Carver RS Series User manual

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280

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 January 2001
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TABLE OF CONTENTS
Location/Description Page
I. General Information...............................................................................................................1
A. Preface............................................................................................................................1
B. Pump Identification..........................................................................................................1
C. Parts Inventory Guide......................................................................................................1
D. Parts Ordering.................................................................................................................1
E. Safety Precautions..........................................................................................................1
F. Equipment Description....................................................................................................2
G. Effects of Fluids...............................................................................................................2
H. Operating Limits..............................................................................................................2
I. Mechanical Seal..............................................................................................................2
J. Bearing Lubrication and Cooling.....................................................................................2
K. Grease Recommendations .............................................................................................4
L. Oil Lube Recommendations............................................................................................4
M. Technical Data ................................................................................................................7
N. Unpackaging ...................................................................................................................8
O. Packaging........................................................................................................................8
P. Inspection upon Arrival....................................................................................................8
Q. Storage of Pump.............................................................................................................8
R. Pump Protection during Prolonged Shutdown ................................................................8
II. Installation..............................................................................................................................9
A. Foundation and Mounting................................................................................................9
B. Grouting...........................................................................................................................9
C. Handling..........................................................................................................................11
D. Coupling..........................................................................................................................11
E. Piping ..............................................................................................................................12
F. Auxiliary Connections......................................................................................................12
III. Operation...............................................................................................................................13
A. Method of Operation........................................................................................................13
B. Pre-Start Cautions...........................................................................................................13
C. Start-Up...........................................................................................................................13
D. Turbine Applications........................................................................................................14
IV. Troubleshooting.....................................................................................................................14
V. Maintenance and Repair........................................................................................................17
A. Scheduled Maintenance..................................................................................................17
B. Bearings..........................................................................................................................17
C. Torque Values.................................................................................................................18
D. Disassembly and Assembly Preparations.......................................................................19
E. Parts Cleaning and Inspection ........................................................................................20
F. Axial Impeller Alignment..................................................................................................21
G. Wear Ring Replacement.................................................................................................23
H. Oil Lubrication and Water Cooling Service .....................................................................23
I. Pump Disassembly and Assembly RS A, RS B, RS C (with standard sleeve bearing) ..27
J. Pump Disassembly and Assembly RS D and RS E (with standard sleeve bearing).......35
K. Pump Disassembly and Assembly RSA, RS B, RS C (with optional mechanical seals) 43
L. Pump Disassembly and Assembly RS D and RS E (with optional mechanical seals)....51

RS Series –Multi-Stage, Ring Section Pumps January 2001
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LIST OF TABLES
Table Page
1. Grease Recommendations....................................................................................................4
2. Oil Recommendations ...........................................................................................................4
3. Bearing Cooling Flow Rates ..................................................................................................4
4. Shaft Dimensions...................................................................................................................7
5. Sleeve Bearing Dimensions...................................................................................................7
6. Standard Mechanical Seal Settings.......................................................................................7
7. Optional Mechanical Seal Settings (Non-Cartridge)..............................................................7
8. Minimum Flow Rates.............................................................................................................14
9. Pumping Unit Troubleshooting ..............................................................................................15
10. Recommended Torque Values..............................................................................................19
11. Recommended Tools ............................................................................................................19
12. Axial Impeller Alignment Control Dimensions........................................................................22
13. Maximum Wear Ring Clearances..........................................................................................23
14. New Wear Ring Clearance Limits..........................................................................................23
15. Recommended Spare Parts ..................................................................................................59
LIST OF FIGURES
Figure Page
A. Ordering Codes .....................................................................................................................3
1. Water Cooling........................................................................................................................5
2. Stuffing Box ...........................................................................................................................6
3. Grouting and Foundation Bolting...........................................................................................10
4. Unit Leveling..........................................................................................................................10
5. Coupling Alignment................................................................................................................11
6. Adjusting Alignment...............................................................................................................11
7. Fluid Line Schematic .............................................................................................................12
8. Axial Impeller Alignment........................................................................................................22
9. Cooling Options RS A, RS B, RS C, RS D, and RS E...........................................................25
10. Sectional Assembly, RS A and RS B (with standard sleeve bearing)....................................31
11. Sectional Assembly, RS C (with standard sleeve bearing)....................................................33
12. Sectional Assembly, RS D (with standard sleeve bearing)....................................................39
13. Sectional Assembly, RS E (with standard sleeve bearing)....................................................41
14. Sectional Assembly, RS A and RS B (with optional mechanical seals).................................47
15. Sectional Assembly, RS C (with optional mechanical seals).................................................49
16. Sectional Assembly, RS D (with optional mechanical seals).................................................55
17. Sectional Assembly, RS E (with optional mechanical seals).................................................57

RS Series –Multi-Stage, Ring Section Pumps January 2001
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I. General Information
A. 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.
B. 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. When
ordering a pump, refer to Figure A, Ordering
Codes. 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.
C. 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, through
17.
D. Parts Ordering
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 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.
If a driver or driver parts are ordered, specify
name of manufacturer and all other data found
on the driver nameplate.
E. Safety Precautions
The following general safety precautions do not
relate to any specific procedure and therefore,
do not appear elsewhere in this publication.
Personnel must understand and apply the
recommended precautions throughout the many
phases of operation and maintenance of the
pump. Personnel must also understand and
apply the electrical driver, which is used to drive
the pump. The safety precautions are as follows:
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.

RS Series –Multi-Stage, Ring Section Pumps January 2001
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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.
The following specific safety precautions
apply to the pumping unit:
1. Hydro suction case separately if unit
hydro is greater than 620 PSIG.
2. Isolate pump for system hydro.
3. Do NOT exceed maximum suction
pressure of 415 PSIG on suction case.
4. Do NOT exceed maximum discharge
pressure of 1200 PSIG on discharge
case.
F. Equipment Description
RS high-pressure pumps are multi-stage,
centrifugal pumps with vertically split casings.
The pump consists of a suction case and 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 and stage casings are provided
with wear rings. Due to prolonged operation,
wear rings become worn and/or damaged.
Replace all worn and/or damaged wear rings
with new wear rings. The bearing frame is
attached to the suction case and discharge case
by bolts.
The pump shaft is protected against corrosion
and wear by interstage sleeves, spacer sleeves,
and shaft sleeves. Impellers are secured on the
pump shaft by keys. All impellers face the same
direction on the shaft.
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 bearings.
G. Effects of Fluids
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 viscosity, other than which the pump
was originally designed, check with Carver
Pump Company.
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. 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 is
dangerous, as it might overload the driver, or
exceed the pump case allowable pressure.
H. Operating Limits
Pump operating temperature for uncooled
bearings should NOT exceed 225 degrees
Fahrenheit (F). Pumps of high temperature
construction are provided with cooled bearings
with an operating temperature range between
225 and 410 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
(60 PSIG MAX.) system.
I. Mechanical Seal
For a listing of mechanical seal options, contact
your local distributor or a representative from
Carver Pump Company.
J. Bearing Lubrication and Cooling
Refer to Figure 9, Cooling Options, for bearing
lubrication and cooling options.

RS Series –Multi-Stage, Ring Section Pumps January 2001
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The following Ordering Code defines the new
RS Series pump and pump/motor and baseplate
arrangements. When quoting or ordering an RS
pump this Ordering Code must be used. This
Ordering Code enables Carver Pump Company
to accept orders quickly and assures timely and
correct manufacture of the desired pump.
EXAMPLE
Figure A. Ordering Codes
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RS Multistage Ring Section Pump Series NEMA Motor @ 230/460 Volt, 60 Hz
6
- 600 lb. Discharge flange (assigned by Carver)
A
- 1750 RPM, ODP, standard efficiency
9
- 900 lb. Discharge flange (assigned by Carver)
B
- 3500 RPM, ODP, standard efficiency
C
- 1750 RPM, ODP, premium efficiency
D
- 3500 RPM, ODP, premium efficiency
E
- 1750 RPM, TEFC, standard efficiency
F
- 3500 RPM, TEFC, standard efficiency
Casing Nozzle and Impeller Sizes
G
- 1750 RPM, TEFC, premium efficiency
A
- 3 x 2 x 6 Low Flow
H
- 3500 RPM, TEFC, premium efficiency
B
- 3 x 2 x 6 High Flow
J
- 1750 RPM, Explosion proof, standard efficiency
C
- 4 x 2.5 x 7
K
- 3500 RPM, Explosion proof, standard efficiency
D
- 6 x 3 x 8
E
- 6 x 4 x 10
X
- Special
Z
- No motor - bare RS pump only
Basic Materials of Construction
A -
Ductile iron casing and wear rings with cast iron impellers
Motor Size (for assemblies with base, etc.)
B -
Ductile iron casing with CD4 impellers and carbon wear rings
K
- 25 HP
Q
- 75 HP
V
- 250 HP
C
- CD4 casing and impellers with carbon wear rings
L
- 30 HP
R
- 100 HP
Y
- 300 HP
X
- Special
M
- 40 HP
S
- 125 HP
N
- 50 HP
T
- 150 HP
X
- Special or above 300 HP
Number of Stages
P
- 60 HP
U
- 200 HP
Z
- No motor - bare pump only
A
- 2 stages
F
- 7 stages
M
- 12 stages
B
- 3 stages
G
- 8 stages
N
- 13 stages
Base and Coupling
C
- 4 stages
H
- 9 stages
P
- 14 stages
A
- Standard base with standard coupling and guard
D -
5 stages
J
- 10 stages
Q
- 15 stages
B
- Standard base with spacer-type coupling and guard
E
- 6 stages
K
- 11 stages
X
- Special
Z
- No base, coupling guard or motor - bare pump only
Outboard (High Pressure Discharge) End Sealing Arrangement
A -
No seal, antimony impregnated carbon sleeve bearing (standard)
B
- Type 8B -1 seal with carbon on Si C faces, EPDM and 316 SS components
C
- Type 8B -1 seal as above with Plan 21 flush and external heat exchanger
X
- Special seal and/or flush plan
Inboard (Suction Inlet, Low Pressure) End Sealing Arrangement
A -
Type 1 seal with carbon on ni-resist faces,Viton and 316 SS parts (standard)
B -
Type 1 seal with carbon on Si C faces, EPDM and 316 SS parts
X
- Special seal and/or flush plan
Bearing Lubrication Arrangement
A
- Grease lubricated (standard)
B
- Oil lubricated
C
- Oil lubricated with jacketed casing for external cooling
X
- Special
R S
B C G
A A A
A P B
6

RS Series –Multi-Stage, Ring Section Pumps January 2001
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K. Grease Recommendations
Standard pump bearings are grease lubricated.
Refer to Section V, paragraph B, for grease-
lubricated bearings.
A 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 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.
L. Oil Lube Recommendations
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 B for oil-
lubricated bearings.
Table 1. Grease Recommendations
Manufacturer Number
Amoco 2EP
Aero Shell 22
Mobil 28
Table 2. Oil Recommendations
Manufacturer ISO Grade 68
Royal Purple Snyfilm 68
Texaco Regal R&O 68
Phillips Magnus 68
Exxon Teresstic 68
Mobil DTE 16 M
Table 3. Bearing Cooling Flow Rates (60 PSIG MAX.)
Temperature Range Flow Rate
-20 degrees to 180 degrees F Grease Lube -Air
-20 degrees to 225 degrees F Oil Lube -Air
225 degrees to 285 degrees F Oil Lube -Water-1 Gallons Per Minute (GPM)
285 degrees to 410 degrees F Oil Lube -Water-2 GPM