RS Series multi-stage centrifugal pumps

RS Series multi-stage centrifugal pumps
Operating Instructions
I-280 ATEX REV.0
Inch Units
RS Series multi-stage
centrifugal pumps
ATEX Safety and Operation Manual
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.
EC Declaration of Conformity
MANUFACTURER:
CARVER PUMP COMPANY
2415 PARK AVE.
MUSCATINE, IOWA, USA 52761
PRODUCT DESCRIPTION:
RS-6, RS-9 Multi-stage Pump
PART NUMBER:
SERIAL NUMBER:
DATE MANUFACTURED:
APPLICABLE EUROPEAN DIRECTIVES:
Machinery:
ATEX:
98/37/EC
94/9/EC
APPLICABLE INTERNATIONAL STANDARDS:
Machinery:
ATEX:
EN 12100-1, EN 12100-2
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:
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
SERVICE RECORD PAGE
Service No. ________________ Size and Type ______________ Make ________________________
Cust. Order No. ________________________ Date Installed __________________________________
Installation Date
Location
Application
PUMP RATING
Capacity (GPM) __________________________ Total Head (ft) _______________________________
Suction Pressure _________________________ Speed (RPM) ________________________________
Liquid __________________________________ Temperature ________________________________
Specific Gravity __________________________ Viscosity ____________________________________
Impeller Diameter (inches) ______________________________________________________________
PUMP MATERIALS
Casings ___________________ Impeller ___________________ Diffuser _______________________
Shaft ____________________________________ Wear Ring ________________________________
O-rings _______________________________ Bearing Frame _______________________________
Mechanical Seal, Suction End (Low Pressure) ______________________________________________
Mechanical Seal, discharge End (High Pressure) ____________________________________________
DRIVER DATA
Motor _________________ Make ________________________ Serial No. ______________________
Type __________________ Frame _______________________ AC or DC ______________________
HP ____________________ RPM ________________________ Volts _________________________
Phase _________________ Cycles _______________________
NOTES ON INSPECTION AND REPAIRS
INSPECTION DATE
REPAIR TIME
REPAIRS
COST
REMARKS
RS Series – Multi-Stage, Ring Section Pumps
February 2008
TABLE OF CONTENTS
Location/Description
Page
I.
General Information .............................................................................................................. 1
1. Preface ........................................................................................................................... 1
2. Safety.............................................................................................................................. 2
3. Transport and Interim Storage........................................................................................ 5
4. Equipment Description ................................................................................................... 5
5. Effects of Fluids .............................................................................................................. 6
6. Noise............................................................................................................................... 6
7. Mechanical Seal ............................................................................................................. 6
8. Bearing Lubrication and Cooling .................................................................................... 6
9. Technical Data................................................................................................................ 10
10. Unpackaging................................................................................................................... 11
II.
Installation ............................................................................................................................. 12
1. Foundation and Mounting............................................................................................... 12
2. Grouting .......................................................................................................................... 12
3. Handling.......................................................................................................................... 14
4. Coupling.......................................................................................................................... 14
5. Piping.............................................................................................................................. 15
6. Auxiliary Connections ..................................................................................................... 15
III.
Operation .............................................................................................................................. 16
1. Method of Operation....................................................................................................... 16
2. Pre-Start Cautions .......................................................................................................... 16
3. Start-Up .......................................................................................................................... 16
4. Turbine Applications ....................................................................................................... 16
5. Minimum/Maximum Flow Calculation for Fluids other than water.................................. 17
IV.
Troubleshooting .................................................................................................................... 18
V.
Maintenance and Repair ....................................................................................................... 21
1. Scheduled Maintenance ................................................................................................. 21
2. Bearings.......................................................................................................................... 21
3. Torque Values ................................................................................................................ 22
4. Disassembly and Assembly Preparations ...................................................................... 23
5. Parts Cleaning and Inspection........................................................................................ 24
6. Axial Impeller Alignment ................................................................................................. 24
7. Wear Ring Replacement ................................................................................................ 26
8. Oil Lubrication and Water Cooling Service..................................................................... 27
9. Cartridge Seal Replacement .......................................................................................... 28
10. Pump Disassembly and Assembly RS A – RS E (with standard sleeve bearing).......... 31
11. Pump Disassembly and Assembly RSA - RS E (with optional mechanical seals)......... 36
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RS Series – Multi-Stage, Ring Section Pumps
February 2008
LIST OF TABLES
Table
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Page
Grease Recommendations ................................................................................................... 7
Oil Recommendations........................................................................................................... 7
Bearing Cooling Flow Rates ................................................................................................. 7
Shaft Dimensions .................................................................................................................. 10
Sleeve Bearing Dimensions.................................................................................................. 10
Standard Mechanical Seal Settings ...................................................................................... 10
Optional Mechanical Seal Settings (Non-Cartridge) ............................................................. 10
Minimum Flow Rates............................................................................................................. 17
Pumping Unit Troubleshooting.............................................................................................. 18
Recommended Torque Values ............................................................................................. 22
Recommended Tools ............................................................................................................ 23
Axial Impeller Alignment Control Dimensions ....................................................................... 25
Maximum Wear Ring Clearances ......................................................................................... 26
New Wear Ring Clearance Limits ......................................................................................... 26
Recommended Spare Parts.................................................................................................. 42
LIST OF FIGURES
Figure
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Page
Water Cooling ....................................................................................................................... 8
Stuffing Box........................................................................................................................... 9
Grouting and Foundation Bolting .......................................................................................... 13
Unit Leveling ......................................................................................................................... 13
Coupling Alignment ............................................................................................................... 14
Adjusting Alignment .............................................................................................................. 14
Fluid Line Schematic............................................................................................................. 15
Axial Impeller Alignment........................................................................................................ 25
Cooling Options RS-A thru RS-E .......................................................................................... 29
Sectional Assembly, RS-A thru RS-E (with standard sleeve bearing).................................. 34
Sectional Assembly, RS-A thru RS-E (with optional mechanical seals)............................... 40
ii
RS Series – Multi-Stage, Ring Section Pumps
February 2008
I. General Information
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.
1. PREFACE
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.
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.
These instructions must always be kept
close to the product's operating location or
directly with the product.
These instructions are intended to facilitate
familiarization with the product and its permitted use
to help satisfy ATEX safety requirements. These
instructions may not have taken into account local
regulations; ensure such regulations are observed by
all, including those installing the product. Always
coordinate repair activity with operations personnel,
and follow all plant safety requirements and
applicable safety and health laws/regulations.
1.4 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. When ordering spare parts,
check to make sure that the serial number and
model number of the pump are correct. 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.
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.
1.1 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 with the applicable CE
Marking Directives for Equipment for Potentially
Explosive Atmospheres (ATEX).
1.5. Parts Inventory Guide
To avoid unnecessary delays for maintenance, spare
parts should be readily available 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 15,
Recommended Spare Parts. Part numbers
correspond to Figures 9 and 10.
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.
1.5 Parts Ordering
1.2 Disclaimer
When ordering replacement parts, please specify:
•
Serial number of pump (located on nameplate)
•
Part name (located on parts list)
•
Quantity of parts needed
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.
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.
1.3 Personnel qualification and training
All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
1
RS Series – Multi-Stage, Ring Section Pumps
February 2008
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.
requirement still applies even if the VFD is in a
safe area.
If a driver or driver parts are ordered, specify name of
manufacturer and all other data found on the driver
nameplate.
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.
2. SAFETY
2.4 Safety Awareness
2.1 Summary of safety marking
Ex symbol relates to additional requirements
which must be adhered to when the pump is operated
in potentially explosive atmospheres.
These instructions contain the following specific
ATEX safety marking where non-observance of the
instruction will cause a hazard.
2.5 Safety Instructions for the Operator / User
This symbol indicates explosive atmosphere
marking according to ATEX. It is used in safety
instructions where non-compliance in the hazardous
area would cause the risk of an explosion.
-
-
2.2 Products used in potentially
explosive atmospheres
-
Measures are required to:
• Avoid excess temperature
• Prevent build up of explosive mixtures
• Prevent the generation of sparks
• Prevent leakages
• Maintain the pump to avoid hazard
-
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.
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 hazardous
fluids (e.g. explosive, toxic, hot) must be
contained so as to avoid any danger to persons
or the environment. Pertinent legal provisions
must be adhered to.
Electrical hazards must be eliminated. (In this
respect refer to the relevant safety regulations
applicable to different countries and/or the local
energy supply companies.)
If the pumps/units are located in potentially
explosive atmospheres, it is imperative to make sure
that unauthorized modes of operation are prevented.
Non-compliance may result in the specified
temperature limits being exceeded.
2.3 Scope of compliance
2.6 Safety Instructions for Maintenance,
Inspection and Installation Work
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.
The operator is responsible for ensuring that all
maintenance, inspection and installation work be
performed by authorized, qualified specialist
personnel who are thoroughly familiar with the
manual.
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 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.
To ensure dafe operation the roller
bearings must be replaced at 20000 hours of
service or when ever the mechanical seal is
inspected or serviced.
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
2
The pump must have cooled down to ambient
temperature, pump pressure must have been
released and the pump must have been drained.
Work on the machine / unit must be carried out only
during standstill. The shutdown procedure described
in the manual for taking the unit out of service must
be adhered to without fail.
RS Series – Multi-Stage, Ring Section Pumps
February 2008
Pumps or pump units handling fluids injurious to
health must be decontaminated.
Immediately following completion of the work, all
safety-relevant and protective devices must be reinstalled and / or re-activated. Please observe all
instructions set out in the chapters on
Installation/Operation before returning the unit to
service.
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)
2.7 Unauthorized Modification and Manufacture of
Spare Parts
Modifications or alterations of the equipment supplied
are only permitted after consultation with the
manufacturer and to the extent permitted by the
manufacturer . Original spare parts and accessories
authorized by the manufacturer ensure safety. The
use of other parts can invalidate any liability of the
manufacturer for consequential damage.
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
2.8 Unauthorized Modes of Operation
c = Constructional safety
(in accordance with EN13463-5)
The warranty relating to the operating reliability and
safety of the unit supplied is only valid if the
equipment is used in accordance with its designated
use as described in the following sections. The limits
stated in the data sheet must not be exceeded under
any circumstances.
Gas Group (Equipment Category 2 only)
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)
2.9 Explosion Protection
If the pumps/units are installed in potentially explosive
atmospheres, the measures and instructions given in
the following sections 2.9.1 to 2.9.6 must be adhered
to without fail, to ensure explosion protection.
Maximum surface temperature (Temperature Class)
(see section 2.9.5)
2.9.3 Checking the Direction of Rotation
2.9.1 Unit Fill
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.
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.
2.9.4 Pump Operating Mode
If the operator cannot warrant this condition,
appropriate monitoring devices must be used.
Make sure that the pump is always started up with the
suction-side shut-off valve fully open and the
discharge-side 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 run-up process (see 6.1.7 ).
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.
Pump operation with the shut-off valves in the
suction and/or discharge pipes closed is not
permitted.
2.9.2 Marking
The marking on the pump only refers to the
pump part, i.e. the coupling and motor must be
regarded separately. The coupling must have an EC
manufacturer’s declaration. The driver must be
regarded separately.
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
3
RS Series – Multi-Stage, Ring Section Pumps
cause excessive stresses on the pump materials or
even bursting.
The minimum flows indicated in Table 8 of Section III
refer to water and water-like liquids. Longer operating
periods with these liquids and at the flow rates
indicated will not cause an additional increase in the
temperatures on the pump surface. However, if the
physical properties of the fluids handled are different
from water, it is essential to check if an additional heat
build-up may occur and if the minimum flow rate must
therefore be increased.
To check, proceed as described in Section III E.
In addition, the instructions given in section III of this
operating manual must be observed.
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.
2.9.5 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 bearing
areas. The surface temperature at the pump casing
corresponds to the temperature of the fluid handled.
If the pump is heated, it must be ensured that the
temperature classes stipulated for the plant are
observed.
In the bearing bracket area, the unit surfaces must be
freely exposed to the atmosphere.
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.
120 °C
T3
185 °C
T2
280 °C
Based on an ambient temperature of 40°C and proper
maintenance and operation, compliance with
temperature class T4 is warranted in the area of the
rolling element bearings. A special design is required
for compliance with temperature class T6 in the
bearing area. In such cases, and if ambient
temperature exceeds 40°C, contact the manufacturer.
Pump operating temperature for bearings
should NOT exceed 225 degrees Fahrenheit (F).
Pumps of high temperature construction are provided
with cooled bearings for a unit operating temperature
range between 225 and 300 degrees F. Cooling water
flows through cavities of the bearing frame and keeps
temperature of the bearings within acceptable limits.
Refer to Table 3 for cooling flow rates of water
temperature of 60 degrees F for bearings. Refer to
Figure 1 illustrating the water cooling (30 PSIG MAX.)
system.
2.9.6 Maintenance
Only a pump 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 rolling
element 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 bearings running hot or
defective bearing seals.
2.9.7 General Safety Instructions
Temperature limit of
fluid handled
85 °C
T4
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.
The correct function of the shaft seal must be
checked regularly.
Any auxiliary systems installed must be monitored, if
necessary, to make sure they function correctly.
The table 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.
Temperature class
to EN 13463-1:
T5
February 2008
1.
2.
3.
Safety note:
4
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.
RS Series – Multi-Stage, Ring Section Pumps
Do NOT wear loose or torn clothing around
rotating machines.
5. While working near electricity, do NOT use
metal rules, flashlights, metallic pencils, or
any other objects having exposed
conducting material.
6. Make sure you are NOT grounded while
adjusting electrical equipment or using
measuring equipment.
7. In general, use only one hand when
servicing live electrical equipment.
8. Make sure to de-energize all electrical
equipment before connecting or
disconnecting meters or test leads.
9. For connecting a meter to terminals for
measurement, use a range higher than the
expected voltage.
10. Check to make sure that the frameof the
driver and starter panel are securely
grounded before operating pumping unit or
performing any tests or measurements.
11. 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.
12. Do NOT use test equipment known to be
damaged or in poor condition.
February 2008
4.
The following specific safety precautions
apply to the pumping unit:
1.
2.
3.
4.
Hydro suction case separately on RS-9
units.
Isolate pump for system hydro.
Do NOT exceed maximum suction pressure
of 415 PSIG on suction case.
Do NOT exceed maximum rated
discharge pressure on discharge case.
Fig. 3.1-1 Transport of the pump
Fig. 3.1-2 Transport of the complete unit
3.2 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!
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.
3 Transport and Interim Storage
4. Equipment Description
3.1 Transport
Transport of the unit requires proper preparation and
handling. Always make sure that the pump or the
unit remains in horizontal position during transport
and cannot slip out of the transport suspension
arrangement. Do not use lifting slings on the free
shaft end of the pump or on the motor eyebolt.
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
intermediate (stage) casings, all secured with tie
bolts. Diffusers are inserted in individual stage
casings. O-rings seal the individual stage casings.
Suction casing, stage 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. The
bearing frame is attached to the suction case and
discharge case by bolts.
If the pump / unit slips out of the suspension
arrangement, it may cause personal injury and
damage to property.
The pump shaft is protected against wear by
interstage sleeves, spacer sleeves, and shaft sleeves.
Impellers are secured on the pump shaft by keys and
located by sleeves and shims. All impellers face the
same direction on the shaft.
5
RS Series – Multi-Stage, Ring Section Pumps
February 2008
Neither capacity nor total head will be affected by a
change in the specific gravity of the fluid pumped.
However, since the discharge pressure in pounds per
square inch (psi) and the brake horsepower required
to drive the pump are functions of the specific gravity
of the fluid, both will be affected in direct proportion to
any change in specific gravity. Therefore, an increase
in specific gravity will raise the discharge pressure
and may overload the driver, or exceed the pump
case allowable pressure.
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.
5. Effects of Fluids
Solids in Fluid Pumped.
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.
6. Noise
The RS pump is incorporated into a high energy
machine. Noise levels may exceed 85dBa at 1
meter during operation. Ear protection must be
worn whenever working in high noise locations.
Effects of Viscosity
The pump is designed to deliver rated capacity at
rated head for a fluid with a particular viscosity. If the
pump is handling heavy viscous fluid, the fluid may
have to be heated prior to starting the pump in order
to travel through the pump easier. If contemplating
operating the pump at a high viscosity, check with
Carver Pump Company.
7. Mechanical Seal
Component or cartridge seals may be used.
Complete cartridge seal instructions should be
obtained from the manufacture.
Effects of Specific Gravity
The capacity and total head in feet of fluid developed
by a centrifugal pump are fixed for every point on the
curve and are always the same for the same speed.
8. Bearing Lubrication and Cooling
Refer to Figure 9, Cooling Options, for bearing
lubrication and cooling options.
6
RS Series – Multi-Stage, Ring Section Pumps
February 2008
compatible with lithium or soda soap base greases.
Therefore, the type of grease added should NOT
vary. Refer to Table 1 for specific recommended
grease types.
8.1. Grease Recommendations
Standard pump bearings are grease lubricated. Refer
to Section V; paragraph 2, for grease-lubricated
bearings.
8.2 Oil Lube Recommendations
Non-soap, polyurea thickened grease with a drop
point of 450 degrees Fahrenheit is recommended for
bearing grease. This grease is selected due to its
suitability to extreme pressures and its high
temperature stability. Never mix greases with differing
properties. Polyurea base greases are NOT
Pumps with oil lubrication are shipped with no oil in
the bearing frame. Adequate lubrication with ISO
Grade 68 oil is essential at all times. Refer to Table 1,
Oil Recommendations, for specific oil types. Refer to
Section V; paragraph 2 for oil-lubricated bearings.
Table 1. Grease Recommendations
Manufacturer
Number
Amoco
Aero Shell
2EP
22
Mobil
28
Table 2. Oil Recommendations
Manufacturer
ISO Grade 68
Royal Purple
Synfilm 68
Texaco
Regal R&O 68
Phillips
Magnus 68
Exxon
Teresstic 68
Mobil
DTE 16 M
Table 3. Bearing Cooling Flow Rates (30 PSIG MAX.)
Temperature Range
Flow Rate
-20 degrees to 180 degrees F
Grease Lube – Air
-20 degrees to 225 degrees F
225 degrees to 285 degrees F
Oil Lube – Air
Oil Lube - Water-1 Gallons Per Minute (GPM)
285 degrees to 300 degrees F
Oil Lube - Water-2 GPM
7
RS Series – Multi-Stage, Ring Section Pumps
February 2008
OPTIONAL DESIGN
STANDARD DESIGN
OIL
DRAIN
IN/OUT
¼ NPT
IN/OUT
¼ NPT
END VIEW
SIDE VIEW
Figure 1. Water Cooling
8
RS Series – Multi-Stage, Ring Section Pumps
February 2008
Figure 2. Stuffing Box
9
RS Series – Multi-Stage, Ring Section Pumps
February 2008
9. Technical Data
necessary information upon receipt of the
pumping unit.
Specifications and operating limits should be
recorded on the Service Record Page located in
the front matter of this manual. Record the
Table 4. Shaft Dimensions
Pump Model
At Impeller
At Coupling
RS A
1.437 inches
1.250 inches
RS B
1.437 inches
1.250 inches
RS C
1.437 inches
1.250 inches
RS D
1.574 inches
1.500 inches
RS E
1.771 inches
1.625 inches
Table 5. Sleeve Bearing Dimensions
Pump Model
Sleeve Bearing
Sleeve
New
Replace
New
Replace
RS A
1.755/1.756 inches
>1.758 inches
1.751/1.749 inches
>1.746 inches
RS B
1.755/1.756 inches
>1.758 inches
1.751/1.749 inches
>1.746 inches
RS C
1.755/1.756 inches
>1.758 inches
1.751/1.749 inches
>1.746 inches
RS D
1.969/1.970 inches
>1.972 inches
1.965/1.963 inches
>1.961 inches
RS E
2.380/2.381 inches
>2.383 inches
2.375/2.373 inches
>2.371 inches
Table 6. Standard Design Pump Mechanical Seal Settings (from end of sleeve to face of collar)
Pump Model
Suction End
RS A
3.100 inches
RS B
3.100 inches
RS C
3.100 inches
RS D
3.590 inches
RS E
4.500 inches
Table 7. Optional Design Pump Mechanical Seal Settings (from face of box to face of collar)
Pump Model
Discharge End (Seal Type 8B1)
(for reference only)
Suction End (Seal Type 1 or 21)
RS A
1.375 inches
1.000 inch
RS B
1.375 inches
1.000 inch
RS C
1.375 inches
1.000 inch
RS D
1.750 inches
1.312 inch
RS E
1.812 inches
1.594 inch
10
RS Series – Multi-Stage, Ring Section Pumps
February 2008
•
10. Unpackaging
After receiving the pumping unit, inspect for
missing hardware, flange covers or possible
damage. In general, check to make sure the
shipment complies with the purchase order.
Inspect any parts containers that may be
shipped with unit (i.e. coupling, seals, etc.).
Immediately report any damage or shortage to
the carrier’s agent or factory. Claims that are
made at a later time cannot be accepted.
The plant (or department) is shut down for
periods of longer than 30 days.
caution
A pump which is made of ductile iron
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.
Storage requirements vary depending
on the length of storage, the climatic
environment, and the equipment. For
storage periods of three months or
longer, contact a representative from
Carver Pump Company for specific
instructions. Improper storage will
damage the equipment and will require
non-warranty restoration and/or nonwarranty product failures. Refer to
Section V, Maintenance and Repair, for
pump disassembly and assembly
procedures. When disassembling the
pump, replace and repair rusted parts,
as necessary.
10.1 Packaging
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 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.
10.2. Inspection upon Arrival
10.4. Pump Protection during
Prolonged Shutdown
NOTE
The pump and equipment, as shipped
from Carver Pump Company, have
adequate protection for short-term
storage. If the equipment is NOT
immediately installed and operated,
store the equipment in a covered, clean,
dry, well-ventilated location, free from
vibrations, moisture, and rapid or wide
variations in temperature.
NOTE
If the customer anticipates that the
pump/equipment will be subject to an
extended period of storage after
installation, (for example, a unit used for
seasonal operation), contact a
representative from Carver Pump
Company. If this is the case, Carver will
provide specific instructions and special
protection for the equipment during the
extended period of storage. In general, if
a pump is to be shut down for an
extended period, the following steps are
recommended:
10.3. Storage of Pump
If the equipment is NOT immediately installed
and operated, Carver Pump Company
recommends rotating each shaft several
revolutions at least once every two weeks to
prevent flat spots on ball bearings.
1. Shut down the pumping unit in
accordance with the Operating
Procedures outlined in this manual.
2. Shut off system suction and
discharge valves.
3. Drain the unit.
4. Fill unit with mineral oil or suitable
non-corrosive protectant that is
compatible with the system.
5. Provide pump and motor with a
protective cover.
Consider a unit to be in storage when any of the
following situations occur:
• The pump has been delivered to the job site
and is waiting to be installed.
• The pump has been installed but operation
is delayed pending completion of
construction.
• There are long (30 days or more) periods
between operating cycles.
11
RS Series – Multi-Stage, Ring Section Pumps
February 2008
II. Installation
enough to provide uniform support of the base
plate. Adjust the metal supports or wedges until
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
supports or wedges under the base plate.
1. Foundation and Mounting
A hoist or suitable lifting device should
be used to lift the pumping unit. Do NOT
lift the complete unit by the driver, the
pump shafts or the driver lifting eyes.
See Section I.3
2. 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:
1. Lightly tighten foundation bolts evenly
but not fully. Refer to Figure 3, Grouting
and Foundation Bolting.
2. Build a wooden dam around the base
plate to retain the grout.
3. Pour grout through grouting holes
provided in base plate. This should be
done until the entire space under base
plate is filled. While filling the holes,
make sure there are no voids or air
pockets.
4. Insert a stiff wire through the grouting
holes to work the grout and release any
voids or air pockets.
5. After grout has hardened (usually 48
hours), remove the dam and shims or
wedges under the base plate, if desired.
Fill remaining holes by the shims with
grout.
6. Tighten foundation bolts loosely. Allow
the grout to fully cure before firmly
tightening the foundation bolts.
Hydraulic Institute (HI) recommends a
foundation capable of absorbing vibration at
least five times the weight of the pumping unit
and to form a permanent, rigid support for the
base plate. Consequently, maintaining the
alignment is important for a flexible coupled unit.
Refer to Figure 5 and Figure 6 illustrating
alignment. 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 3,
Grouting and Foundation Bolting.
As soon as the pump and driver, mounted on a
base plate, is placed on the foundation, remove
the coupling guard and disconnect coupling
halves. Reconnect the coupling after alignment
operations have been completed. The base
plate should be supported on either rectangular
metal blocks with shims or on metal wedges
having a small taper. The support pieces should
be placed close to the foundation bolts. Refer to
Figure 4, Unit Leveling. Place supports directly
under the part of the base plate, which carries
the greatest weight. Space the supports closely
12
RS Series – Multi-Stage, Ring Section Pumps
February 2008
1/4“
BASEPLATE
FINISHED GROUTING
GROUT
3/4“ TO 1-1/2” ALLOWANCE
FOR GROUTING
LEVELING WEDGES OR SHIMS - LEFT IN PLACE
DAM
PIPE SLEEVE
WASHER
LUG
Figure 3. Grouting and Foundation Bolting
Figure 4. Unit Leveling
13
TOP OF FOUNDATION LEFT
ROUGH - CLEAN AND WET
DOWN
RS Series – Multi-Stage, Ring Section Pumps
February 2008
Proceed as follows with parallel alignment:
3. Handling
NOTE
The corrections, which are made to the
alignment in one direction, may affect
the alignment in the other direction.
Angular and parallel misalignment are
corrected by means of shims. The shims
are placed under the driver mounting
feet to align the coupling. Refer to
Figure 6, Adjusting Alignment.
A hoist or suitable lifting device should
be used to lift pumping unit. Do NOT lift
the complete unit by the driver, the
pump shafts or the driver lifting eyes.
See section I-3
The complete pumping unit must be handled
with care. Do NOT pass the lifting slings through
the lifting eyes on driver.
4. Coupling
1. Check the parallel misalignment by
fastening the dial indicator to the pump
half of the coupling.
The coupling should NOT be reconnected until
the alignment has been completed. Align
coupling using a dial indicator to attain more
accurate coupling alignment. Refer to Figure 5,
Coupling Alignment.
2. Set the dial on the indicator to zero
and rotate both hubs 360 degrees. With
the dial indicator needle against the face
of the other hub, take indicator readings
at four points, 90 degrees apart.
Parallel
Angular
Figure 5. Coupling Alignment
shims
Figure 6. Adjusting Alignment
14
RS Series – Multi-Stage, Ring Section Pumps
February 2008
3. Shim all mounting feet on the driver until all
four readings are identical (0.005) maximum
Total Indicator Runout (TIR).
caution
Extreme care should be taken when
connecting new piping to make sure that
no foreign matter such as dirt, slag,
chips, tools, etc., are in the piping.
Otherwise, the debris will be drawn into
the pump and will cause excessive
damage. During initial installation and
testing, a strainer should be installed in
suction piping to keep debris from
entering pump.
Proceed as follows with angular alignment:
1. Check the angular misalignment by
fastening dial indicator to one coupling
hub.
2. Set the dial on the indicator to zero and
rotate both hubs 360 degrees. With the
dial indicator needle in contact with the
surface of the outside diameter of the
opposite coupling hub, take indicator
readings at four points, 90 degrees
apart.
3. Adjust driver until all four readings are
identical (0.008 maximum TIR).
4. Reconnect coupling halves.
5. Reinstall coupling guard.
Suction lift lines should be laid with a
rising slope toward the pump and
positive suction-head lines should be
laid with a downward slope. This is done
to avoid air pocket formation. Suction
piping must be at least the same size as
pump suction nozzle. Compensation for
heat elongation must be provided where
required.
5. Piping
The pump is shipped with flange covers to
protect flange faces and to prevent foreign
matter from entering pump. Flange covers
should remain intact until suction and discharge
piping are connected to pump flanges.
If necessary, the coupling should be realigned
after installing piping. Realign, if necessary, by
adjusting the driver end. Refer to Figure 6.
All piping should be supported so that no undue
piping strain or weight is placed upon the pump.
Do NOT force piping. Never use pump as an
anchorage point for the piping.
Connect auxiliary connections. For an illustration
of bearing cooling, refer to Figure 1, Water
Cooling. Figure 7, Fluid Line Schematic,
illustrates the heat exchanger and cooling water
for the seal.
6. Auxiliary Connections
T1
WHEN
SPECIFIED
RECIRCULATION FROM PUMP
CASE THROUGH HEAT
EXCHANGER TO SEAL
RECIRCULATION FROM PUMP
CASE TO SEAL
PLAN 11
PLAN 21
Figure 7. Fluid Line Schematic
15
RS Series – Multi-Stage, Ring Section Pumps
February 2008
III. Operation
checked before operating the pumping
unit.
7. If necessary, turn on cooling lines to
check for sufficient flow. Refer to Table
8 for minimum cooling flow rates.
1. Method of Operation
Pumped fluid enters suction case and passes
into first stage impeller, which propels fluid into
first stage diffuser. The fluid then flows into the
next impeller. This process is repeated from one
stage to the next. Through each stage, fluid
pressure increases (this is termed “stage head”).
After leaving final stage diffuser, fluid enters
discharge case and passes into discharge
piping.
3. Start-Up
Before starting the pumping unit, refer to the
safety precautions in Section I. Refer to Table 8
for minimum flow rates.
2. Pre-Start Cautions
Before starting the pumping unit, make the
following checks:
Do NOT operate pumping unit against a
closed discharge system. If pump has
any chance of 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 8,
Minimum and Minimum Continuous
Flow Rates.
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 unit is activated while being worked
on.
1. Rotate both shafts by hand to assure all
moving parts are free.
2. Check motor for correct rotation before
connecting the coupling.
3. If necessary, recheck coupling
alignment.
4. Install closed guards around all exposed
rotating parts.
5. Check to make sure that fluid in the
pump is clean, clear, and free of debris.
Never run pump dry because the close
running fits that are within the pump are
lubricated by the fluid being pumped.
Dry running may result in pump
seizure or mechanical seal failure.
6. Standard grease lubricated pumps are
shipped with factory lubrication packed
bearings. Lubrication is adequate for a
minimum of 1,000 operating hours or six
months of continuous operation under
normal conditions. After extended
storage or exposure to unusually humid
or hot environmental conditions, the
bearings and their lubricant should be
Proceed as follows to start the pumping
unit:
1. Completely open system valve in
suction line to pump and fill with fluid.
2. Open system valve in discharge line to
pump to allow a minimum design flow.
3. Open valves to pressure gauges in the
system.
4. Start electrical power supply to driver.
5. Slowly open system valve in discharge
line until pumping unit reaches specified
pumping conditions. (Refer to the pump
nameplate for design point condition.)
4. Turbine Applications
For turbine applications, consult your local
distributor or a representative from Carver Pump
Company.
16
RS Series – Multi-Stage, Ring Section Pumps
February 2008
Table 8. Minimum Flow Rates RS-6 & RS-9
Pump Model
Speed
Minimum Flow
Min. Continuous Flow
RS A
1450 RPM
15 GPM
30 GPM
1750 RPM
20 GPM
20 GPM
2900 RPM
25 GPM
40 GPM
3500 RPM
35 GPM
50 GPM
1450 RPM
15 GPM
40 GPM
1750 RPM
20 GPM
50 GPM
2900 RPM
25 GPM
80 GPM
3500 RPM
35 GPM
100 GPM
1450 RPM
30 GPM
75 GPM
1750 RPM
40 GPM
90 GPM
2900 RPM
50 GPM
150 GPM
3500 RPM
100 GPM
180 GPM
1450 RPM
30 GPM
125 GPM
1750 RPM
50 GPM
150 GPM
2900 RPM
120 GPM
250 GPM
3500 RPM
200 GPM
300 GPM
1450 RPM
30 GPM
200 GPM
1750 RPM
50 GPM
250 GPM
2900 RPM
150 GPM
400 GPM
RS B
RS C
RS D
RS E
3500 RPM
200 GPM
5. Minimum/Maximum Flow Calculation for Fluids other than water.
500 GPM
Unless specified otherwise 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
The data refer to water and water-like liquids. However, if the physical properties of the fluids handled are different
from water, the calculation formula below must be used to check if an additional heat build-up may lead to a
dangerous temperature increase at the pump surface. If necessary, the minimum flow must be increased.
T o=T f+Δ ∇
g*H
Δ∇ =
*(1-η)
c*η
c Specific heat
g Acceleration due to gravity
H Pump head
T f Temperature of fluid handled
T o Temperature of casing surface
η Pump efficiency at duty point
Δ ∇ Temperature difference
[J / kg K]
[m/s_]
[m]
[°C]
[°C]
[ -]
[°C]
17
RS Series – Multi-Stage, Ring Section Pumps
February 2008
IV. Troubleshooting
If the installation and starting procedures
outlined in this manual have been followed, the
pump should provide reliable service and long
life. However, if operating problems occur, use
Table 9, Pumping Unit Troubleshooting, to
eliminate the most common causes of those
problems, or contact a representative from
Carver Pump Company.
Table 9. Pumping Unit Troubleshooting
Symptom
Pump does not deliver
rated capacity
Leakage at case joints.
Bearings run hot.
Immediate Action
1. Stop driver.
1. Stop driver.
1. Stop driver.
Probably Cause
Corrective Action
1. Excessive system
pressure.
1. Check GPM and head
against design conditions;
pump impeller may be too
small. Consult local distributor
or Carver Pump Company.
2. Incomplete priming or
venting of pump or piping
1. Prime pump and piping
again and carefully vent.
3. Suction line or strainer
clogged.
1. Clean out suction line or
strainer.
4. Positive suction head is
too low.
1. Reduce the distance from
centerline of pump to source of
liquid being pumped.
5. Valves are not fully open.
1. Open valves and if
necessary, lock valves open to
prevent accidental closure.
6. Clogged impeller.
1. Dismantle pump and clean
impeller, if necessary.
7. Reverse rotation.
1. Correct rotation is clockwise
when viewed from driver end.
8. Improperly installed
impeller.
1. Disassembly pump and
correctly axial align impeller.
9. Excessive wear of internal
parts.
1. Disassemble pump and
replace worn parts.
1. Tie Bolts not sufficiently
tightened.
1. Release the pressure and
tighten tie bolts evenly.
2. O-rings damaged.
1. Replace o-rings.
1. Pump and driver shafts
are misaligned.
1. Check coupling alignment.
2. Check pipe strain.
2. Piping causes pump to
“warp”.
18
1. Ensure piping transmits
no stress to pump. Alter
piping layout, if
necessary. Realign
pump and driver shafts.
RS Series – Multi-Stage, Ring Section Pumps
February 2008
Table 9. Pumping Unit Troubleshooting (CONT.)
Symptom
Pump discharge pressure
excessive.
Immediate Action
1. Stop driver.
Probably Cause
Corrective Action
3. Unsuitable grease.
1. Check for incorrect
grease.
4. Over greased or oiled
bearings.
1. Remove excess grease or
oil.
5. Insufficient grease (or oil)
to bearings.
1. Add grease (or oil), as
necessary.
6. Insufficient cooling of
bearing frame.
1. Check cooling flow rate to
bearing frame.
7. Worn bearings.
1. Replace bearings.
8. Worn/damaged wear rings
or bushings
1. Replace wear ring or
bushings
1. Excessive speed.
1. Check speed precisely.
Decrease speed, if possible.
2. Wrong impeller trim.
1. Trim outlet tips of impeller
vanes. Consult Carver Pump
Company specifying exact
operating conditions.
3. Pump is pumping fluid with
specific gravity in excess of
that specified. (If temperature
of fluid is lower, then
specified specific gravity will
be higher.)
1. If prescribed fluid
temperature or specific
gravity can not be attained,
one or more of the following
measures can be taken:
a. Partially close discharge
valve,
reducing pump capacity to a
point where driver is not
overloaded.
b. Remove one or more
impellers and their diffusers
and install special blind
stage parts.
c. Trim one or more
impellers.
d. Install more powerful
driver. Consult Carver Pump
Company specifying exact
operating conditions.
19
RS Series – Multi-Stage, Ring Section Pumps
February 2008
Table 9. Pumping Unit Troubleshooting (CONT.)
Symptom
Driver overloaded.
Immediate
Action
1. Stop driver.
Probably Cause
Corrective Action
1. Pump discharge
pressure is lower
than design point
(check pump
nameplate)
1. Partially close discharge
valve until pressure at
discharge flange is as
specified. Decrease speed
or trim impellers if driver
remains overloaded (consult
Carver Pump Company
before taking this step).
2. Same as 3 under
“Pump Discharge
Pressure
Excessive.”
1. Same as 3 under pump
discharge pressure
excessive.
3. Wrong impeller trim.
1. Trim outlet tips of impeller
vanes. Consult Carver
Pump Company specifying
exact operating conditions.
20
RS Series – Multi-Stage, Ring Section Pumps
February 2008
V. Maintenance and Repair
1. Scheduled Maintenance
2. Bearings
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. A
pump service record and an inspection and repair
record are provided for this purpose in the front matter
of this manual.
The thrust bearings are installed back-to-back. The
standard package has a matched set of bearings
located on the suction end. The optional package has
a matched set of bearings located on the discharge
end with a single bearing on the suction. Always
replace the roller bearings when disassembling unit
for seal service.
Regular inspection and service are essential for
safe operation of the pump in ATEX applications.
Grease Lubricated
The pump has grease-lubricated bearings, which are
packed at the factory for six months or 1,000 hours
continuous operation under normal conditions without
re-lubrication. Carver Pump Company lubricates
bearings with Rykon premium grease; a non-soap
polyurea thickened grease with a drop point of 450
degrees F. This grease was selected due to the
suitability to extreme pressures and high temperature
stability. Never mix greases with differing properties.
Polyurea base greases are NOT compatible with
lithium or sodium soap base greases. Therefore, the
type of grease added should NOT vary. If it is
necessary to change grease type, the following items
should be removed, cleaned and flushed with a
suitable solvent: bearings, bearing frame, and bearing
caps. Refer to Section I, paragraph K, Grease
Recommendations. If changing grease type, use the
following procedure:
1. Place bearings, bearing frame end of
bearing frame, and bearing caps in a wire or
mesh basket and suspend basket in a light
mineral solvent and allow to soak, preferably
overnight.
2. After soaking and cleaning, bearings,
bearing frame end of bearing frame, and
bearing caps, rinse in a clean, light mineral
solvent and agitate vigorously to remove all
loosened hard grease and dirt.
3. Dip bearings in clean, light oil and spin by
hand, ensuring that all foreign matter has
been removed. Failure to remove all foreign
matter could cause poor bearing
performance later.
4. After cleaning, repack bearings on both
sides with recommended grease. The
bearings themselves should be packed to
nearly 100% full. Do NOT fill the entire
bearing cap so that excess grease will have
room to move on start-up. Excess grease
will be purged through the vent hole in the
bearing cap.
Daily Inspection:
•
Visually inspect unit.
•
Check bearing temperatures.
•
Refer to Table 3, to check bearing cooling flow
rates, if applicable.
•
Check for leakage at mechanical seals.
•
Check that oil level is at center of bullseye, if
applicable.
Weekly Inspection:
•
Check power (amps) readings.
•
Check pump discharge pressure. Prescribed
operating discharge pressure should never drop
below 90 percent of design point pressure.
•
Check vibration on pump and driver bearings.
Vibration should NOT exceed 1.8 overall
displacement (unfiltered) peak to peak mils
(0.001”) at 3600 RPM and 3.5 overall
displacement (unfiltered) peak to peak mils
(0.001”) at 1750 RPM.
Monthly Inspection:
•
Check coupling alignment.
•
If necessary, grease coupling. Do NOT over
grease.
•
Check foundation bolts.
Semi-annual Inspection:
•
Grease bearings or change oil. Do NOT over
grease or add excess oil.
•
Check coupling alignment due to settling of
foundation.
•
If stand-by pumps are installed, it is advisable to
operate pumps on a rotation system to give each
pump a certain duty. This ensures that stand-by
pumps will always be in good condition for instant
start-up.
20000 Hours
-
Replace roller bearings.
Inspect casings for corrosion, erosion or
other damage. 3mm limit of metal loss in
casings (items 1, 9 and 111).
If bearing temperatures increase by 10 to 15 degrees
F during a period of one week and there is not a
variance in ambient or liquid temperature, add grease
to bearings through grease fittings on top of bearing
frame with a hand-operated grease gun. Over
greasing will cause bearings to overheat.
21
RS Series – Multi-Stage, Ring Section Pumps
February 2008
Pump should run a minimum of one hour to permit
expulsion of excess grease through overflow opening
in bearing cap.
To drain old oil from bearing frames, remove pipe
plug (425) at the bottom of the outboard oil cap (37)
on units with outboard mechanical seal and plug (425)
from the side of the inboard oil cap (35). Add oil to
bearing frame (99) through breather vent (405) until
oil is at the center of the bullseye sight (143). Use
bullseye sight(s) (143) to check oil level in bearing
frame(s) (99). Refer to Section I, paragraph L, Oil
Lube Recommendations. Carver recommends
changing the oil every 1,000 service hours under
normal conditions.
After greasing, bearing temperatures may
exceed 200 degrees F at 80 degrees ambient due to
excess grease in bearing frame. After the run-in
period, bearing temperatures should stabilize and
NOT exceed 185 degrees F at 80 degrees ambient. If
bearing temperatures remain high, the pump should
be shut down and the cause determined. Refer to
Table 9, Pumping Unit Troubleshooting, for common
causes of high bearing temperatures.
3. Torque Values
Refer to Table 10, 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
torqued evenly and in stages. Refer to your torque
wrench manual for the proper use of your wrench.
Before the pumping unit is started after prolonged
shutdown, grease level must be checked. Add
grease, as necessary. Check temperature of bearings
and listen for quiet running at regular intervals.
Oil Lubricated
Refer to the pump nameplate to determine your pump
model for tie rod torques.
NOTE
Pumps are shipped without oil and should be
filled with oil before starting. Failure to
operate without oil could result in damaged
pump or parts.
The first Shaft Jam Nut is to have 15 ft-lbs torque
while holding the coupling end of the shaft. The
second Shaft Jam Nut is to be tightened to 30 ft-lbs
while holding on the first nut.
Table 10. Recommended Torque Values
Fastener Size
1/4-20 UNC
Torque (foot pounds)
5
5/16-18 UNC
10
3/8-16 UNC
15
1/2-13 UNC
30
SHAFT JAM NUTS
15/30 (see Section V Paragraph C.)
RS6-A,B,C,D TIE ROD
160
RS9-A,B,C,D TIE ROD
315
RS9-E TIE ROD
446
22
RS Series – Multi-Stage, Ring Section Pumps
February 2008
4. Disassembly and Assembly Preparations
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 11, Recommended Tools, for proper tooling
during disassembly and assembly. Refer to
appropriate sectional drawing, for location of parts
followed by an item number. Assemble the pump in
accordance with accepted rules of engineering
practice. Coat individual components with a suitable
lubricant before assembling. Assembly of unit should
be performed on a flat surface.
NOTE
Refer to Section V, paragraph 2 for oil
lubrication and water cooling disassembly
and assembly procedures.
During disassembly, match mark parts so they can be
replaced in their original position. All parts should be
thoroughly cleaned or replaced with new, if
necessary. Sealing faces should be perfectly clean.
Carver Pump Company recommends that all o-rings
and shims are only used once.
NOTE
While assembling the pumping unit, Carver Pump
Company recommends that the following parts be
replaced with new:
To avoid damage to o-rings, check to make
sure all parts are free of sharp edges or
burrs.
•
•
•
•
•
Close suction and/or discharge valves. The pump
cases should be cooled down to ambient
temperature. Cases must be empty and not under
pressure.
After prolonged operation, components may not be
easily removed from shaft
O-rings
Shims
Bearings
Grease seals
Mechanical seals
If new impellers or new shaft protecting sleeves are
fitted, impellers must be axially aligned with respect to
diffusers. Refer to paragraph F of this section for
procedures regarding axial impeller alignment.
Table 11. Recommended Tools
Tools
Materials
Testing Equipment
Spanner wrench
Grease (Rykon) or oil
Coupling alignment gauges
Rawhide or wood mallet
Wooden wedge
Allen wrench set
Socket, open, & box wrench set
Vice grips
“C” clamp
23
RS Series – Multi-Stage, Ring Section Pumps
February 2008
Prepare the pumping unit for disassembly using the
following list:
1. Read this entire section and review the
applicable sectional assembly drawing and
parts list before disassembling the pump. For
cooling options, refer to Figure 9.
1.
Discard used oil seals and o-rings.
Thoroughly wash and clean all parts with a
suitable solvent.
2. 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.
3. Inspect mechanical seals. Repair or replace
mechanical seals that are extremely dirty or
damaged.
4. Check all shaft sleeves and spacer sleeves
visually for score marks, scratches, pits,
grooves or burrs. Touch up sleeves with
polishing cloth and inspect for remaining
grooves or deep scratches. Remove burrs
with a file. Shaft sleeves and spacer sleeves
should be replaced if any marks, pits or
grooves are still visible after touching up.
5. Inspect impellers for pitting, erosion, or
clogged vanes. Replace impellers that are
damaged. If new impellers are installed,
check to make sure all impellers are
balanced and axially aligned with respect to
the diffusers. Refer to paragraph F of this
section for axial alignment procedures.
6. This pump is equipped with Rulon wear rings
and bushings for greater life and higher
efficiency. These are available as “to-size”
spare parts and not as “under-size” parts.
Inspect wear ring clearance for each stage
as follows:
a.
Measure outside diameters of impeller
hubs in three places.
b.
Measure the inside diameters of
corresponding wear rings in three
places.
c.
Corresponding differences between
high readings of inside diameters of
wear rings and low readings of
outside diameters of impellers. Refer
to Table 13 and Table 14 for specified
clearance of wear rings.
d.
If wear ring replacement is required,
replace wear rings as described in
paragraph G of this section.
necessary, install shims between the impeller and the
shaft sleeve, as shown in Figure 8. Repeat measuring
and shimming until the correct control dimension is
achieved.
Before attempting to disassemble the pump,
the electrical power supply from the driver
must be locked and tagged in the “OFF”
position to prevent injury or death to
personnel servicing the pump.
2.
3.
4.
Stop the pumping unit.
Disconnect suction, discharge, and gauge
lines. Disconnect auxiliary connections, as
applicable.
Remove coupling guard. Uncouple the pump
from the driver.
caution
Use of a hoist with adequate capacity is
recommended for removing the pump from
the base.
5. Remove the bolts that hold the pump to
the base. Remove the pump from the base
and take to a suitable work area.
5. Parts Cleaning and Inspection
NOTE
Mark or number each component while
dismantling according to sequence.
IMPORTANT: Check for shims between
impellers and spacer sleeves, and mark the
sequence accordingly. The individual
components should be unscrewed or
removed.
During disassembly of the pump, individual parts
should be cleaned and inspected as follows:
6. Axial Impeller Alignment
If new parts are fitted during assembly, such as
impellers and/or sleeves, the impellers must be axially
aligned with respect to the diffuser. Refer to Figure 8
and Table 12.
Optional Mechanical Seal
Measure distance from the inboard face of the
interstage case to the inboard face of the impeller
hub. Compare the measured distance to the
dimensions given in Table 12, Axial Impeller
Alignment Control Dimensions. If shimming is
necessary, install shims between the impeller and the
shaft sleeve, as shown in Figure 8. Repeat measuring
and shimming until the correct control dimension is
achieved.
Standard Sleeve Bearing
Measure distance from the outboard face of the
suction or interstage case to the back shroud of the
impeller. Compare the measured distance to the
dimensions given in Table 12, Axial Impeller
Alignment Control Dimensions. If shimming is
24
RS Series – Multi-Stage, Ring Section Pumps
February 2008
Table 12. Axial Impeller Alignment Control Dimensions
Pump Model
Distance “A” ± 0.020 inch
Distance “B” ± .0.020 inch
Standard Sleeve Bearing
RS A
0.772
0.772
RS B
0.770
0.766
RS C
0.905
0.904
RS D
1.088
1.147
RS E
1.512
1.470
Optional Mechanical Seals
RS A
- 0.110
-0.110
RS B
+ 0.210
-0.110
RS C
+0.538
-0.125
RS D
+0.792
+0.137
RS E
+0.250
+0.185
Figure 8. Axial Impeller Alignment
25
RS Series – Multi-Stage, Ring Section Pumps
February 2008
diffuser. This can best be accomplished
by peeling out the old ring.
2. Insert the new wear ring in suction case,
interstage case and/or diffuser.
Be sure that there are no deposits or
debris in the locating groove before
inserting the part.
7. Wear Ring Replacement
To replace wear rings and bushings, proceed as
follows:
1. Remove old wear ring or bushing from
suction case, interstage case and/or
Table 13. Maximum Wear Ring Clearances
Pump Model
RS A
Maximum Diametrical Clearance
0.022 inch (casing & diffuser)
RS B
0.022 inch (casing & diffuser)
RS C
0.022 inch (casing & diffuser)
RS D
0.022 inch (casing & diffuser)
RS E
0.022 inch (casing & diffuser)
Table 14. New Wear Ring Clearance Limits
Pump Model
Casing Diametrical Clearance
Limit
RS A
0.009 to 0.011 inches
Diffuser Diametrical Clearance
Limit
0.009 to 0.011 inches
RS B
0.009 to 0.011 inches
0.009 to 0.011 inches
RS C
0.009 to 0.011 inches
0.009 to 0.011 inches
RS D
0.009 to 0.011 inches
0.009 to 0.011 inches
RS E
0.009 to 0.011 inches
0.009 to 0.011 inches
26
RS Series – Multi-Stage, Ring Section Pumps
February 2008
8. Oil Lubrication and Water Cooling
Service (Refer to Figure 9.)
NOTE
Mark or number each component during
disassembly and assembly according to
sequence.
NOTE
Do not remove oil cooler (215A) from
cap (35)
DISASSEMBLY
1. Remove plugs (425) from bearing cap
(37) on the outboard ends, if applicable.
This allows cooling cover to drain.
2. Remove plug (425) from bottom of oil
caps (35) and drain oil from inboard
end.
3. To remove cooling connecting line,
disconnect male connector retaining
nuts from tube connector body (412).
Remove tube (409). Retaining nuts will
remain with tube if applicable (Not
Shown).
4. Remove bearing caps (35 or 37) by
removing bolts (601). Remove o-ring
(89F) from bearing frame (99).
ASSEMBLY
1. Install new o-rings (89F) on bearing
frame (99). Install new oil seal (168) on
oil cap (35).
2. Install bearing caps (35) and (37) and
secure to bearing frame (99) with bolts
(601).
3. Install tube (409). Secure tube by
tightening retaining nuts on tube
connector (412). (Not Shown)
4. Install plug (425) in bottom of oil cap
(37).
5. Install plugs (425) in bearing caps (35).
Fill through breather vent (405) to center
of bullseye with oil according to Table 2.
6. If removed, apply liquid gasket to mating
surfaces of gasket (73) and install oil
pan (215) and oil cooler (215A) with bolt
(605).
27
RS Series – Multi-Stage, Ring Section Pumps
February 2008
13. Remove nuts (615) from studs (630) on
seal gland (17A) and remove gland.
9. Cartridge Seal Replacement (Refer
to sectional assembly Figure 10 or Figure
11+ vendor seal drawings.)
ASSEMBLY
DISASSEMBLY
Refer to the applicable sectional drawing for
location of parts followed by an item number.
Carver recommends all nuts and bolts be
torqued according to Table 10, Recommended
Torque Values.
NOTE
NOTE
1. Refer to Section I, paragraph , Safety
Precautions, before disassembling
pump.
2. For seal/seal design pumps; Do not
remove both bearing frames at the
same time. Complete replacement of
one seal before proceeding to the
second seal. Care is to be taken to
avoid axial movement of the shaft during
seal replacement. Installing the seal
locating tabs before starting installation
will help prevent movement.
Carefully deburr and polish the shaft
sleeve where center-drilled to prevent
damage to the seal o-ring during
installation.
1. Before starting the installation, read the
following instructions carefully.
2. Remove the seal from its packaging,
inspect for any damage, and wipe clean.
3. Lubricate sleeve O-ring with appropriate
lubricant. Lubricate shaft sleeve
sparingly. Lubricate gland plate
bolts/nuts as required.
Make sure that gland plate gasket or o-ring
is properly positioned, and that collar set
screws do not extend past sleeve ID. Slide
complete cartridge seal assembly onto shaft
sleeve. Slide cartridge onto studs until
gasket or o-ring is flush against the face of
seal chamber. Hand tighten gland plate
bolts/nuts.
1. Remove coupling half from pump shaft
(6). Remove coupling key (46).
2. Install seal locating tabs in seal(s).
3. Drain pump by removing the following
plugs: plug (424) from the bottom of
each interstage case (111), plug (421)
from suction case (9) and plug (422)
from discharge case (1).
4. Clamp down suction case foot to steady
pump during disassembly.
5. Disconnect male connector retaining
nuts from male connector (410), (411),
and (413) bodies, as applicable.
6. Remove tubing (400) or (408), as
applicable. Retaining nuts will remain
with tubing.
7. Remove bolts (601) and remove bearing
cap (35).
8. Un-crimp locking tab of bearing
lockwasher (69). Remove bearing
locknut (22) and bearing lockwasher
(69). Remove male connector (410)
body from seal gland (17A).
9. Remove bolts (600). Remove bearing
frame (99). Radial bearing (16) and oil
seal (169) will come off with bearing
frame (99).
10. Inspect bearing (16 and/or 18) and oil
seal (169) for wear, corrosion or
contamination. Carver recommends
replacing bearings (16 & 18) and oil
seals (168 & 169) after they have been
removed from shaft (6). Refer to
paragraph B of this section for bearing
maintenance.
11. Remove slinger (40).
12. Loosen setscrews retaining seal sleeve
to the pump sleeve.
NOTE: Always use a lubricant that is
compatible with your machinery and
product. Use lubricant sparingly, only
enough to install seal with ease.
4. Reassemble pump in reverse order as
disassembly above.
5. Continue tightening gland plate
bolts/nuts in an alternating pattern until
secure (1/4 turns, 180˚ apart), with
gland plate and face of pump seal
chamber metal-to-metal. Do not overstress or distort gland plate.
6. Remove seal locking setscrews and
counter-drill to prevent seal slippage
during operation.
7. Tighten collar set screws evenly (1/4
turns, 180˚ apart), securing cartridge
seal to shaft.
8. Remove spacers and save. Make
appropriate piping connections to the
sea l assembly.
28
RS Series – Multi-Stage, Ring Section Pumps
February 2008
Figure 9. Cooling Options
RS A, B, C, D and E
29
RS Series – Multi-Stage, Ring Section Pumps
February 2008
Blank
30
30
RS Series – Multi-Stage, Ring Section Pumps
February 2008
10. Pump Disassembly and
Assembly RS-A Thru RS-E (with
standard sleeve bearing) (Refer to
8. Remove jam nuts (614) and washer (28)
from shaft (6). Remove shaft sleeve
(14X) from shaft (6).
9. Remove discharge case (1).
Figure 10.)
DISASSEMBLY
Refer to Table 5, Sleeve Bearing
Dimensions to determine if replacement
of sleeve bearing is required.
NOTE
Refer to Section I, paragraph E, Safety
Precautions, before disassembling
pump.
10. If replacing sleeve bearing, remove
sleeve bearing (63Y) from discharge
case (1).
11. Remove wear ring (7X) with last stage
diffuser (5X).
12. Remove sleeve key (32X), if applicable.
13. Remove last stage impeller (2X).
Remove impeller key (32A), as
applicable.
14. Remove interstage casing (111) with
casing o-ring (89D), diffuser (5A),
bushings (63) and wear ring (7X) intact.
Remove o-ring (89D) from interstage
casing (111).
15. If necessary, remove diffuser (5A) with
wear ring (7X). Remove impeller (2X).
16. 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.
17. Repeat steps 14 through 16 for each
stage.
18. Remove the first stage impeller (2A).
Remove spacer sleeve (14D).
19. Remove hex nuts (615) from studs (630)
on seal gland (17A).
20. Remove bolts (600). Remove bearing
frame (99). Shaft (6), mechanical seal
(90), seal gland (17A) and oil seal (169)
will come off with bearing frame (99).
21. Remove bolts (601) and remove bearing
cap (35).
22. Uncrimp locking tab of bearing
lockwasher (69). Remove bearing
locknut (22) and bearing lockwasher
(69). Remove male connector (413)
body from seal gland (17A).
23. Remove back-to-back bearings (16) with
bearing frame (99).
24. Inspect back-to-back bearings (16) and
oil seal (169) for wear, corrosion or
contamination. Carver recommends
replacing back-to-back bearings (16)
and oil seal (169) after they have been
removed from shaft (6). Refer to
NOTE
Pump should be dismantled from
discharge end. Mark or number each
component while dismantling according
to sequence. IMPORTANT: Check for
shims between impellers and spacer
sleeves, and mark the sequence
accordingly. The individual components
should be unscrewed or removed.
1. Remove coupling half from pump shaft
(6). Remove coupling key (46).
2. Drain pump by removing the following
plugs: plug (424) from the bottom of
each interstage case (111), plug (422)
from suction case (9) and plug (421)
from discharge case (1).
3. Clamp down suction case foot to steady
pump during disassembly.
4. Disconnect all male connector retaining
nuts from male connector (410), (411),
and (413) bodies, as applicable.
Remove tubing (400) and (401), as
applicable. Retaining nuts will remain
with tubing.
5. Support interstage cases (111) before
dismantling to prevent from being
dropped while discharge case (1) is
removed.
6. Remove hex nuts (616) and washers
(645). Remove tie bolts (173)
connecting discharge case (1) and
suction casing (9).
caution
Use of a hoist with adequate capacity is
recommended for lifting the discharge
case (1).
7. Remove nut (615) from stud (631).
Remove end cap (37A) from discharge
case (1). Remove o-ring (89H) from end
cap (37A).
NOTE
31
RS Series – Multi-Stage, Ring Section Pumps
February 2008
paragraph B of this section for bearing
maintenance.
25. Remove bearing spacer (78) with slinger
(40) intact, from shaft (6).
26. Remove snap ring (176).
27. Remove spacer sleeve (14A).
2.
NOTE
Do NOT remove rotating element of
mechanical seal (90) from shaft sleeve
(14A) at this point, especially if
mechanical seal (90) is relatively clean
and in good working condition.
28. Remove o-ring (89X).
29. If necessary to replace mechanical seal,
remove stationary element of
mechanical seal (90) in seal gland
(17A). Remove gland o-ring (89H) from
seal gland (17A).
30. Remove sleeve (14A) and rotating
element of mechanical seal (90). Inspect
rotating element of mechanical seal
(90). If replacement is required, remove
element from sleeve (14A).
31. Remove key (32X) from shaft (6).
3.
4.
5.
6.
NOTE
Do NOT remove seal collar (68), unless
sleeve (14A) needs replaced.
7.
8.
32. Remove setscrews (665) from shaft
collar (68). Remove shaft collar (68)
from sleeve (14A).
Slide shaft sleeve (14A) onto end of
shaft (6), lining up keyway of shaft
sleeve (14A) with sleeve key (32X).
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 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 (68) to
shaft sleeve (14A) with setscrews
(665).
Lubricate both gland (17A) and
stationary element of mechanical
seal (90) with petroleum jelly or
suitable lubricant. Insert stationary
element of mechanical seal (90) into
gland (17A). Install o-ring (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).
Install oil seal (169) in frame.
Install end of shaft (6) through
inboard side of bearing frame (99).
caution
While installing back-to-back bearings,
do NOT unnecessarily hit bearings. If
damage to bearings occurs, replace
damaged bearings with new bearings.
Refer to Section V, paragraph B.
ASSEMBLY
Refer to the applicable sectional drawing for
location of parts followed by an item number.
Assemble the pump in accordance with
accepted rules of engineering practice.
Assembly of the pumping unit should be
performed on a flat surface. Carver recommends
all nuts and bolts be torqued according to Table
10, Recommended Torque Values. Check to
make sure components are fitted in correct
sequence. Assembly begins at the suction
(inboard end) of the pump. Perform the following
procedures to assemble the pumping unit:
9. Install new bearing (16) back-to-back on
shaft (6).
10. Install bearing lockwasher (69) so that
tab of lockwasher (69) fits into keyway
on shaft (6).
11. Install bearing locknut (22) and tighten
against lockwasher (69). Crimp
lockwasher tab into slot provided on
outside of bearing locknut (22).
12. Secure bearing cap (35) to bearing
frame (99) with bolts (601).
13. Install shaft assembly through inboard
side of suction casing (9).
14. Secure bearing frame (99) to suction
casing (9) by tightening bolts (600).
NOTE
To ensure proper seating of bearing
parts, rotate the bearing while clamping
the parts.
1. Install sleeve key (32X) into keyway
in shaft (6). Install o-ring (89X).
32
RS Series – Multi-Stage, Ring Section Pumps
February 2008
27. Install the last stage impeller (2X). Install
key (32X), if required (Not Shown).
28. Slide outboard shaft sleeve (14X) onto
outboard end of shaft (6), aligning
keyway in sleeve (14X) with impeller key
(32A) or sleeve key (32X).
NOTE
Secure gland (17A) loosely in place with
hex nuts (615) on studs (630). Do NOT
tighten hex nuts (615) at this point.
15. Slide spacer sleeve (14D) onto outboard
end of shaft (6), next to shaft sleeve
(14A).
16. Install impeller key (32A) into keyway on
shaft (6).
Refer to Table 5, Sleeve Bearing
Dimensions.
NOTE
29. Install sleeve bearing (63Y) in discharge
casing (1).
30. Install discharge casing (1) with diffuser
(5X),and wear ring (7X) on interstage
casing (111).
31. Install tie bolts (173), washers (645) and
hex nuts (616).
32. Install washer (28). Install and tighten
jam nut (614).
33. Install new lubricated o-ring (89H) on
bearing cap (37A).
34. Secure bearing cap (37A) to discharge
casing (1) with nuts (615) on studs
(631).
35. Rotate shaft (6) by hand to ensure
smooth rotation. Tighten nut (615) on
gland (17A).
36. Install tubing (400) and (401), as
applicable. Secure tubing by tightening
nuts on male tube connector (410),
(411) and (413) bodies, as applicable.
37. Install plugs (421), (422), (423), (424)
and (429).
38. Install pump on base and secure with
capscrews.
39. Install coupling key (46). Install coupling
half on pump shaft (6).
40. Align coupling as outlined in Section II,
paragraph D, Coupling, and reference
Figure 5, Coupling Alignment.
41. Install coupling guard.
42. Connect suction, discharge and gauge
lines. After connection of piping, check
for smooth rotation of shaft.
43. Open system valves.
44. Unlock and connect electrical power
supply to motor. Remove tags. Start
pumping unit according to Section III,
paragraph C, Start-Up.
Replace the same number of new
interstage shims (73G) during assembly
that were removed during disassembly.
NOTE
IMPORTANT: Assemble any shims
found during disassembly in correct
sequence only if no sleeves or impellers
were replaced.
NOTE
Check alignment in accordance with
Figure 8, Axial Impeller Alignment.
17. Check to make sure wear ring (7A) is in
casing (9). Slide first stage impeller (2A)
onto shaft (6) from outboard end, fitting
keyway of impeller to impeller key (32A)
on shaft (6).
18. Install interstage sleeve (58).
19. Check impeller setting in accordance
with Table 12, Axial Impeller Alignment
Control Dimensions.
20. Check to make sure wear ring (7X) is in
interstage casing (111). Lubricate and
install o-ring (89D) onto suction casing
(9). Check to make sure wear ring (7X)
and bushing (63) are in diffuser (5A).
Install new lubricated o-ring (89D) in
groove provided on interstage casing
(111). Lightly tap diffuser (5A) into
interstage casing (111). Align diffuser
vanes on either side of boss located in
interstage casing (111).
21. Install impeller (2X).
22. Clamp interstage casing (111) to suction
casing (9) and check impeller setting in
accordance with Table 12.
23. Install interstage assembly onto
previous interstage casing (111).
24. Install interstage casing assembly over
shaft (6) and fit onto suction casing (9).
25. Repeat steps 17 through 25 for each
stage.
26. Install impeller key (32A) into keyway in
shaft (6) before installing last impeller
(2X).
33
RS Series – Multi-Stage, Ring Section Pumps
February 2008
Figure 10. Sectional Assembly
RS-A Thru RS-E with standard
Bearing
34
RS Series – Multi-Stage, Ring Section Pumps
February 2008
35
Blank
35
RS Series – Multi-Stage, Ring Section Pumps
February 2008
10. Remove spacer sleeve (14G) with
slinger (40) intact.
11. Remove nuts (615) from studs (630) on
seal gland (17A) and remove gland.
11. Pump Disassembly and
Assembly RS-A Thru RS-E, (with
optional mechanical seals) (Refer to
Figure 11.)
NOTE
DISASSEMBLY
Do NOT remove rotating element of
mechanical seal (90) from sleeve (14A)
at this point, especially if mechanical
seal (90) is relatively clean, in good
working condition.
NOTE
Refer to Section I, paragraph E, Safety
Precautions, before disassembling
pump.
NOTE
12. Remove sleeve (14A) and rotating
element of mechanical seal (90). Inspect
rotating element of mechanical seal
(90). If replacement is required, remove
element from sleeve (14A).
13. If necessary to replace mechanical seal,
remove stationary element of
mechanical seal (90) in seal gland
(17A). Remove gland o-ring (89H) from
seal gland (17A).
14. Remove hex nuts (616) and washers
(645). Remove tie bolts (173)
connecting suction case (9) and
discharge case (1).
Pump should be dismantled from
suction end. Mark or number each
component while dismantling according
to sequence. IMPORTANT: Check for
shims between impellers and spacer
sleeves, and mark the sequence
accordingly. The individual components
should be unscrewed or removed.
1. Remove coupling half from pump shaft
(6). Remove coupling key (46).
2. Drain pump by removing the following
plugs: plug (424) from the bottom of
each interstage case (111), plug (422)
from suction case (9) and plug (422)
from discharge case (1).
3. Clamp down discharge case foot to
steady pump during disassembly.
4. Disconnect male connector retaining
nuts from tube connector bodies (410),
(411) and (413). Remove tube (400) and
(408). Retaining nuts will remain with
tube.
5. Support interstage cases (111) before
dismantling to prevent them from
dropping when suction case (9) is
removed.
6. Remove bolts (601) and remove bearing
cap (35).
7. Uncrimp locking tab of bearing
lockwasher (69). Remove bearing
locknut (22) and bearing lockwasher
(69). Remove male connector (410)
body from seal gland (17A).
8. Remove bolts (600). Remove bearing
frame (99). Radial bearing (16) and oil
seal (169) will come off with bearing
frame (99).
9. Inspect radial bearing (16) and oil seal
(169) for wear, corrosion or
contamination. Carver recommends
replacing radial bearing (16) and oil seal
(169) after they have been removed
from shaft (6). Refer to paragraph B of
this section for bearing maintenance.
caution
Use of a hoist with adequate capacity is
recommended for lifting suction case
(9).
NOTE
Refer to Table 13, Maximum Wear Ring
Clearances, before removing wear ring
from casing.
15. Remove wear ring (7A) and suction
case (9).
16. Remove case o-ring (89D) from suction
casing (9).
17. Remove sleeve o-ring (89X) and key
(32X). Remove spacer sleeve (14D) or
(14E). Remove first impeller (2A).
18. Remove interstage case (111) with wear
ring (7X), diffuser (5A) and case o-ring
(89D) intact. Remove o-ring (89D) from
interstage case (111).
19. Remove impeller key (32A). Remove
interstage sleeve (58). Remove
interstage shims (73G), as necessary,
from both sides of interstage sleeve
(58).
20. Remove interstage impeller (2X).
21. Repeat steps 18 through 20 for each
remaining stage. Number and match
mark impellers during removal.
36
RS Series – Multi-Stage, Ring Section Pumps
February 2008
Assemble the pump in accordance with
accepted rules of engineering. Assembly of the
pumping unit should be performed on a flat
surface. Carver recommends all nuts and bolts
be torqued according to Table 10,
Recommended Torque Values. Check to make
sure components are fitted in correct sequence.
Assembly begins at the discharge (outboard)
end of the pump. Perform the following
procedures to assemble the pumping unit:
22. If required for wear ring replacement,
remove wear ring (7X) and last stage
diffuser (5X), which holds bushing
(63X). Do NOT remove bushing
(63X/63XR) from last stage diffuser
(5X).
23. Remove spacer sleeve (14E), if
applicable.
24. Remove nut (615) from stud (630).
25. Remove bolts (600).
26. Remove bearing frame assembly with
seal (91) and shaft (6).
27. Remove bolts (601) from bearing cap
(37). Remove bearing cap (37).
28. Uncrimp locking tab of bearing
lockwasher (69). Remove bearing
locknut (22) and bearing lockwasher
(69). Remove male connector (410)
body from seal gland (17X).
29. Remove bearing frame (99). Bearings
(18) and oil seal (169) will come off with
bearing frame (99).
30. Inspect back-to-back bearings (18) and
oil seal (169) for wear, corrosion or
contamination. Carver recommends that
the back-to-back bearings (18) and oil
seal (169) be replaced after removed
from shaft (6). Refer to paragraph B of
this section for bearing maintenance.
31. Remove bearing spacer (78) and slinger
(40) from shaft (6).
32. Remove snap ring (176).
NOTE
To ensure proper seating of bearing
parts, rotate the bearing while clamping
the parts.
1. Secure discharge casing 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 (6), lining up
keyway of shaft sleeve (14X) with
sleeve key (32X).
4. Install rotating element of mechanical
seal (91) onto shaft sleeve (14X).
Tighten setscrews in mechanical seal
(91).
5. Install sleeve (14X) on shaft (6) with
rotating element through discharge
casing (1).
6. If stationary element of mechanical seal
is replaced, clean, dry, and lubricate
seal gland (17X).
7. Lubricate and install stationary element
of mechanical seal (91) in 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. Secure seal
gland (17X) with nuts (615) on studs
(630) to discharge case (1), finger tight.
10. Install snap ring (176).
11. Install slinger (40) on onto shaft sleeve
(14X)
12. Install bearing spacer (78) onto shaft
(6).
13. Install oil seal (169) into bearing frame
(99).
NOTE
Do NOT remove rotating element of
mechanical seal (91) from sleeve (14X)
at this point, especially if mechanical
seal (91) is relatively clean, in good
working condition.
33. If necessary to replace mechanical seal,
remove stationary element from
mechanical seal (91) in seal gland
(17X). Remove gland o-ring (89H) from
seal gland (17X).
34. Remove sleeve o-ring (89X). Remove
seal sleeve (14X) and sleeve key (32X),
as applicable.
35. Remove rotating element of mechanical
seal (91). If replacement is required,
remove from shaft sleeve (14X).
36. Remove remaining impeller key (32A),
as necessary.
ASSEMBLY
Refer to the applicable sectional drawing for
location of parts followed by an item number.
37
RS Series – Multi-Stage, Ring Section Pumps
February 2008
NOTE
caution
While installing back-to-back bearings,
do NOT hit ball bearings. If damage to
the bearings occurs, replace damaged
bearings with new bearings. Refer to
Section V, paragraph B.
Check alignment in accordance with
Figure 8, Axial Impeller Alignment.
28. Install interstage casing (111) into
discharge casing (1).
29. Install the next stage impeller (2X) and
impeller key (32A).
30. Repeat steps 23 through 25 for each
stage.
31. Install spacer sleeve (14D) or (14E) onto
shaft (6).
32. Install key (32X).
33. Install sleeve (14A).
34. Mark sleeve and end of shaft to
determine location of key aligning key to
keyway.
35. Lubricate and install o-ring (89D) onto
suction casing (9).
36. Install suction casing (9) and tap into
place against interstage casing (111).
37. Install tie bolts (173) and secure with flat
washers (645) and hex nuts (616).
Tighten hex nuts (616) firmly and
evenly. Refer to Table 10 for
recommended torque requirements.
38. Scribe a mark on sleeve (14A) flush with
stuffing box face.
39. Remove sleeve (14A). Make second
scribe mark according to Table 7.
40. Install locking collar (68) with setscrews
(665) to the impeller side of the second
scribed mark for seal setting on sleeve
(14A).
41. Lubricate and install o-ring (89X) and
slide into groove on shaft (6).
42. Lubricate inside of sleeve (14A).
43. Align keyway to mark scribed in step 34.
44. Slide sleeve (14A) over o-ring (89X).
45. If stationary element of mechanical seal
is replaced, clean, dry and lubricate seal
gland (17A).
46. Install stationary element of mechanical
seal into seal gland.
47. Lubricate and install o-ring (89H) on
seal gland (17A).
48. Install rotating elements of mechanical
seal onto sleeve (14A).
49. Install seal gland with elements of
mechanical seal gland (17A) onto
suction casing with studs (630) and nuts
(615) finger tight.
50. Install bearing spacer sleeve (14C) with
slinger (40) onto shaft (6).
51. Install bearing frame oil seal (169).
52. Install bearing frame (99) to suction
casing (9) with bolts (600).
15. Install end of shaft (6) through outboard
side of bearing frame (99).
16. Install new bearings (18) back-to-back
on shaft (6).
17. Install bearing lockwasher (69) so that
tab of lockwasher (69) fits into keyway
on shaft (6).
18. Install bearing locknut (22) and tighten
against lockwasher (69). Crimp
lockwasher tab into slot provided on
outside of bearing locknut (22).
19. Install bearing cap (37) with bolts (601)
on bearing frame (99).
20. Install bearing frame (99) with bolts
(600).
21. Install impeller key (32A). Install wear
ring (7X) in diffuser (5X).
22. Install last stage diffuser (5X) with
bushings (63X/63XR) into discharge
casing (1).
23. Install the last stage impeller (2X).
Check depth reading in accordance with
Figure 8 and Table 12.
NOTE
Replace the same number of new
interstage shims (73G) during assembly
that were removed during disassembly.
NOTE
IMPORTANT: Assemble any shims
found during disassembly in correct
sequence only if no sleeves or impellers
were replaced.
24. Install shims (73G), as necessary.
25. Install impeller key (32A) and interstage
sleeve (58).
26. Lubricate and install o-ring (89D) into
interstage casing (111).
27. Install wear ring (7X) and bushing (63)
in diffuser (5A) into interstage casing
(111). Check to make sure locking tab
engages the diffuser to keep from
rotating.
38
RS Series – Multi-Stage, Ring Section Pumps
February 2008
caution
While installing bearings, do NOT
unnecessarily hit bearings. If damage to
the bearings occurs, replace damaged
bearings with new bearings. Refer to
Section V, paragraph B.
53. Install new radial bearing (16) on shaft
(6).
54. Install bearing lockwasher (69) so that
tab of lockwasher (69) fits into keyway
on shaft (6).
55. Install bearing locknut (22) and tighten
against lockwasher (69). Crimp
lockwasher tab into slot provided on
outside of bearing locknut (22).
56. Secure bearing cap (35) onto bearing
frame (99) with bolts (601).
57. Rotate shaft (6) by hand to ensure
smooth rotation. Tighten nut (615) on
gland (17A).
58. Add grease to bearings through grease
zerks in bearing frame (99). Refer to this
section, paragraph B, Bearings, for
bearing maintenance.
59. Install tubing (408) to orifice assembly
with male tube connector (410) and
(411) bodies.
60. Install tubing (400) with male tube
connector (410) and (411) bodies. After
connecting tubing, inspect shaft for
concentricity.
61. Install plugs (422) for stuffing box, (423)
for gauge connector and (424) for the
casing drain.
62. Return pump to installation site. Install
pump on base and secure with bolts.
63. Install coupling key (46). Install coupling
half on pump shaft (6). Align coupling as
outlined in Section II, paragraph D,
Coupling, and reference Figure 5,
Coupling Alignment.
64. Install coupling guard.
65. Connect suction, discharge and gauge
lines. After connecting piping, check
once more for smooth rotation of shaft.
66. Open system valves.
1. 69. Unlock and reconnect the
electrical power supply to the driver.
Remove all tags. Start the pumping
unit in accordance with paragraph
C, Start-Up, of Section III,
Operation.
39
RS Series – Multi-Stage, Ring Section Pumps
February 2008
Figure 11. Sectional Assembly
RS-A Thru RS-E with optional
mechanical seals
40
RS Series – Multi-Stage, Ring Section Pumps
February 2008
41
Blank
RS Series – Multi-Stage, Ring Section Pumps
February 2008
Table 15. Recommended Spare Parts
Quantity
Item No.
1
2A
Impeller, First Stage
AR
2X
Impeller, Per Stage
1
6
1
7A
Wear Ring
AR
7B
Wear Ring
AR
7X
Wear Ring
1
14A
Shaft Sleeve
1
14X
Shaft Sleeve, Bushing
AR
14D
Spacer Sleeve, Suction End and/or Discharge End
AR
14E
Spacer Sleeve, Suction End and/or Discharge End
1
14G
Spacer Sleeve, Suction End
1
16
1
17A
2
18
Ball Bearing, Discharge End
1
22
Bearing Locknut
1
28
Washer
1
32A
Key, Impeller
1
32X
Key, Sleeve
1
46
Key, Coupling
AR
58
Interstage Sleeve
AR
63
Diffuser Bushing, Rulon
1
63Y
2
69
AR
73G
Shims, Interstage Sleeve
2
89X
O-Ring, Sleeve
AR
89D
O-Ring, Case
2
*89F
O-Ring, Bearing Cap
2
*89H
O-Ring, Bearing Gland
2
*89J
O-Ring, Bearing Cap O.B.
AR
89Y
O-Ring, Plugs & Fittings
1
90
Mechanical Seal, Suction End
1
*91
Mechanical Seal, Discharge End
176
Snap Ring
1
AR = As Required
* Options
Description
Shaft
Ball Bearing, Suction End
Gland
Sleeve Bearing
Bearing Lockwasher
42
RS Series – Multi-Stage, Ring Section Pumps
February 2008
Notes:
43
RS Series – Multi-Stage, Ring Section Pumps
I-280 ATEX, REV. 0
February 2008
February 2008
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