RS Series Multi-Stage Centrifugal Pump

RS Series Multi-Stage Centrifugal Pump
I-280
DEC 2015
ATEX
Inch Units
RS Series Multi-Stage
Centrifugal Pump
For Units Built After July 2010
through December 2015
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.
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
EC Declaration of Conformity
MANUFACTURER:
CARVER PUMP COMPANY
2415 PARK AVE.
MUSCATINE, IOWA, USA 52761
PRODUCT DESCRIPTION:
www.carverpump.com
Phone: 1-563-263-3410
Email: [email protected]
RS Series Multi-Stage Centrifugal Pump
PART NUMBER:
SERIAL NUMBER:
DATE MANUFACTURED:
APPLICABLE EUROPEAN DIRECTIVES:
Machinery: The designated product complies with the following basic requirements of Directive 2006/42/EC:
Appendix I, section 1.1.2, 1.1.3., 1.1.5., 1.3.1., 1.3.2., 1.3.3., 1.3.4., 1.3.7., 1.3.8., 1.4.1., 1.4.2.1.,
1.5.1., 1.5.8., 1.5.9., 1.5.13., 1.6.1., 1.6.4., 1.6.5., 1.7.
ATEX:
94/9/EC
APPLICABLE INTERNATIONAL STANDARDS:
Machinery:
ATEX:
EN ISO 12100:2010
EN ISO 13732-1:2008
EN 626-1:2008
EN ISO 13857:2008
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 T2
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:
Kurt Doren
Quality/ ISO Manager
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.
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
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 ______________________________________
Service ______________________________________
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 ________________________
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
NOTES ON INSPECTION AND REPAIRS
INSPECTION DATE
REPAIR TIME
REPAIRS
COST
REMARKS
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
INSTALLATION, OPERATION AND
MAINTENANCE INSTRUCTIONS
TABLE OF CONTENTS
SECTION/PARAGRAPH
PAGE
I.
GENERAL DESCRIPTION ............................... 1
A. General Information ................................... 1
B. ATEX Directive 94/9/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........................... 7
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 ........................ 16
A. Inspection ................................................... 16
B. Packing for Return ..................................... 16
C. Storage of Pump ........................................ 16
VII.
INSTALLATION ................................................ 17
A. Location ...................................................... 17
B. Handling ..................................................... 17
C. Foundation ................................................. 17
SECTION/PARAGRAPH
PAGE
D.
E.
F.
G.
H.
I.
Leveling of Unit .......................................... 18
Grouting ..................................................... 18
Coupling Alignment .................................... 20
Pre-Installation Procedures ....................... 21
Piping ......................................................... 21
Auxiliary Piping Connection
and Gauges ........................................... 21
J. Motor .......................................................... 21
K. Direction of Rotation .................................. 21
VIII. OPERATION .................................................... 22
A. Pre-Start Cautions ..................................... 22
B. Priming ....................................................... 22
C. Starting the Pump ...................................... 23
D. Turbine Applications .................................. 23
E. Minimum/Maximum Flow Calculations ...... 23
F. Operating Checks ...................................... 23
G. Stopping the Pump .................................... 23
H. Indefinite Shutdown ................................... 24
IX.
TROUBLESHOOTING OPERATING
PROBLEMS...................................................... 24
X.
MAINTENANCE ............................................... 26
A. Lubrication of Pump Bearings .................... 26
B. Lubrication of Motor Bearings .................... 27
C. Torque Values ............................................ 27
XI.
SERVICE AND REPAIR ................................... 28
A. Preparations for Disassembly of Pump ..... 28
B. Disassembly of Pump with
Standard Sleeve Bearing ....................... 29
C. Disassembly of Pump with
Optional Mechanical Seals .................... 31
D. Parts Inspection ......................................... 33
E. Reassembly of Pump with
Standard Sleeve Bearing ....................... 34
F. Reassembly of Pump with
Optional Mechanical Seals .................... 36
G. Replacement of Wear Ring ........................ 39
H. Motor .......................................................... 41
I. Check Valve ............................................... 41
XII.
PARTS LISTS AND DRAWINGS ..................... 42
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
TABLE OF CONTENTS - Continued
LIST OF TABLES
NUMBER
TITLE
LIST OF ILLUSTRATIONS
PAGE
1. Fluid Temperature Limits ........................... 5
2. Maximum Allowable Pressures .................. 6
3. Axial Impeller Alignment
Control Dimensions................................ 9
4. Shaft Dimensions ....................................... 12
5. Sleeve Bearing Dimensions ....................... 12
6. Standard Design Pump Mechanical
Seal Settings .......................................... 12
7. Optional Design Pump Mechanical
Seal Settings .......................................... 13
8. Key Mechanical Data ................................. 13
9. Permissible Nozzle Loads ......................... 15
10. Minimum Flow Rates RS-6 and RS-9 ........ 15
11. Pumping Unit Troubleshooting .................. 24
12. Oil Recommendations................................ 27
13. Bearing Cooling Flow Rates
(30 PSIG Max.) ...................................... 27
14. Recommended Torque Values (ft-lbs) ....... 27
15. Recommended Equipment ........................ 27
16. Factory Wear Ring Clearance (Inches) ..... 33
17. New Wear Ring Diametrical
Clearance Limits (Inches) ...................... 40
18. Recommended Spare Parts List ................ 42
NUMBER
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
TITLE
PAGE
Seal Chamber Dimensions .........................11
Standard Seal Flush Plans .........................13
Bearing Frame Water Cooling ....................14
Sling Position for Moving Pump..................17
Sling Position for Moving Pumping Unit .....17
Sling Position for Moving
Pumping Unit with Lifting Lugs ...............17
Grouting and Foundation Bolting ................19
Unit Leveling ...............................................19
Coupling Alignment.....................................20
Constant Level Oiler ...................................27
Sectional Assembly – Standard
Sleeve Bearing .......................................43
Sectional Assembly – Optional
Mechanical Seals ....................................45
Cooling Options ..........................................47
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
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 RS Series Multi-Stage Centrifugal
Pump, 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 11, 12, and 13 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.
B. ATEX DIRECTIVE 94/9/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.
1
RS Series Multi-Stage
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 18, Recommended Spare Parts. Part
numbers correspond to Figures 11, 12 and 13.
G. PARTS ORDERING. When ordering replacement
parts, please specify:
I-280
December 2015
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 94/9/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
2
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
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.
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 ball
bearings must be replaced at 20000 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 shaft seal) of
fluids (e.g. explosive, toxic, hot)
contained so as to avoid any danger
or the environment. Pertinent legal
must be adhered to.
•
hazardous
must be
to persons
provisions
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 VIII 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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RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
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
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.
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
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
casing 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.
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)
To check, proceed as described in Section VIII,
Paragraph E.
T3
365 °F (185 °C)
T2
536 °F (280 °C)
In addition, the instructions given in Section VIII of this
operating manual must be observed.
T1
662 °F (350 °C)
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 casing, at the shaft seal and in the
ball bearing areas. The surface temperature at
the pump casing corresponds to the
temperature of the fluid handled.
CAUTION
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.
5
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
•
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.
Pump liquids over 225˚F (107˚C); pumps
must be equipped with auxiliary cooling.
Pumps of high temperature construction are provided
with cooled ball bearings for a unit operating in
temperature range between 225˚ F and 300˚ F (107˚ C
and 149˚ C). Cooling water flows through cavities of the
bearing frame and keeps temperature of the ball
bearings within acceptable limits. Refer to Table 13 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 or
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.
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.
K.7 General Safety Instructions.
•
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.
The following specific safety precautions apply to the
pumping unit:
•
Hydro suction case separately on RS-9 units.
•
Isolate pump for system hydro.
•
Do NOT exceed maximum rated
pressure unless otherwise rated.
•
Do NOT exceed maximum rated discharge
pressure.
suction
Table 2. Maximum Allowable Pressures
Size
Suction
A
B
C
415 PSIG*
D
E
*Unless otherwise rated.
Discharge
1,475 PSIG
1,475 PSIG
1,475 PSIG
1,810 PSIG
1,460 PSIG
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
III. EQUIPMENT DESCRIPTION.
RS high-pressure pumps are multi-stage, centrifugal
pumps with radially split casings. The pump consists of
a suction case, a discharge case, plus a number of
interstage casings, all secured with tie bolts. Suction
casing, interstage casings and diffusers are provided
with wear rings. Diffusers are provided with bushings.
Due to prolonged operation, wear rings and bushings
may become worn and/or damaged. Replace all worn
and/or damaged parts with new.
RS high-pressure pumps incorporate special design
refinements, which help to absorb the appreciable axial
thrust generated by their high head operation. Residual
axial thrust is absorbed by the thrust bearings.
CAUTION
Be careful not to mix RS6 and RS9 parts
since RS6 parts are not rated for the pressure
of the RS9.
ATEX and CE require bearing isolators
and metal splash guards to meet requirements.
Other customers may use oil seals and plastic
splash guards.
The bare pump consists of following major parts and
options. Refer to Figures 11 and 12, for the location of
parts identified by item numbers.
Item 1 – Discharge Case. The Discharge Case (1)
houses the impeller (2A or 2X) and diffuser (5A or 5X).
The discharge case is fastened to the suction case with
tie bolts (173) and tie bolt nuts (616) with tie bolt
washers (645).
Item 2A – Impeller, 1st Stage.
RS pumps are
equipped with enclosed impellers. The impeller (2A) is
keyed to the shaft (6) by the impeller key (32A) and
located by sleeves and shims. If the RS pump is only a
one stage pump then only the 1st stage impeller is used.
All impellers face the same direction on the shaft.
Item 2X – Impeller. RS pumps are equipped with
enclosed impellers. The impeller (2X) is keyed to the
shaft (6) by the impeller key (32A) and located by
interstage sleeves (58) and shims. All impellers face the
same direction on the shaft.
Item 5A – Diffuser. Diffusers (5A) are inserted in
individual interstage casings. Diffusers are provided with
diffuser bushings (63) and hold wear rings (7X).
Item 5X – Last Stage Diffuser. The last stage diffuser
is located in the discharge case (1). Holds wear ring
(7X) and sits on sleeve bearing (63Y or 63X) depending
on design.
Item 6 – Shaft. The pump shaft is protected against
wear by interstage sleeves, spacer sleeves, and shaft
sleeves. The shaft (6) of the RS 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. The pump
coupling key (46) holds the coupling in place, causing it
to rotate with the shaft.
Item 16 and 18 – Ball Bearings. A deep-groove
Conrad-type, C3 internal fit radial ball bearing and a
back-to-back mounted ball bearing are housed in the
bearing frame (99) depending on design. The ball
bearings will be designated as 7000 series. Ball
bearings designated in the 7000 series will be duplex
40° angular contact ball bearings. The ball bearing is
held in place by the bearing jam nuts (22). The bearings
are oil lubricated by oil bath.
Item 99 – Bearing Frame. The principal function of the
bearing frame (99) 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 (2A or 2X). The bearing
frame has a pair of back-to-back mounted angular
contact thrust ball bearings (16). This bearing frame is
designed to be oil lubricated. The bearing frame is
attached to the suction case (9) and discharge case (1)
by tie bolts.
The use of a sight glass constant level oiler (143)
maintains the oil level high enough on the higher of the
two ball bearings so that the ball bearings themselves
provide the motivation for the oil to be moved through
the races of the ball bearings. In addition to the oil lube,
the bearing frame contains the bearing isolator (169).
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 pump 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. Mechanical seals (90 and
91) are to be used. Complete mechanical seal
instructions should be obtained from the seal
manufacturer. The standard seal chamber dimensions
are shown in Figure 1.
Item 111 – Interstage Case. The interstage case
houses the impeller (2A or 2X) and diffuser (5A). The
7
RS Series Multi-Stage
Centrifugal Pump
interstage casings are all secured with tie bolts to the
suction (9) and discharge (1) casings. Interstage
casings are provided with wear rings (7X). O-rings (89D)
seal the individual interstage casings. A one stage pump
does not have an interstage case.
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
8
I-280
December 2015
pump was originally designed, check with Carver Pump
Company.
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.
Noise Levels. Noise levels may exceed 85dBa at 1
meter during operation. Ear protection must be worn
whenever working in high noise locations.
Axial Impeller Alignment Control Dimensions. Axial
impeller alignment control dimension are located in
Table 3 and are arranged by pump size.
Seal Chamber Dimensions. Standard seal chamber
dimensions are located in Figure 1 and are arranged by
pump size.
Basic Design Features. Basic design features of the
pump are located in Tables 3, 4, 5, 6, 7, 10, and Figures
2 and 3 and are arranged by pump model.
Key Mechanical Data. Key mechanical data for the
pump is located in Table 8 and is arranged by pump
model.
Permissible Nozzle Loads. The forces and moments
in Table 9 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.
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
Table 3. Axial Impeller Alignment Control Dimensions
1
2 - 18
SUCTION CASING
Stages
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Pump Size A
(Inches)
.772
.769
.766
.763
.760
.757
.754
.751
.748
.745
.742
.739
.736
.733
.730
.727
.724
.721
Pump Size B
(Inches)
.770
.763
.760
.757
.754
.751
.748
.745
.743
.740
.737
.734
.731
.728
.725
.722
.719
.716
Pump Size C
(Inches)
.905
.901
.898
.895
.892
.889
.886
.883
.880
.877
.874
.871
N/A
N/A
N/A
N/A
N/A
N/A
Pump Size D
(Inches)
1.088
1.144
1.141
1.138
1.135
1.132
1.129
1.126
1.123
1.120
1.117
1.114
N/A
N/A
N/A
N/A
N/A
N/A
Pump Size E
(Inches)
1.542
1.477
1.474
1.471
1.468
1.465
1.462
1.459
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
*Additional stages will require compensation for interstage compression, on average .003 inch per stage. Use .010
inch shim as needed. Refer to Section XI, Paragraphs E.
NOTE: You will reach a point in which you run out of clearance between the impeller and diffuser. This is best found
by checking the centering distance without the interstage sleeve (58) installed and then rechecking with the
interstage sleeve installed. If you find that the distance is the same or close to each other, you will have to add a
shim (73G) until you have clearance behind the impeller and diffuser.
9
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
Table 3. Axial Impeller Alignment Control Dimensions - Continued
1 (Discharge Side)
2 - 18
Low NPSH Impeller
(Suction)
Stages
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Pump Size A
(Inches)
-.110
-.113
-.116
-.119
-.122
-.125
-.128
-.131
-.134
-.137
-.140
-.143
-.146
-.149
-.152
-.155
-.158
-.161
Pump Size B
(Inches)
-.110
-.113
-.116
-.119
-.122
-.125
-.128
-.131
-.134
-.137
-.140
-.143
-.146
-.149
-.152
-.155
-.158
-.161
Pump Size C
(Inches)
-.125
-.128
-.131
-.134
-.137
-.140
-.143
-.146
-.149
-.152
-.155
-.158
N/A
N/A
N/A
N/A
N/A
N/A
Pump Size D
(Inches)
.137
.134
.131
.128
.125
.122
.119
.116
.113
.110
.107
.104
N/A
N/A
N/A
N/A
N/A
N/A
Pump Size E
(Inches)
.185
.182
.179
.176
.173
.170
.167
.164
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
*Additional stages will require compensation for interstage compression, on average .003 inch per stage. Use .010
inch shim as needed. Refer to Section XI, Paragraphs F.
NOTE: You will reach a point in which you run out of clearance between the impeller and diffuser. This is best found
by checking the centering distance without the interstage sleeve (58) installed and then rechecking with the
interstage sleeve installed. If you find that the distance is the same or close to each other, you will have to add a
shim (73G) until you have clearance behind the impeller and diffuser.
RSA
.210 – (#of stages X .003) = NPSH Impeller Setting
RSB
.210 – (#of stages X .003) = NPSH Impeller Setting
RSC
.538 – (#of stages X .003) = NPSH Impeller Setting
RSD
.792 – (#of stages X .003) = NPSH Impeller Setting
RSE
.210 – (#of stages X .003) = NPSH Impeller Setting
10
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
Figure 1. Seal Chamber Dimensions
11
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
Table 4. Shaft Dimensions
Pump Model
At Impeller (Inches)
At Coupling (Inches)
A
1.437
1.250
B
1.437
1.250
C
1.437
1.250
D
1.574
1.500
E
1.771
1.625
Table 5. Sleeve Bearing Dimensions
Pump
Model
Sleeve Bearing New (Inches)
Sleeve Bearing
Replacement Limits (Inches)
Part Version Reference
Temperature Range
Part Version Reference
(Ø = Diameter Measured)
Sleeve
(Ø = Diameter
Measured)
-01
40-139 °F
-02
140-219 °F
-03
220-299 °F
-01
40-139 °F
-02
140-219 °F
-03
220-299 °F
New
(Inches)
Replace
(Inches)
A
1.758/1.760
1.762/1.764
1.767/1.769
Ø > 1.762
Ø > 1.766
Ø > 1.771
1.751/1.749
Ø < 1.746
B
1.758/1.760
1.762/1.764
1.767/1.769
Ø > 1.762
Ø > 1.766
Ø > 1.771
1.751/1.749
Ø < 1.746
C
1.758/1.760
1.762/1.764
1.767/1.769
Ø > 1.762
Ø > 1.766
Ø > 1.771
1.751/1.749
Ø < 1.746
D
1.972/1.974
1.977/1.979
1.983/1.985
Ø >1.976
Ø >1.981
Ø >1.987
1.965/1.963
Ø < 1.961
E
2.382/2.384
2.387/2.389
2.392/2.394
Ø >2.386
Ø >2.391
Ø >2.396
2.375/2.373
Ø < 2.371
Table 6. Standard Design Pump Mechanical Seal Settings
12
Pump Model
Suction End (Inches)
(from end of sleeve to face of collar)
A
3.100
B
3.100
C
3.100
D
3.590
E
4.500
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
Table 7. Optional Design Pump Mechanical Seal Settings
Pump Model
Discharge End (Seal Type 8B1)
(for reference only) – Inches
(from face of box to face of collar)
Suction end (Seal Type 1 or 21)
- Inches
(from face of box to face of collar)
A
1.375
1.000
B
1.375
1.000
C
1.375
1.000
D
1.750
1.312
E
1.812
1.594
Table 8. Key Mechanical Data
Pump Model
Item
A, B
C
Maximum Speed
E
3500 RPM
Max HP – (17-4 PH shaft)
Max HP – (416 SS Shaft)
2
D
st
2
WR of Rotor – 1 Stage (lb-In )
370
370
603
900
308
308
500
690
14.6
30.8
36.7
106.5
10.2
26.7
31.1
94.4
2
WR of Rotor –
2
each Stage (lb-In )
Lubrication Method (Standard)
Oil – ISO Grade 68
L10 Bearing Life (hrs) - Thrust
50,000
L10 Bearing Life (hrs) - Radial
50,000
Radial Bearing Type
307
307
308
309
Thrust Bearing Type
7307
7307
7308
7309
The standard seal flush plans provided with the optional outboard mechanical seal are shown below.
TI
when
specified
Plan 11
Recirculation from Discharge Point to Seal
Plan 21
Recirculation from Discharge Point thru a TI
and Heat Exchanger to Seal
Figure 2. Standard Seal Flush Plans
13
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
OPTIONAL DESIGN
STANDARD DESIGN
SIDE VIEW
END VIEW
OIL
IN/OUT
¼ NPT
IN/OUT
¼ NPT
Figure 3. Bearing Frame Water Cooling
14
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
Table 9. Permissible Nozzle Loads
X
X
X
Y
Y
Side Connection
Suction Position A
Discharge Position 1
Size
Y
Top Connection
Suction Position B
Discharge Position 2
Side Connection
Suction Position C
Discharge Position 3
Side Connection
Top Connection
FX
FY
FZ
MX
MY
MZ
FX
FY
FZ
MX
MY
MZ
A, B
256
555
567
643
839
370
710
232
732
552
839
266
C
266
573
595
746
988
414
710
244
778
649
988
311
D
399
822
827
1,290
1,599
801
1,130
352
997
1,083
1,599
565
E
599
1,228
1,281
2,361
3,003
1,411
1,673
530
1,575
2,007
3,003
1,011
M = Moments measured in Foot-Pounds (FT-lbs)
F = Forces measured in Pounds (lbs)
Table 10. Minimum Flow Rates RS-6 and RS-9
Pump Model
A
B
C
D
E
Speed (RPM)
Minimum Flow (GPM)
1450
1750
2900
3500
1450
1750
2900
3500
1450
1750
2900
3500
1450
1750
2900
3500
1450
1750
2900
3500
15
20
25
35
15
20
25
35
30
40
50
100
30
50
120
200
30
50
150
200
Minimum Continuous
Flow (GPM)
20
25
40
50
40
50
80
100
75
90
150
180
125
150
250
300
200
250
400
500
15
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
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 bearings with lubricant, retard oxidation and
corrosion, and prevent possible false brinelling.
The motor 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.
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!
16
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
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.
Figure 4. Sling Position for Moving Pump
Figure 5. Sling Position for Moving Pumping Unit
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 4. To lift a horizontal
mounted unit, a hoist or suitable lifting device should be
attached to each corner of base structure, refer to
Figure 5. To lift a horizontal mounted unit, a hoist or
suitable lifting device should be attached to each lifting
lug on the base structure, refer to Figure 6. 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 6. Sling Position for
Moving Pumping Unit with Lifting Lugs
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,
17
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
rigid support for the base plate. Consequently,
maintaining the pump to driver alignment is important for
a flexible coupled unit, refer to Figure 9. 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 7, 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 8; adjust the leveling screws until provided base
Verify that the pump and driver 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 7, 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.
18
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.
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.
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
Figure 7. Grouting and Foundation Bolting
Milled Motor Pad
Milled Pump Pad
Anchor Hole
Leveling Screw
Figure 8. Unit Leveling
19
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
F. COUPLING ALIGNMENT. The pump and motor
are connected by a coupling. Alignment is necessary
when the pump or motor are removed from the base.
The coupling should NOT be reconnected until the
alignment has been completed. Always check the
coupling alignment after shipping. The following is how
to check the coupling alignment.
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 9.
3. When the Parallel Offset is measured by
rotating the hubs in unison with dial indicators
as shown in Figure 9, 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 9.
Parallel Offset (TIR)
Measurement
Figure 9. Coupling Alignment
20
Angular Misalignment
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
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 the 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.
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
8 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 Figure 2 and vendor mechanical seal
drawing for seal line connections to the 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 bearing frame. 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.
21
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
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 in the
bearing frame 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 12. Pumps are shipped
with no oil in the bearing frame.
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 pump 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 13 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.
22
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.
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
casing.
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 casing.
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.
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
C. STARTING THE PUMP.
CAUTION
surface. If necessary, the minimum flow must be
increased.
To=Tf+ΔT
g*H
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 Table 10.
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.
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.
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
Qmax
=
1.25 x Qopt for 4-pole operation
Qopt
=
optimum efficiency
ΔT =
c*η
*(1-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.
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 power input to the motor.
4. Check for leakage at mechanical seals.
G. STOPPING THE PUMP.
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.
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.
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
23
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
H. INDEFINITE SHUTDOWN.
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.
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.
Refer to Figures 11, 12, and 13, for the location of parts
identified by item numbers. Drain pump by removing the
following plugs: plug (424) form the bottom of each
interstage case (111), plug (422) from suction case (9),
and plug (421) from discharge case (1). If necessary,
flush pump to remove corrosive or toxic pumpage.
Collect and dispose of corrosive or toxic material
appropriately. Drain oil from bearing frame by removing
pipe plugs (425) from bearing caps (35 and 37). Drain
all piping if there is a possibility of liquid freezing.
Provide pump and driver with a protective cover.
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 11 to
eliminate the most common causes of those problems.
Immediate action to be taken before proceeding with
corrective actions in Table 11 is to stop the pump, refer
to Section VIII, Paragraph G.
Table 11. 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. Improperly installed impeller.
5. Incomplete priming or venting of pump or
piping.
6. Valves are not fully open.
7. 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.
24
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. Disassemble pump and correct axial
alignment of impeller.
5. Vent piping again carefully and prime
pump.
6. Open valves and if necessary, lock valves
open to prevent accidental closure.
7. 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.
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
Table 11. 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.
1. Tie bolts not sufficiently tightened.
2. O-rings damaged.
1. Release the pressure and tighten the tie
bolts.
2. Replace O-rings.
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.
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.
Leakage at
casing joints.
2. Defective ball bearing.
3. Pump/driver shafts are misaligned.
4. Piping causes pump to “warp”.
8. Balance motor.
25
RS Series Multi-Stage
Centrifugal Pump
X.
I-280
December 2015
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 bearing cooling flow rates, if applicable,
refer to Table 13.
• 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.
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 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 coupling alignment.
• If necessary, grease coupling, but Do NOT over
grease.
• Check foundation bolts.
Semi-annual Inspection:
• Change oil. Do NOT 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.
50/300 Hours
• The first oil change should be carried out after 50
hours of operation. The second oil change should
be carried out after 300 hours of operation
1000 Hours
• After the second oil change at 300 hours
subsequent oil changes should be effected at
intervals of 1000 hours of operation.
•
20,000 Hours - Overhaul
For pump overhaul, complete Section XI, Service
and Repair.
A. LUBRICATION OF PUMP BEARINGS.
CAUTION
Pumps are shipped without oil and
bearing frames should be filled with oil before
starting the pumping unit. Operation of the unit
without proper lubrication can result in
overheating of the bearings, bearing failures,
pump seizures and actual breakup of the
equipment, exposing operating personnel to
injury.
Ball Bearings (16 and 18). The radial ball bearing and
the thrust ball bearings 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. Refer to Figures 11, 12, and 13, for the location
of parts identified by item numbers.
Fill the bearing frame (99) with oil (refer to Table 12 for
oil recommendations) through the breather vent (405)
until oil can be seen in the center of the oil view sight
(143)*.
To change oil, unscrew oil cap pipe plug (425) in
bearing caps (35 and 37) and drain oil. Flush bearing
frame with petrol or benzol. Slowly rotate the shaft by
hand during flushing. Replace oil cap pipe plug and fill
26
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
the bearing frame (99) with oil (refer to Table 12 for oil
recommendations) through the breather vent (405) until
oil can be seen in the center of the oil view sight (143)*.
B. LUBRICATION OF MOTOR BEARINGS.
See
motor manufacturer’s instructions to be sure motor
bearings are properly lubricated.
Table 12. Oil Recommendations
C. TORQUE VALUES.
Refer to Table 14,
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.
Manufacturer
Royal Purple
Texaco
Phillips
Exxon
Mobil
ISO Grade 68
Synfilm 68
Regal R&O 68
Magnus Oil 68
Teresstic 68
DTE 16 M
Flow Rate
The first bearing jam nut (22) is to have 20 ft-lbs torque
while holding the coupling end of the shaft. The second
bearing jam nut is to be tightened to 30 ft-lbs while
holding the coupling end. Loctite the second bearing jam
nut.
Oil Lube - Air
Table 14. Recommended Torque Values (ft-lbs)
Table 13. Bearing Cooling Flow Rates
(30 PSIG MAX.)
Temperature Range
-20˚ to 225˚ F
(-4° to 107° C)
225˚ to 285° F
(107° to 140° C)
285˚ to 300° F
(140° to 148° C)
Refer to the pump nameplate to determine your pump
model for tie rod torques.
Oil-Lube – Water
1 Gallons per Minute (GPM)
Oil-Lube – Water
2 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 10).
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 (99) through
the vent breather (405) 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.
Fastener Size
Torque Value
1/4-20 UNC
5
5/16-18 UNC
10
3/8-16 UNC
15
1/2-13 UNC
30
Bearing Jam Nuts
20/30*
RS6-A, B, C, D Tie Rod*
160
RS9-A, B, C, D Tie Rod*
315 / 50 ft-lbs increments
RS9-E Tie Rod*
446 / 50 ft-lbs increments
*(Refer to Section X, Paragraph C)
Table 15. Recommended Equipment
Tools
Spanner Wrench
Rawhide or
Wood Mallet
Wooden Wedge
Allen Wrench Set
Socket, Open, &
Box Wrench
Set
Vice Grips
Torque Wrench
Jam Nut Wrench
Materials
Oil
O-ring
Lubricant
Test Equipment
Coupling
Alignment
Gauges
Volt-Amp Meter
Figure 10. Constant Level Oiler
27
RS Series Multi-Stage
Centrifugal Pump
XI.
I-280
December 2015
SERVICE AND REPAIR.
Refer to Figures 11, 12, and 13 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.
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.
Parts marked with * are options or vary by
pump or bearing frame size.
O-rings, ball bearings, oil seals/bearing
isolators, mechanical seals and gaskets if
disturbed from position should be replaced.
Close suction and/or discharge valves. The pump
should be cooled down to ambient temperature. The
casings 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 15, Recommended
Equipment, for proper tooling during disassembly and
assembly. Refer to appropriate sectional drawing for
location of parts followed by an item number.
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.
2. Stop the pumping unit; refer to Section VIII,
Paragraph G.
28
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.
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. For cartridge mechanical seals (90* or 91*),
reinstall seal clip.
4. Disconnect piping, gauge lines, and auxiliary
connections, as necessary.
5. Drain pump by removing the following plugs:
plug (424) form the bottom of each interstage
case (111), plug (422) from suction case (9),
and plug (421) from discharge case (1). If
necessary, flush pump to remove corrosive or
toxic pumpage. Collect and dispose of corrosive
or toxic material appropriately.
6. Drain oil from bearing frame by removing pipe
plugs (425) from bearing caps (35 and 37).
7. Confirm water from the oil cooler (215A*) is
drained.
8. Disconnect all male connector retaining nuts
from male connectors (410, 411, and 413)
bodies, as applicable. Remove tubing (400 and
401, and 408*), as applicable. Retaining nuts
will remain with tubing.
9. Remove coupling guard and disconnect
coupling halves.
10. Remove nuts and washers, as applicable from
discharge and suction casing feet (1 and 9)
holding pump to base. Move the pump to a
suitable work area for disassembly; refer to
Section VII, Paragraph B for handling of the
pump.
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
B. DISASSEMBLY OF PUMP WITH STANDARD
SLEEVE BEARING. The instructions that follow are an
aid for properly trained personnel to service your Carver
Pump. Refer to Figures 11 and 13 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.
NOTE
Parts marked with * are options that vary by
pumping unit and bearing frame size.
ATEX and CE require bearing isolators and
metal splash guards. Other customers may use
oils seals and plastic splash guards. These
items fit in the same positions.
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.
CAUTION
Use a hoist with adequate lifting capacity for
lifting the discharge case (1).
9. Remove discharge case (1).
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
Pump should be dismantled from the discharge
end. Mark or number each component while
dismantling according to sequence.
The individual components
unscrewed or removed.
3. Support interstage casings (111) before
dismantling to prevent from being dropped while
discharge case (1) is removed.
4. Remove tie bolt nuts (616) and tie bolt washers
(645). Remove tie bolts (173) connecting the
discharge case (1) and the suction case (9).
5. Remove gland nut (615) from outboard bearing
cap stud (631). Remove outboard bearing cap
(37A) form discharge case (1). Remove gland
O-ring (89H) from outboard bearing cap.
6. Remove male connector (410) body from seal
gland (17A).
7. Remove hex nuts (615) from studs (630) on
seal gland (17A). Slide back seal gland from
suction case (9) to release mechanical seal (90)
tension.
8. Remove jam nuts (614) and bearing washer
(28) from shaft (6). Remove sleeve (14X) from
shaft.
should
be
1. Complete Section XI, Paragraph A before
continuing with disassembly.
2. With pump in a horizontal position clamp down
suction case (9) foot to steady pump during
disassembly.
NOTE
Refer to Table 5, Sleeve Bearing Dimensions to
determine if replacement of sleeve bearing is
required.
IMPORTANT: Check for shims between
impellers and spacer sleeves, and mark the
sequence accordingly.
10. If replacing sleeve bearing (63Y), remove
sleeve bearing from discharge case (1).
11. Remove last stage diffuser (5X) with wear ring
(7X) still intact.
12. Remove impeller (2X). Remove impeller key
(32A).
13. Remove interstage casing (111) with casing Oring (89D), diffuser (5A), diffuser bushing (63)
and wear ring (7X) intact. Remove casing O-ring
from interstage casing.
14. Remove impeller key (32A). Remove interstage
sleeve (58). Remove interstage shims (73G), as
necessary, from both sides of interstage sleeve.
Record the location of all removed shims for
ease of assembly.
29
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
15. Repeat steps 13 and 14 for each stage of the
pump. Number and match mark impellers during
removal.
NOTE
Before removing wear rings from casings
inspect per Section XI, Paragraph D, and step
9. Wear rings should only be removed for
replacement, refer to Section XI, Paragraph G
for wear ring replacement.
16. If replacement is required, remove wear ring
(7X) and diffuser (5X). First wear ring (7A) will
remain in the suction case (9) unless
replacement is required.
17. Remove case O-ring (89D) from suction case
(9).
18. Remove the first stage impeller (2A). Remove
the spacer sleeve (14D).
NOTE
Shaft (6), mechanical seal (90), seal gland
(17A), bearing cap bearing isolator (168*), and
bearing frame bearing isolator (169*) will come
off with bearing frame (99).
19. Remove bolts (600). Remove bearing frame
(99).
NOTE
If ball bearings and/or oil seals/bearing isolators
are disturbed from position replace with new.
20. Remove bolts (601), washer (850), O-ring
(89W), and remove bearing cap (35). Remove
bearing cap bearing isolator (168*) from bearing
cap and discard.
21. If necessary to remove bearings, remove
bearing jam nuts (22).
22. Remove back-to-back ball bearings (16) with
bearing frame (99).
30
23. Remove bearing spacer (78) with slinger (40)
intact, from shaft (6). Remove bearing frame
bearing isolator (169*) from bearing frame (99)
and discard.
24. Remove snap ring (176).
NOTE
Refer to mechanical seal vendor instructions for
proper mechanical seal removal procedure.
Do NOT remove rotating element of
mechanical seal (90) from shaft sleeve (14A) at
this point, especially if mechanical seal is
relatively clean and in good working condition.
25. For cartridge mechanical seals (90*), loosen
setscrews holding the cartridge seal sleeve to
shaft (6).
26. Remove gland (17A) from shaft (6).
27. Remove sleeve (14A) and rotating element of
mechanical seal (90*). Inspect rotating element
of mechanical seal. If replacement is required,
remove element from sleeve.
28. Remove O-ring (89X).
29. If necessary to replace mechanical seal (90*),
remove stationary element of mechanical seal in
seal gland (17A). Remove gland O-ring (89H)
from seal gland.
30. Remove key (32X) from shaft (6).
NOTE
Do NOT remove seal collar (68), unless sleeve
(14A) needs replaced.
31. Remove setscrews (665) from shaft collar (68).
Remove shaft collar (68) from sleeve (14A).
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
C. DISASSEMBLY OF PUMP WITH OPTIONAL
MECHANICAL SEALS. The instructions that follow are
an aid for properly trained personnel to service your
Carver Pump. Refer to Figures 12 and 13 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.
NOTE
Parts marked with * are options that vary by
pumping unit and bearing frame size.
ATEX and CE require bearing isolators and
metal splash guards. Other customers may use
oils seals and plastic splash guards. These
items fit in the same positions.
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.
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
Pump should be dismantled from the suction
end. Mark or number each component while
dismantling according to sequence.
The individual components
unscrewed or removed.
should
3. Support interstage casings (111) before
dismantling to prevent from being dropped while
suction case (9) is removed.
NOTE
If ball bearings and/or oil seals/bearing isolators
are disturbed from position replace with new.
4. Remove bolts (601), washers (850), O-rings
(89W), and remove bearing cap (35). Bearing
cap bearing isolator (168*) will be removed with
bearing cap. Discard bearing cap bearing
isolator.
5. Remove bearing jam nuts (22).
6. Remove male connector (410) body from seal
gland (17A).
7. Remove nuts (615) and washers (646) from
studs (630) on seal gland (17A). Slide back seal
gland from suction case (9) to release
mechanical seal (90) tension.
NOTE
Do not remove both bearing frames at the
same time. Pump should be dismantled from
the suction end.
8. Remove bearing frame bolts (600). Remove
bearing frame (99) from suction case (9). Ball
bearing (16), spacer sleeve (14G), and bearing
frame bearing isolator (169*) will come off with
bearing frame. Discard ball bearing and bearing
frame bearing isolator.
NOTE
Refer to mechanical seal vendor instructions for
proper mechanical seal removal procedure.
9. For cartridge mechanical seals (90*), loosen
setscrews holding the cartridge seal sleeve to
shaft (6).
10. Remove nuts (615) and washers (646) from
studs (630) on mechanical seal gland (17A).
be
1. Complete Section XI, Paragraph A before
continuing with disassembly.
2. With pump in a horizontal position clamp down
discharge case (1) foot to steady pump during
disassembly.
31
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
NOTE
Do NOT remove rotating element of
mechanical seal (90*) from shaft sleeve (14A)
at this point, especially if mechanical seal is
relatively clean and in good working condition.
Do not remove slinger (40) from spacer sleeve
(14A) unless slinger or spacer sleeve need
replaced.
11. Remove seal gland (17A), spacer sleeve (14A),
and slinger (40) together.
12. If necessary to replace mechanical seal (90*),
remove slinger (40) and stationary element of
mechanical seal in seal gland (17A). Remove
gland O-ring (89H) from seal gland.
13. Remove sleeve (14A) and rotating element of
mechanical seal (90*). Inspect rotating element
of mechanical seal. If replacement is required,
remove element from sleeve.
14. Remove tie bolt nuts (616) and tie bolt washers
(645) from tie bolts (173). Remove tie bolts
connecting the suction case (9) and the
discharge case (1).
CAUTION
Use a hoist with adequate lifting capacity for
lifting the suction case (9).
NOTE
Before removing wear rings from casings
inspect per Section XI, Paragraph D, and step
9. Wear rings should only be removed for
replacement, refer to Section XI, Paragraph G
for wear ring replacement.
15. If replacement is required, remove first wear
ring (7A) and suction case (9). First wear ring
will remain in the suction case unless
replacement is required.
16. Remove case O-ring (89D) from suction casing
(9).
NOTE
IMPORTANT: Check for shims between
impellers and spacer sleeves, and mark the
sequence accordingly.
17. Remove sleeve O-ring (89X) and key (32X)
from shaft (6). Remove spacer sleeve (14D or
14E). Remove first impeller (2A).
32
18. Remove interstage case (111), diffuser (5A)
with wear ring (7X), diffuser bushing (63), and
casing O-ring (89D) intact. Remove O-ring
(89D) from interstage case.
19. Remove impeller key (32A). Remove interstage
sleeve (58). Remove interstage shims (73G), as
necessary, from both sides of interstage sleeve
(58). Record the location of all removed shims
for ease of assembly.
20. Remove interstage impeller (2X).
21. Repeat steps 18 through 20 for each stage of
the pump. Number and match mark impellers
during removal.
22. Remove spacer sleeve (14E*).
23. Remove nuts (615) and washers (646) from
studs (630) on mechanical seal gland (17X).
Slide back seal gland from discharge case (1) to
release mechanical seal (91) tension.
24. Remove bolts (600) from bearing frame (99)
and discharge case (1).
NOTE
Shaft (6), mechanical seal (91), seal gland
(17X), bearing cap (37), and bearing frame
bearing isolators (169) will come off with
bearing frame (99).
25. Remove bearing frame (99) assembly.
26. Remove bearing cap bolts (601) from bearing
cap (37). Remove bearing cap (37).
NOTE
If ball bearings and/or oil seals/bearing isolators
are disturbed from position replace with new.
27. If necessary to remove bearings, remove
bearing jam nuts (22).
28. Remove male connector (410) body from seal
gland (17X).
29. Remove back-to-back bearings (18) and
bearing frame bearing isolators (169*) with
bearing frame (99) from shaft (6).
30. Remove bearing spacer (78) from shaft (6).
31. Remove snap ring (176).
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
NOTE
Refer to mechanical seal vendor instructions for
proper mechanical seal removal procedure.
Do NOT remove rotating element of
mechanical seal (90) from shaft sleeve (14X) at
this point, especially if mechanical seal is
relatively clean and in good working condition.
32. For cartridge mechanical seals (91*), loosen
setscrews that hold the cartridge seal sleeve to
seal sleeve (14X).
33. Remove bearing spacer (78).
34. Remove O-ring (89X).
35. If necessary to replace mechanical seal (91),
remove stationary element of mechanical seal in
seal gland (17X). Remove gland O-ring (89H)
from seal gland.
36. Remove sleeve (14X) with slinger (40X) and
rotating element of mechanical seal (91).
Inspect rotating element of mechanical seal. If
replacement is required, remove element from
sleeve.
37. Remove key (32X) from shaft (6).
D. 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
ball bearings, mechanical seals, gaskets, Orings, oil seals/bearing isolators, and locking
devices with a nylock feature are to be replaced
with new if disturbed from position.
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 the discharge, interstage and suction
casings for pitting, scoring, and erosion. The
inside of the discharge, interstage and suction
casings should be free of any pits or grooves.
The maximum allowable depth is 1/8” (3mm).
Replace the discharge, interstage or suction
casings if any of these defects are present.
5. Inspect mechanical seal.
Replace
the
mechanical seal that is disturbed from position
or damaged.
6. Inspect impeller, sleeve, 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. If an impeller is
restored or replaced check the dynamic balance
of the rotor before reassembly of the pump.
9. Check the wear ring clearance as follows:
a. Measure outside diameter of front impeller
hub (2A or 2X) in three places.
b. Measure inside diameter of wear ring (7A)
in three places.
c. If difference between the high reading of the
inside diameter of the wear ring (7A) and
the low reading of the outside diameter of
the impeller (2A or 2X) wear ring exceeds
double the new maximum clearances given
in Table 16, replace the wear ring according
to Section XI, Paragraph G.
d. Measure outside diameter of back impeller
hub (2A or 2X) in three places.
e. Measure inside diameter of the back wear
ring (7X) in three places.
f. If difference between the high reading of the
inside diameter of the back wear ring (7X)
and the low reading of the outside diameter
of the back impeller (2A or 2X) wear ring
exceeds double the new maximum
clearances given in Table 16, replace the
back wear ring according to Section XI,
Paragraph G.
Table 16. Factory Wear Ring Clearance (Inches)
Pump Size
New Maximum
Diametrical Clearance
(Casing & Diffuser)
A
0.030
B
0.030
C
0.024
D
0.022
E
0.026
33
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
E. REASSEMBLY OF PUMP WITH STANDARD
SLEEVE BEARING. Read this entire section before
reassembling the pump. The instructions that follow are
an aid for properly trained personnel to assemble your
Carver Pump. Refer to Figures 11 and 13 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 14 for recommended torque values.
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. During
reassembly, install parts as applicable. Assembly begins
at the suction (inboard end) of the pump.
CAUTION
During reassembly, install new O-rings, ball
bearings,
oil
seals/bearing
isolators,
mechanical seals and gaskets if disturbed from
position.
O-rings,
ball
bearings,
oil
seals/bearing isolators, mechanical seals and
gaskets may have been damaged during
disassembly.
NOTE
To ensure proper seating of ball bearing parts,
rotate the ball bearing while clamping the parts.
4.
5.
6.
7.
8.
mechanical seal installation is complete. Center
drill setscrews on cartridge mechanical seal to
prevent cartridge mechanical seal sleeve from
moving during operation.
To determine placement of seal collar (68*) on
shaft sleeve (14A), refer to Table 6. For
Installation of mechanical seal (90*) rotating
element, refer to the following procedure:
a. Scribe a mark on the shaft sleeve (14A) at
the distance from coupling end. Refer to
Table 6, Standard Mechanical Seal
Settings, for specified distance.
b. Install seal collar (68*) immediately to the
impeller side of the scribe mark. Secure
seal collar to shaft sleeve (14A) with
setscrews (665).
Lubricate both gland (17A) and stationary
element of mechanical seal (90) with suitable
lubricant.
Insert
stationary
element
of
mechanical seal (90) into gland (17A). Install Oring (89H).
Slide gland (17A) onto end of shaft (6). As
applicable, ensure tap flush lines in gland (17A)
is positioned so flush lines can be connected.
Install snap ring (176) on shaft (6).
Install slinger (40) on bearing spacer (78). Slide
bearing spacer (78) onto end of shaft (6).
CAUTION
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.
Handle inboard bearing isolator (169) with care.
Mishandling could damage faces of inboard
bearing isolator.
Parts marked with * are options that vary by
pumping unit and bearing frame size.
9. Install bearing isolator (169) in bearing frame
(99).
1. Secure suction casing (9) to work area.
2. Install sleeve key (32X) into keyway in shaft (6).
Install O-ring (89X). Slide shaft sleeve (14A)
onto end of shaft (6), lining up keyway of shaft
sleeve with sleeve key.
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.
NOTE
Refer to mechanical seal vendor instructions for
complete
mechanical
seal
installation
procedures.
3. If applicable, install cartridge mechanical seal
(90*) on suction casing (9) with hex nuts (615)
on studs (630). Do not remove seal clip until
34
After 20,000 Hours of service, replace the
ball bearings.
10. Install new ball bearings (16) back-to-back in
bearing frame (99).
11. Slide bearing frame (99) and ball bearings (16)
on the coupling end of the shaft (6) up to the
bearing spacer (78).
RS Series Multi-Stage
Centrifugal Pump
12. Install first jam nut (22) and temporarily torque
to 3 ft/lbs. Install second jam nut and
temporarily toque to 3 ft/lbs.
13. Secure bearing cap (35) to bearing frame (99)
with O-rings (89W), washers (850), and bolts
(601).
14. Install shaft assembly through inboard side of
suction casing (9). Check gland (17A) for flush
line positioning.
15. Secure bearing frame (99) to suction casing (9)
by tightening bolts (600). Do NOT install hex
nuts (615) at this point.
16. Slide spacer sleeve (14D) onto outboard end of
shaft (6), next to shaft sleeve (14A).
17. Install impeller key (32A) into keyway on shaft
(6).
NOTE
Rotate pump to a vertical standing position
using a fixture that holds the suction casing feet
for the purpose of proper axial impeller
alignment. This eliminates sag and helps with
figuring compression due to the tie rod
torqueing.
Replace the same number of interstage shims
(73G) during assembly that were removed
during disassembly.
IMPORTANT: Assemble any shims found
during disassembly in correct sequence only if
no sleeves or impellers were replaced.
Check alignment in accordance with Table 3,
Axial Impeller Alignment Control Dimensions.
18. Check to make sure wear ring (7A) is in suction
casing (9). Slide first stage impeller (2A) onto
shaft (6) from outboard end, fitting keyway of
impeller to impeller key (32A) on shaft (6).
19. Check impeller alignment in accordance with
Table 3.
20. Install interstage sleeve (58).
21. Check to make sure wear ring (7X) is in
interstage casing (111). Lubricate and install
new O-ring (89D) onto suction casing (9). Check
to make sure wear ring and bushing (63) are in
diffuser (5A). Install new lubricated O-ring (89D)
in groove provided on interstage casing. Lightly
tap diffuser into interstage casing.
22. Install interstage casing assembly over shaft (6)
and fit onto suction casing (9).
I-280
December 2015
NOTE
Replace the same number of interstage shims
(73G) during assembly that were removed
during disassembly.
IMPORTANT: Assemble any shims found
during disassembly in correct sequence only if
no sleeves or impellers were replaced.
23. Install impeller key (32A) into keyway on shaft
(6).
24. Install interstage sleeve (58) and interstage
shims (73G) as needed.
25. Install impeller (2X).
26. Clamp interstage casing (111) to suction casing
(9) or previous interstage casing and check
impeller (2X) alignment in accordance with
Table 3.
27. Install interrstage assembly onto previous
interstage casing (111).
28. Repeat steps 24 through 28 for each stage up
to 7 stages. After 7 stages proceed as follows:
a. After the seventh stage interstage assembly
install impeller (2X) without interstage
sleeve (58).
b. Take measurement of impeller (2X) to
check impeller alignment with the previous
interstage case (111).
c. Remove impeller (2X) and install interstage
sleeve (58).
d. Install impeller (2X) back on the shaft (6)
and take measurement. If measurement is
the same remove impeller and install
interstage shims (73G) until impeller moves
0.005 to 0.010 inches.
e. Install interstage assembly onto previous
interstage casing (111)
f. Repeat steps a through e for rest of stages.
29. Install impeller key (32A) into keyway in shaft
(6) before install last impeller (2X).
30. Install the last stage impeller (2X). Install key
(32X), if required (Not Shown).
31. Slide outboard shaft sleeve (14X) onto outboard
end of shaft (6), aligning keyway in sleeve (14X)
with impeller key (32) or sleeve key (32X).
35
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
NOTE
CAUTION
Refer to Table 5, Sleeve Bearing Dimensions.
32. Install sleeve bearing (63Y) in discharge casing
(1).
33. Install the discharge casing (1) with diffuser
(5X), and wear ring (7X) on interstage casing
(111).
34. Install tie bolts (173), washers (645) and hex
nuts (618).
35. Install washer (28). Install and tighten jam nut
(614).
36. Install new lubricated O-ring (89H) on bearing
cap (37A).
37. Secure bearing cap (37A) to discharge casing
(1) with nuts (615) on studs (631).
38. Rotate shaft (6) by hand to ensure smooth
rotation. Install and tighten nuts (615) on gland
(17A).
39. Install tubing (400 and 401), as applicable.
Secure tubing by tightening nuts on male tube
connector (410, 411 and 413) bodies, as
applicable.
40. Install plugs (421, 422, 423, 424, and 429).
CAUTION
Use a hoist with adequate lifting capacity; refer
to Section VII, Paragraph B.
41. Shim for soft foot or loosen the tie bolt nuts to
flatten pump feet.
42. Return assembly to installation site. Install pump
on base and secure with capscrews.
43. Rotate shaft (6) by hand to insure shaft (6)
rotates freely and no rubbing noises are
present.
44. Install coupling key (46). Install coupling half on
pump shaft (6).
45. Align coupling according to Section VII,
Paragraph F.
46. Reinstall coupling guard.
47. Reconnect piping, gauge lines, and auxiliary
connections, as necessary. Check for smooth
shaft rotation.
36
Pump bearing frames 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.
48. Fill bearing frame with oil (refer to Section X,
Paragraph A and Table 12.
49. Confirm water is turned on to external flush lines
for pumps equipped with water cooling for either
the oiler or the mechanical seal.
50. Remove all tags from valves and switches.
51. Start pumping unit in accordance with Section
VIII, Paragraph C.
F. REASSEMBLY OF PUMP WITH OPTIONAL
MECHANICAL SEALS. Read this entire section before
reassembling the pump. The instructions that follow are
an aid for properly trained personnel to assemble your
Carver Pump. Refer to Figures 12 and 13 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 14 for recommended torque values.
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. During
reassembly, install parts as applicable. Assembly begins
at the discharge (outboard end) of the pump.
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
CAUTION
During reassembly, install new O-rings, ball
bearings,
oil
seals/bearing
isolators,
mechanical seals and gaskets if disturbed from
position.
O-rings,
ball
bearings,
oil
seals/bearing isolators, mechanical seals and
gaskets may have been damaged during
disassembly.
NOTE
To ensure proper seating of bearing parts,
rotate the ball bearing while clamping the parts.
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.
Parts marked with * are options that vary by
pumping unit and bearing frame size.
1. Secure discharge casing (1) to work area.
2. Lubricate and install sleeve O-ring (89X) into
groove on discharge end of shaft.
3. Install sleeve key (32X) into keyway in shaft (6).
Lubricate inside of shaft sleeve (14X) and slide
onto shaft, lining up keyway of shaft sleeve with
sleeve key.
NOTE
Refer to mechanical seal vendor instructions for
complete
mechanical
seal
installation
procedures.
4. If applicable, install cartridge mechanical seal
(91*) on discharge casing (1) with hex nuts
(615) on studs (630). Remove seal clip after
pump assembly is complete.
5. If applicable, install rotating element of
mechanical seal (91*) onto shaft sleeve (14X).
Tighten setscrews in mechanical seal.
6. Install sleeve (14X) on shaft (6) with rotating
element through discharge casing (1).
7. If stationary element of mechanical seal (91*) is
replaced, clean, dry, and lubricate seal gland
(17X).
8. Lubricate and install O-ring (89H) on seal gland
(17X).
9. Install seal gland (17X) over shaft (6), onto
discharge casing (1). Check to make sure seal
gland is correctly positioned to orient piping.
10. Install snap ring (176).
11. Install slinger (40) onto shaft sleeve (14X).
12. Install bearing spacer (78) onto shaft (6).
13. Install bearing isolator (169*) into bearing frame
(99).
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 20,000 Hours of service, replace the
ball bearings.
14. Install end of shaft (6) through outboard side of
bearing frame (99).
15. If removed, press new thrust ball bearings (18)
back-to-back on shaft (6).
16. Install bearing lockwasher (69) so that tab of
bearing lockwasher fits into keyway on shaft.
17. Install bearing jam nuts (22) and tighten.
18. Install bearing cap (37) with bolts (601) on
bearing frame (99).
19. Install bearing frame (99) with bolts (600).
20. Install impeller key (32A). Install wear ring (7X)
in diffuser (5X).
21. Install last stage diffuser (5X) with bushings
(63X and/or 63XR) into discharge casing (1).
22. Install the last stage impeller (2X). Check the
depth reading in accordance with Table 3.
NOTE
Replace the same number of interstage shims
(73G) during assembly that were removed
during disassembly.
IMPORTANT: Assemble any shims found
during disassembly in correct sequence only if
no sleeves or impellers were replaced.
Check alignment in accordance with Table 3,
Axial Impeller Alignment Control Dimensions.
23. Install shims (73G), as necessary.
37
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
24. Install impeller key (32A) and interstage sleeve
(58).
25. Lubricate and install new O-ring (89D) into
interstage casing (111).
26. Confirm wear ring (7X) and bushing (63) are in
diffuser (5A). Install diffuser into interstage
casing (111). Check to make sure locking tab
engages the diffuser to keep from rotating.
NOTE
Check alignment in accordance with Table 3,
Axial Impeller Alignment Control Dimensions.
27. Install interstage casing (111) into discharge
casing (1) or previous interstage case.
28. Install the next stage impeller (2X) and impeller
key (32A).
29. Repeat steps 23 through 28 for each stage up
to 7 stages. After 7 stages proceed as follows:
a. After the seventh stage interstage assembly
install impeller (2X) without interstage
sleeve (58).
b. Take measurement of impeller (2X) to
check impeller alignment with the previous
interstage case (111).
c. Remove impeller (2X) and install interstage
sleeve (58).
d. Install impeller (2X) back on the shaft (6)
and take measurement. If measurement is
the same remove impeller and install
interstage shims (73G) until impeller moves
0.005 to 0.010 inches.
e. Install interstage assembly onto previous
interstage casing (111)
f. Repeat steps a through e for rest of stages.
30. Install spacer sleeve (14D or 14E) onto shaft
(6).
31. Install key (32X).
32. Install sleeve (14A).
33. Mark sleeve (14A) and end of shaft (6) to
determine location of key aligning key to
keyway.
34. Lubricate and install O-ring (89D) onto suction
casing (9).
35. Install suction casing (9) and tap into place
against interstage casing (111).
38
NOTE
Ensure that the pump feet are on a milled flat
surface or the base before tie rod hex nuts are
torqued.
36. Install tie bolts (173) and secure with flat
washers (645) and hex nuts (616). Tighten hex
nuts (616) firmly and evenly. Refer to Table 14
for recommended torque requirements.
NOTE
Refer to mechanical seal vendor instructions for
complete seal installation procedure.
37. If applicable, install cartridge mechanical seal
(90*) on suction casing (9) with hex nuts (615)
on studs (630). Remove seal clip after pump
assembly is complete.
38. If applicable, to determine placement of seal
collar (68*) on shaft sleeve (14A), refer to Table
6. For Installation of mechanical seal (90*)
rotating element, refer to the following
procedure:
a. Scribe a mark on the shaft sleeve (14A)
flush with stuffing box face. Refer to Table
6, Standard Mechanical Seal Settings, for
specified distance and make a second
scribe mark.
b. Install seal collar (68*) immediately to the
impeller side of the second scribe mark.
Secure seal collar to shaft sleeve (14A) with
setscrews (665).
39. Lubricate and install O-ring (89X) and slide into
groove on shaft (6).
40. Lubricate inside of shaft sleeve (14A).
41. Align keyway to mark scribe in step 33.
42. Slide sleeve (14A) over O-ring (89X).
43. If stationary element of mechanical seal is
replaced, clean, dry, and lubricate seal gland
(17A*).
44. Lubricate both gland (17A*) and stationary
element of mechanical seal (90*) with suitable
lubricant.
Insert
stationary
element
of
mechanical seal (90*) into gland (17A*). Install
O-ring (89H*).
45. Install rotating elements of mechanical seal onto
sleeve (14A).
46. Slide gland (17A*) with elements of mechanical
seal (90*) over end of shaft (6) onto suction
casing (9) with studs (630) and nuts (615) finger
tight. As applicable, ensure tap flush lines in
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
gland (17A*) is positioned so flush lines can be
connected.
47. If removed install slinger (40) on shaft sleeve
(14A).
CAUTION
Handle inboard bearing isolator (169) with care.
Mishandling could damage faces of inboard
bearing isolator.
48. Install bearing isolator (169) in bearing frame
(99).
49. Secure bearing frame (99) to suction casing (9)
by tightening bolts (600).
CAUTION
While installing radial ball bearings, do NOT
unnecessarily hit bearings. If damage to ball
bearings occurs, replace damaged ball
bearings with new ball bearings.
After 20,000 Hours of service, replace the
ball bearings.
50. Install new radial ball bearing (16) on shaft (6).
51. Install bearing lockwasher (69) so that the tab of
the bearing lockwasher fits into keyway on the
shaft (6).
52. Install bearing locknut (22) and tighten against
lockwasher (69). Crimp lockwasher tab into slot
provided on outside of bearing locknut (22).
53. Secure bearing cap (35) to bearing frame (99)
with bolts (601).
54. Rotate shaft (6) by hand to insure shaft (6)
rotates freely and no rubbing noises are
present. Tighten nuts (615) on seal gland
(17A*).
55. Install tubing (408) to orifice assembly with male
tube connector (410 and 411) bodies.
56. Install tubing (400) with male tube connector
(410 and 411) bodies.
57. Install plugs (422) for stuffing box, (423) for
gauge connector, and (424) for the casing drain.
CAUTION
Use a hoist with adequate lifting capacity; refer
to Section VII, Paragraph B.
58. Return assembly to installation site. Install pump
on base and secure with capscrews.
59. Rotate shaft (6) by hand to insure shaft (6)
rotates freely and no rubbing noises are
present.
60. Install coupling key (46). Install coupling half on
pump shaft (6).
61. Align coupling according to Section VII,
Paragraph F.
62. Reinstall coupling guard.
63. Reconnect piping, gauge lines, and auxiliary
connections, as necessary. Check for smooth
shaft rotation.
CAUTION
Pump bearing frames 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.
64. Fill bearing frame with oil (refer to Section X,
Paragraph A and Table 7.
65. Confirm water is turned on to external flush lines
for pumps equipped with water cooling for either
the oiler or the mechanical seal.
66. Remove all tags from valves and switches.
67. Start pumping unit in accordance with Section
VIII, Paragraph C.
G. REPLACEMENT OF WEAR RING. The pump has
replaceable wear rings (7A and 7X) inserted into the
diffuser (5A or 5X), suction casing (9), and interstage
casing (111). 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 D.
39
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
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.
For pumps with hardened metal wear rings the
impellers need replaced if not within the
specified clearance listed in Table 17.
First Stage Wear Ring (7A).
The suction case (9) must be removed from the base to
replace the first stage wear ring (7A). To replace the first
stage wear ring (7A) follow these steps:
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. Disassemble pump per Section XI, Paragraph
C, steps 1 through 16.
2. Remove suction case (9) from base and take
suction case and first stage impeller (2A) to a
work area with access to machine shop
equipment.
3. Remove the first wear ring (7A) from the suction
case (9). This can best be accomplished on a
lathe for composite wear rings. Hardened metal
wear ring can be pried out of case.
4. Press the new first wear ring (7A) into the
suction case (9). The beveled edge of the first
wear ring is installed away from the first stage
impeller (2A).
5. Place impeller (2A) 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.
6. Turn the front outside wear ring surface of the
impeller (2A) until a 63 RMS or better finish is
obtained.
7. Measure the outside diameter of the front
impeller wearing surface and record this value.
See measurement instructions in Section XI,
Paragraph D.
8. Mount the suction case (9) with new first wear
ring (7A) installed in a lathe. Indicate female
rabbet to within 0.002 TIR maximum.
40
NOTE
When replacing first wear ring with the standard
first wear ring, (part number beginning with
"00") machining in step 9 is not required. When
replacing first wear ring with the undersize first
wear ring (part number beginning with "US")
machining in step 9 is required.
9. If replacing with an undersized wear ring, bore
wear ring (7A) to within the specified tolerance
listed in Table 17 over the recorded size of the
outside diameter of the front impeller wearing
surface.
10. Reinstall suction case (9) on base.
11. Reassemble pump. Refer to Section XI,
Paragraph F, steps 28 through 67.
Table 17. New Wear Ring
Diametrical Clearance Limits (Inches)
Pump Size
Casing Limits
Diffuser Limits
A
0.007 to 0.015
0.007 to 0.015
B
0.007 to 0.015
0.007 to 0.015
C
0.006 to 0.012
0.006 to 0.012
D
0.005 to 0.011
0.005 to 0.011
E
0.007 to 0.013
0.007 to 0.013
Front Wear Ring (7X).
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 C, steps 1
through 17 before continuing.
2. Remove interstage case (111) with front wear
ring (7X) still installed and the impeller (2X) to a
work area with access to machine shop
equipment.
3. Remove the front wear ring (7X) from the
interstage case (111). This can best be
accomplished on a lathe for composite wear
rings. Hardened metal wear rings can be pried
out of case.
4. Press the new front wear ring (7X) into the
interstage case (111).
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
5. Place impeller (2X) 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.
6. Turn the front outside wear ring surface of the
impeller (2X) until a 63 RMS or better finish is
obtained.
7. Measure the outside diameter of the front
impeller wearing surface and record this value.
See measurement instructions in Section XI,
Paragraph D.
8. Mount the interstage case (111) with new front
wear ring (7X) installed in a lathe. Indicate
female rabbet to within 0.002 TIR maximum.
4.
5.
6.
7.
NOTE
8.
When replacing front wear ring with the
standard front wear ring, (part number
beginning with "00") machining in step 9 is not
required. When replacing front wear ring with
the undersize front wear ring (part number
beginning with "US") machining in step 9 is
required.
NOTE
When replacing back wear ring with the
standard front wear ring, (part number
beginning with "00") machining in step 9 is not
required. When replacing back wear ring with
the undersize back wear ring (part number
beginning with "US") machining in step 9 is
required.
9. If replacing with an undersized front wear ring,
bore wear ring (7X) to within the specified
tolerance listed in Table 17 over the recorded
size of the outside diameter of the back impeller
wearing surface.
10. Reassemble pump. Refer to Section XI,
Paragraph F, steps 25 through 67.
9. If replacing with an undersized back wear ring,
bore wear ring (7X) to within the specified
tolerance listed in Table 17 over the recorded
size of the outside diameter of the back impeller
wearing surface.
10. Reassemble pump. Refer to Section XI,
Paragraph F, steps 25 through 67.
Back Wear Ring (7X).
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 C, steps 1
through 17 before continuing.
2. Remove interstage case (111) with back wear
ring (7X) still installed and the impeller (2X) to a
work area with access to machine shop
equipment.
3. Remove the back wear ring (7X) from the
interstage case (111). This can best be
accomplished on a lathe for composite wear
rings. Hardened metal wear rings can be pried
out of case.
Press the new back wear ring (7X) into the
interstage case (111).
Place impeller (2X) 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.
Turn the back outside wear ring surface of the
impeller (2X) until a 63 RMS or better finish is
obtained.
Measure the outside diameter of the back
impeller wearing surface and record this value.
See measurement instructions in Section XI,
Paragraph D.
Mount the interstage case (111) with new back
wear ring (7X) installed in a lathe. Indicate
female rabbet to within 0.002 TIR maximum.
H. MOTOR. The motor should be maintained in
accordance with the manufacturer’s instructions.
I.
CHECK VALVE. If applicable, the check valve
should be maintained in accordance with the
manufacturer’s instructions.
41
RS Series Multi-Stage
Centrifugal Pump
XII.
I-280
December 2015
PARTS LISTS AND DRAWINGS.
for this pumping unit. Refer to Figures 11, 12, and 13,
for the location of parts identified by item numbers.
This section contains listings of parts and corresponding
drawings. Table 18 notes the recommended spare parts
Table 18. Recommended Spare Parts List
Item
Number
Description
Item
Number
2A
Impeller, First Stage
63
2X
Impeller, Per Stage
*63X
6
Shaft
*63XR
Bushing, Last Stage Diffuser
Rulon Bushing, Last Stage Diffuser
Wear Ring, First Stage
7X
Wear Ring
69
Bearing Lockwasher
14A
Sleeve
73
Gasket, Bearing Cap/Cooler
14X
Sleeve
73G
Gasket, Interstage Sleeve
14D
Spacer Sleeve, Suction and/or
Discharge End
89D
O-ring, Case
14E
Spacer Sleeve, Suction and/or
Discharge End
*89F
O-ring, Bearing Cap
14G
Spacer Sleeve, Suction End
*89H
O-ring, Bearing Gland
Ball Bearing, Inboard (Suction)
*89J
O-ring, Bearing Cap Outboard
Gland
89W
O-ring, Bearing Cap Bolt
18
Ball Bearing, Outboard (Discharge)
89X
O-ring, Sleeve
22
Bearing Locknut
89Y
O-ring, Plugs and Fittings
28
Bearing Washer
90
Mechanical Seal, Inboard
32A
Key, Impeller
*91
Mechanical Seal, Outboard
32X
Key, Sleeve
168
Bearing Isolator, Inboard Bearing Cap
46
Coupling Key - Pump
169
Bearing Isolator, Bearing Frame
58
Interstage Sleeve
176
Snap Ring
17A
*Parts are options that vary by pumping unit and bearing frame size.
42
Diffuser Bushing, Rulon
7A
16
*63Y
Description
Sleeve Bearing
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
NOTE
Oil lube air cooled shown. See
Figure 13 for other cooling options.
Figure 11. Sectional Assembly – Standard Sleeve Bearing
43/(44 blank)
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RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
NOTE
Oil lube air cooled shown. See
Figure 13 for other cooling options.
Figure 12. Sectional Assembly – Optional Mechanical Seals
45/(46 blank)
This page intentionally left blank.
RS Series Multi-Stage
Centrifugal Pump
I-280
December 2015
Figure 13. Cooling Options
47/(48 blank)
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This page intentionally left blank.
I-280
DEC 2015
For Units Built After July 2010
Through December 2015
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