API MAXUM centrifugal pumps
API MAXUM
centrifugal pumps
Operating Instructions
I-400 ATEX REV.0
Inch Units
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:
API MAXUM 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 T1
The product described in this Declaration of Conformity complies with the Applicable European Directives
and relevant sections of the Applicable International Standards. The signature on this document
authorizes the distinctive European mark to be applied to the equipment described. A Technical
Construction File is available for inspection by designated bodies
Authorized Signature:
Date:
Important safety information is contained in the installation, operation and service manuals; read
and understand this information prior to installing or using this equipment
This Document applies only to the equipment described above and is invalid if not reproduced in its entirety
Carver API MAXUM Pumps
May 2009
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 _______________________
Carver API MAXUM Pumps
May 2009
NOTES ON INSPECTION AND REPAIRS
INSPECTION DATE
REPAIR TIME
REPAIRS
COST
REMARKS
Carver API MAXUM Pumps
May 2009
TABLE OF CONTENTS
Location/Description
Page
I.
General Information .............................................................................................................. 3
1. Preface ........................................................................................................................... 3
2. Safety.............................................................................................................................. 4
3. Transport and Interim Storage........................................................................................ 7
4. Equipment Description ................................................................................................... 7
5. Effects of Fluids .............................................................................................................. 9
6. Mechanical Seal ............................................................................................................. 9
7. Bearing Lubrication and Cooling .................................................................................... 10
8. Technical Data................................................................................................................ 11
9. Unpackaging................................................................................................................... 15
II.
Installation ............................................................................................................................. 16
1. Foundation and Mounting............................................................................................... 16
2. Grouting .......................................................................................................................... 16
3. Handling.......................................................................................................................... 18
4. Coupling.......................................................................................................................... 18
5. Piping.............................................................................................................................. 19
6. Auxiliary Connections ..................................................................................................... 19
III.
Operation .............................................................................................................................. 20
1. Method of Operation....................................................................................................... 20
2. Pre-Start Cautions .......................................................................................................... 20
3. Start-Up .......................................................................................................................... 20
4. Turbine Applications ....................................................................................................... 20
5. Minimum/Maximum Flow Calculation............................................................................. 21
6. Operating Checks........................................................................................................... 21
7. Stopping the Pump ......................................................................................................... 21
IV.
Troubleshooting .................................................................................................................... 22
V.
Maintenance and Repair ....................................................................................................... 25
1. Scheduled Maintenance ................................................................................................. 25
2. Bearings.......................................................................................................................... 25
3. Torque Values ................................................................................................................ 25
4. Disassembly and Assembly Preparations ...................................................................... 26
5. Parts Cleaning and Inspection........................................................................................ 27
6. Wear Ring Replacement ................................................................................................ 28
7. Pump Disassembly and Assembly ................................................................................. 30
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Carver API MAXUM Pumps
May 2009
LIST OF TABLES
Table
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Page
Fluid Temperature Limits............................................................................................................. 6
Oil Recommendations ................................................................................................................. 10
Bearing Cooling Flow Rates ........................................................................................................ 10
Estimated Noise Characteristics.................................................................................................. 11
Basic Design Data ....................................................................................................................... 13
Key Mechanical Data................................................................................................................... 13
Permissible Nozzle Loads ........................................................................................................... 14
Pumping Unit Troubleshooting .................................................................................................... 22
Recommended Torque Values.................................................................................................... 26
Recommended Tools .................................................................................................................. 26
Wear Ring Clearances ................................................................................................................ 29
Parts List ................................................................................................................................. 35
Recommended Spare Parts ........................................................................................................ 36
LIST OF FIGURES
Figure
1.
2.
3.
4.
5.
6.
7.
8.
9.
Page
Transportation of the Pump ......................................................................................................... 7
Transportation of Complete Unit.................................................................................................. 7
Stuffing Boxes.............................................................................................................................. 12
Grouting and Foundation Bolting................................................................................................. 17
Unit Leveling ................................................................................................................................ 17
Coupling Alignment ..................................................................................................................... 18
Adjusting Alignment..................................................................................................................... 18
Sectional Assembly, Bare Pump ................................................................................................. 33
Sectional Assembly, with Base.................................................................................................... 34
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Carver API MAXUM Pumps
May 2009
I. General Information
1.3 Personnel qualification and training
1. PREFACE
All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved. If the
personnel in question do not already possess the
necessary knowledge and skill, appropriate training
and instruction must be provided. If required the
operator may commission the manufacturer/supplier
to provide applicable training.
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.
These instructions must always be kept
close to the product's operating location or
directly with the product.
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 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
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).
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.
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.
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 13,
Recommended Spare Parts. Part numbers
correspond to Figures 8 and 9.
1.2 Disclaimer
1.6 Parts Ordering
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.
When ordering replacement parts, please specify:
•
Serial number of pump (located on nameplate)
•
Part name (located on parts list)
•
Quantity of parts needed
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
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Carver API MAXUM Pumps
May 2009
factory or company representative. Never return parts
to the factory without authorization from Carver Pump
Company.
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.
The output from a variable frequency drive (VFD) can
cause additional heating affects in the motor and so,
for pump sets with a VFD, the ATEX Certification for
the motor must state that it covers the situation where
electrical supply is from the VFD. This is particular
requirement still applies even if the VFD is in a
safe area.
2.4 Safety Awareness
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
2.1 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.
4
To ensure safe operation the roller
bearings must be replaced at 25000 hours of
service or when ever the mechanical seal is
inspected or serviced.
Carver API MAXUM Pumps
May 2009
The pump must have cooled down to ambient
temperature, pump pressure must have been
released and the pump must have been drained.
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.
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.
Pumps or pump units handling fluids injurious to
health must be decontaminated.
An example of ATEX equipment marking is shown
below. The actual classification of the pump will be
engraved on the nameplate.
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.
II 2 GD c IIC 135 ºC (T4)
Equipment Group
I = Mining
II = Non-mining
2.7 Unauthorized Modification and
Manufacture of Spare Parts
Category
2 or M2 = high level protection
3 = normal level of protection
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.
Gas and/or dust
G = Gas
D = Dust
c = Constructional safety
(in accordance with EN13463-5)
2.8 Unauthorized Modes of Operation
Gas Group (Equipment Category 2 only)
IIA – Propane (typical)
IIB – Ethylene (typical)
IIC – Hydrogen (typical)
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.
Maximum surface temperature (Temperature Class)
(see section 2.9.5)
2.9 Explosion Protection
2.9.3 Checking the Direction of Rotation
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.
2.9.1 Unit Fill
It is assumed that the system of suction and
discharge lines and thus the wetted pump internals
are completely filled with the fluid to be handled at all
times during pump operation, so that an explosive
atmosphere is prevented.
If the 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.
2.9.4 Pump Operating Mode
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.
If the operator cannot warrant this condition,
appropriate monitoring devices must be used.
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.
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Carver API MAXUM Pumps
May 2009
In this condition, there is a risk of the pump
casing taking on high surface temperatures after a
very short time, due to a rapid temperature rise in the
pumped fluid inside the pump. Additionally, the
resulting rapid pressure build-up inside the pump may
cause excessive stresses on the pump materials or
even bursting.
The minimum flows calculated in paragraph 5 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 and the fan inlet
flow must be unimpeded.
Table 1. Fluid Temperature Limits
Temperature class
to EN 13463-1:
T5
Temperature limit of
fluid handled
85 °C
T4
120 °C
T3
185 °C
T2
280 °C
T1
350 °C
Safety note:
The permissible operating temperature of the pump in
question is indicated on the data sheet. If the pump is
to be operated at a higher temperature, the data
sheet is missing or if the pump is part of a pool of
pumps, the maximum permissible operating
temperature must be enquired from the pump
manufacturer.
Based on an ambient temperature of 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
without auxiliary cooling should NOT exceed 400
degrees Fahrenheit (F).
Pumps of high temperature construction are provided
with cooled bearings for a unit operating temperature
range between 400 and 650 degrees F. Cooling water
is piped 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.
2.9.6 Maintenance
Only a pump unit which is properly serviced
and maintained in perfect technical condition will give
safe and reliable operation.
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.
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.
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.
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.
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Carver API MAXUM Pumps
May 2009
2.9.7 General Safety Instructions
1.
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.
2. 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.”
3. All circuits NOT known to be dead must be
considered live at all times.
4. 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 frame of 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.
If the pump / unit slips out of the suspension
arrangement, it may cause personal injury and
damage to property.
Fig. 1 Transport of the pump
Fig. 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.
3. Transport and Interim Storage
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.
3.1 Transport
4. Equipment Description
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.
The API Maxum is our process pump for handling
hydrocarbons in refining and process industry
applications. It is offered as a centerline mounted
unit. Hydraulic performance extends to 9,000 GPM
and 720 feet of head. The design is restricted as
noted below.
The following specific safety precautions
apply to the pumping unit:
1.
Do NOT exceed maximum
discharge pressure on discharge case.
The Maxum pump unit consists of a pump, base,
coupling, coupling guard and a driver unit. The driver is
usually an electric motor, but can be a steam turbine or
any other power conversion device that can provide the
7
Carver API MAXUM Pumps
May 2009
required horsepower at the proper RPM. Drivers other
than electric motors must be reviewed for compliance
with the applicable directives.
thrust bearing (18) is held in place by the bearing
locknut (22) and bearing lockwasher (69). The bearings
are oil lubricated. Either oil bath lubrication or an oil
mist system may be employed.
The Maxum pump is supplied with a volute that should
always be mounted solidly on an adequate bedplate.
No shims should be used under the feet of the casing.
Item 19 - Bearing Frame. The principal function of the
bearing frame (19) is to carry the loads from the liquid
end of the pump to the base and to transport power
from the power unit to the impeller. The bearing frame
(19) has a radial bearing (16) located in the front end of
the house (nearest to the volute) and a pair of
back-to-back mounted angular contact thrust bearings
(18) in the rear of the frame. This bearing frame (19) is
designed to be oil lubricated, which can be
accomplished in several ways.
The Maxum pump is designed as a back pullout unit.
Therefore it should always be used with a spacer
coupling. The spacer width should permit the entire
rotating assembly to be removed from the casing.
Normally the casing should be left in place on the base
and remain connected to the suction and discharge
piping.
The bare pump consists of following major parts and
options. Please refer to figure 1.A, the sectional
assembly drawing for the location of parts identified by
item numbers.
Item 1 - Casing. The casing (1) houses the impeller
(2) and wear ring (7) and consists of the suction inlet,
discharge volute, and discharge nozzle. The backcover
(11) is held in place between the casing (1) and the
frame (19). The casing (1) is fastened to the backhead
(11) with studs (631) and nuts (616) with lockwashers
(655).
Item 2 - Impeller. Maxum pumps are equipped with
enclosed impellers. The impeller (2) is keyed to the
shaft (6) by the impeller key (32) and is locked in place
by the impeller nut (24).
The first method involves the use of a sight glass
automatic oiler. The frame is designed so that it can be
used with a sight glass automatic oiler. The sight glass
maintains the oil level high enough on the higher of the
two bearings so that the bearings themselves provide
the motivation for the oil to be moved through the races
of both bearings.
A second method is to provide an oil flinger which
mounts on the shaft and literally flings the oil
throughout the bearing frame. An oil view gauge
indicator is usually used with this system to make sure
that the oil level within the frame can be observed and
maintained at the proper level.
A third method is the oil mist system. All Maxum pumps
are equipped so that they can be used or can be
converted to oil mist units without any field machining-.
Item 6 - Shaft. The shaft of the Maxum pump is
designed for maximum deflection of 0.002 inch at the
face of the mechanical seal. The shaft is also designed
to provide stabilization to the rotor system when pump
operates away from the best efficiency point. A
coupling connects the pump shaft (6) to the driver
shaft. The coupling key (46) holds the coupling in
place, causing it to rotate with the shaft (6).
Oil Mist system for ATEX applications require a
user installed system of safety controls or alarms to
insure that the pump is shut down in event of an oil mist
failure.
Item 11 - Backcover. The backcover (11) is fastened
to the casing (1) with studs (631), nuts (616), and
lockwashers (655). The backcover (11) houses wear
ring (7X). The backcover (11) is positioned in the volute
bore by gasket (73C) or o-ring (89A). If gasket (73C) is
on pump, o-ring (89A) is used only during pump
testing.
The bearing frame (19) is attached to the backcover
(11) with stud (632), Nut (617) and lockwashers (656).
The backcover (11) contains forcing screws (610) to
aid in loosening the backcover (11) from casing (1).
Item 16 and 18 - Bearings. A deep-groove
Conrad-type, C3 internal fit radial bearing (16) and
light preload, back-to-back mounted thrust bearings
(18) are housed in the bearing frame (19). The thrust
bearings (18) will be designated as 7000 or 8000
series. Thrust bearings (18) designated in the 7000
series will be duplex 40 degree angular contact
bearings. Thrust bearings (18) designated in the 8000
series will have 40 and 15 degree angular contact. The
8
In addition to the oil lube system, the power frame
contains the shaft oil seals or oil containment system.
The Maxum pump bearing frame can be equipped with
a magnetic oil seal assembly which operates as a
mechanical seal when running and becomes a static
seal when shutdown or stopped. It is necessary to use
an expansion chamber with the magnetic seal device.
The Maxum pump can also be furnished with a number
of labyrinth seal assemblies being offered on the
market.
Baseplate. A groutable baseplate is designed to
provide adequate support for the pump and motor so
pump can be operated without baseplate deflection,
excessive vibration, or resonance. The casing (1) is
bolted to the baseplate with capscrews. Grouting of this
type of baseplate is required by Carver Pump
Company.
Carver API MAXUM Pumps
May 2009
increase in specific gravity will raise the discharge
pressure and is dangerous. as it might overload the
pump's driver, or exceed the pump casing allowable
pressure.
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. Mechanical Seal
Net positive suction head (NPSH).
Any liquid, hot or cold, must be pushed into the impeller
of the pump by some absolute pressure, such as the
atmosphere or the vessel pressure from which the
pump takes its action.
The head in feet of liquid necessary to maintain the
required flow into the pump is called the Net Positive
Suction Head (NPSH). This value is measured above
the vapor pressure of the liquid at the pumping
temperature.
NPSH is commonly expressed in two ways: the NPSH
required by the pump, and shown on the pump curve,
is the head needed to cover the losses in the pump
suction and the energy required to enable the liquid to
climb onboard the leading edge of the impeller vane.
The NPSH available is that inherent in the system,
taking into account friction losses in suction piping,
valves, fittings, etc. In all cases, the NPSH available,
measured above vapor pressure, must exceed the
NPSH required in order to push the liquid into the
pump.
Changing Pump Speed.
Changing the speed of a centrifugal pump affects the
capacity, total head, NPSH required and the brake
horsepower. In general the capacity will vary in a direct
ratio with the speed, whereas the total head and NPSH
required will vary as the ratio of the speed squared.
The brake horsepower will vary as the ratio of the
speed cubed.
Effects of Viscosity.
The pump is designed to deliver rated capacity at rated
head for a liquid with a particular viscosity. When pump
is handling heavy viscous liquid, the viscosity of the
liquid must allow it to be pumped easily. The liquid may
have to be heated prior to starting the pump. When
contemplating operation at some viscosity other than
that for which the pump was originally designed, check
with Carver Pump Company.
Effects of Specific Gravity.
The capacity and total head in feet of liquid developed
by a centrifugal pump are fixed for every point on the
curve and are always the same for the same speed.
Neither capacity nor total head will be affected by a
change in the specific gravity of the liquid pumped.
However, since the discharge pressure in psi (pounds
per square inch) and the brake horsepower required to
drive the pump are functions of the specific gravity of
the liquid, both will be affected in direct proportion by
any change in specific gravity. Therefore, an in
9
Cartridge seals are to be used. Complete cartridge
seal instructions should be obtained from the seal
manufacturer.
The standard stuffing box dimensions are shown in
Figure 3.
Carver API MAXUM Pumps
May 2009
7. Bearing Lubrication and Cooling
Fill constant level oiler reservoir and allow it to fill
bearing frame (19). To avoid adding too much oil,
never finish filling oil in bearing frame (19) through plug
at top of the bearing frame (19). It may take repeated
fittings of constant level oiler reservoir to fill oil well. Use
constant level oiler's glass sight to check oil level in
bearing frame (19).
CAUTION
Operation of the unit without proper lubrication
can result in overheating of the bearings, bearing
failures, pump seizures and actual breakup of the
equipment, exposing operating personnel to injury.
See Section V, Scheduled Maintenance for further
instructions
The API Maxum pump comes equipped with
appropriate connections for the installation of an oil
mist system by the customer if oil mist lubrication is
desired. Oil mist lubrication provides the greatest
protection against contamination by dirt and water.
Pumps are shipped with the bearing frames empty of
oil. ISO Grade 68 mineral oils are recommended for
proper lubrication of the pump. Refer to table 2 for
specific recommended oil types.
The top port of the bearing frame (19) remains plugged
for oil mist lubricated bearings. The plug in the bottom
of the power frame should be removed so that
condensed oil vapor can be drained and/or removed
from the bearing frame (19).
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 (100 PSIG MAX.)
Temperature Range
Flow Rate
-20 degrees to 400 degrees F
Oil Lube – Air
400 degrees to 650 degrees F
Oil Lube - Water-3 GPM
10
Carver API MAXUM Pumps
May 2009
8. Technical Data
Specifications and operating limits should be recorded on the Service Record Page located in the front matter of this
manual. Record the necessary information upon receipt of the pumping unit.
Table 4. Estimated Noise Characteristecs
11
Carver API MAXUM Pumps
May 2009
Seal Chamber Dimensions
Max Gland
Diameter
d4
Total
Length
C
Clear
Length
E
Box
Depth
C-E
Stud Size
d2
Stud
Circle
d3
1.575
3.543
4.921
6.625
6.500
4.000
2.500
1/2”-13
4
1.968
3.937
5.512
6.625
6.900
4.400
2.500
5/8”-11
5
2.362
4.725
6.219
7.750
6.900
4.400
2.500
5/8”-11
6
2.756
5.118
6.693
7.750
6.900
4.400
2.500
5/8”-11
8
3.543
6.219
8.070
10.875
7.290
4.790
2.500
3/4”-10
Bearing
Frame
Number
Shaft
Diameter
d1
Box Bore
3
Figure 3. Stuffing Boxes Dimensions
12
(USC)
Carver API MAXUM Pumps
May 2009
Table 5. Basic Design Features
Pump Size
Bearing
Frame
Max Speed
(RPM)
1st Critical
Speed (RPM)
Casing Design
Discharge
Shaft
Stiffness
L3/D4
Shaft Deflection @ 20% BEP
Volute(s)
@ Seal (in.)
@ Impeller (in.)
WK2 @ Max.
Impeller Dia.
AA- 1½ x 1 x 6
3
3500
13068
Centerline
Single
0.0002
0.0009
183.3
9.500
AB - 2 x 1½ x 6
3
3500
12098
Centerline
Single
0.0006
0.0019
183.3
10.45
AC- 3 x 1½ x 6
3
3500
11317
Centerline
Single
0.0006
0.0021
183.3
11.40
AD - 3 x 2 x 6
3
3500
12098
Centerline
Single
0.0011
0.0036
183.3
10.45
AE - 4 x 3 x 6
3
3500
10122
Centerline
Single
0.0021
0.0070
183.3
15.20
BA - 1½ x 1 x 8
4
3500
12262
Centerline
Single
0.0003
0.0011
83.6
34.31
BB - 2 x 1½ x 8
4
3500
10754
Centerline
Single
0.0005
0.0017
83.6
41.42
BC - 3 x 1½ x 8
4
3500
11193
Centerline
Single
0.0006
0.0022
83.6
39.05
BD - 3 x 2 x 8
4
3500
11193
Centerline
Single
0.0008
0.0029
83.6
39.05
BE – 4 x 3 x 8
4
3500
10363
Centerline
Dual
0.0004
0.0014
83.6
43.79
BF - 6 x 4 x 8
4
3500
10012
Centerline
Dual
0.0005
0.0017
83.6
46.16
CA – 2 x 1½ x 10
5
3500
13192
Centerline
Single
0.0002
0.0012
42.3
92.29
CB - 3 x 1½ x 10
5
3500
13192
Centerline
Single
0.0002
0.0011
42.3
92.29
CC - 3 x 2 x 10
5
3500
12773
Centerline
Single
0.0004
0.0022
42.3
92.29
CD - 4 x 3 x 10
5
3500
12042
Centerline
Single
0.0006
0.0032
42.3
108.6
CE - 6 x 4 x 10
5
3500
10429
Centerline
Dual
0.0002
0.0012
42.3
141.3
CF - 6 x 6 x 10
5
1750
8288
Centerline
Dual
0.0002
0.0010
42.3
141.3
CG - 8 x 6 x 10
5
1750
10020
Centerline
Dual
0.0002
0.0012
42.3
152.2
DA - 2 x 1½ x 13
6
3500
11224
Centerline
Dual
0.0003
0.0019
35.0
209.6
DB - 3 x 2 x 13
6
3500
8511
Centerline
Dual
0.0005
0.0026
35.0
201.8
DC - 4 x 3 x 13
6
3500
9515
Centerline
Dual
0.0009
0.0054
35.0
263.8
DD - 6 x 4 x 13
6
3500
9098
Centerline
Dual
0.0002
0.0013
35.0
287.1
DE - 6 x 6 x 13
6
1750
8306
Centerline
Dual
0.0002
0.0010
35.0
310.3
DF - 8 x 6 x 13
6
1750
7130
Centerline
Dual
0.0003
0.0016
35.0
310.3
DG - 10 x 8 x 13
6
1750
6728
Centerline
Dual
0.0004
0.0023
35.0
418.9
DH – 12 x 10 x 13
6
1750
6215
Centerline
Dual
0.0008
0.0043
35.0
418.9
ED- 6 x 4 x 16
1750
8223
Centerline
Dual
0.0001
0.0005
19.5
563.6
EA- 8 x 6 x 16
8
8
1750
7885
Centerline
Dual
0.0001
0.0011
19.5
647.3
EB - 10 x 8 x 16
8
1750
9053
Centerline
Dual
0.0001
0.0012
19.5
595.9
EE - 12 x 10 x 16
8
1750
7840
Centerline
Dual
0.0001
0.0006
19.5
722.6
EC - 14 x 12 x 16
8
1750
7752
Centerline
Dual
0.0004
0.0035
19.5
849.4
FA - 8 x 6 x 20
8
1750
7478
Centerline
Dual
0.0001
0.0012
19.5
1232.0
FB - 10 x 8 x 20
8
1750
7288
Centerline
Dual
0.0002
0.0018
19.5
1495.0
FC - 12 x 10 x 20
8
1750
6714
Centerline
Dual
0.0003
0.0026
19.5
1859.0
FD - 14 x 12 x 20
8
1750
6075
Centerline
Dual
0.0005
0.0039
19.5
2298.0
Table 6. Key Mechanical Data
Bearing Frame
Item
3
4
5
6
@ 3500 RPM
150
240
550
550
-
@ 1750 RPM
75
120
275
275
1500
@ 1150 RPM
50
80
180
180
1000
radial bearing
6211
6211
6213
6213
6219
thrust bearing
7311
7311
7313
7313
7318
13.198
Max power (BHP)
Bearing type -
Lubrication method (standard)
L10 bearing life (hrs) -
8
Oil - ISO Grade 68
radial
50,000
thrust
50,000
Radial to thrust bearing centerline (in.)
5.192
5.192
8.939
8.939
Shaft diameter (in.)
@ coupling
1.375
1.375
2.000
2.000
3.000
@ impeller hub (standard ext.)
1.000
1.375
1.375
1.875
2.375
Coupling Key –
@ radial bearing
2.166
2.166
2.559
2.559
3.741
@ thrust bearing
2.166
2.166
2.559
2.559
3.544
@ seal box
3.543
1.575
1.968
2.362
2.500
width (in.)
0.313
0.313
0.500
0.500
0.750
length (in.)
2.625
2.625
2.000
2.000
5.000
13
Carver API MAXUM Pumps
May 2009
Table 7.
Permissible Nozzle Loads
Suction
Pump Size
Mx
Discharge
Fx
Fy
Fz
Fx
Fy
Fz
AA- 1½ x 1 x 6
200
160
130
340
My
170
Mz
260
160
130
200
Mx
340
My
170
Mz
200
AB - 2 x 1½ x 6
200
160
130
340
170
260
160
130
200
340
170
200
AC- 3 x 1½ x 6
300
240
200
700
350
530
160
130
200
340
170
200
AD - 3 x 2 x 6
300
240
200
700
350
530
160
130
200
340
170
200
AE - 4 x 3 x 6
400
320
260
980
500
740
240
200
300
700
350
530
BA - 1½ x 1 x 8
200
160
130
340
170
260
160
130
200
340
170
200
BB - 2 x 1½ x 8
200
160
130
340
170
260
160
130
200
340
170
200
BC - 3 x 1½ x 8
300
240
200
700
350
530
160
130
200
340
170
200
BD - 3 x 2 x 8
300
240
200
700
350
530
160
130
200
340
170
200
BE – 4 x 3 x 8
400
320
260
980
500
740
240
200
300
700
350
530
BF - 6 x 4 x 8
700
560
460
1700
870
1,300
320
260
400
980
500
740
CA – 2 x 1½ x 10
200
160
130
340
170
260
160
130
200
340
170
200
CB - 3 x 1½ x 10
300
240
200
700
350
530
160
130
200
340
170
200
CC - 3 x 2 x 10
300
240
200
700
350
530
160
130
200
340
170
200
CD - 4 x 3 x 10
400
320
260
980
500
740
240
200
300
700
350
530
CE - 6 x 4 x 10
700
560
460
1700
870
1,300
320
260
400
980
500
740
CF - 6 x 6 x 10
700
560
460
1700
870
1,300
560
460
700
1700
870
1300
CG - 8 x 6 x 10
1100
850
700
2600
1,300
1,900
560
460
700
1700
870
1300
DA - 2 x 1½ x 13
200
160
130
340
170
260
160
130
200
340
170
200
DB - 3 x 2 x 13
300
240
200
700
350
530
160
130
200
340
170
200
DC - 4 x 3 x 13
400
320
260
980
500
740
240
200
300
700
350
530
DD - 6 x 4 x 13
700
560
460
1700
870
1,300
320
260
400
980
500
740
DE - 6 x 6 x 13
700
560
460
1700
870
1,300
560
460
700
1700
870
1300
DF - 8 x 6 x 13
1100
850
700
2600
1,300
1,900
560
460
700
1700
870
1300
DG - 10 x 8 x 13
1500
1200
1000
3700
1800
2800
850
700
1100
2600
1,300
1,900
DH – 12 x 10 x 13
2800
1800
1500
1200
4500
2200
3400
1200
1000
1500
3700
1800
ED- 6 x 4 x 16
700
560
460
1700
870
1,300
320
260
400
980
500
740
EA- 8 x 6 x 16
1100
850
700
2600
1,300
1,900
560
460
700
1700
870
1300
EB - 10 x 8 x 16
1500
1200
1000
3700
1800
2800
850
700
1100
2600
1,300
1,900
EE - 12 x 10 x 16
1800
1500
1200
4500
2200
3400
1200
1000
1500
3700
1800
2800
EC - 14 x 12 x 16
2000
1600
1300
4700
2300
6300
1,500
1200
1800
4500
2200
3400
FA - 8 x 6 x 20
1100
850
700
2600
1,300
1,900
560
460
700
1700
870
1300
FB - 10 x 8 x 20
1500
1200
1000
3700
1800
2,870
850
700
1100
2600
1,300
1,900
FC - 12 x 10 x 20
1800
1500
1200
4500
2200
3400
1200
1000
1500
3700
1800
2800
FD - 14 x 12 x 20
2000
1600
1300
4700
2300
6300
1,500
1200
1800
4500
2200
3400
14
Carver API MAXUM Pumps
May 2009
9. 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 damages or shortages
to the carrier’s agent or factory. Claims that are made
at a later time cannot be accepted.
A pump which is made of iron or steel that
sits in extreme heat, high humidity, or full or
partially full water over 30 days will rust and
will most likely seize. If the pump rusts
and/or seizes, a complete overhaul and
repair may be necessary to refurbish the
pump.
9.1 Packaging
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 nonwarranty restoration and/or non-warranty
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.
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.
9.4. Pump Protection during
Prolonged Shutdown
9.2. Inspection upon Arrival
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:
9.3. 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.
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.
• The plant (or department) is shut down for
2.
3.
4.
5.
periods of longer than 30 days.
15
Shut down the pumping unit in
accordance with the Operating
Procedures outlined in this manual.
Shut off system suction and discharge
valves.
Drain the unit.
Fill unit with mineral oil or suitable noncorrosive protectant that is compatible
with the system.
Provide pump and motor with a
protective cover.
Carver API MAXUM Pumps
May 2009
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 4, 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 6 and Figure 7 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 4,
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 5, Unit Leveling. Place supports directly
under the part of the base plate, which carries
the greatest weight. Space the supports closely
16
Carver API MAXUM Pumps
May 2009
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 4. Grouting and Foundation Bolting
Figure 5. Unit Leveling
17
TOP OF FOUNDATION LEFT
ROUGH - CLEAN AND WET
DOWN
Carver API MAXUM Pumps
May 2009
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 7, 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 6,
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 6. Coupling Alignment
shims
Figure 7. Adjusting Alignment
18
Carver API MAXUM Pumps
May 2009
3. Shim all mounting feet on the driver until all
four readings are identical (0.005) maximum
Total Indicator Runout (TIR).
If necessary, the coupling should be realigned
after installing piping. Realign, if necessary, by
adjusting the driver end. Refer to Figure 7.
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.
6. Auxiliary Piping Connections and
Gauges
Any auxiliary piping connections and gauges
should be installed now. Refer to vendor seal
drawing for seal line connections to the seal
cartridge.
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.
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.
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.
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.
19
Carver API MAXUM Pumps
May 2009
III. Operation
8. If necessary, turn on cooling lines to
check for sufficient flow. Refer to Table
3 for minimum cooling flow rates.
1. Method of Operation
Pumped fluid enters suction and passes into the
impeller, which propels the fluid into the
discharge case and finally into discharge piping.
3. Start-Up
2. Pre-Start Cautions
Before starting the pumping unit, refer to the
safety precautions in Section I. Refer to 5.
below for minimum flow rates.
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 5. below for
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 the pump and driver 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.
6. Dry running may result in pump
seizure or mechanical seal failure.
Proceed as follows to start the pumping
unit:
1. Completely open system valve in
suction line to pump and fill with fluid.
2. Partially 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.)
7. Pumps are shipped with no oil in the
bearing frame. Adequate lubrication with
ISO Grade 68 oil is essential at all
times. Refer to Table 2, Oil
Recommendations, for specific oil types.
Turn on oil mist system*, wait for proper
oil quantity and check monitoring
system.
4. Turbine Applications
For turbine applications, consult your local
distributor or a representative from Carver Pump
Company.
20
Carver API MAXUM Pumps
May 2009
5. Minimum/Maximum Flow Calculation.
3. If unit is equipped with seal cooling lines, check
for adequate lubricating liquid flow to the seal.
4. Check that pump is operating within design
criteria and perimeters.
5. Check and record bearing temperature. It
should not exceed 185 degrees F. Both radial and
thrust bearing temperatures should be measured and
recorded at a minimum of 15 minute intervals until
bearing temperatures stabilize. Stabilization of
bearing temperature can be defined as the results of
three consecutive readings at approximately 15
minute intervals with no temperature rise.
6. Check and record amp draw of the driver.
7. If unit is equipped with a constant level oiler,
check oil level in the constant level oiler and refill as
required.
Unless specified otherwise in the characteristic curves
or on the data sheets, the following applies:
Qmin
Qmin
Qmax
Qmax
Qopt
= 0.1 x Qopt for short operation
= 0.3 x Qopt for continuous operation
= 1.1 x Qopt for 2-pole operation
= 1.25 x Qopt for 4-pole operation
= optimum efficiency
The data above refers to water and water-like liquids.
However, if the physical properties of the fluids
handled are different from water, the calculation
formula below must be used to check if an additional
heat build-up may lead to a dangerous temperature
increase at the pump surface. If necessary, the
minimum flow must be increased.
7. Stopping the Pump
To=Tf+ΔT
1. Begin to partially close discharge valve.
2. Tag out and lock power to driver according to
OSHA Standard 1910.147 or applicable local laws
and regulations.
3. Completely close discharge and suction valves.
4. If unit is equipped with seal cooling lines, turn
off external cooling water line to seal. For information
regarding seal circulation refer to "mechanical seal*"
appendix.
g*H
ΔT =
*(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 T Temperature difference
[J / kg K]
[m/s_]
[m]
[°C]
[°C]
[ -]
[°C]
6. Operating Checks
When pump is handling hazardous fluid,
extreme care must be taken to ensure safety of
personnel when attempting to drain pump. Suitable
protection devices should be used and/or protective
clothing should be worn.
Remove casing plug to drain casing. Drain all piping if
there is a possibility of liquid freezing. Provide pump
and driver with a protective cover.
1. Check for undue vibration or noise. If any occurs
and does not stop within a short period of time, turn
off the pump. For determination of the cause and its
remedy refer to "Troubleshooting" in section V or
consult a Carver Pump Company representative.
2. Check mechanical seals for leakage.
21
Carver API MAXUM Pumps
May 2009
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 8, Pumping Unit Troubleshooting, to
eliminate the most common causes of those
problems, or contact a representative from
Carver Pump Company.
Table 8. Pumping Unit Troubleshooting
Symptom
Pump does not deliver
rated capacity
Immediate Action
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. Motor Running on two
phases only
1.replace defective fuse
2. check electrical cable
connections
9. Excessive wear of internal
parts.
1. Disassemble pump and
replace worn parts.
Leakage at case joints.
1. Stop driver.
1. O-rings damaged.
1. Replace o-rings
Bearings run hot.
1. Stop driver.
1. Pump and driver shafts
are misaligned.
1. Check coupling alignment.
2. Check pipe strain.
2. Piping causes pump to
“warp”.
22
1. Ensure piping transmits
no stress to pump. Alter
piping layout, if
necessary. Realign
pump and driver shafts.
Carver API MAXUM Pumps
May 2009
Table 8. Pumping Unit Troubleshooting (CONT.)
Symptom
Pump discharge pressure
excessive.
Immediate Action
1. Stop driver.
Probably Cause
Corrective Action
3. Unsuitable oil.
1. Check for incorrect oil.
4. Over oiled bearings.
1. Remove excess oil.
5. Insufficient oil to bearings.
1. Add 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. Trim one or more
impellers.
c. Install more powerful
driver. Consult Carver Pump
Company specifying exact
operating conditions.
23
Carver API MAXUM Pumps
May 2009
Table 8. 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.
24
Carver API MAXUM Pumps
May 2009
V. Maintenance and Repair
1. Scheduled Maintenance
•
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.
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.
-
Replace roller bearings.
Inspect casings for corrosion, erosion or
other damage. 3mm limit of metal loss in
casing and backhead (Items 1 and 11).
25000 Hours
Parts marked with * are options or vary by pump
or bearing frame size.
2. Bearings
Regular inspection and service are essential for
safe operation of the pump in ATEX applications.
The thrust bearings are installed back-to-back.
Always replace the roller bearings when
disassembling unit for seal service.
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. If equipped with a constant level oiler,
check oil level in the constant level oiler and refill
as required. Insure proper oil mist if applicable.
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.
Weekly Inspection:
•
Check power (amps) readings.
•
Check pump discharge pressure. Prescribed
operating discharge pressure should never drop
below 90 percent of design point pressure.
•
Check vibration on pump and driver bearings.
Vibration should NOT exceed 1.5 overall
displacement (unfiltered) peak to peak mils
(0.001”) at 3600 RPM and 3.0 overall
displacement (unfiltered) peak to peak mils
(0.001”) at 1750 RPM.
To drain old oil from bearing frames, remove pipe
plug (420) at the bottom of the bearing frame (19).
Add oil to bearing frame (19) through breather vent
(45) until oil is at the center of the bullseye sight
(143). Use bullseye sight (143) to check oil level in
bearing frame (19). Refer to Section I, paragraph 7,
Oil Lube Recommendations. Carver recommends
changing the oil every 4,000 service hours under
normal conditions.
Monthly Inspection:
•
Check coupling alignment.
•
If necessary, grease coupling. Do NOT over
grease.
•
Check foundation bolts.
Refer to Table 9, Recommended Torque Values.
Clean and properly lubricate threads and bearing face
of the fastener to obtain the proper fastener loading
from these torque values. Fasteners should be
tightened evenly and in stages. Refer to your torque
wrench manual for the proper use of your wrench.
3. Torque Values
Semi-annual Inspection:
•
Grease bearings or change oil. Do NOT over
grease or add excess oil.
•
Check coupling alignment due to settling of
foundation.
The Impeller Nut is to have 30 ft-lbs torque while
holding the coupling end of the shaft.
25
Carver API MAXUM Pumps
May 2009
Table 9. 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
5/8-11 UNC
65
3/4-10 UNC
110
7/8-9 UNC
150
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 clean, flat surface.
4. Disassembly and Assembly
Preparations
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.
While assembling the pumping unit, Carver Pump
Company recommends that the following parts be
replaced with new:
NOTE
•
•
•
•
•
To avoid damage to o-rings, check to make
sure all parts are free of sharp edges or
burrs.
Close suction and/or discharge valves. The pump
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. In such instances, rust
solvent may be used and suitable extracting tools
applied wherever possible. Do NOT use force under
any circumstances. Refer to Table 10, Recommended
O-rings / gaskets
Shims
Bearings
Grease seals
Mechanical seals
Factory Authorized parts must be used to safely
maintain your CARVER Pump.
Table 10. Recommended Tools
Tools
Materials
Testing Equipment
Spanner wrench
Oil
Coupling alignment gauges
Rawhide or wood mallet
O-ring Lubricant
Volt-Amp Meter
Wooden wedge
Allen wrench set
Socket, open, & box wrench set
Vice grips
Torque Wrench
Bearing Heater
26
Carver API MAXUM Pumps
May 2009
Prepare the pumping unit for disassembly using the
following list:
1.
5. Parts Cleaning and Inspection
NOTE
Read this entire section and review the
applicable sectional assembly drawing and
parts list before disassembling the pump.
Mark or number each component while
dismantling according to sequence. The
individual components should be unscrewed
or removed.
During disassembly of the pump, individual parts
should be cleaned and inspected as follows:
Before attempting to disassemble the pump,
the electrical power supply to the driver must
be locked and tagged in the “OFF” position
to prevent injury or death to personnel
servicing the pump.
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.
Properly decontaminate pump and piping
before disconnecting unit. Applicable hazardous
material procedures must be followed.
3.
Inspect mechanical seals. Repair or replace
mechanical seals that are extremely worn or
damaged.
3. Disconnect suction, discharge, and gauge
lines. Disconnect auxiliary connections, as
applicable.
4.
Inspect impeller for pitting, erosion, or
clogged vanes. Replace an impeller that is
damaged. If a new impeller is installed,
check to make sure that it is balanced and of
the correct trim.
5.
Inspect casing and backhead for pitting,
corrosion and erosion. The maximum
allowable depth is 1/8” (3mm).
6.
This pump is equipped with metal wear
rings. These are available as “under-size”
parts. Inspect wear ring clearance for each
stage as follows:
2.
Stop the pumping unit.
4. Drain casing by removing pipe plug (422)*. If
necessary, flush pump to remove corrosive or
toxic pumpage. Reinstall pipe plug (422) in casing
(1) when fluid has completely drained.
5. Drain oil from bearing frame (19). If a constant
level oiler (143) provides lubrication for bearings,
drain oil from the bearing frame by removing pipe
plug (420) at bottom of bearing frame (19). If
bearings are oil mist lubricated, drainage of
bearing frame (19) is continuous.
6.
a.
b.
Remove coupling guard. Uncouple the pump
from the driver.
c.
Use of a hoist with adequate capacity is
recommended for removing the pump from
the base. See Section I.3.
6. Remove the bolts that hold the pump to
the base. Remove the pump from the base
and take to a suitable work area.
d.
27
Measure outside diameters of impeller
hubs in three places.
Measure the inside diameters of
corresponding wear rings in three
places.
Corresponding differences between
high readings of inside diameters of
wear rings and low readings of
outside diameters of impellers. Refer
to Table 11 for specified clearance of
wear rings. Wear ring should be
renewed when the measured
clearance is twice that given in table
11.
If wear ring replacement is required,
replace wear rings as described in
paragraph 6 of this section.
Carver API MAXUM Pumps
May 2009
8. Mount the casing (1) with new wear ring (7)
installed in a lathe. Indicate female rabbet to within
0.002 TIR maximum.
6. Wear Ring Replacement
NOTE
Note
Refer to Section I, paragraph 2, Safety
Precautions, before disassembling
pump.
When replacing wear ring with the standard wear ring,
(part number beginning with "00") machining in step 9
is not required. When replacing wear ring with the
undersize wear ring (part number beginning with "US" )
machining in step 9 is required.
9. If replacing with an undersize wear ring, bore wear
ring (7) to within the specified tolerance listed in table
11 over the recorded size of the outside diameter of the
front impeller wearing surface.
10. Reinstall casing (1) on base and secure with
fastener. Reconnect suction and discharge piping.
When pump is handling hazardous fluid,
extreme care must be taken to ensure safety of
personnel when attempting to drain pump.
Suitable protection devices should be used and/or
protective clothing should be worn.
6.2 Backcover Wear Ring (7X) .
The API Maxum pump has a replaceable wear ring (7)
inserted in the casing (1) and a replaceable wear ring
(7X) inserted in the backcover (11).
To replace the wear ring (7X) in the backcover (11)
follow these steps:
1. If pump is not disassembled, disassemble pump
according to section V, paragraph 7, steps 1 through 4
to remove backcover (11).
2. Remove setscrews (667) from wear ring (7X).
Remove the wear ring (7X) from the backcover (11).
This can best be accomplished on a lathe. Take this
work to a machine shop.
3. Press the new wear ring (7X) into backcover
(11). The beveled edge of the wear ring (7X) is installed
towards the impeller wearing surface.
4. Drill and tap two holes 180 degrees apart along
edge of each wear ring (7X). Secure new wear ring
(7X) to backcover (11) by inserting setscrews (667) into
these holes.
5. Place impeller (2) on an arbor and mount
between centers in a lathe or a grinder. Indicate back of
impeller hub to within 0.002 TIR maximum to be sure
the arbor and impeller are running square.
6. Turn the wear ring surface of impeller (2) until a
63 RMS or better finish is obtained.
7. Measure the outside diameter of the back
impeller wearing surface and record this value. See
measurement instructions in Section V paragraph 5.
8. Mount the backcover (11) with new wear ring (7X)
installed in a lathe. Indicate male rabbet to within 0.002
TIR maximum.
The wear ring clearances will increase with wear.
Internal leakage will result and pump performance will
decrease. The allowable clearance and method of
measurement is described in paragraph 5.6 of the
precceding section.
6.1 Casing Wear Ring (7).
The casing (1) must be removed from the base to
replace the wear ring (7) in casing (1). To replace the
wear ring (7) in the casing (1) follow these steps:
1. Disconnect suction and discharge piping. Unbolt
casing (1) from base and take casing (1) and impeller
(2) to a work area with access to machine shop
equipment.
2. Remove setscrews (667) from wear ring (7).
Remove the wear ring (7) from the casing (1). This can
best be accomplished on a lathe. Take this work to a
machine shop.
3. Press the new wear ring (7) into casing (1). The
beveled edge of the wear ring (7) is installed away from
the impeller.
4. Drill and tap two holes 180 degrees apart along
edge of wear ring (7). Secure new wear ring (7) to
casing (1) by inserting setscrews (667) into these
holes.
5. Place impeller (2) on an arbor and mount
between centers in a lathe or a grinder. Indicate
impeller hub to within 0.002 TIR maximum to be sure
the arbor and impeller are running square.
6. Turn the wear ring surface of impeller (2) until a
63 RMS or better finish is obtained.
7. Measure the outside diameter of the front
impeller wearing and record this value. See
measurement instructions in Section V, paragraph 5
above.
NOTE
When replacing wear ring with the standard wear ring,
part number beginning with "00" machining in step 9 is
not required. When replacing wear ring with the
undersize wear ring, part number beginning with "US"
machining in step 9 is required.
9. If replacing with an undersize wear ring, bore wear
ring (7X) to within the specified tolerance listed in table
11 over the recorded size of the outside diameter of the
back impeller wearing surface.
10. Reassemble pump according to section V,
section 7.2.
28
Carver API MAXUM Pumps
May 2009
Table 11. Maximum Wear Ring Clearances
Factory Standard Diameteric
Clearance
Pump Size
Minimum
Maximum
AA- 1½ x 1 x 6
0.012
0.017
AB - 2 x 1½ x 6
0.015
0.020
AC- 3 x 1½ x 6
0.014
0.019
AD - 3 x 2 x 6
0.016
0.021
AE - 4 x 3 x 6
0.016
0.021
BA - 1½ x 1 x 8
0.012
0.017
BB - 2 x 1½ x 8
0.012
0.017
BC - 3 x 1½ x 8
0.014
0.019
BD - 3 x 2 x 8
0.016
0.021
BE – 4 x 3 x 8
0.017
0.022
BF - 6 x 4 x 8
0.017
0.022
CA – 2 x 1½ x 10
0.012
0.017
CB - 3 x 1½ x 10
0.015
0.020
CC - 3 x 2 x 10
0.016
0.021
CD - 4 x 3 x 10
0.017
0.022
CE - 6 x 4 x 10
0.018
0.023
CF - 6 x 6 x 10
0.018
0.023
CG - 8 x 6 x 10
0.019
0.024
DA - 2 x 1½ x 13
0.016
0.021
DB - 3 x 2 x 13
0.016
0.021
DC - 4 x 3 x 13
0.017
0.022
DD - 6 x 4 x 13
0.018
0.023
DE - 6 x 6 x 13
0.018
0.023
DF - 8 x 6 x 13
0.020
0.025
DG - 10 x 8 x 13
0.021
0.026
DH – 12 x 10 x 13
0.023
0.028
ED- 6 x 4 x 16
0.018
0.023
EA- 8 x 6 x 16
0.020
0.025
EB - 10 x 8 x 16
ED - 12 x 10 x 16
EC - 14 x 12 x 16
0.021
0.023
0.024
0.026
0.028
0.029
FA - 8 x 6 x 20
0.020
0.025
FB - 10 x 8 x 20
0.021
0.026
FC - 12 x 10 x 20
0.023
0.028
FD - 14 x 12 x 20
0.025
0.030
`
29
Carver API MAXUM Pumps
May 2009
7. Pump Disassembly and Assembly
4. For Cartridge seals, reinstall seal clip and
loosen setscrews hold the cartridge seal sleeve to
shaft (6). Remove bolts (600) holding backcover
(11) to bearing frame (19) and remove backcover.
Remove nut (615) and remove seal (90) from
backhead (11).
The instructions that follow are an aid for
properly trained personnel to service your
Carver Pump. These instructions refer to
Figures 8 and 9 as an example. If a specific
sectional assembly drawing exists for a
particular job then that drawing should be
referred to for service work.
NOTE
Refer to Mechanical Seal vendor instructions for
proper seal removal procedure.
Parts marked with * are options or vary by pump
or bearing frame size.
5. Remove capscrews (601) fastening bearing
cap (35) to bearing frame (19). Remove bearing
cap (35) and inboard magnetic seal or labyrinth
seal (47) from shaft (6). Remove gasket (73) from
between bearing cap (35) and bearing frame (19).
7.1 DISASSEMBLY
Read this entire section and study figures 8 and 9
before disassembling the pump.
NOTE
Handle inboard magnetic seal or labyrinth seal
(47) with care. Mishandling could damage faces
of magnetic seal or labyrinth seal (47).
Refer to Section I, paragraph 2, Safety
Precautions, before disassembling
pump.
6. If necessary, remove inboard magnetic
seal or labyrinth seal (47) from bearing cap (35).
If necessary, remove inboard magnetic seal
housing (311)* (if equipped) from bearing cap
(35).
NOTE
It is not normally necessary to remove the
inboard magnetic seal housing (311)*
When pump is handling hazardous fluid,
extreme care must be taken to ensure safety of
personnel when attempting to drain pump.
Suitable protection devices should be used and/or
protective clothing should be worn.
NOTE
7. Remove pump coupling halves and
coupling key (46).
The individual components should be
unscrewed or removed.
8. Remove nuts (603), lockwashers (651) and
washers (640), fastening bearing cap (37) and
fan guard (131) to bearing frame (19) and remove
guard. Loosen setscrews (668) and remove fan
(40) from shaft (6). Remove fan key (32F) from
shaft (6). Remove bearing cap (37) and outboard
magnetic seal or labyrinth seal (49) from shaft (6).
Use of a hoist with adequate capacity is
recommended for lifting. See Section I.3
for instructions.
1. Remove coupling guard (131) and disconnect
coupling halves. Remove coupling spacer
between coupling halves.
2. Remove nuts (616) and lockwashers (655)
from studs (631 & 631X) fastening casing (1) to
backhead (11). Use forcing screws (610) to
loosen rabbet fit of backhead (11) and casing (1).
Pull rotating element back from casing (1) and
take it to a suitable work area.
3. Remove impeller nut (24) and washer (28).
Pull impeller (2) from shaft (6).
9. Remove o-ring (89-C) from bearing frame
(19).
Handle outboard magnetic seal or labyrinth seal
(49) with care. Mishandling could damage faces
of magnetic seal or labyrinth seal (49).
10. Remove outboard magnetic seal or
labyrinth seal (49) from bearing cap (37). If
necessary, remove outboard magnetic seal
30
Carver API MAXUM Pumps
May 2009
housing (310)* (if equipped) from bearing cap
(43).
NOTE
It is not normally necessary to remove the
outboard magnetic seal housing (310)*
After 25000 Hours of service replace the
roller bearings.
1. If removed, press thrust bearings (18) on
shaft (6). A bearing heater is recommended for
installation. Secure thrust bearing (18) with
bearing lockwasher (69) and bearing locknut (22).
Crimp tang of lockwasher (69) in groove provided
in bearing locknut (22).
2. If removed, press radial bearing (16) on
shaft (6). A bearing heater is recommended for
installation.
3. Install shaft (6) in bearing frame (19).
4. Install new o-ring (89C) in groove provided
around outboard end of bearing frame (19).
5. If removed, press outboard magnetic seal
housing (310)* (if equipped) into bearing cap (43).
Install outboard magnetic seal or labyrinth seal
(49) in bearing cap (37).
11. Remove shaft (with radial and thrust
bearing assemblies) from outboard end of
bearing frame (19).
12. Un-crimp tang on bearing lockwasher
(69). Remove bearing locknut (22) and bearing
lockwasher (69).
NOTE
It is recommended that bearings removed from
the shaft be replaced.
13. If desired, pull thrust bearing (18) from
shaft (6).
14. If desired, pull radial bearing (16) from
shaft (6).
7.2 ASSEMBLY
Refer to the applicable sectional drawing for
location of parts followed by an item number.
Handle outboard magnetic seal or labyrinth seal
(49) with care. Mishandling could damage faces
of magnetic seal or labyrinth seal (49).
Assemble the pump in accordance with
accepted rules of engineering practice.
Assembly of the pumping unit should be
performed on a clean, flat surface. Carver
recommends all nuts and bolts be tightened
according to Table 9, Recommended Torque
Values. Check to make sure components are
fitted in correct sequence. Perform the following
procedures to assemble the pumping unit:
6. Reinstall bearing cap (37) on shaft (6).
7. Reinstall fan (40) over key (32F) on shaft
(6), with setscrews (668). Install fan shroud with
nuts (603), lockwashers (651) and washers (640)
8. Press inboard magnetic seal housing
(311)* (if equipped) in bearing cap (35). Install
inboard magnetic seal or labyrinth seal (47) in
bearing cap (35).
NOTE
To ensure proper seating of bearing
parts, rotate the bearing while clamping
the parts.
Handle inboard magnetic seal or labyrinth seal
(47) with care. Mishandling could damage faces
of magnetic seal or labyrinth seal (47).
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
2.
9. Install new gasket (73) on bearing cap (35).
Reinstall bearing cap (35) on shaft (6). Secure
bearing cap (35) to bearing frame (19) with
capscrews (601).
10. Install seal (90) on backhead (11) with nut
(615). Mount backcover (11) to frame (19) with
nut (617) and lockwasher (656).
31
Carver API MAXUM Pumps
May 2009
NOTE
Refer to Mechanical Seal vendor instructions for
complete seal installation procedure.
11. Reinstall impeller key (32) in keyway on
shaft (6).
12. Reinstall impeller (2) on shaft (6). Secure
impeller (2) with impeller nut (24) and impeller
washer (28).
13. Insure new gasket (73C)* or o-ring (89A)*
is installed on casing (1).
14. Reinstall rotating element in casing (1).
Secure backhead (11) to casing (1) with nuts
(616) and lockwashers (655) on studs (631 &
631X).
15. Rotate shaft (6) by hand to insure shaft (6)
rotates freely and no rubbing noises are present.
16. Reinstall coupling. Align coupling according
to section II, paragraph 4. Reinstall coupling
guard.
17. Remove all tags from valves and switches.
18. Start pumping unit in accordance with
section III.
32
Carver API MAXUM Pumps
May 2009
Figure 8 Sectional Assembly – Bare Pump
33
Carver API MAXUM Pumps
May 2009
Figure 9 – Pump with Base
34
Carver API MAXUM Pumps
May 2009
Table 12 - Parts List
Item No.
Description
Item No.
Description
1
Volute
410
Tubing - Cooler
2
Impeller
420
Pipe Plug – Bearing Frame
6
Shaft
421
Pipe Plug – Oil Mist Port
Wear Ring – Case
422
Drain Plug - Case
7X
7
Wear Ring - Backhead
532
Male Connecter - BT
11
Backhead
564
Male Connecter - 90 degrees
15X
Shim – Motor / Base
601
Capscrew – I.B Cap / Frame
16
Ball Bearing, Radial
602
Capscrew – Oil Pan
18
Ball Bearing, Thrust
603
Capscrew – Fan Shroud / Guard
19
Bearing Frame
604
Bolt – Coupling Guard
22
Bearing Locknut
605
Bolt – Coupling Guard
23
Base
606
Capscrew – Seal Guard
24
Impeller Nut
608
Bolt – Motor / Base
28
Impeller Washer
610
Forcing Bolt
32
Key, Impeller
611
Foot Leveling Bolt
Key, Fan
612
Adjusting Bolt - Motor
35
Bearing Cap, Inboard
615
Hex Nut – Seal
37
Bearing Cap, Outboard
616
Hex Nut – Volute
32F
40
Fan, Frame Cooling
617
Hex Nut - Backhead
42
Coupling
618
Hex Nut – Fan Shroud
45
Vent Breather
619
Hex Nut – Coupling Guard
46
Coupling Key - Pump
621
Flatwasher – Fan Shroud
46X
Coupling Key - Motor
622
Flatwasher – Coupling Guard
47
Bearing Isolator – IB
623
Flatwasher – Seal Guard
49
Bearing Isolator – OB
630
Stud – Seal
60
Oil Flinger
631
Stud – Volute / Adaptor
69
Bearing Lockwasher
631X
73
Gasket, Frame - Cap
632
Stud – Backhead
*73C
Gasket, Casing
633
Stud – Bearing Cap
89A
O-Ring, Backcover-Case
654
Lockwasher – Volute / Base
89B
O-Ring, Oil Pan
655
Lockwasher – Volute / Backhead
89C
O-Ring, Bearing Cap
656
Lockwasher – Adaptor / Frame
Mechanical Seal
657
Lockwasher – Cap / Frame
90
131
Stud – Volute / Adaptor (Guide)
Guard, Coupling
658
Lockwasher – Seal Guard
131A
Fan shroud
659
Lockwasher – Coupling Guard
132
Guard, Seal
660
Lockwasher – Motor / Base
143
Oiler
667
Setscrew – Wear Ring
190
Electric Motor
668
Setscrew – Fan
215
310**
311**
* Options
Oil Pan
864
Housing – Magnetic Seal
*890**
Housing – Magnetic Seal
** Not Shown
35
Setscrew – Flinger
Vibration Transmitter, RTD, ETC
Carver API MAXUM Pumps
May 2009
Table 13. Recommended Spare Parts
Quantity
Item No.
Description
1
2
Impeller
1
7
Wear Ring
1
7X
Wear Ring
1
16
Ball Bearing, Suction End
2
18
Ball Bearing, Discharge End
1
22
Bearing Locknut
1
28
Washer
1
32
Key, Impeller
1
46
Key, Coupling
1
47
Bearing Isolator - IB
1
49
Bearing Isolator - OB
2
69
Bearing Lockwasher
2
73
Gasket, Frame – I.B. Bearing Cap
2
*73C
Gasket, Casing
2
89A
O-Ring, Backcover-Case
2
89C
O-Ring, Bearing Cap
2
89D
O-Ring, Oil Pan
1
90
Mechanical Seal
* Options
36
Carver API MAXUM Pumps
May 2009
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37
I-400 ATEX, REV. 0
May 2009
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