Carver GVC Series, GVT Series Installation, Operation And Maintenance Manual

(GVC) I-460 Rev. 02
(GVT) I-470 Rev. 02
SERVICE RECORD PAGE
Service No. ________________ Size and Type ______________ Make _____ ___________________ Cust. Order No. ________________________ Date Installed ___________ _______________________
Installation Date
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 Rin g ________________________________ O-rings _______________________________ Beari ng 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 _______________________
INSPECTION DATE
NOTES ON INSPECTION AND REPAIRS
REPAIR TIME
REPAIRS
COST
REMARKS
TABLE OF CONTENTS
LOCATION/DESCRIPTION PAGE
SERVICE RECORD PAGE ...............FRONT
NOTES ON INSPECTION AND
REPAIRS...........................................FRONT
I. GENERAL INFORMATION .........1
A. Preface....................................1
B. Pump Identification .................1
C. Parts Inventory Guide.............1
D. Parts Ordering.........................1
E. Safety Precautions..................1
II. INSPECTION AND STORAGE ...2
A. Inspection Upon Arrival...........2
B. Storage of Pump.....................2
III. INSTALLATION ...........................4
IV. ALIGNMENT................................4
V. OPERATION................................4
A. Prestart Cautions....................4
B. Starting the Pump...................4
C. Stopping the Pump .................4
VI. MAINTENANCE...........................5
A. Field Inspection.......................5
B. Stuffing Box.............................5
C. Bearing Temperature..............5
D. Bearing Lubrication.................5
VII. TROUBLESHOOTING.................6
VIII. SERVICE AND REPAIR..............9
A. Disassembly and Assembly....9
B. Parts Inspection......................14
LOCATION/DESCRIPTION PAGE
C. Adjusting Impeller Clearance on Pump Equipped with
Semi-Open Impeller................16
D. Replacement of Optional Wear Ring on Pump Equipped
with Enclosed Impeller............16
IX. PARTS LIST AND FIGURES...... 17
LIST OF TABLES
TABLE TITLE PAGE
A. Recommended Torque Values .....5
1. Troubleshooting ............................7
2. Throttle Bushing Dimensions........ 15
3. Enclosed Impeller Clearance........ 15
4. Impeller/Wear Ring Matching
Materials........................................16
5. Recommended Spare Parts..........17
6. Pump Parts List for GVC 1520 and
GVC 1530/1540 ............................18
7. Pump Parts List for GVT 1520 and
GVT 1530/1540............................. 18
LIST OF ILLUSTRATIONS
FIGURE TITLE PAGE
A. Ordering Codes.............................3
1. GVC (1520 Frame)
Sectional Drawing .........................19
2. GVC (1530 Frame)
Sectional Drawing .........................20
3. GVC (1540 Frame)
Sectional Drawing .........................21
4. GVT (1520 Frame)
Sectional Drawing .........................22
5. GVT (1530 Frame)
Sectional Drawing .........................23
6. GVT (1540 Frame)
Sectional Drawing .........................24
7. Optional Wear Ring....................... 25
i
I. GENERAL INFORMATION
A. PREFACE. General vertical cantilevered
(GVC) pumps are designed for industrial service. All
wetted surfaces are available in all iron, stainless fitted, and stainless steel construction. The general vertical top pullout (GVT) design provides fast, easy access to all working parts without disconnecting pipes.
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 during maintenance of pump, spare parts should be readily available for normal service. Most matters can be handled with proper usage of this manual. For every one to three pumps, stock one spare set consisting of items listed in Table 5, Recommended Spare Parts. Part numbers correspond to the drawings (figures 1 through 7) found at the back of this manual.
A nameplate is attached to each pump. The data on the nameplate should be recorded and filed for easy reference. Nameplate data should be furnished to Carver Pump Company or its representative when ordering spare parts or requesting information.
D. PARTS ORDERING. Carver Pump Company
strives to provide prompt, accurate service. To ensure quality customer service, please provide the following information:
Serial number of pump (located on nameplate)
Part name (refer to Table 6 and Table 7)
Item number (refer to Table 6, Table 7,
and figures 1 through 7)
Quantity of parts needed
Carver may ship an interchangeable part that is not identical in appearance or symbol. This is done only if the part has been improved. Examine the parts carefully on receipt before calling the factory or a company representative. Never return parts to the factory without authorization from Carver Pump Company.
If an impeller is ordered, specify diameter across blade tips. Check to make sure diameter was NOT trimmed further than diameter shown on Carver Pump Company records.
If a motor/motor parts are ordered, specify the name of the manufacturer and all other data found on the driver nameplate.
E. SAFETY PRECUATIONS. This manual
contains descriptions and instructions, which are the result of carefully conducted engineering and research efforts. The manual is written with the intent to provide instructions for the safe and efficient installation, operation, and maintenance of the pump. Failure or neglect to properly install, operate, or maintain the pump may result in personal injury, property damage, or unnecessary damage to the pump and/or parts.
Variations exist in both the equipment used with these pumps and in particular, installation of the pump and driver. Therefore, specific operating instructions are not within the scope of this manual. This manual contains general rules for installation, operation, and maintenance of the pump.
Observe and understand all caution or danger tags attached to the equipment. Observe and understand all cautions and warnings included in this manual.
The following general safety precautions do not relate to any specific procedure within this manual but are pertinent to providing a safe working environment for personnel.
CAUTION
Various federal, state and local laws and the regulations concerning OSHA affect installation, use, and operation of pumping equipment. Compliance with such laws relating to the proper installation and safe operation of pumping equipment is the responsibility of the equipment owner and all necessary steps should be taken by the owner to assure compliance with such laws before operating the equipment.
PUMP
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.
DRIVER
5. Prior to working on pump or driver,
6. All circuits NOT known to be dead must
7. Do NOT wear loose or torn clothing
8. While working near electricity, do NOT
ensure all switches and circuit breakers have been locked in the open (off) position and tagged, “Out of Service.”
be considered live at all times. around rotating machines. Do NOT wear
jewelry or watches around rotating machines.
use metal rules, flashlights, metallic
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pencils, or any other objects having exposed conducting material.
9. Ensure you are NOT grounded while adjusting electrical equipment or using measuring equipment.
10. In general, use only one hand when servicing live electrical equipment.
11. De-energize all electrical equipment before connecting or disconnecting meters or test leads.
12. When connecting a meter to terminals for measurement, use a range higher than the expected voltage.
13. Check to make sure the frame of the driver and starter panel are securely grounded before operating pumping unit or performing any tests or measurements.
14. If a test meter is held or adjusted while voltage is applied, ground case of meter before starting measurement. Do NOT touch live equipment while holding meter. Some moving vane-type meters should not be grounded nor held during measurements.
15. Do NOT use test equipment known to be damaged or in poor condition.
16. Reference Table A, Torque Values, to avoid equipment damage and injury to personnel.
II. INSPECTION AND STORAGE
A. INSPECTION UPON ARRIVAL. Upon
receipt of the shipment, check for missing or damaged items. Unpack and inspect the pump, driver assemblies, and individual parts. Carefully inspect all boxes and packing material for loose parts before discarding. Immediately report any missing parts or damage incurred during shipment to the factory and to the transportation company. File your “damaged and/or lost in shipment” claim with the carrier.
NOTE
The pump and equipment, as shipped from Carver Pump Company, have appropriate 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.
B. 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.
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 periods of longer than 30 days.
CAUTION
A pump, which is made of cast or ductile iron that sits in extreme heat, high humidity, or full or partially full water over 30 days will rust and will most likely seize. If the pump rusts and/or seizes, a complete overhaul and repair may be necessary to refurbish the pump.
Storage requirements vary depending on the length of storage, the climatic environment, and the equipment. For storage periods of three months or longer, contact a representative from Carver Pump Company for specific instructions. Improper storage will damage the equipment and will require non­warranty restoration and/or non-warranty product failures. Refer to Section VIII, Service and Repair, for pump disassembly and assembly procedures. When disassembling the pump, replace and repair rusted parts, as necessary.
NOTE
If the customer anticipates 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 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:
1. Shut down the pumping unit in
accordance with the operating procedures outlined throughout this manual.
2. Shut off system suction and discharge
valves.
3. Drain the unit.
4. Fill unit with mineral oil or suitable non-
corrosive protectant that is compatible with the system.
5. Provide pump and motor with a
protective cover.
2
The following Ordering Code defines the new
g
g
g
g
g
g
g
g
g
g
Q
g
g
g
g
A
g
g
A
g
g
g
g
g
g
g
g
g
Q
Q
g
g
g
g
g
g
g
g
g, g
g
g
GV Series pump and pump/motor and top plate arrangements. When quoting or ordering a GV
Ordering Code enables Carver Pump Company to accept orders quickly, assuring timely and correct manufacture of the desired pump.
pump, this Ordering Code must be used. This
EXAMPLE
---
Pump Series Coupling, Motor Mounting Bracket and Motor GV - General Vertical A - Standard couplin
Mountin
Style C - Standard coupling, TEFC motor, standard efficiency C - Cantilever desi T - Top pull out desi S - Sump desi
Casin
Nozzle and Impeller S i ze s
BA - 1 1/4 x 1 x 7 DA - 2 x 1 x 11 Motor Ratin BB - 1 1/2 x 1 1/4 x 7 DB - 4 x 2 x 11 A - 1.5 HP @ 1750 RPM K - 15 HP @ 1750 RPM V - 75 HP @ 1750 RPM BC - 2 1/2 x 2 x 7 DC - 4 x 3 x 11 B - 2 . 0 H P @ 17 50 R P M M - 15 HP @ 3500 RPM W - 100 HP @ 1750 RPM BD - 3 x 2 1/2 x 7 DD - 5 x 4 x 11 C - 3.0 HP @ 1750 RPM N - 20 HP @ 1750 RPM BE - 4 x 3 x 7 DE - 8 x 6 x 11 D - 5.0 HP @ 1750 RPM P - 20 HP @ 3500 RPM X - S p e ci al or over 100 HP BF - 5 x 4 x 7 E - 5.0 H P @ 35 00 R P M
CA - 1 1/2 x 1 1/4 x 10 EB - 2 1/2 x 2 x 13 G - 7.5 HP @ 35 00 R P M S - 40 HP @ 1750 RPM CB - 2 x 1 1/2 x 10 EC - 3 x 2 1/2 x 13 H - 10 HP @ 1750 RPM T - 50 HP @ 1750 RPM CC - 2 1/2 x 2 x 10 ED - 4 x 3 x 13 J - 10 HP @ 3500 RPM U - 60 HP @ 1750 RPM CD - 3 x 2 1/2 x 10 EE - 5 x 4 x 13 CE - 4 x 3 x 10 EF - 6 x 5 x 13 CF - 5 x 4 x 10 EG - 8 x 6 x 13 (GVC & T only) Top Plate and Dischar CG - 6 x 5 x 10 A - Small steel top plate (no dischar
Basic Mate rials and Construction
ll cast iron construction
A -
316 stainless steel fitted cast iron construction
B -
ll 316 stainless steel construction for major components
C -
- Special
X
Column Depth (1.0 and 2.0 ft for GVC & T only) L - L A - 1.0 ft (GVC & T) L - 11.0 ft (GVS only) M - L B - 2.0 ft (GVC & T) M - 12.0 ft (GVS only)
C - 4.0 ft (GVS only) P - 14.0 ft (GVS only) P - L D - 5.0 ft (GVS only) E - 6.0 ft (GVS only) R - 16.0 ft (GVS only) F - 7.0 ft (GVS only) S - 17.0 ft (GVS only) R - Lar G - 8.0 ft (GVS only) T - 18.0 ft (GVS only) S - Lar J - 9.0 ft (GVS only) U - 19.0 ft (GVS only) T - Lar K - 10.0 ft (GVS only) V - 20.0 ft (GVS only)
Throttle Bushin A - Teflon bushin B - 17-4 PH bushin
C - Bronze lineshaft bearin D - Bronze lineshaft bearin E - Carbon lineshaft bearin
X - Special
n D - S tandard coupling, TEFC motor, Hostile Duty
n E - Standard coupling, X-P motor, standard efficiency
n
EA - 2 1/2 x 1 1/2 x 13 F - 7.5 HP @ 17 50 R P M R - 30 HP @ 1750 RPM Z - No motor - bare pump
N - 13.0 ft (GVS only) N - L
- 15.0 ft (GVS only)
, Lineshaft Bearing and Flush Lines W - Large 316 SS top plate, double oversized 316 SS discharge (GVC & T only)
(standard for GVC & T)
, 416 SS shaft sleeve (GVC & T only) X - Special
reased for life (standard for GVS) Z - No top plate or discharge pipe - bare pump only (standard for GVC & T) , externally flushed (GVS only) , externally flushed (GVS only)
Z Z ZB A ZG V B E AC
B - Standard couplin
X - Special couplin
Z - No couplin
B - Small steel top plate (no dischar C - Small 316 SS top plate (no dischar
D - L
. steel plate, no underliner, standard steel discharge pipe (standard for GVS)
E - L
. steel plate, no underliner, oversized steel discharge pipe (GVC & T only)
F - L
. steel plate, no underliner, dbl. oversized steel discharge pipe (GVC & T only)
. steel plate, 316 SS underliner, standard size steel discharge pipe
G - L H - L
. steel plate, 316 SS underliner, oversized steel discharge GVC & T only)
J - L
. steel plate, 316 SS underliner, dbl. oversized steel discharge (GVC & T only)
. steel plate, no underliner, standard size 316 SS discharge pipe
K - L
. steel plate, no underliner, oversized 316 SS discharge (GVC & T only)
. steel plate, no underliner, dbl. oversized 316 SS discharge (GVC & T only)
. steel plate, 316 SS underliner, standard size 316 SS discharge pipe
. steel plate, 316 SS underliner, oversized 316 SS discharge (GVC & T only)
- Lg. steel plate, 316 SS underliner, dbl. o'sized 316 SS discharge (GVC & T only)
e 316 SS top plate, standard size steel discharge pipe e 316 SS top plate, oversized steel discharge (GVC & T only) e 316 SS top plate, double oversized steel discharge (GVC & T only)
U - Lar
e 316 SS top plate, standard size 316 SS discharge pipe
V - Lar
e 316 SS top plate, oversized 316 SS discharge (GVC and GVT only)
, ODP motor, standard efficiency , ODP motor, Hostile Duty
, motor enclosure or motor speed
or motor - bare pump only
(when require d)
- 25 HP @ 1750 RPM
e Pipe Arrangement
e pipe), no underliner (GVC & T only) e pipe), 316 SS underliner (GVC & T only)
e pipe), no underliner
Inlet Pipe and Strainer A - Zinc plated steel strainer with steel tailpipe B - 304 SS strainer with 316 SS tailpipe
X - Special strainer and/or tailpipe
Z - No strainer or tailpipe (standard)
* Casing Nozzle and Impeller Sizes containing codes BA through BF and CA through CG have semi-open impellers. Casing Nozzle and Impeller Sizes containing codes DA through DE and EA through EG have closed impellers.
Figure A. Ordering Codes
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III. INSTALLATION.
V. OPERATION.
Skilled personnel should install the pump in accordance with engineering standards. Faulty installation will result in operating troubles and premature wear of parts.
The pump and driver should be easily accessed with enough headroom to perform periodic inspection and maintenance. The pump should always be submerged enough to prevent vortexes from forming, which might allow air to enter the suction.
When pump is supplied with coupling, motor, and baseplate, the complete set is assembled at Carver Pump Company. After ascertaining that the unit has suffered no damage in transit, one may install the pumping unit. Proceed as follows:
1. Make sure the mounting surface is level. Attach the base to the mounting surface. Check that pump rotates freely.
CAUTION
Pipe strain will cause wear and/or damage to parts.
2. Connect discharge piping. Extreme care should be taken when connecting new piping lines to be sure that no foreign matter such as dirt, chips, tools, etc., is in the piping, tank, or return piping as the debris will be drawn into the pump and cause excessive damage. Any debris caught in the pump passageways will throw the pumping unit out of balance.
3. Connect any necessary auxiliary piping and gauge lines.
4. Since the pumping unit is shipped with bearings packed, initial greasing will not be necessary unless pumping unit has been in storage for an extended period of time (refer to section II).
5. Turn pump and motor shafts by hand to be sure they rotate freely.
6. Connect wiring to motor. Due to high voltage required to operate the pumping unit, personnel working with the equipment should be familiar with electrical safety practices and modern methods of resuscitation.
7. Connect electrical power supply to motor.
8. Open system valves.
IV. ALIGNMENT.
A flexible coupling connects the pump and motor. The motor bracket aligns the pump and motor. No
further alignment is necessary.
A. PRESTART CAUTIONS.
1. Before starting or operating the pump, read this entire manual, especially the following instructions.
2. Before starting the pump, rotate shaft by hand to assure all moving parts are free.
3. Before starting the pump, install closed guards around all exposed rotating parts.
4. Observe all caution or danger tags attached to the equipment.
5. Never run pump dry. Dry running may result in pump seizure.
6. If excessive vibration or noise occurs during operation, shut the pump down and consult a Carver representative.
7. Use of a check valve in discharge piping is recommended if there is a high volume of reverse flow.
8. Check level in tank to see that the pump is submerged in fluid.
B. STARTING THE PUMP. The pumping unit will
operate without operator intervention once system valves have been adjusted to the specified pumping conditions. The casing of the pump will be submerged in the fluid being pumped, thus rendering it self­priming. Proceed with operation as follows:
1. Make sure no one is working on the pumping unit.
2. If the pumping unit has been idle for a period of time, make sure unit is firmly attached to its foundation.
3. Open valves to pressure gauges in system.
CAUTION
Check level of liquid in tank to be sure casing is under liquid level.
4. Jog starter switch on motor to check direction of rotation. Direction of rotation is clockwise from fan end of motor.
5. Partially open discharge valve.
6. Start the pumping unit in accordance with the directions on the electrical power supply.
7. Slowly adjust discharge valve to operating condition required.
8. Pumping unit is now in full operation.
C. STOPPING THE PUMP. To stop the pump,
use the following process:
1. If pump is being stopped for overhaul, slowly close the discharge valve. Otherwise leave discharge valve set at condition.
2. Stop the pumping unit in accordance with the directions on the electrical power supply.
3. If the pump is being stopped for overhaul, close pressure gauge valves.
4
4. The pumping unit is now in the off position.
VI. MAINTENANCE.
Generally, the pump does not require continuous supervision. Occasional visual checks are recommended. Data should be recorded for each pump to keep track of maintenance, which has been performed and note operational problems. A pump service record page is provided for this purpose in the front matter of this manual.
Before disassembly/assembly, review Table A, Torque Values to avoid equipment damage and injury to personnel.
Table A. Recommended Torque Values (ft-lbs)
Bolt Size
Composite
¼”-20 5 5 7
5/16”-18 11 11 12
3/8”-16 18 18 21
½”-13 33 39 45
5/8”-11 54 83 97
¾”-10 80 105 132 7/8”-9 109 160 203
1”-8 144 236 300
A. FIELD INSPECTION. Shutdown is not
required. Perform field inspection at regular intervals and cover the following procedures:
1. Check and record the suction and discharge pressures to establish differential head. It should conform to the pump nameplate.
2. Check and record the power input and speed of the driver.
3. Check and record pumping temperatures.
4. Check pump for quiet running.
B. STUFFING BOX. The stuffing box is equipped
with a throttle bushing which requires no regular maintenance. The inside diameter of the throttle bushing will increase with wear. The throttle bushing should be inspected after pump disassembly. The throttle bushing requires replacement if the inside diameter is more than 0.020 inch out of round.
C. BEARING TEMPERATURE. Bearing
temperature should be monitored periodically. Normal operating temperatures are 120 degrees F to 160 degrees F, depending on the ambient temperature. Bearings may appear to run hot when pump is first started. This is caused by the shaft seal, not the bearing. When the seal is seated, temperature should drop to normal.
Material
Steel (or
otherwise
noted)
316
Stainless
Steel
Check bearing temperature by placing a pyrometer against the bearing frame while pump is running. A temperature rise above 180 degrees F indicates possible damage that requires checking. The most common cause of high bearing temperatures is overgreased bearings.
D. BEARING LUBRICATION. Lubrication
frequency depends on operating conditions. Normal duty calls for relubrication every 1000 hours of operation. Bearings are lubricated at Carver Pump Company with Amoco Rykon Premium Grease No. 2EP, non-soap, polyurea thickened grease with a drop point of 450 degrees F. This grease was 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. However, if it is necessary to change grease types, the bearings, bearing frame, and bearing cap/cartridge should be thoroughly cleaned and flushed with suitable solvent to remove all traces of old grease. Disassemble pump, remove shaft and bearings from bearing frame, and follow these procedures:
1. Place bearings, bearing frame, and bearing cap/cartridge in a wire or mesh basket and suspend the basket in a light mineral solvent. Allow it to soak, preferably overnight.
2. After soaking and cleaning, the bearings, bearing frame, and bearing cap/cartridge should be rinsed in a clean, light mineral solvent and agitated vigorously to remove all loosened hard grease and dirt.
3. Dip bearings in clean, light oil and spin by hand to determine that all foreign matter has been removed.
4. After cleaning, repack bearings half full on both sides with a good quality ball bearing grease.
To relubricate bearings use the following procedure:
CAUTION
Overgreasing creates heat and is the cause of many problems requiring repair. DO NOT OVERGREASE.
1. Never relubricate pump bearings while unit is running. If necessary, shut down pump according to section V, paragraph C.
2. Remove plugs opposite grease fittings on both ends of bearing frame.
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