internal parts.
Excessive
power
consumption.
1. Head lower than rating: trying to pump too
much liquid or operating at end of
performance curve.
2. Specific gravity or viscosity of liquid is too
high.
3. Mechanical defects such as binding rotating
elements.
4. System head lower than design condition.
5. Incorrect impeller diameter.
22
CORRECTIVE ACTION
1. Check pump rating against actual head
condition.
2. Adjust and/or reverse valve.
3. Inspect suction line and impeller. Clean as
necessary.
4. Vent piping again carefully and prime
pump.
5. Open valves and if necessary, lock valves
open to prevent accidental closure.
6. Disassemble pump and replace worn parts.
1. Adjust pressure flow.
2. Check liquid temperature and adjust as
necessary.
3. Check for excessive pipe strain. Check
foundation bolting. Replace defective parts.
4. Adjust system head. Trim impellers to
actual condition.
5. Replace impeller or trim impeller to correct
diameter. Consult with Carver Pump before
trimming impellers.
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610 11 Edition Centrifugal Pump
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November 2013
Table 6. Pumping Unit Troubleshooting - Continued
SYMPTOM
Insufficient
discharge or
flow.
PROBABLE CAUSE
1. Discharge head above shutoff.
2. Air or gases in liquid.
3. Impeller or suction partially clogged.
4. Wrong direction of rotation.
5. Specific gravity or viscosity of liquid is too
high.
6. Incorrect impeller diameter.
Vibration
excessive.
CORRECTIVE ACTION
1. Check pump rating against actual head
condition.
2. Adjust and/or redesign suction system. Add
liquid to system.
3. Inspect suction and impeller and clean as
necessary.
4. Reverse direction of rotation.
5. Check liquid temperature and adjust as
necessary.
6. Replace impeller or trim impeller to correct
diameter. Consult with Carver Pump before
trimming impeller.
1. Foundation bolting loose.
2. Coupling halves not properly oriented
relative to each other.
3. Impeller partially blocked.
4. Wrong rotation.
5. Insufficient foundation.
6. Pipe strain.
7. Coupling key to motor or coupling key to
pump is not correct length.
8. Motor improperly balanced.
1. Torque bolting to proper values.
2. Adjust coupling halves system relative to
match marks.
3. Inspect impeller and clean as necessary.
4. Adjust direction of rotation.
5. Stiffen foundation as necessary.
6. Modify piping as necessary.
7. Replace with key of correct length.
Oil leak.
1. Loose connection.
2. Defective oil seal.
3. Loose or defective gasket.
1. Tighten connectors.
2. Replace oil seal.
3. Tighten bolting and/or replace gasket.
Ball bearing
temperature
excessive.
1. Lubrication, insufficient lubrication.
1. Lubricate according to Section X,
Paragraph A.
2. Replace ball bearing.
3. Check coupling alignment.
4. Ensure piping transmits no stress to pump.
Alter piping layout, if necessary. Realign
pump and driver shafts.
2. Defective ball bearing.
3. Pump/driver shafts are misaligned.
4. Piping causes pump to “warp”.
8. Balance motor.
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X.
MAINTENANCE.
Generally the pump does not need continuous
supervision. The pump should always run quietly and
smoothly, without vibration. To ensure such operation,
the following maintenance schedule should be applied
at regular intervals during operation of the pump.
Occasional visual checks are recommended. Data
should be recorded periodically for each pump to keep
track of maintenance which has been performed and to
note operational problems. A sample maintenance
record sheet is provided for this purpose at the front of
this manual.
Regular inspection and service are
essential for safe operation of the pump in
ATEX applications.
NOTE
Parts marked with * are options or vary by
pump or bearing frame size.
Daily Inspection:
• Visually inspect unit.
• Check ball bearing temperatures.
• Check ball bearing cooling flow rates, if
applicable, refer to Table 8.
• Check for leakage at mechanical seal.
• Check that oil level is at center of bullseye, if
applicable. If equipped with a constant level oiler*,
check oil level in the constant level oiler and refill
as required. Insure proper oil mist if applicable.
Weekly Inspection:
• Check power (amps) readings.
• Check pump discharge pressure. Prescribed
operating discharge pressure should never drop
below 90 percent of design point pressure.
• Check vibration on pump and driver ball bearings.
Vibration should NOT exceed 1.5 of overall
displacement (unfiltered) peak to peak mils
(0.001”) at 3600 RPM and 3.0 of overall
displacement (unfiltered) peak to peak mils
(0.001”) at 1750 RPM.
Monthly Inspection:
• Check foundation bolts.
• If necessary, grease coupling, but Do NOT over
grease.
• Check foundation bolts.
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Semi-annual Inspection:
• Grease ball bearings or change oil. Do NOT over
grease or add excess oil.
• Check coupling alignment due to settling of
foundation.
• If stand-by pumps are installed, it is advisable to
operate pumps on a rotational system to give
each pump a periodic duty. This ensures that
stand-by pumps will have periodic operation and
always be in good condition for instant start-up.
300 Hours
• The first oil change should be carried out after 300
hours of operation.
3000 Hours
• After the first oil change at 300 hours subsequent
oil changes should be effected at intervals of 3000
hours of operation
•
25000 Hours - Overhaul
For pump overhaul, complete Section XI, Service
and Repair.
A. LUBRICATION OF PUMP BALL BEARINGS.
Ball Bearings (16 and 18). The radial ball bearing (16)
and the thrust ball bearings (18) are lubricated by oil in
the bearing frame. The thrust ball bearings are installed
back to back. Replace the ball bearings when
disassembling the pumping unit for mechanical seal
service.
CAUTION
Pumps are shipped without oil and should
be filled with oil before starting the pumping
unit. Operation of the unit without proper
lubrication can result in overheating of the ball
bearings, ball bearing failures, pump seizures
and actual breakup of the equipment, exposing
operating personnel to injury.
To change oil, unscrew bearing frame pipe plug (420) in
bearing frame (19) and drain oil. Flush bearing frame
with petrol or benzol. Slowly rotate the shaft by hand
during flushing. Replace bearing frame pipe plug and fill
the bearing frame with oil (refer to Table 7 for oil
recommendations) through the breather vent (45). Fill
bearing frame until oil can be seen in the center of the
bullseye sight.
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Table 7. Oil Recommendations
Manufacturer
Royal Purple
Texaco
Phillips
Exxon
Mobil
ISO Grade 68
Synfilm 68
Regal R&O 68
Magnus Oil 68
Teresstic 68
DTE 16 M
Table 8. Ball Bearing Cooling Flow Rates
(100 PSIG MAX.)
Temperature Range
-20˚ to 650˚ F
(-4° to 343° C)
400˚ to 650° F
(204° to 650° C)
Flow Rate
Oil Lube - Air
Oil-Lube – Water (Optional)
– 3 GPM
*Constant Level Oiler. If equipped with a constant
level oiler, fill reservoir with oil, place thumb over spout,
invert and screw reservoir into upper casting. Allow
reservoir to empty, filling the bearing frame (Figure 7).
Several fillings of the reservoir may be required before
the actual oil level is reached. To avoid adding too much
oil, never finish filling oil in bearing frame (19) through
the vent breather (45) at top of the bearing frame. Never
use lower casting only as a fill spout, always fill thru
reservoir. When oil level is reached, no more oil will run
out of the reservoir bottle. Use constant level oiler's
glass sight to check oil level in bearing frame. When oil
level is reached tighten the three setscrews on the side
of the upper oiler. The constant level oiler (143) should
be topped up as required during operation.
should be removed so that condensed oil vapor can be
drained and/or removed from the bearing frame.
B. LUBRICATION OF MOTOR BALL BEARINGS.
See motor manufacturer’s instructions to be sure motor
ball bearings are properly lubricated.
C. TORQUE VALUES.
Refer to Table 9,
Recommended Torque Values. Clean and properly
lubricate threads and bearing face of the fastener to
obtain the proper fastener loading from these torque
values. Fasteners should be tightened evenly and in
stages. Refer to your torque wrench manual for the
proper use of your wrench.
Table 9. Recommended Torque Values (ft-lbs)
Bolt Size
Material
316
Steel
Stainless
UNC
Composite
(or otherwise
Steel
noted)
1/4”-20
5
5
7
5/16”-18
11
11
12
3/8”-16
18
18
21
1/2”-13
33
39
45
5/8”-11
54
83
97
3/4”-10
80
105
132
7/8”-9
109
160
203
1”-8
144
236
300
Impeller Nut - 30 ft-lbs while holding the coupling end
of the shaft.
Table 10. Recommended Equipment
Tools
Figure 7. Constant Level Oiler
*Oil Mist. The API Maxum pump comes equipped with
appropriate connections for the installation of an oil mist
system by the customer if oil mist lubrication is desired.
Oil mist lubrication provides the greatest protection
against contamination by dirt and water. The top port of
the bearing frame (19) is plugged for oil mist lubricated
ball bearings. The plug in the bottom of the power frame
Spanner Wrench
Rawhide or
Wood Mallet
Wooden Wedge
Allen Wrench Set
Socket, Open, &
Box Wrench
Set
Vice Grips
Torque Wrench
Bearing Heater
Materials
Oil
O-ring
Lubricant
Test Equipment
Coupling
Alignment
Gauges
Volt-Amp Meter
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610 11 Edition Centrifugal Pump
XI.
SERVICE AND REPAIR.
Refer to Figures 9 and 10 to locate the pump parts by
item number and parts list.
A. PREPARATIONS FOR DISASSEMBLY OF PUMP.
During disassembly, match mark parts so they can be
replaced in their original position. All parts should be
thoroughly cleaned or replaced with new, if necessary.
Sealing faces should be perfectly clean. Carver Pump
Company recommends that all O-rings and shims are
only used once.
The back pull-out design of the pump enables the pump
to be disassembled without disconnecting the piping or
removing the pump volute from the base. When the
pump is fitted with optional spacer coupling, the driver
can also remain bolted on the base.
I-401
November 2013
Prepare the pumping unit for disassembly using the
following list:
1. Read this entire section and study the
applicable sectional view drawing and parts list
before disassembling the pump.
CAUTION
Before attempting to disassemble the pump,
the electrical power supply to the driver must
be locked and tagged in the “OFF” position to
prevent injury or death to personnel servicing
the pumping unit.
2. Stop the pumping unit; refer to Section VIII,
Paragraph G.
CAUTION
CAUTION
Factory authorized parts must be used to
safely maintain your Carver Pump.
NOTE
To avoid damage to O-rings, check to make
sure all parts are free of sharp edges or burrs.
Close suction and/or discharge valves. The pump volute
should be cooled down to ambient temperature. The
volute must be empty and not under pressure.
After prolonged operation, components may not be
easily removed from shaft. In such instances, rust
solvent may be used and suitable extracting tools
applied wherever possible. Do NOT use force under any
circumstances. Refer to Table 10, Recommended
Equipment, for proper tooling during disassembly and
assembly. Refer to appropriate sectional drawing for
location of parts followed by an item number. Assemble
the pump in accordance with accepted rules of
engineering practice. Coat individual components with a
suitable lubricant before assembling. Assembly of unit
should be performed on a clean, flat surface.
While assembling the pumping unit, Carver Pump
Company recommends that the following parts be
replaced with new:
•
•
•
•
•
26
O-rings / Gaskets
Shims
Ball Bearings
Grease seals
Mechanical seals
When pump is handling hazardous fluid,
extreme care must be taken to ensure safety of
personnel when attempting to drain pump and
piping before disconnecting the pumping unit.
Suitable protection devices should be used
and/or protective clothing should be worn.
3. Remove capscrews (606), flatwasher (623) and
lockwasher (658) and remove seal guard (132).
4. Disconnect piping, gauge lines, and auxiliary
connections, as necessary.
5. Drain volute (1) by opening volute drain blind
flange (422). If necessary, flush pump to
remove corrosive or toxic pumpage. Close
volute drain blind flange when fluid is completely
drained. Collect and dispose of corrosive or
toxic material appropriately.
6. Remove bearing frame pipe plug (420) in
bearing frame (19) and drain oil. If a constant
level oiler (143*) provides lubrication for ball
bearings, drain oil from the bearing frame by
removing bearing frame pipe plug at bottom of
bearing frame. If bearings are mist lubricated,
drainage of bearing frame is continuous.
7. Remove hex nuts (619) from bolts (604 and
605). Remove lockwashers (659), flat washers
(621) and bolts (604 and 605) from coupling
guard (131). Remove bolts (603), flat washers
(621), and lockwashers (658) from fan
shroud/coupling guard. Remove coupling guard
and disconnect coupling (42) halves. Remove
coupling spacer between coupling halves.
8. Remove hex nuts (616) and lockwashers (655)
from studs (631 & 631X) fastening volute (1) to
backhead (11). Use forcing bolts (610) to loosen
API Maxum
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610 11 Edition Centrifugal Pump
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rabbet fit of backhead (11) and volute (1). Pull
rotating element back from volute (1) and take it
to a suitable work area, refer to Section VII,
Paragraph B for handling of pump.
B. DISASSEMBLY OF PUMP. The instructions that
follow are an aid for properly trained personnel to
service your Carver Pump. Refer to Figures 9 and 10 to
locate the pump parts by item number and parts list. If a
specific sectional assembly drawing exists for a
particular job then that drawing should be referred to for
service work. Read this entire section before
disassembling the pump.
The back pull-out design of the pump enables the pump
to be disassembled without disconnecting the piping or
removing the pump volute from the base. When the
pump is fitted with optional spacer coupling, the driver
can also remain bolted on the baseplate.
NOTE
Parts marked with * are options that vary by
pumping unit and bearing frame size.
Refer to Section II for Safety precautions before
disassembling pump.
After completion of dismantling, all parts should be
thoroughly cleaned or replaced by new ones if
necessary. All gaskets and sealing faces should be
perfectly clean. When cutting new gaskets, make sure
they are exactly the same thickness as the old ones.
Refer to mechanical seal vendor instructions for
proper mechanical seal removal procedure.
3. For cartridge mechanical seals (90), reinstall
seal clip and loosen setscrews hold the
cartridge seal sleeve to shaft (6).
4. Remove hex nut (617) and lockwasher (656)
from stud (632) holding backhead (11) to
bearing frame (19) and remove backhead.
5. Backhead wear ring (7X) will remain in
backhead
(11)
unless
replacement
is
necessary. Throttle bushing (63*) may come off
with backhead, if still on shaft (6) remove
throttle bushing. Remove O-ring (89A*) from
backhead and discard. Remove volute gasket
(73C*) from backhead and discard.
6. Remove hex nut (615) from stud (630) and
remove mechanical seal (90) from backhead
(11).
CAUTION
Handle inboard bearing isolator (47) with care.
Mishandling could damage faces of inboard
bearing isolator.
NOTE
CAUTION
Use a hoist with adequate lifting capacity; refer
to Section VII, Paragraph B.
When pump is handling hazardous fluid,
extreme care must be taken to ensure safety of
personnel when attempting to drain pump and
piping before disconnecting the pumping unit.
Suitable protection devices should be used
and/or protective clothing should be worn.
NOTE
Mark or number each component
dismantling according to sequence.
The individual components
unscrewed or removed.
2. Remove impeller nut (24) or inducer (24*) and
impeller washer (28). Pull impeller (2) from shaft
(6). Impeller key (32) may come off with
impeller.
NOTE
should
while
be
1. Complete Section XI, Paragraph A before
continuing with disassembly.
It is not normally necessary to remove the
inboard magnetic bearing isolator (310*) unless
replacement of ball bearings is required.
7. If necessary, remove inboard bearing isolator
(47) from inboard bearing cap (35). If equipped,
remove inboard magnetic bearing isolator (310*)
from inboard bearing cap.
8. Remove capscrews (601) fastening inboard
bearing cap (35) to bearing frame (19). Remove
inboard bearing cap from shaft (6). Remove
gasket (73) from between inboard bearing cap
and bearing frame and discard.
9. Remove pump coupling half and pump coupling
key (46).
10. Remove locknuts (670) and flatwashers (672)
from studs (671) fastening fan shroud (131A) to
bearing frame (19) and remove fan shroud.
Note any flatwashers on inside of fan shroud on
studs for spacing.
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610 11 Edition Centrifugal Pump
11. Loosen hose clamp (590) and remove frame
cooling fan (40) from shaft (6). Remove fan key
(32F) from shaft (6).
12. Remove hex nut (618), lockwasher (657), and
flatwasher (621) from stud (633), remove
outboard bearing cap (37) and outboard bearing
isolator (49) from shaft (6).
13. Remove O-ring (89C) from bearing frame (19)
and discard.
CAUTION
Handle outboard bearing isolator (49) with care.
Mishandling could damage faces of outboard
bearing isolator.
NOTE
It is not normally necessary to remove the
outboard magnetic bearing isolator (310*)
unless replacement of ball bearings is required.
14. Remove outboard bearing isolator (49) from
bearing cap (37). Remove outboard magnetic
bearing isolator (310*) from bearing cap.
15. Remove shaft (6) (with radial and thrust bearing
assemblies) from outboard end of bearing frame
(19).
16. Un-crimp tang on bearing lockwasher (69).
Remove bearing locknut (22) and bearing
lockwasher (69).
NOTE
It is recommended that ball bearings removed
from the shaft be replaced.
17. If necessary, pull thrust ball bearing (18) and
radial ball bearing (16) from shaft (6).
18. If required for maintenance loosen flinger
setscrew (864*) and remove oil flinger (60*)
from shaft (6).
C. PARTS INSPECTION.
1. All parts should be thoroughly cleaned with a
suitable solvent or replaced with new ones if
necessary.
2. All sealing faces should be perfectly clean. All
gaskets, O-rings, oil seals, and locking devices
with a nylock feature are replaced with new if
disturbed from position.
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3. Check shaft for runout, scratches, grooves, or
any possible damage. Touch up scratches and
grooves with a polishing cloth and inspect for
remaining grooves or deep scratches. A bent or
excessively damaged shaft should be replaced.
4. Inspect volute and backhead for pitting, scoring,
and erosion. The inside of the volute and
backhead should be free of any pits or grooves.
The maximum allowable depth is 1/8” (3mm).
Replace the volute or backhead if any of these
defects are present.
5. Inspect mechanical seal. Repair or replace
mechanical seal that is extremely worn or
damaged.
6. Inspect impeller, fan, and coupling keys for
distortion and push fit into keyways. The keys
should be square on all four edges. They should
fit without having to be forced. The keys should
not rock in keyway. Replace keys or shaft if
necessary.
7. Inspect tubing for kinking. Replace kinked
tubing.
8. If the impeller shows excessive wear due to
erosion or pitting, so that performance cannot
be restored, it must be replaced. If a new
impeller is installed, check to make sure that it is
balanced and of the correct trim.
9. Check the wear ring clearance as follows:
a. Measure outside diameter of front impeller
hub (2) in three places.
b. Measure inside diameter of volute wear ring
(7) in three places.
c. If difference between the high reading of the
inside diameter of the volute wear ring (7)
and the low reading of the outside diameter
of the impeller (2) hub exceeds double the
maximum clearances given in Table 11,
replace the volute wear ring according to
Section XI, Paragraph E.
d. Measure outside diameter of back impeller
hub (2) in three places.
e. Measure inside diameter of the backhead
wear ring (7X) in three places.
f. If difference between the high reading of the
inside diameter of the backhead wear ring
(7X) and the low reading of the outside
diameter of the back impeller (2) hub
exceeds double the maximum clearances
given in Table 11, replace the backhead
wear ring according to Section XI,
Paragraph E.
API Maxum
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610 11 Edition Centrifugal Pump
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November 2013
Table 11. Factory Wear Ring Clearance (Inches)
Pump Size
AA- 1½ x 1 x 6
AB - 2 x 1½ x 6
AC- 3 x 1½ x 6
AD - 3 x 2 x 6
AE - 4 x 3 x 6
BA - 1½ x 1 x 8
BB - 2 x 1½ x 8
BC - 3 x 1½ x 8
BD - 3 x 2 x 8
BE – 4 x 3 x 8
BF - 6 x 4 x 8
CA – 2 x 1½ x 10
CB - 3 x 1½ x 10
CC - 3 x 2 x 10
CD - 4 x 3 x 10
CE - 6 x 4 x 10
CF - 6 x 6 x 10
CG - 8 x 6 x 10
DA - 2 x 1½ x 13
DB - 3 x 2 x 13
DC - 4 x 3 x 13
DD - 6 x 4 x 13
DE - 6 x 6 x 13
DF - 8 x 6 x 13
DG - 10 x 8 x 13
DH – 12 x 10 x 13
ED- 6 x 4 x 16
EA- 8 x 6 x 16
EB - 10 x 8 x 16
ED - 12 x 10 x 16
EC - 14 x 12 x 16
FA - 8 x 6 x 20
FB - 10 x 8 x 20
FC - 12 x 10 x 20
FD – 14 x 12 x 20
Factory Standard Diametric
Clearance (inch)
Minimum
Maximum
0.012
0.015
0.014
0.016
0.016
0.012
0.012
0.014
0.016
0.017
0.017
0.012
0.015
0.016
0.017
0.018
0.018
0.019
0.016
0.016
0.017
0.018
0.018
0.020
0.021
0.023
0.018
0.020
0.021
0.023
0.024
0.020
0.021
0.023
0.025
0.017
0.020
0.019
0.021
0.021
0.017
0.017
0.019
0.021
0.022
0.022
0.017
0.020
0.021
0.022
0.023
0.023
0.024
0.021
0.021
0.022
0.023
0.023
0.025
0.026
0.028
0.023
0.025
0.026
0.028
0.029
0.025
0.026
0.028
0.030
D. REASSEMBLY OF PUMP. The instructions that
follow are an aid for properly trained personnel to
assemble your Carver Pump. Refer to Figures 9 and 10
to locate the pump parts by item number and parts list. If
a specific sectional assembly drawing exists for a
particular job then that drawing should be referred to for
assembly. Refer to Table 9 for recommended torque
values. Read this entire section before reassembling the
pump. During reassembly, install parts as applicable.
CAUTION
During reassembly, install new locknuts, as
they have a self-locking feature. Locknuts with
a self-locking feature may not provide adequate
security once disturbed from position.
During reassembly, install new O-rings, oil
seals, and gaskets if disturbed from position. Orings, oil seals and gaskets may have been
damaged during disassembly.
During reassembly, Carver recommends that
the ball bearings be replaced if disturbed from
position.
NOTE
If ball bearings were removed, proceed to step
1, if not removed proceed to step 4.
All parts should be thoroughly cleaned or
replaced with new ones if necessary. All
sealing faces should be perfectly clean, but do
not scratch or alter surface finish on seal faces.
To ensure proper seating of bearing parts,
rotate the ball bearing while clamping the parts.
Parts marked with * are options that vary by
pumping unit and bearing frame size.
CAUTION
While installing back-to-back ball bearings, do
NOT unnecessarily hit ball bearings. If damage
to ball bearings occurs, replace damaged ball
bearings with new ball bearings.
After 25000 Hours of service replace the
ball bearings.
1. If removed, press thrust ball bearings (18) on
shaft (6). A bearing heater is recommended for
installation. Secure thrust ball bearings (18) with
bearing lockwasher (69) and bearing locknut
(22). Crimp tang of lockwasher (69) in grooves
provided in bearing locknut (22).
2. If removed, install oil flinger (60*) on shaft (6)
and tighten flinger setscrew (864*).
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610 11 Edition Centrifugal Pump
3. If removed, press radial ball bearing (16) on
shaft (6). A bearing heater is recommended for
installation.
4. Install shaft (6) (with radial and thrust bearing
assemblies) from outboard end of bearing frame
(19) in bearing frame. Seating the thrust ball
bearings (18) in the bearing frame.
5. Install new O-ring (89C) in groove provided
around outboard end of bearing frame (19).
CAUTION
Handle outboard bearing isolator (49) with care.
Mishandling could damage faces of outboard
bearing isolator.
6. If removed, press outboard magnetic seal
isolator (311*) into outboard bearing cap (37).
Install outboard bearing isolator (49) in outboard
bearing cap.
7. Reinstall outboard bearing cap (37) on shaft (6).
Secure outboard bearing cap with flatwashers
(621), lockwasher (657), and hex nut (618) on
stud (633).
8. Install fan key (32F) in shaft (6). Reinstall frame
cooling fan (40) over fan key on shaft, and
secure with hose clamp (590).
NOTE
Flatwashers (672) are used inside fan shroud
(131A) on studs (671) for spacing of fan
shroud. Number of flatwashers should have
been noted during disassembly.
9. Install flatwashers (672), noted during
disassembly, on studs (671). Install fan shroud
(131A) on bearing frame (19) with flatwashers
and locknuts (670) on studs.
CAUTION
Handle inboard bearing isolator (47) with care.
Mishandling could damage faces of inboard
bearing isolator.
10. If removed, press inboard magnetic bearing
isolator (311*) into inboard bearing cap (35).
Install inboard bearing isolator (47) in inboard
bearing cap.
11. Install gasket (73) on inboard bearing cap (35).
Install inboard bearing cap on shaft (6). Secure
30
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November 2013
inboard bearing cap to bearing frame (19) with
capscrews (601).
12. Confirm backhead wear ring (7X) is in backhead
(11). Install throttle bushing (63*) in backhead.
Install O-ring (89A*) on backhead.
NOTE
Refer to mechanical seal vendor instructions for
complete seal installation procedure.
13. Install mechanical seal (90) on backhead (11)
with hex nuts (615) on studs (630). Remove
seal clip after mechanical seal installation is
complete.
14. Install backcover (11) to bearing frame (19) with
hex nut (617) and lockwasher (656) on stud
(632).
15. Install impeller key (32) in keyway on shaft (6).
16. Reinstall impeller (2) on shaft (6). Secure
impeller (2) with impeller washer (28) and
impeller nut (24) or inducer (24*).
17. Install pump coupling key (46) in shaft (6).
Install coupling (42) half on shaft.
CAUTION
Use a hoist with adequate lifting capacity; refer
to Section VII, Paragraph B.
18. Return assembly to installation site.
19. Confirm that forcing bolts (610) are below the
sealing surface of the backhead (11). Confirm
volute wear ring (7) is in volute (1).
20. Install rotating element in volute (1). Secure
backhead (11) to volute with hex nuts (616) and
lockwashers (655) on studs (631 & 631X).
21. Rotate shaft (6) by hand to insure shaft (6)
rotates freely and no rubbing noises are
present.
22. Install coupling (42) spacer. Reconnect coupling
halves. Align coupling according to Section VII,
Paragraph F.
23. Reinstall coupling guard. Secure coupling guard
(131) with flatwashers (621), lockwashers (659),
and hex nuts (619), on bolts (604 and 605).
Secure coupling guard to fan shroud with bolts
(603), flatwashers (621), and lockwashers
(658).
24. Reconnect piping, gauge lines, and auxiliary
connections, as necessary. Confirm volute is
secure to base.
API Maxum
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610 11 Edition Centrifugal Pump
25. Install seal guard (132) on bearing frame (11).
Secure seal guard with flatwashers (623),
lockwashers (658), and capscrews (606).
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November 2013
Volute Wear Ring.
The volute (1) must be removed from the base to
replace the volute wear ring (7). To replace the volute
wear ring (7) follow these steps:
CAUTION
CAUTION
Pumps should be filled with oil before
starting the pumping unit. Operation of the unit
without proper lubrication can result in
overheating of the ball bearings, ball bearing
failures, pump seizures and actual breakup of
the equipment, exposing operating personnel to
injury.
26. Fill bearing frame with oil (refer to Section X,
Paragraph A and Table 7). If ball bearings are
oil mist lubricated, turn on system, wait for
proper oil quantity and check monitoring
system.
27. Remove all tags from valves and switches.
28. Start pumping unit in accordance with Section
VIII, Paragraph C.
E. REPLACEMENT OF WEAR RING. The pump has
a replaceable wear rings (7 and 7X) inserted into the
volute (1) and backhead (11). The clearance between
the wear ring and impeller hub will increase with wear.
Internal leakage will result and pump performance will
decrease. The allowable clearance and method of
measurement is described in Section XI, Paragraph C.
NOTE
Parts marked with * are options that vary by
pumping unit and bearing frame size.
Refer to Section II for Safety precautions before
disassembling pump.
When pump is handling hazardous fluid,
extreme care must be taken to ensure safety of
personnel when attempting to drain pump and
piping before disconnecting the pumping unit.
Suitable protection devices should be used
and/or protective clothing should be worn.
1. Complete Section XI, Paragraph A before
continuing with disassembly.
2. Remove impeller nut (24) and impeller washer
(28). Pull impeller (2) from shaft (6). Impeller
key (32) may come off with impeller.
3. Disconnect suction and discharge piping.
Remove hex nuts (614) from studs (634) to
remove volute (1) from base and take volute
and impeller (2) to a work area with access to
machine shop equipment.
4. Remove the volute wear ring (7) from the volute
(1). This can best be accomplished on a lathe.
5. Press the new volute wear ring (7) into the
volute (1). The beveled edge of the volute wear
ring is installed away from the impeller (2).
6. Secure the new volute wear ring (7) to the
volute (1) by tack welding in two places 180
degrees apart along edge of volute wear ring.
7. Place impeller (2) on an arbor and mount
between centers in a lathe or a grinder. Indicate
front outside impeller hub to within 0.002 TIR
maximum to be sure the arbor and impeller are
running square.
8. Turn the front outside wear ring surface of the
impeller (2) until a 63 RMS or better finish is
obtained.
9. Measure the outside diameter of the front
impeller wearing surface and record this value.
See measurement instructions in Section XI,
Paragraph C.
10. Mount the volute (1) with new volute wear ring
(7) installed in a lathe. Indicate female rabbet to
within 0.002 TIR maximum.
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610 11 Edition Centrifugal Pump
NOTE
When replacing volute wear ring with the
standard volute wear ring, (part number
beginning with "00") machining in step 11 is not
required. When replacing volute wear ring with
the undersize volute wear ring (part number
beginning with "US") machining in step 11 is
required.
11. If replacing with an undersized volute wear ring,
bore volute wear ring (7) to within the specified
tolerance listed in Table 11 over the recorded
size of the outside diameter of the front impeller
wearing surface.
12. Reinstall volute (1) on base and secure with hex
nuts (614) on studs (634).
13. Reassemble pump. Refer to Section XI,
Paragraph D, steps 15 through 28.
Backhead Wear Ring (7X).
CAUTION
When pump is handling hazardous fluid,
extreme care must be taken to ensure safety of
personnel when attempting to drain pump and
piping before disconnecting the pumping unit.
Suitable protection devices should be used
and/or protective clothing should be worn.
1. Complete Section XI, Paragraph B, steps 1
through 5 before continuing. Remove backhead
(11) with backhead wear ring (7X) still installed
and the impeller (2) to a work area with access
to machine shop equipment.
2. Remove the backhead wear ring (7X) from the
backhead (11). This can best be accomplished
on a lathe.
3. Press the new backhead wear ring (7X) into the
backhead (11). The beveled edge of the
backhead wear ring is installed away from the
impeller (2).
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November 2013
4. Secure the new backhead wear ring (7X) to the
volute (1) by Tack welding in two places 180
degrees apart along edge of backhead wear
ring.
5. Place impeller (2) on an arbor and mount
between centers in a lathe or a grinder. Indicate
back outside impeller hub to within 0.002 TIR
maximum to be sure the arbor and impeller are
running square.
6. Turn the back outside wear ring surface of the
impeller (2) until a 63 RMS or better finish is
obtained.
7. Measure the outside diameter of the back
impeller wearing surface and record this value.
See measurement instructions in Section XI,
Paragraph C.
8. Mount the backhead (11) with new backhead
wear ring (7X) installed in a lathe. Indicate
female rabbet to within 0.002 TIR maximum.
NOTE
When replacing backhead wear ring with the
standard backhead wear ring, (part number
beginning with "00") machining in step 9 is not
required. When replacing backhead wear ring
with the undersize backhead wear ring (part
number beginning with "US") machining in step
9 is required.
9. If replacing with an undersized backhead wear
ring, bore backhead wear ring (7X) to within the
specified tolerance listed in Table 11 over the
recorded size of the outside diameter of the
back impeller wearing surface.
10. Reassemble pump. Refer to Section XI,
Paragraph D, steps 12 through 28.
F. MOTOR. The motor should be maintained in
accordance with the manufacturer’s instructions.
G. CHECK VALVE. If applicable, the check valve
should be maintained in accordance with the
manufacturer’s instructions.
API Maxum
th
610 11 Edition Centrifugal Pump
XII.
I-401
November 2013
PARTS LISTS AND DRAWINGS.
This section contains listings of parts and corresponding
drawings. Table 12 notes the recommended spare parts
for this pumping unit. Refer to Figure 9, the Sectional
Assembly and Figure 10, Pump with Base, drawings for
the location of parts identified by item numbers.
Table 12. Recommended Spare Parts List
Item
Number
Description
Item
Number
Description
2
Impeller
49
Bearing Isolator - OB
7
Wear Ring
69
Bearing Lockwasher
7X
Wear Ring
73
Gasket, Frame – IB Bearing Cap
16
Ball Bearing, Radial
*73A
Gasket, Auxiliary Piping
18
Ball Bearing, Thrust
*73B
Gasket, Drain
22
Bearing Locknut
*73C
Gasket, Casing
28
Impeller Washer
*89A
O-Ring, Backhead-Volute
32
Key, Impeller
89B
O-Ring, Oil Pan
Key, Fan
89C
O-Ring, OB Bearing Cap
32F
46
Coupling Key - Pump
90
Mechanical Seal
46X
Coupling Key - Motor
670
Locknut – Fan Shroud
47
Bearing Isolator - IB
*Parts are options that vary by pumping unit and bearing frame size.
Item
Number
Description
1
Volute
2
Impeller
6
Shaft
24*
Inducer
*Option
*
Figure 8. Inducer
33
API Maxum
th
610 11 Edition Centrifugal Pump
I-401
November 2013
Figure 9. Sectional Assembly – Bare Pump
34
API Maxum
th
610 11 Edition Centrifugal Pump
I-401
November 2013
Figure 10. Pump with Base
35
API Maxum
th
610 11 Edition Centrifugal Pump
I-401
November 2013
Table 13. Parts List
Item
Number
1
2
6
7
7X
11
15X
16
18
19
22
23
24
24*
28
32
32F
35
37
40
42
45
46
46X
47
49
*60
*63
69
73
*73A**
*73B
*73C
81
*89A
89B
89C
90
131
131A
132
*143
190
200
215
*310**
*311**
*410
36
Description
Volute
Impeller
Shaft
Wear Ring – Volute
Wear Ring - Backhead
Backhead
Shim – Motor / Base
Ball Bearing, Radial
Ball Bearing, Thrust
Bearing Frame
Bearing Locknut
Base
Impeller Nut
Inducer
Impeller Washer
Key, Impeller
Key, Fan
Bearing Cap, Inboard
Bearing Cap, Outboard
Fan, Frame Cooling
Coupling
Vent Breather
Coupling Key - Pump
Coupling Key - Motor
Bearing Isolator – IB
Bearing Isolator – OB
Oil Flinger
Throttle Bushing
Bearing Lockwasher
Gasket, Frame - Cap
Gasket, Auxiliary Piping
Gasket, Drain
Gasket, Volute
Motor Adjusting Block
O-Ring, Backhead-Volute
O-Ring, Oil Pan
O-Ring, Bearing Cap
Mechanical Seal
Guard, Coupling
Fan shroud
Guard, Seal
Oiler
Electric Motor
Motor
Oil Pan
Bearing Isolator – IB, Magnetic
Bearing Isolator – OB, Magnetic
Tubing - Cooler
* Option
** Not Shown
Item
Number
420
421
422
*532
*564
590
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
630
631
631X
632
633
634
654
655
656
657
658
659
660
668
670
671
672
*864
*890**
Description
Pipe Plug – Bearing Frame
Pipe Plug – Oil Mist Port
Blind Flange - Volute Drain
Male Connecter - BT
Male Connecter - 90 degrees
Hose Clamp – Frame Cooling Fan
Capscrew – I.B Cap / Frame
Capscrew – Oil Pan
Capscrew – Fan Shroud / Guard
Bolt – Coupling Guard
Bolt – Coupling Guard
Capscrew – Seal Guard
Bolt - Drain Flange
Bolt – Motor / Base
Bolt – Coupling Guard / Fan Shroud
Forcing Bolt
Foot Leveling Bolt
Adjusting Bolt - Motor
Bolt – Adjusting Block/Base
Hex Nut – Volute/Base
Hex Nut – Seal
Hex Nut – Volute
Hex Nut - Backhead
Hex Nut – Fan Shroud
Hex Nut – Coupling Guard
Flatwasher – Drain
Flatwasher – Fan Shroud
Flatwasher – Coupling Guard
Flatwasher – Seal Guard
Stud – Seal
Stud – Volute / Adaptor
Stud – Volute / Adaptor (Guide)
Stud – Backhead
Stud – Bearing Cap
Stud – Volute/Base
Lockwasher – Volute / Base
Lockwasher – Volute / Backhead
Lockwasher – Adaptor / Frame
Lockwasher – Cap / Frame
Lockwasher – Seal Guard / Guard
Lockwasher – Coupling Guard
Lockwasher – Motor / Base
Setscrew – Fan
Locknut – Fan Shroud
Stud – Fan Shroud
Flatwasher – Fan Shroud
Setscrew – Flinger
Vibration Transmitter, RTD, ETC
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I-401
NOV 2013
Revision 0
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