Carver Pump RSA, RS Series, RSB, RSC, RSE Installation, Operation And Maintenance Instructions

...

Part Number: _______________________________________

Serial Numbers: _____________________________________

These operating instructions contain fundamental information and precautionary notes. Please read the manual

thoroughly prior to installation of unit, electrical connection and commissioning. It is imperative to comply with all other operating instructions referring to components of individual units.

I-280

280 – 16.03.EN

ATEX

Inch Units

For Units Built After December 2015

RS – Multi-Stage, Centrifugal Pump

INSTALLATION, OPERATION AND

MAINTENANCE INSTRUCTIONS

This manual shall always be kept close to the unit’s location of operation or directly on the pump set.

RS – Multi-Stage, I-280

EC Declaration of Conformity

www.carverpump.com Phone: 1-563-263-3410 Email: sales@carverpump.com

Kurt Doren Quality/ ISO Manager

Centrifugal Pump 280 – 16.03.EN

MANUFACTURER: CARVER PUMP COMPANY 2415 PARK AVE. MUSCATINE, IOWA, USA 52761

PRODUCT DESCRIPTION: RS – Multi-Stage, Centrifugal Pump PART NUMBER: SERIAL NUMBER: DATE MANUFACTURED: APPLICABLE EUROPEAN DIRECTIVES:

Machinery: The designated product complies with the following basic requirements of Directive 2006/42/EC:

Appendix I, section 1.1.2, 1.1.3., 1.1.5., 1.3.1., 1.3.2., 1.3.3., 1.3.4., 1.3.7., 1.3.8., 1.4.1., 1.4.2.1.,

1.5.1., 1.5.8., 1.5.9., 1.5.13., 1.6.1., 1.6.4., 1.6.5., 1.7.

ATEX: 94/9/EC

APPLICABLE INTERNATIONAL STANDARDS:

Machinery: EN ISO 12100:2010 EN ISO 13732-1:2008 EN 626-1:2008 EN ISO 13857:2008 ATEX: EN 1127-1, EN 13463-1, EN 13463-5

NOTIFIED BODY

Det Norske Veritas, ATEX NB 0575 retains a copy of the Technical File

ATEX product marking: II 2 G c T2

The product described in this Declaration of Conformity complies with the Applicable European Directives and relevant sections of the Applicable International Standards. The signature on this document authorizes the distinctive European mark to be applied to the equipment described. A Technical Construction File is available for inspection by designated bodies

Authorized Signature: Date:

Important safety information is contained in the installation, operation and service manuals; read and

understand this information prior to installing or using this equipment

This Document applies only to the equipment described above and is invalid if not reproduced in its entirety.

RS – Multi-Stage, I-280

Installation Date

Location

Application

Centrifugal Pump 280 – 16.03.EN

SERVICE RECORD PAGE

Service No. ______________________ Model _________________________ Size and Type _______________ Customer Order No. ____________________________ Date Installed __________________________________

PUMP RATING

Capacity _____________________________________ Total Head ____________________________________ Suction Pressure ______________________________ Speed (RPM) __________________________________ Liquid pumped ________________________________ Temperature ___________________________________ Specific Gravity _______________________________ Viscosity ______________________________________ Service ______________________________________

PUMP MATERIALS

Casing _________________________ Impeller _______________________ Shaft _______________________ Gaskets _____________________________________ Bearing Frame _________________________________ Mechanical Seal/Packing ________________________

MOTOR DATA

Motor __________________________ Make _________________________ Serial No. ___________________ Type ___________________________ Frame ________________________ AC or DC ___________________ HP _____________________________ RPM _________________________ Volts _______________________ Phase __________________________ Cycles ________________________

RS – Multi-Stage, I-280

INSPECTION DATE

REPAIR TIME

REPAIRS

COST REMARKS

Centrifugal Pump 280 – 16.03.EN

NOTES ON INSPECTION AND REPAIRS

RS – Multi-Stage, I-280 Centrifugal Pump 280 – 16.03.EN

INSTALLATION, OPERATION AND

MAINTENANCE INSTRUCTIONS

TABLE OF CONTENTS

SECTION/PARAGRAPH PAGE

I. GENERAL DESCRIPTION ............................... 1

A. General Information ................................... 1

B. ATEX Directive 94/9/EC ............................. 1

C. Disclaimer .................................................. 1

D. Personnel Qualification and Training ......... 1

E. Pump Identification..................................... 1

F. Parts Inventory Guide ................................ 2

G. Parts Ordering ............................................ 2

II. SAFETY ............................................................ 2

A. Safety Precautions ..................................... 2

B. Summary of Safety Marking ....................... 2

C. Products Used in Potentially Explosive

Atmospheres ......................................... 2

D. Scope of Compliance ................................. 2

E. Safety Awareness ...................................... 3

F. Safety Instructions for the Operator/User .. 3 G. Safety Instructions for Maintenance

Inspection and Installation Work ............ 3

H. Non-Compliance with Safety Instructions .. 3 I. Unauthorized Modification and

Manufacture of Spare Parts ................... 3

J. Unauthorized Modes of Operation ............. 4

K. Explosion Protection .................................. 4

III. EQUIPMENT DESCRIPTION ........................... 7

IV. EFFECTS OF FLUIDS ..................................... 8

A. Net Positive Suction Head (NPSH) ............ 8

B. Changing Pump Speed .............................. 8

C. Effects of Viscosity ..................................... 8

D. Effects of Specific Gravity .......................... 8

V. TECHNICAL DATA ........................................... 8

VI. INSPECTION AND STORAGE ........................ 16

A. Inspection ................................................... 16

B. Packing for Return ..................................... 16

C. Storage of Pump ........................................ 16

VII. INSTALLATION ................................................ 17

A. Location ...................................................... 17

B. Handling ..................................................... 17

C. Foundation ................................................. 17

D. Leveling of Unit .......................................... 18

E. Grouting ..................................................... 18

F. Coupling Alignment .................................... 20

G. Pre-Installation Procedures ....................... 21

H. Piping ......................................................... 21

I. Auxiliary Piping Connection

and Gauges ........................................... 21

J. Motor .......................................................... 21

K. Direction of Rotation .................................. 21

VIII. OPERATION .................................................... 22

A. Pre-Start Cautions ..................................... 22

B. Priming ....................................................... 22

C. Starting the Pump ...................................... 23

D. Turbine Applications .................................. 23

E. Minimum/Maximum Flow Calculations ...... 23

F. Operating Checks ...................................... 23

G. Stopping the Pump .................................... 23

H. Indefinite Shutdown ................................... 24

IX. TROUBLESHOOTING OPERATING

PROBLEMS ...................................................... 24

X. MAINTENANCE ............................................... 26

A. Lubrication of Pump Bearings .................... 26

B. Lubrication of Motor Bearings .................... 27

C. Torque Values ............................................ 27

XI. SERVICE AND REPAIR ................................... 28

A. Preparations for Disassembly of Pump ..... 28

B. Disassembly of Pump with

Standard Sleeve Bearing ....................... 29

C. Disassembly of Pump with

Optional Mechanical Seals .................... 31

D. Parts Inspection ......................................... 33

E. Reassembly of Pump with

Standard Sleeve Bearing ....................... 35

F. Reassembly of Pump with

Optional Mechanical Seals .................... 39

G. Replacement of Wear Ring ........................ 42

H. Motor .......................................................... 44

I. Check Valve ............................................... 44

XII. PARTS LISTS AND DRAWINGS ..................... 44

RS – Multi-Stage, I-280 Centrifugal Pump 280 – 16.03.EN

TABLE OF CONTENTS - Continued

LIST OF TABLES

NUMBER TITLE PAGE

1. Fluid Temperature Limits ........................... 5

2. Maximum Allowable Pressures .................. 6

3. Axial Impeller Alignment

Control Dimensions................................ 9

4. Shaft Dimensions ....................................... 12

5. Sleeve Bearing Dimensions ....................... 12

6. Standard Design Pump Mechanical

Seal Settings .......................................... 12

7. Optional Design Pump Mechanical

Seal Settings .......................................... 13

8. Key Mechanical Data ................................. 13

9. Permissible Nozzle Loads ......................... 15

10. Minimum Flow Rates RS-6 and RS-9 ........ 15

11. Pumping Unit Troubleshooting .................. 24

12. Oil Recommendations................................ 27

13. Bearing Cooling Flow Rates

(30 PSIG Max.) ...................................... 27

14. Recommended Torque Values (ft-lbs) ....... 27

15. Recommended Equipment ........................ 27

16. Factory Wear Ring Clearance (Inches) ..... 34

17. New Wear Ring Diametrical

Clearance Limits (Inches) ...................... 43

18. Recommended Spare Parts List ................ 45

LIST OF ILLUSTRATIONS

NUMBER TITLE PAGE

1. Seal Chamber Dimensions .........................11

2. Standard Seal Flush Plans .........................13

3. Bearing Frame Water Cooling ....................14

4. Sling Position for Moving Pump ..................17

5. Sling Position for Moving Pumping Unit .....17

6. Sling Position for Moving

Pumping Unit with Lifting Lugs ...............17

7. Grouting and Foundation Bolting ................19

8. Unit Leveling ...............................................19

9. Coupling Alignment .....................................20

10. Constant Level Oiler ...................................27

11. Bushing Not Torqued Interference .............38

12. Mechanical Seal Not Torqued

Interference .................................................42

13. Sectional Assembly – Standard

Sleeve Bearing .......................................49

14. Sectional Assembly – Optional

Mechanical Seals ....................................51

15. Cooling Options ..........................................52

RS – Multi-Stage, I-280 Centrifugal Pump 280 – 16.03.EN

I. GENERAL DESCRIPTION AND

SAFETY PRECAUTIONS.

A. GENERAL INFORMATION. Carver Pump

Company products are carefully engineered and manufactured and, if properly installed, maintained, and operated, should provide maintenance-free operation and a long service life.

CAUTION

These instructions must always be kept close to the product's operating location or directly with the product.

This manual is designed to provide sufficient material to properly maintain the total pumping unit. The information presented should improve your knowledge and understanding of the RS Multi-Stage Centrifugal Pump, thus upgrading the reliability, service life, and quality of pump maintenance.

These operating instructions are intended to facilitate familiarization with the product and its permitted use to help satisfy ATEX safety requirements. These operating instructions do not take into account local regulations; the operator must ensure that such regulations are strictly observed by all, including the personnel called in for installation. Compliance with such laws relating to the proper installation and safe operation of the pumping equipment is the responsibility of the equipment owner and all necessary steps should be taken by the owner to assure compliance with such laws before operating the equipment. These instructions are intended to facilitate familiarization with the product and its permitted use to help satisfy safety requirements. Always coordinate repair activity with operations personnel, and follow all plant safety requirements and applicable safety and health laws/regulations.

Refer to Figures 13, 14, and 15 to locate the pump parts by item number. Variations do exist between configurations, not all parts described in the text may be on your configuration.

CAUTION

These instructions should be read prior to installing, operating, using and maintaining the equipment in any region worldwide and in conjunction with the main user instructions provided. The equipment must not be put into service until all the conditions relating to safety instructions have been met.

B. ATEX DIRECTIVE 94/9/EC. It is a legal requirement that machinery and equipment put into service within certain regions of the world shall conform to the applicable CE Marking Directives for Equipment for Potentially Explosive Atmospheres (ATEX).

Where applicable the Directive covers important safety aspects relating to the equipment, its use and the satisfactory provision of technical documents. Where applicable this document incorporates information relevant to these Directives. To establish if the product itself is CE marked for a Potentially Explosive Atmosphere check the nameplate and the Certification provided.

C. DISCLAIMER. Information in these User Instructions is believed to be reliable. In spite of all the efforts of Carver Pump Company to provide sound and all necessary information the content of this manual may appear insufficient and is not guaranteed by Carver Pump Company as to its completeness or accuracy.

D. PERSONNEL QUALIFICATION AND TRAINING. All personnel involved in the operation, installation, inspection and maintenance of the unit must be qualified to carry out the work involved. If the personnel in question do not already possess the necessary knowledge and skill, appropriate training and instruction must be provided. If required the operator may commission the manufacturer/supplier to provide applicable training.

Follow instructions in this manual carefully. Factory warranty applies only when pump operates under conditions as specified on order acknowledgment, and if pump is properly installed and maintained as recommended herein. A copy of this manual should be available to operating personnel. Additional copies of this manual are available upon request from Carver Pump Company and your local distributor. For comments and/or questions about information provided, please contact Carver Pump Company or your local distributor.

E. PUMP IDENTIFICATION. The type of pump, pump size, operating data, and serial number are all stamped on the nameplate attached to the pump. Pump specifications should be recorded upon receipt of the pumping unit. Record all necessary information on the pump service record page and inspection and repair record provided at the front of this manual. This information must be included in all correspondence regarding the unit. This will ensure that the correct pump and/or parts are ordered in a timely manner.

RS – Multi-Stage, I-280 Centrifugal Pump 280 – 16.03.EN

F. PARTS INVENTORY GUIDE. To avoid unnecessary delays for maintenance, spare parts should be readily available, purchase before and keep in

used in safety instructions where noncompliance in the hazardous area would cause

the risk of an explosion. stock, for normal service. Most conditions will be covered if this manual is followed. For every one to three pumps, stock one spare set consisting of items listed in Table 19, Recommended Spare Parts. Part

General hazard sign to ISO 7000 - 0434.

numbers correspond to Figures 11, 12 and 13.

The word "Caution" is used to introduce safety

G. PARTS ORDERING. When ordering replacement parts, please specify:

instructions whose non-observance may lead to damage to the machine and its functions.

Instructions attached directly to the machine, e.g.

 Serial number of pump (located on nameplate)  Part name (located on parts list)  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

 Arrow indicating the direction of rotation

 Markings for fluid connections must always be

complied with and be kept in a perfectly legible condition at all times.

Observe all notes, caution or danger tags attached to the equipment or included in this manual.

company representative. Never return parts to the factory without authorization from Carver Pump Company.

C. PRODUCTS USED IN POTENTIALLY EXPLOSIVE ATMOSPHERES

If an impeller is ordered, specify diameter across blade tips. Be sure diameter was NOT trimmed further than diameter shown on Carver Pump Company records.

If a driver or driver parts are ordered, specify name of manufacturer and all other data found on the driver nameplate.

II. SAFETY.

A. SAFETY PRECAUTIONS. The manual is designed

to provide adequate instructions for the safe and efficient installation, operation, or maintenance of the pump. Failure or neglect to properly install, operate, or maintain the pump may result in personal injury, property damage, or unnecessary damage to the pump. This manual must be read and understood both by the installing personnel and the responsible trained personnel/operators prior to installation and operation, and it must always be kept close to the location of the pumping unit for easy access.

B. SUMMARY OF SAFETY MARKING. The safety instructions contained in this manual follow specific ATEX safety marking where non-observance of the instruction will cause a hazard is specially marked with the symbol:

Measures are required to:

 Avoid excess temperature

 Prevent buildup 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.

D. SCOPE OF COMPLIANCE.

Use equipment only in the zone for which it is appropriate. Always check that the driver, drive coupling assembly, seal and pump equipment are suitably rated and/or certified for the classification of the specific atmosphere in which they are to be installed.

This symbol indicates explosive

atmosphere marking according to ATEX. It is

Where Carver Pump has supplied only the bare shaft pump, the Ex rating applies only to the pump. The party responsible for assembling the pump set shall select the

RS – Multi-Stage, I-280 Centrifugal Pump 280 – 16.03.EN

coupling, driver, seal and any additional equipment, with the necessary CE Certificate/Declaration of Conformity establishing it is suitable for the area in which it is to be installed.

The output from a variable frequency drive (VFD) can cause additional heating affects in the motor and so, for

G. SAFETY INSTRUCTIONS FOR MAINTENANCE, INSPECTION AND INSTALLATION WORK. The

operator is responsible for ensuring that all maintenance, inspection and installation work be performed by authorized, qualified personnel who are thoroughly familiar with the manual and pumping unit.

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.

To ensure safe operation the ball bearings must be replaced at 20000 hours of service or whenever the mechanical seal is inspected or serviced.

E. SAFETY AWARENESS. It is imperative to comply with the safety instructions contained in this manual, the relevant national and international explosion protection regulations, health and safety regulations and the

operator’s own internal work, operation and safety

regulations.

Ex symbol relates to additional requirements which must be adhered to when the pump is operated in potentially explosive atmospheres.

F. SAFETY INSTRUCTIONS FOR THE OPERATOR /USER.

 Any hot or cold components that could pose a

hazard must be equipped with a guard by the operator.

 Guards which are fitted to prevent accidental

contact with moving parts (e.g. coupling) must not be removed whilst the unit is operating.

 Leakages (e.g. at the shaft seal) of 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.

The pumping unit must have cooled down to ambient temperature, pump pressure must have been released and the pump must have been drained before working on any pumping unit. Work on the pumping unit must be carried out during shutdown. The shutdown procedure described in the manual for taking the unit out of service must be adhered to.

Pumps handling fluids that are hazardous to personnel must be decontaminated prior to being worked on.

Immediately following completion of the work, all safety relevant and protective devices must be reinstalled and/or reactivated. Please observe all instructions set out in the Section VIII on start up before returning the pumping unit to service.

H. NON-COMPLIANCE WITH SAFETY INSTRUCTIONS. Non-compliance with safety

instructions may result in personal injury, property damage, or unnecessary damage to the pumping unit. Non-compliance with these safety instructions will also lead to forfeiture of any and all rights to claims for damages. Non-compliance, can for example, result in:

 Failure of important pumping unit functions.  Failure of prescribed maintenance and servicing

practices.

 Electrical hazards must be eliminated. (In this

respect refer to the relevant safety regulations applicable to different countries and/or the local energy supply companies.)

If the pumps/units are located in potentially explosive atmospheres, it is imperative to make sure that unauthorized modes of operation are prevented. Noncompliance may result in the specified temperature limits being exceeded.

 Hazard to personnel by electrical, mechanical,

and chemical effects as well as explosion.

 Hazard to the environment due to leakage of

hazardous substances.

I. UNAUTHORIZED MODIFICATION AND MANUFACTURE OF SPARE PARTS. Modifications or

alterations of the pumping unit supplied are only permitted after consultation with Carver Pump and to the extent permitted by Carver Pump. Original spare parts and accessories authorized by Carver Pump ensure safety. The use of other parts can invalidate any liability of Carver Pump for consequential damage and/or warranty.

RS – Multi-Stage, I-280 Centrifugal Pump 280 – 16.03.EN

J. UNAUTHORIZED MODES OF OPERATION. The warranty relating to operating reliability and safety of the unit supplied is only valid if the pumping unit is used in

An example of ATEX equipment marking is shown below. The actual classification of the pump will be

engraved on the nameplate. accordance with its designated use as described in the following sections. The limits stated on the nameplate must not be exceeded under any circumstances.

K. EXPLOSION PROTECTION. If the pumps/units are installed in potentially explosive atmospheres, the measures and instructions given in the following sections K.1 to K.6 must be adhered to without fail, to ensure explosion protection.

K.1 Unit Fill.

Equipment Group

I = Mining

II = Non-mining

Category

2 or M2 = high level protection

3 = normal level of protection

II 2 GD c IIC 135 ºC (T4)

Gas and/or dust

It is assumed that the system of suction

and discharge lines and thus the wetted pump

G = Gas

D = Dust

internals are completely filled with the fluid to be handled at all times during pump operation, so that an explosive atmosphere is prevented.

c = Constructional safety

(in accordance with EN13463-5)

Gas Group (Equipment Category 2 only)

If the operator cannot warrant this condition, appropriate monitoring devices must be used.

IIA – Propane (typical) IIB – Ethylene (typical) IIC – Hydrogen (typical)

CAUTION

In addition, it is imperative to make sure that the seal chambers, auxiliary systems of the shaft seal and the heating and cooling systems are properly filled.

K.2 Marking.

The marking on the pump only refers to the pump, i.e. the coupling and driver must be regarded separately. The coupling must have an EC manufacturer’s declaration. The driver must be regarded separately.

Maximum surface temperature (Temperature Class) (Refer to Section II, Paragraph K.5)

K.3 Checking the Direction of Rotation.

If the explosion hazard also exists during the installation phase, the direction of rotation must never be checked by starting up the unfilled pump unit, even for a short period, to prevent temperature increases resulting from contact between rotating and stationary components.

K.4 Pump Operating Mode.

Make sure that the pump is always started up with the suction-side shut-off valve fully open and the dischargeside shut-off valve slightly open. However, the pump can also be started up against a closed swing check valve. The discharge-side shut-off valve shall be adjusted to comply with the duty point immediately following the runup process.

RS – Multi-Stage, I-280

Temperature class

to EN 13463-1:

Temperature limit of

fluid handled

185 °F (85 °C)

284 °F (120 °C)

365 °F (185 °C)

536 °F (280 °C)

662 °F (350 °C)

Centrifugal Pump 280 – 16.03.EN

In the ball bearing bracket area, the unit surfaces must

Pump operation with the shut-off valves in

the suction and/or discharge pipes closed is not

be freely exposed to the atmosphere and the fan inlet flow must be unimpeded.

permitted.

CAUTION

In this condition, there is a risk of the pump casing taking on high surface temperatures after a very short time, due to a rapid temperature rise in the pumped fluid inside the pump. Additionally, the resulting rapid pressure build-up inside the pump may cause excessive stresses on the pump materials or even bursting.

The minimum flows calculated in Section VIII, Paragraph E, refer to water and water-like liquids. Longer operating periods with these liquids and at the flow rates indicated will not cause an additional increase in the temperatures on the pump surface. However, if the physical properties of the fluids handled are different from water, it is essential to check if an additional heat build-up may occur and if the minimum flow rate must therefore be increased.

To check, proceed as described in Section VIII, Paragraph E.

In addition, the instructions given in Section VIII of this operating manual must be observed.

In any case, responsibility for compliance with the specified fluid temperature (operating temperature) lies with the plant operator. The maximum permissible fluid temperature depends on the temperature class to be complied with.

Table 1 below lists the temperature classes to EN 13463-1 and the resulting theoretical temperature limits of the fluid handled. In stipulating these temperatures, any temperature rise in the shaft seal area has already been taken into account.

Table 1. Fluid Temperature Limits

Mechanical seals may exceed the specified temperature limits if run dry. Dry running may not only result from an inadequately filled seal chamber, but also from excessive gas content in the fluid handled.

Pump operation outside its specified operating range may also result in dry running.

K.5 Temperature Limits.

In normal pump operation, the highest temperatures are to be expected on the surface of the pump casing, at the shaft seal and in the ball bearing areas. The surface temperature at the pump casing corresponds to the temperature of the fluid handled.

If the pump is heated, it must be ensured that the temperature classes stipulated for the plant are observed.

CAUTION

The permissible operating temperature of the pump in question is indicated on the data sheet. If the pump is to be operated at a higher temperature, the data sheet is missing or if the pump is part of a pool of pumps, the maximum permissible operating temperature must be enquired from the pump manufacturer.

Based on an ambient temperature of 104˚ Fahrenheit (F) [40˚ Celsius (C)] and proper maintenance and operation, compliance with temperature class T4 is warranted in the area of the rolling element ball bearings. A special design is required for compliance with temperature class T6 in the ball bearing area. In such cases, and if ambient temperature exceeds 104˚F (40˚C), contact the manufacturer.

RS – Multi-Stage, I-280

Size

Suction

Discharge

415 PSIG*

1,475 PSIG

1,810 PSIG

1,460 PSIG

*Unless otherwise rated.

Centrifugal Pump 280 – 16.03.EN

 Make sure you are NOT grounded while

Pump liquids over 225˚F (107˚C); pumps

must be equipped with auxiliary cooling.

adjusting electrical equipment or using measuring equipment.

Pumps of high temperature construction are provided with cooled ball bearings for a unit operating in temperature range between 225˚ F and 300˚ F (107˚ C and 149˚ C). Cooling water flows through cavities of the bearing frame and keeps temperature of the ball bearings within acceptable limits. Refer to Table 13 for cooling flow rates of water temperature of 60˚ F (140˚C) for ball bearings.

K.6 Maintenance.

Only a pumping unit which is properly serviced and maintained in perfect technical condition will give safe and reliable operation.

This also applies to the reliable function of the thrust or radial ball bearings whose actual lifetime largely depends on the operating mode and operating conditions. Regular checks of the lubricant and the running noises will prevent the risk of excessive temperatures as a result of the thrust or radial ball bearings running hot or defective bearing isolators.

The correct function of the bearing isolators must be checked regularly. Any auxiliary systems installed must be monitored, as necessary, to make sure that they function correctly.

 In general, use only one hand when servicing

live electrical equipment.

 Make sure to de-energize all electrical

equipment before connecting or disconnecting meters or test leads.

 For connecting a meter to terminals for

measurement, use a range higher than the expected voltage.

 Check to make sure that the frame of the driver

and starter panel are securely grounded before operating pumping unit or performing any tests or measurements.

 If a test meter must be held or adjusted while

voltage is applied, ground case of meter before starting measurement. DO NOT touch live equipment while holding the meter. Some moving vane-type meters should not be grounded nor held during measurements.

 DO NOT use test equipment known to be

damaged or in poor condition.

The following specific safety precautions apply to the pumping unit:

 Hydro suction case separately on RS-9 units.

K.7 General Safety Instructions.

 Various federal, state, and local laws affect

installation, use, and operation of pumping equipment. Compliance with such laws relating to proper installation and safe operation of pumping equipment is the responsibility of the equipment owner.

 Prior to working on pump or driver, ensure all

switches and circuit breakers have been locked

in the open (off) position and tagged, “Out of

Service.”

 All circuits NOT known to be dead must be

considered live at all times.

 DO NOT wear loose or torn clothing around

rotating machines.

 While working near electricity, DO NOT use

metal rules, flashlights, metallic pencils, or any other objects having exposed conducting material.

 Isolate pump for system hydro.  DO NOT exceed maximum rated suction

pressure unless otherwise rated.

 DO NOT exceed maximum rated discharge

pressure.

Table 2. Maximum Allowable Pressures

RS – Multi-Stage, I-280 Centrifugal Pump 280 – 16.03.EN

III. EQUIPMENT DESCRIPTION.

RS high-pressure pumps are multi-stage, centrifugal pumps with radially split casings. The pump consists of a suction case, a discharge case, plus a number of interstage casings, all secured with tie bolts. Suction casing, interstage casings and diffusers are provided with wear rings. Diffusers are provided with bushings. Due to prolonged operation, wear rings and bushings may become worn and/or damaged. Replace all worn and/or damaged parts with new.

RS high-pressure pumps incorporate special design refinements, which help to absorb the appreciable axial thrust generated by their high head operation. Residual axial thrust is absorbed by the thrust bearings.

CAUTION

Be careful not to mix RS6 and RS9 parts since RS6 parts are not rated for the pressure of the RS9.

ATEX and CE require bearing isolators and metal splash guards to meet requirements. Other customers may use oil seals and plastic splash guards.

The bare pump consists of following major parts and options. Refer to Figures 11 and 12, for the location of parts identified by item numbers.

Item 1 – Discharge Case. The Discharge Case (1) houses the impeller (2A or 2X) and diffuser (5A or 5X). The discharge case is fastened to the suction case with tie bolts (173) and tie bolt nuts (616) with tie bolt washers (645).

Item 2A – Impeller, 1st Stage. RS pumps are equipped with enclosed impellers. The impeller (2A) is keyed to the shaft (6) by the impeller key (32A) and located by sleeves and shims. If the RS pump is only a one stage pump then only the 1st stage impeller is used. All impellers face the same direction on the shaft.

Item 2X – Impeller. RS pumps are equipped with enclosed impellers. The impeller (2X) is keyed to the shaft (6) by the impeller key (32A) and located by interstage sleeves (58) and shims. All impellers face the same direction on the shaft.

Item 5A – Diffuser. Diffusers (5A) are inserted in individual interstage casings. Diffusers are provided with diffuser bushings (63) and hold wear rings (7X).

Item 5X – Last Stage Diffuser. The last stage diffuser is located in the discharge case (1). Holds wear ring (7X) and sits on sleeve bearing (63X).

Item 6 – Shaft. The pump shaft is protected against wear by interstage sleeves, spacer sleeves, and shaft sleeves. The shaft (6) of the RS pump is designed for maximum deflection of 0.002 inch at the face of the mechanical seal (90). The shaft is also designed to provide stabilization to the rotor system when pump operates away from the best efficiency point. A coupling connects the shaft to the driver shaft. The pump coupling key (46) holds the coupling in place, causing it to rotate with the shaft.

Item 16 and 18 – Ball Bearings. A deep-groove Conrad-type, C3 internal fit radial ball bearing and a back-to-back mounted ball bearing are housed in the bearing frame (99) depending on design. The ball bearings will be designated as 7000 series. Ball bearings designated in the 7000 series will be duplex 40° angular contact ball bearings. The ball bearing is held in place by the bearing jam nuts (22). The bearings are oil lubricated by oil bath.

Item 99 – Bearing Frame. The principal function of the bearing frame (99) is to carry the loads from the liquid end of the pump to the base and to transport power from the power unit to the impeller (2A or 2X). The bearing frame has a pair of back-to-back mounted angular contact thrust ball bearings (16). This bearing frame is designed to be oil lubricated. The bearing frame is attached to the suction case (9) and discharge case (1) by tie bolts.

The use of a sight glass constant level oiler (143) maintains the oil level high enough on the higher of the two ball bearings so that the ball bearings themselves provide the motivation for the oil to be moved through the races of the ball bearings. In addition to the oil lube, the bearing frame contains the bearing isolator (169).

Item 23 – Base. A grout-able base (23) is designed to provide adequate support for the pump and motor so pump can be operated without base deflection, excessive vibration, or resonance. The pump is attached to the base with stud (634) and hex nut (614). Grouting of this type of base is required by Carver Pump Company.

Item 90 and 91 – Mechanical Seal. Mechanical seals (90 and 91) are to be used. Complete mechanical seal instructions should be obtained from the seal manufacturer. The standard seal chamber dimensions are shown in Figure 1.

Item 111 – Interstage Case. The interstage case houses the impeller (2A or 2X) and diffuser (5A). The interstage casings are all secured with tie bolts to the

RS – Multi-Stage, I-280 Centrifugal Pump 280 – 16.03.EN

suction (9) and discharge (1) casings. Interstage casings are provided with wear rings (7X). O-rings (89D) seal the individual interstage casings. A one stage pump does not have an interstage case.

IV. EFFECTS OF FLUIDS.

Solids in the fluid pumped may cause internal damage to pump casing and damage to the seal faces with resulting Hazardous conditions. Care is to be taken to ensure that the process fluid is clear of solids and debris.

A. NET POSITIVE SUCTION HEAD (NPSH). Any liquid, hot or cold, must be pushed into the impeller of the pump by some absolute pressure, such as the atmosphere or the vessel pressure from which the pump takes its action.

The head in feet of liquid necessary to maintain the required flow into the pump is called the Net Positive Suction Head (NPSH). This value is measured above the vapor pressure of the liquid at the pumping temperature.

NPSH is commonly expressed in two ways: the NPSH required by the pump, and shown on the pump curve, is the head needed to cover the losses in the pump suction and the energy required to enable the liquid to climb onboard the leading edge of the impeller vane. The NPSH available is that inherent in the system, taking into account friction losses in suction piping, valves, fittings, etc. In all cases, the NPSH available, measured above vapor pressure, must exceed the NPSH required in order to push the liquid into the pump.

B. CHANGING PUMP SPEED. Changing the speed of a centrifugal pump affects the capacity, total head, NPSH required and the brake horsepower. In general the capacity will vary in a direct ratio with the speed, whereas the total head and NPSH required will vary as the ratio of the speed squared. The brake horsepower will vary as the ratio of the speed cubed.

C. EFFECTS OF VISCOSITY. The pump is designed to deliver rated capacity at rated head for a liquid with a particular viscosity. When pump is handling heavy viscous liquid, the viscosity of the liquid must allow it to be pumped easily. The liquid may have to be heated prior to starting the pump. When contemplating operation at some viscosity other than that for which the pump was originally designed, check with Carver Pump Company.

D. EFFECTS OF SPECIFIC GRAVITY. The capacity and total head in feet of liquid developed by a centrifugal pump are fixed for every point on the curve and are always the same for the same speed. Neither capacity nor total head will be affected by a change in the specific gravity of the liquid pumped. However, since the discharge pressure in Pounds per Square Inch (PSI) and the brake horsepower required driving the pump are functions of the specific gravity of the liquid, both will be affected in direct proportion by any change in specific gravity. Therefore, an increase in specific gravity will raise the discharge pressure and is dangerous as it might overload the pump's driver, or exceed the pump casing allowable pressure.

V. TECHNICAL DATA.

Specifications and operating limits should be recorded on a Service Record Page; an example is located in the front matter of this manual. Record the necessary information upon receipt of the pumping unit.

Noise Levels. Noise levels may exceed 85dBa at 1 meter during operation. Ear protection must be worn whenever working in high noise locations.

Axial Impeller Alignment Control Dimensions. Axial impeller alignment control dimension are located in Table 3 and are arranged by pump size.

Seal Chamber Dimensions. Standard seal chamber dimensions are located in Figure 1 and are arranged by pump size.

Basic Design Features. Basic design features of the pump are located in Tables 3, 4, 5, 6, 7, 10, and Figures 2 and 3 and are arranged by pump model.

Key Mechanical Data. Key mechanical data for the pump is located in Table 8 and is arranged by pump model.

Permissible Nozzle Loads. The forces and moments in Table 9 are to be understood as the limit for a single acting force or moment along the particular coordinate axes or any resultant of two or more forces and moment.

RS – Multi-Stage, I-280

Stages

Pump Size A

(Inches)

Pump Size B

(Inches)

Pump Size C

(Inches)

Pump Size D

(Inches)

Pump Size E

(Inches)

1.147

1.150

1.267

1.580

2.093

1.144

1.143

1.263

1.635

1.998

1.141

1.140

1.260

1.632

1.995

1.138

1.137

1.257

1.629

1.992

1.135

1.134

1.254

1.626

1.989

1.132

1.131

1.251

1.623

1.986

1.129

1.128

1.248

1.620

1.983

1.126

1.125

1.245

1.617

1.980

1.123

1.122

1.242

1.614

N/A

1.12

1.119

1.239

1.611

N/A

1.117

1.116

1.236

1.608

N/A

1.114

1.113

1.233

1.605

N/A

1.111

1.110

N/A

1.108

1.107

N/A

1.105

1.104

N/A

1.102

1.101

N/A

1.099

1.098

N/A

1.096

1.095

N/A

Centrifugal Pump 280 – 16.03.EN

Table 3. Axial Impeller Alignment Control Dimensions

*Additional stages will require compensation for interstage compression, on average .003 inch per stage. Use .010 inch shim as needed. Refer to Section XI, Paragraphs E.

RS – Multi-Stage, I-280

Stages

Pump Size A

(Inches)

Pump Size B

(Inches)

Pump Size C

(Inches)

Pump Size D

(Inches)

Pump Size E

(Inches)

-.110

-.125

.137

.185

-.113

-.128

.134

.182

-.116

-.131

.131

.179

-.119

-.134

.128

.176

-.122

-.137

.125

.173

-.125

-.140

.122

.170

-.128

-.143

.119

.167

-.131

-.146

.116

.164

-.134

-.149

.113

N/A

-.137

-.152

.110

N/A

-.140

-.155

.107

N/A

-.143

-.158

.104

N/A

-.146

N/A

-.149

N/A

-.152

N/A

-.155

N/A

-.158

N/A

-.161

N/A

Low NPSH

Impeller

See note below

2 - 18

1 (Discharge Side)

Low NPSH Impeller (Suction)

Centrifugal Pump 280 – 16.03.EN

Table 3. Axial Impeller Alignment Control Dimensions - Continued

*Additional stages will require compensation for interstage compression, on average .003 inch per stage. Use .010 inch shim as needed. Refer to Section XI, Paragraphs F.

RSA No NPSH Impeller RSB .210 – [#of stages X (.003) - Gaps] = NPSH Impeller Setting RSC .538 – [#of stages X (.003) - Gaps] = NPSH Impeller Setting RSD .792 – [#of stages X (.003) - Gaps]= NPSH Impeller Setting RSE .210 – [#of stages X (.003) - Gaps] = NPSH Impeller Setting

RS – Multi-Stage, I-280 Centrifugal Pump 280 – 16.03.EN

Figure 1. Seal Chamber Dimensions

RS – Multi-Stage, I-280

Pump Model

At Impeller (Inches)

At Coupling (Inches)

1.437

1.250

1.437

1.250

1.437

1.250

1.574

1.500

1.771

1.625

Pump Model

Sleeve Bearing New

(Inches)

Sleeve Bearing

Replacement Limits

(Inches)

Sleeve

(Ø = Diameter Measured)

New (Inches)

Replace (Inches)

1.758/1.760

Ø > 1.762

1.751/1.749

Ø < 1.746

1.758/1.760

Ø > 1.762

1.751/1.749

Ø < 1.746

1.758/1.760

Ø > 1.762

1.751/1.749

Ø < 1.746

1.972/1.974

Ø >1.976

1.965/1.963

Ø < 1.961

2.382/2.384

Ø >2.386

2.375/2.373

Ø < 2.371

Pump Model

Suction End (Inches)

(from end of sleeve to face of collar)

3.100

4.322

4.500

Centrifugal Pump 280 – 16.03.EN

Table 4. Shaft Dimensions

Table 5. Sleeve Bearing Dimensions

Table 6. Standard Design Pump Mechanical Seal Settings

RS – Multi-Stage, I-280

Pump

Model

Discharge End (Seal Type 1) (for reference only) – Inches

(from face of box to face of

collar)

Discharge End (Seal Type

8B1) (for reference only) –

Inches

(from face of box to face of

collar)

Suction end (Seal Type 1 or

21)

- Inches

(from face of box to face of

collar)

.750

1.375

1.000

.750

1.375

1.000

.750

1.375

1.000

2.062

1.750

1.312

1.792

1.812

1.594

Item

Pump Model

A, B C D

Maximum Speed

3500 RPM

Max HP – (17-4 PH shaft)

370

603

900

Max HP – (416 SS Shaft)

308

500

690

WR2 of Rotor – 1st Stage (lb-In2)

14.6

30.8

36.7

106.5

WR2 of Rotor – each Stage (lb-In2)

10.2

26.7

31.1

94.4

Lubrication Method (Standard)

Oil – ISO Grade 68

L10 Bearing Life (hrs) - Thrust

50,000

L10 Bearing Life (hrs) - Radial

50,000

Radial Bearing Type

307

308

309

Thrust Bearing Type

7307

7308

7309

Plan 13

Plan 11

Plan 13

Plan 23

Plan 21

Centrifugal Pump 280 – 16.03.EN

Table 7. Optional Design Pump Mechanical Seal Settings

Table 8. Key Mechanical Data

The standard seal flush plans provided with the optional outboard mechanical seal are shown below.

Recirculation from Suction Point to Seal Recirculation from Discharge Point thru a TI

and Heat Exchanger to Seal

Figure 2. Standard Seal Flush Plans

+ 43 hidden pages

Carver Pump RSA, RS Series, RSB, RSC, RSE Installation, Operation And Maintenance Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual