Work_Item_506_Reference_2.1.pdf

T9531-AU-MMC-010

T9531-AU-MMC-01C

PUBLISHED BY DIRECTION OF COMMANDER MILITARY SEALIFT COMMAND

0910-LP-111-2775 CHANGE C

TECHNICAL MANUAL

DISTILLING PLANT & BROMINATION

DISINFECTION SYSTEM, MODEL SPD 35-53TPD

FOR

USNS LEWIS AND CLARK (T-AKE 1) CLASS

OPERATING, MAINTENANCE AND TROUBLESHOOTING INSTRUCTIONS

(AQUA-CHEM, INC.)

E. JOHN SEVIER HIGHWAY, KNOXVILLE, TN

N00024-02-C-2300

DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED.

(FOR REPRODUCTION PURPOSES ONLY 2)

DEPARTMENT OF THE NAVY

MILITARY SEALIFT COMMAND

WASHINGTON, D.C. 20398-5050

CHANGE INSTRUCTION SHEET

TECHNICAL MANUAL DISTILLING PLANT & NAVSEA T9531-AU-MMC-010

BROMINATION DISINFECTION SYS CHANGE C: 2 JUNE 2011

PUBLISHED BY DIRECTION OF COMMANDER, MILITARY SEA LIFT COMMAND

GENERAL INSTRUCTIONS:

After the attached enclosures have been inserted, record this change on the change record sheet and insert this change guide between the front cover and title page.

The attached enclosures incorporate modifications made for administrative corrections and add drawings for T-AKE installed equipment.

Holders of this volume shall incorporate this change in the correct numerical sequence when it has been determined that the superseded information will no longer be required.

SPECIFIC INSTRUCTIONS:

1. Incorporate the attached enclosures as follows:

REMOVE PAGES INSERT PAGES

Title/A Title/A

- DWG: 505-D-7589 (4 pages) Insert After DWG: 255-D-8150

(FOR REPRODUCTION PURPOSES ONLY 3)

(FOR REPRODUCTION PURPOSES ONLY 4)

PUBLISHED BY DIRECTION OF COMMANDER MILITARY SEALIFT COMMAND

2 JUNE 2011 CHANGE C

0910-LP-111-2775

TECHNICAL MANUAL

DISTILLING PLANT & BROMINATION

DISINFECTION SYSTEM, MODEL SPD 35-53TPD

USNS LEWIS AND CLARK (T-AKE 1) CLASS

OPERATING, MAINTENANCE AND TROUBLESHOOTING INSTRUCTIONS

(AQUA-CHEM, INC.)

E. JOHN SEVIER HIGHWAY, KNOXVILLE, TN

N00024-02-C-2300

DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED.

(FOR REPRODUCTION PURPOSES ONLY 5)

A

List of Effective Pages Date of original pages is:

Original: 02 November 2005 Change A: 16 November 2007

Change B: 03 July 2009 Change C: 2 June 2011

Total number of pages in this publication is 204 consisting of the following:

Page No. * Change No. Page No. * Change No.

Title/A ............................................................ C CH 9. 5-1 through 5-2

Page 1 through Page 4................................. 0 CH 9. 6-1 through 6-6

Page 5..............................................................A CH 9. 7-1

CH 1. Page 6 through Page 7...................... 0 CH 9. FP-1 through FP-3

CH 2. Page 8 ................................................0 CH 9. LSI-1 through LSI-2

CH 3. Page 9..................................................... 0 CH 9. 8-1, REAR COVER

CH 4. Page 10 through Page 11....................0 CH 9. App A, i through ii

CH 5. Page 12 through Page 14....................B CH 9. App A, 1-1 through 1-4

CH 5 Page 15............................................... 0 CH 9. App A, 2-1 through 2-4

CH 6. Page 16 through Page 17....................0 CH 9. App A, 3-1 through 3-6

CH 7. Page 1 through Page 18......................0 CH 10. Cover Sht, 1 through 52

CH 8. Dwg No. 627-B-11428, 4 sheets..........0 CH 11. Cover, 1 through 12 ......................... A

CH 8. Dwg No. 627-D-11393, 2 sheets ........A

CH 8. Dwg No. 641-C-9855, 10 sheets ........A

CH 8. Dwg No. 656-B-9396, 4 sheets ..........A

CH 8. Dwg No. 627-D-11599, 2 sheets.........A

CH 8. Dwg No. 508-D-9400, 2 sheets...........A

CH 8. Dwg No. 118-C-11469, 1 sheet..........A

CH 8. Dwg No. 389-10322, 1 sheet..............B

CH 8. Dwg No. 389-10323, 1 sheet..............A

CH 8. Dwg No. 255-D-8150, 1 sheet............A

CH 8. Dwg No. 505-D-7589, 2 sheets..........C

CH 8. Page 1 through Page 2.......................A

CH 9. Cover, Serv Rec, Notes, i through ix .. 0

CH 9. 1-1 through 1-2

CH 9. 2-1 through 2-5

CH 9. 3-1

CH 9. 4-1 through 4-5

* Zero in this column indicates an original page

(FOR REPRODUCTION PURPOSES ONLY 6)

ILS Parts List

9. Carver Pump/Baldor Motor Documentation (Seawater Pump)

10. LMI Documentation (Chemical Dosing Unit)

11. Grundfos Documentation (Fresh Water Pump) n42474 641-C-9855 n42474 656-B-9396

SP 4"

n50241 Text Box

CH-CHN SS Horizontal Multi-Stage End- Suction Pump n50241 Text Box

1.34 kW n50241 Text Box

CHANGE A

(FOR REPRODUCTION PURPOSES ONLY 7)

overboard valve and starting up the eductor pump.

Check that the steam-turning plate above the evaporator and the demister is correctly placed and that the gasket sealing to main frame is Dot "cuf' or has a leakage, so that DO salt-water drops pass with the steam through to the condenser.

Manual No. 08542-04 Rev. 0 August 27, 2004 Page 11

(FOR REPRODUCTION PURPOSES ONLY 8)

CHAPTER 5

SERVICE & MAINTENANCE

CLEANING OF THE PLANT

Although the working temperature of the Fresh Water Distiller kept at 40-48QC, scaling on the plates of the evaporator will gradually occur, causing a reduction of the capacity of the Seawater Plate Distiller and cleaning of the plates will be necessary.

The frequency of the cleaning depends very much on the working conditions, but normally a chemical cleaning 2-3 times a year as well as an opening of the plate pack once a year or every second year for total cleaning/inspection will be sufficient.

Cleaning by opening of Seawater Plate Distiller When the plant bas been stopped as descnbed under "Stopping the Planf' open the Seawater Plate Distiller and inspect condenser, evaporator, demister and the interior of the Seawater Plate Distiller and carry out the required cleaning.

Normally it is necessary only to separate the evaporator and clean the plates by means ofthe chemicals described under "CHEMICAL CLEANING". The interior of the Seawater Plate Generator should be cleaned at the same time using the same chemicals.

Clean the evaporator as follows:

entire load alone.

3. Remove the follower and take out the plates one by one and note their position in order not to get a "disorganized" plate pack when you re assemble.

4. Submerge plates completely in a hot, inhibited AC-2 (pin 803-7523) bath at maximum 50°C.

For further information about chemical please refer to "CHEMICAL

CLEANING".

WARNING

CarefuUy follow the supplier's instructions when using inhibited acids.

Remember to neutralize according to supplier instructions

5. Examine plates and gaskets for possible damage and remove damaged andlor replace damaged gaskets.

NOTE: See Upper-Condensor Plate 38910322 and Lower-Evaporator Plate 38810323 drawings in Chapter 8 for plate arrangement and compression values.

Manual No. 08542-04 Rev. 0 August 27, 2004 Page 12

CHANGE B

(FOR REPRODUCTION PURPOSES ONLY 9)

6. If a defective plate is found, remove the plate together with the other plates in this group. The start plate and the end plate in the plate pack can't be removed without being replaced by a new plate.

7. When assembling a separated evaporator, it should be checked that the gaskets have not been damaged - change defective gaskets, if any. Cut gaskets as shown on the plate diagram. Assemble the plates in due succession according to plate arrangement drawing and be aware that they are positioned correct. Clamp the plate pack to the correct dimension according to the number ofplates.

NOTE:There are four patterns for each plate pack that determine the flow.

The correct pattern is 1,2,3,4 only. Failure to follow the correct pattern will result in reduced or no t1ow. If the plates are installed in a pattern, such as 1,4,3.2. they will appear to be correct, but flow will be restricted. Always refer to Upper-Condensor Plate 389 J0322 or Lower-Evaporator Plate 3890323 Drawings in Chapter 8 for correct plate pack and pattern arrangement and compression values upon re-assembly.

8. Pressure test evaporator plates before closing front cover.

This is done by slowly opening the by-pass valve for hot water into normal position let the water flow through.

9. The condenser plates are pressure tested by letting seawater from the combined cooling water/eductor pump circulate through the section.

]O. When the evaporator/condenser plates are found to be tight, close front cover and tighten the bolts.

] l. Re-tighten, when vacuum has been re-established.

RENEWAL OF HEAT EXCHANGER GASKET

NEW GASKET On the enclosed evaporator and condenser exchanger diagram an order list for the gaskets is shown.

The gaskets are cut out of an ordinary gasket. Therefore please note the cutting out of the old gaskets before removing them.

In the evaporator, a piece of gasket, cut out on the sea water side and only on the sea water side, is used for guiding the seawater flow stream over the plate.

Therefore please note that this gasket piece is glued as shown on the figure on the next page.

Manual No. 08542-04 Rev. 0 August 27, 2004 Page 13

CHANGEB

(FOR REPRODUCTION PURPOSES ONLY 10)

~[j

CAUTION

Always refer to Table or illustration in Upper-Condensor Plate 3890322 or Lower-Evaporator Plate 3890323 Plate Pack Assembly Drawings for correct Plate arrangement and Compression values. Failure to comply can result in reduced or no flow of the plates ifre-assembled incorrectly.

GLUE TYPE PLIOBOND 25 I SCOTCHGRIP 847 are nitrile rubber glues on soluble basis (25% solid materials). The glues are partly thermoplastic so the old gaskets can be loosened with boiling water.

DETERGENT For cleaning and degreasing new gaskets and gasket grooves use "ACETONE". Charred or loose glue and rubber remains must be removed, e.g.

by using a rotation stainless steel brush. It is very important that every detergent is evaporated before putting glue on.

WARNING

Solvents are dangerous to inhale.

GLUING After wiping gaskets and gasket grooves with a cloth moistened with degreasing substance the gluing itself can begin. The gluing areas must be quite clean free from fingerprints etc. The gaskets are covered by a brush with a thin coat ofglue on the gluing area and placed on a clean and dry place in order to dry.

The gluing process is done easiest on a solid table. After the gaskets have been put into the plate gasket grooves, the plates are stacked.

When the gluing is fInished the plates are hung into the unit again and heat exchanger is clamped together. The heat exchanger can be wanned up by bot water if the glue is to dry quickly - but without pressure on the water!

Manual No. 08542-04 Rev. 0 August 27, 2004 Page 14

CHANGEB

Chapter 7

Chapter 8

Page 8-1

Page 8-2

Page 8-3

Page 8-4

CHANGE A

n50241

CHAPTER 8

CHANGE A

n50241

Page 8-15

Text Box

CHAPTER 8

n50241

CHANGE A

n50241

CHANGE A

n50241

CHANGE A

n50241

CHANGE A

n50241

Line n50241 Line n50241 Line n50241 Text Box n50241 Text Box

05/22/06 JLP

n50241 Text Box ON LINE 100 MOVED 119 FROM 0 TO C. ON LINE 119 CONTACT WAS N.O. & 3 WAS 6. ISSUED W3742 SMB n50241 Line n50241 Line n50241 Line n50241 Text Box n50241 Text Box

10/06/06 JLP

n50241 Text Box ON LINE 100 MOVED 119 FROM C TO 0 & MOVED 105, 116 TO C ON LINE 105 CONTACT WAS 4 & 7. ON LINE 116 CONTACT WAS 5 & 8. W3839 SMB/RLB n50241 Line n50241 Text Box

CHANGE A

n50241

C n50241 Text Box n50241 Line n50241 Line n50241 Text Box

ENERGIZE - NO ALARM

DE-ENERGIZED - ALARM

n50241 Text Box

NO

n50241 Text Box

NC

n50241 Text Box

NO

n50241 Text Box

NC

Line n50241 Line n50241 Line n50241 Line n50241 Line n50241 Line n50241 Line n50241 Line n50241 Text Box n50241 Line n50241 Line n50241 Line n50241 Text Box

05/22/06 JLP

n50241 Text Box

ON LINE 100

MOVED 119 FROM 0 TO C. ON LINE 119 CONTACT WAS N.O. & 3 WAS 6

ISSUED W3742 SMB

n50241 Line n50241 Line n50241 Line n50241 Text Box n50241 Text Box

10/06/06 JLP

n50241 Text Box ON LINE 100 MOVED 119 FROM C TO 0 & MOVED 105, 116 TO C. ON LINE 105 CONTACT WAS 4 & 7 ON LINE 116 CONTACT WAS 5 & 8 W3839 SMB/RLB n50241 Line n50241 Text Box

CHANGE A

n50241

CHANGE A

n50241

CHANGE A

n50241

CHANGE A

n50241

(FOR REPRODUCTION PURPOSES ONLY 11)

PLATE 10 TABLE DATE

ISSUED DWG. 071191201l6TOP PLATE IFLOW ON GASKET IHORIZONTAL CHANNEL AT BOTTOM ISLANTED TO VERTICAL '/13742 RLB

EDGE SIDE OF PLATE OF PLATE ON GASKET SIDE RIDGE CONTACT

N I "VERTICAL GROOVE YES

GASKETED I HORIZONTAL RIDGE YES

D o 1~7-~G~AiS~KE~TE~O~~H~O~R~IZ~O~NT*A~L--~--~~~~~~

• EXCEPT VERY FIRST PLATE-FULL GASKET. NO fLOW ON GASK!=r SIDE.

COMPRESSI:)N TABLE

PACK 84 PLATES

mm

MIN COMPRESSION MIN COMPRESSION

MAX DIMENSIO IMAX DIMENSION) I 361

MAX COMPRESSION

IMIN DIMENSION) I 32. ,. ". I NESTING LIP

., DIRECTION TYP.

/' ALL PLATES

PIN 255-8132 QTY(l) 4E

BLANK

PLATE

c c

".ttIIt-"'

"", ~.. 1

~. PIN 255-8128 QTY(20)

PIN ~55-8131 QTY(2~

....."-COMBINATION OF 1 THRU 4

PIN 255-8130 QTY(21) UNTIL LAST PLATE COMBINATION

WHERE BLANK PLATE IS USED

COOLING / 2

SEAWATER // PIN 255-8129 QTY(21)

INLET ~

FRESHWATER

1S

OUTLET PIN 255-8127 QTY(l)

COLLECTED DISTILLATE VERT.

DOWN FLOWS AT DOTS. --i\--- ------ WATkR TECHNOLOG1ESOIVI5ION f:-:-:-:-====:-I-------j----j CODE IDENT. aqua-chern, Inc.

07/1912006 OEXU3 MILWALJKHf. Wls(;ONSJNC®

4 R KNOXVillE:, It:NNE$SE~___07119;2006

A 3 ", ,.....-. r

A2 PLATE PACK ASS T ,:,r-u "v-v" ------~'--------____1

1 UPPER-CONDENSER

THIRD ANGLE PROJECTION

PLATE FLOW DETAIL SSE IDWG',NO. 389-10322 _1 Rr

WEIGHT: SHEET1 OF 1

8 2

8-37

) ~ z a m

;0

0 ;0 m

;0

" 0 c::

(1

Z

0 z (3

" c::

Z

0 " c:

'" 0 z

S!:

i'} z '"

SEAWATER

INLET

JACKET WATER

OUTLET

JACKET WATER

INLET

BRINE/VAPOR

OUTLET

COMBINATION OF 1 THRU 4

UNTIL LAST PLATE COMBINATION

WHERE BLANK PLATE IS USED.

BLANK

PLATE

4EC

3C

2C

1C

4C

3C

2C

1S

NESTING LIP

DIRECTION

TYP. ALL

PLATES

* EXCEPT VERY FIRST PLATE-FULL GASKET, NO FLOW ON GASKET SIDE.

PLATE FLOW DETAIL

BOILING SEAWATER

VERTICAL UP FLOWS AT DOTS

P/N 255-8127 QTY(1)

P/N 255-8152 QTY(17)

P/N 255-8153 QTY(17)

P/N 255-8154 QTY(16)

P/N 255-8155 QTY(1)

P/N 255-8151 QTY(16)

CROSSOVER

HEATING JACKET WATER

HORIZONTAL FLOWS

REVISIONS

ZONE REV. DESCRIPTION DATE

1 ISSUED DWG.

W3742 RLB 07/19/2006

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1

THIRD ANGLE PROJECTION

1389-10323

SHEET 1 OF 1

PLATE PACK ASS'Y SPD35-53

07/19/2006

07/19/2006

07/19/2006RGF

RLB

RAR

UNLESS OTHERWISE SPECIFIED:

SCALE: 1:12 WEIGHT:

REVDWG. NO.

B

SIZE

aqua-chem, Inc.

SIGNATURES DATE CODE IDENT.

ENG APPR.

CHECKED

DRAWNDIMS ARE IN INCHES TOLERANCES:

FRACTIONAL 1/8"

MACHINED FRACTIONS 1/32"

ANGULAR: 2

TWO PLACE DECIMAL 0.010"

THREE PLACE DECIMAL 0.005"

PROPRIETARY AND CONFIDENTIAL

THE INFORMATION CONTAINED

IN THIS DRAWING IS THE SOLE

PROPERTY OF AQUA-CHEM, INC.

ANY REPRODUCTION IN PART OR

AS A WHOLE WITHOUT THE

WRITTEN PERMISSION OF

AQUA-CHEM, INC. IS PROHIBITED.

LOWER - EVAPORATOR

OEXU3

WATER TECHNOLOGIES DIVISION

MILWAUKEE, WISCONSIN

KNOXVILLE, TENNESSEE

R

COMMENTS:

PLATE

TYPE

TOP PLATE

EDGE

FLOW ON GASKET

SIDE OF PLATE

HORIZONTAL CHANNEL AT BOTTOM

OF PLATE ON GASKET SIDE

SLANTED TO VERTICAL

RIDGE CONTACT

1 *OPEN *VERTICAL GROOVE YES

2 GASKETED HORIZONTAL RIDGE YES

3 OPEN VERTICAL GROOVE NO

4 GASKETED HORIZONTAL RIDGE NO

PLATE ID TABLE

mm IN

MIN COMPRESSION

(MAX DIMENSION) 4.3 0.169

MAX COMPRESSION

(MIN DIMENSION) 3.9 0.154

PER PLATE

COMPRESSION TABLE

mm IN

MIN COMPRESSION

(MAX DIMENSION) 292 11 1/2

MAX COMPRESSION

(MIN DIMENSION) 265 10 7/16

PACK 68 PLATES

COMPRESSION TABLE

n50241 Text Box

CHANGE A

n50241

2 1/4"R

3 1/4"

HOLD

31 1/2"

1.9 REF

SECTION A-A

DETAIL - ITEM 2

SCALE 1 : 2

1/8

1/8

TYP. (2)

PLACES

3/16"3 1/16"

COMMENTS:

THIRD ANGLE PROJECTION

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1

E

F

E

F

255-D-8150

SHEET 1 OF 1

PLATE ASSEMBLY,

07/12/2006

07/12/2006

07/12/2006RLB

RLB

RAR

UNLESS OTHERWISE SPECIFIED:

SCALE: 1:4 WEIGHT:

REVDWG. NO.

aqua-chem, Inc.

SIGNATURES DATE CODE IDENT.

ENG APPR.

CHECKED KNOXVILLE, TENNESSEE

0.010"

WRITTEN PERMISSION OF

PROPRIETARY AND CONFIDENTIAL

OEXU3

EVAP. FOLLOWER

DRAWN

0.005"

AQUA-CHEM, INC.IS PROHIBITED.

TWO PLACE DECIMAL

THREE PLACE DECIMAL

WATER TECHNOLOGIES DIVISION

DIMENSIONS ARE IN INCHES TOLERANCES:

FRACTIONAL 1/8"

MACHINED FRACTIONS 1/32"

ANGULAR: 2

THE INFORMATION CONTAINED IN THIS

DRAWING IS THE SOLE PROPERTY OF

AQUA-CHEM, INC. ANY REPRODUCTION

IN PART OR AS A WHOLE WITHOUT THE

MILWAUKEE, WISCONSIN

MODEL SPD35-53

R

REVISIONS

ZONE REV. DESCRIPTION DATE

1 ISSUED DWG.

W3838 RLB 07/12/2006

ITEM QTY. PART NUMBER DESCRIPTION WIDTH LENGTH CERT WEIGHT

2 1 900-00443-000 SST316L PIPE 1.5 X .145 W SA312 36.063 X 1.04

1 1 059-10650-000 COVER, PLATE PACK COMPRESS - MOD SPD35 22.500 42.875 O 174.58

A A

3/4" REF

CHANGE A

n50241

REVISIONS

ZONE REV. DESCRIPTION DATE

1 ISSUED DRAWING FOR MANUFACTURING.

RWM/DF/RGF 03/01/2011

EXCEPT WHERE NOTED

BRINE SUCTION

MATERIAL: ALUM-BRZ ASTM B505 C95400

SEAWATER

MOTIVE

ITEM QTY. PART NUMBER DESCRIPTION WIDTH LENGTH CERT WEIGHT

2 1 022-08357-000 SWIRLER, AIR - EDUCTOR MODEL AE 35-43 1 1/4" X 0.1

1 1 934-08485-000 EDUCTOR, AE 35-43 X 64.5

UNLESS OTHERWISE SPECIFIED:

TWO PLACE DECIMAL

THIRD ANGLE PROJECTION MODEL AE 35-43

COMMENTS:

A Q U A

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3

0EXU3

2 1

E

F

C H E M

AQUA-CHEM, INC.IS PROHIBITED.

E

F

SHEET 1 OF 2

505-D-7589

EDUCTOR ASSEMBLY

03/01/2011DF

03/01/2011RGF

SCALE: 1:4 WEIGHT: 64.6

REVDWG. NO.

SIGNATURES

MAT'L ALUMINUM BRONZE

0.005"

CHECKED

RWM

THREE PLACE DECIMAL

DATE

PROPRIETARY AND CONFIDENTIAL

0.010"

DRAWN 03/01/2011

CODE IDENT.

ENG APPR.

DIMENSIONS ARE IN INCHES TOLERANCES:

FRACTIONAL 1/8"

MACHINED FRACTIONS 1/32"

ANGULAR: 2

THE INFORMATION CONTAINED IN THIS

DRAWING IS THE SOLE PROPERTY OF

AQUA-CHEM, INC. ANY REPRODUCTION

IN PART OR AS A WHOLE WITHOUT THE

WRITTEN PERMISSION OF

KNOXVILLE, TENNESSEE

OVERBOARD

3" BACK-UP FLANGE

150# GALV.

4" BACK-UP FLANGE

150# GALV.

5" BACK-UP FLANGE

150# GALV.

8" NPT

DISCHARGE

AIR SUCTION

7 5/8"

6 5/8"

20 7/8"

2.716

28 1/2"

A A

4.

SEE SECTION AM-AM ON SHEET 2 FOR REPLACEMENT PARTS LIST.

SECTION A-A

5.

NOTES:

THE FOLLOWING SHOULD BE STAMPED ON BOTH SIDES OF THE BODY: 1.

"AE 35-43"

"43 45 54"

REF LOWER LEVEL DWG. 934-D-8485 FOR ORDERING INFORMATION.2.

PRESSURE:3.

WORKING: 60 PSIG

TEST: 90 PSIG

BRINE NOZZLE REMOVAL TOOL - 943-8849

CHAPTER 8 CHANGE C

(FOR REPRODUCTION PURPOSES ONLY 7)

THIS PAGE INTENTIONALLY LEFT BLANK

(FOR REPRODUCTION PURPOSES ONLY 8)

SWIRLER, AIR - EDUCTOR MODEL AE 35-43022-08357-000115

NOZZLE, AIR EDUCTOR MODEL AE 35934-08485-014114

O-RING EPDM SAE SIZE 2-236

REPLACEMENT PARTS

ITEM QTY PART NUMBER DESCRIPTION

1 1 934-08485-001 BODY, EDUCTOR MODEL AE 35

2 1 934-08485-002 NOZZLE, BRINE, EDUCTOR MODEL AE 35

3 1 934-08485-003 TAIL, EDUCTOR MODEL AE 35

4 1 934-08485-004 TAILPIECE, SUCTION EDUCTOR MODEL AE 35

5 1 934-08485-005 TAILPIECE, MOTIVE EDUCTOR MODEL AE 35

6 1 934-08485-006 TAILPIECE, DISCHARGE EDUCTOR MODEL AE 35

7 1 849-09794-000 FLG, BK-UP STL GALV FLKR AFR 5.0 IPS

8 1 849-08426-000 FLG, BK-UP STL GALV FLKR AFR 4.0 IPS

9 1 849-08425-000 FLG, BK-UP STL GALV FLKR AFR 3.0 IPS

10 2 853-10220-000 O-RING EPDM SAE SIZE 2-228

11 1 853-10218-000 O-RING EPDM SAE SIZE 2-230

12 1 853-10219-000 O-RING EPDM SAE SIZE 2-234

13 1 853-10221-000

REVISIONS

ZONE REV. DESCRIPTION DATE

- - See Sheet1 -

CODE IDENT.

ENG APPR.

CHECKED

DRAWN

0.005" 03/01/2011

PROPRIETARY AND CONFIDENTIAL

TWO PLACE DECIMAL

UNLESS OTHERWISE SPECIFIED:

SCALE: 1:2

THREE PLACE DECIMAL

0EXU3

COMMENTS: MAT'L ALUMINUM BRONZE

MODEL AE 35-43

C H E M

THIRD ANGLE PROJECTION

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1

AQUA-CHEM, INC.IS PROHIBITED.

E

F

E

A Q U A

F

DATE

0.010"

SIGNATURES

DWG. NO.

EDUCTOR ASSEMBLY

REV

WEIGHT: 64.6

505-D-7589

DF

03/01/2011

RGF

SHEET 2 OF 2

RWM

03/01/2011

DIMENSIONS ARE IN INCHES TOLERANCES:

FRACTIONAL 1/8"

MACHINED FRACTIONS 1/32"

ANGULAR: 2

THE INFORMATION CONTAINED IN THIS

DRAWING IS THE SOLE PROPERTY OF

AQUA-CHEM, INC. ANY REPRODUCTION

IN PART OR AS A WHOLE WITHOUT THE

WRITTEN PERMISSION OF

KNOXVILLE, TENNESSEE

SECTION AM-AM

11 6

CHAPTER 8 CHANGE C

(FOR REPRODUCTION PURPOSES ONLY 9)

THIS PAGE INTENTIONALLY LEFT BLANK

(FOR REPRODUCTION PURPOSES ONLY 10)

DISTILLING PLANT HULL NO. 471 -- SPD 35

ITEM

NUMBER

INDENTURE

LEVEL

(OPTIONAL)

SUPPLIER PART

NUMBER

SUPPLIER

CAGE CODE

OEM PART

NUMBER

OEM

CAGE

CODE

NOMENCLATURE / DESCRIPTION

COMPONENT

CHARACTERISTICS

MODEL

NUMBER

UNIT

OF

ISSUE

QTY COST

LEAD TIME

IN MONTHS

SHELF

LIFE

SPECIAL STORAGE

REQ'TS

SERIAL

NUMBER

VOLUME/

DIMENSIONS WEIGHT

Aqua- Chem, Inc. 627-11393 09647 627-11393 09647

DISTILLING PLANT AND

BROMINATION DISINFECTION

SYSTEM (HULL NO. 471)

SEAWATER

DISTILLER 60 PFL2-53 S/S 2 $179,125.00 18 SPD-35

SP04-

19073

SP04-

19074

2000Kg

TWO YEAR SPARE PARTS

1. Aqua-Chem, Inc.

032-11073-000 09647 032-11073-000 09647 Gasket Set, Condenser Plate Pack Garlock 3200 SPD35 Ea. 1 $18.00 2 N/A Dry Storage N/A N/A N/A

2. Aqua-Chem, Inc.

032-11074-000 09647 032-11074-000 09647 Gasket Set, Heating Water Plate Pack Garlock 3200 SPD35 Ea. 1 $18.00 2 N/A Dry Storage N/A N/A N/A

3. Aqua-Chem, Inc.

032-11075-000 09647 032-11075-000 09647 Gasket Set, Evaporator Vessel Rubber SPD35 Ea. 1 $192.00 2 2 Years Dry Storage N/A N/A N/A

4. Aqua-Chem, Inc.

902-09068-000 09647 902-09068-000 09647 Mechanical Seal Distillate Pump Packing SPD35 Ea. 1 $210.00 2 N/A Dry Storage N/A N/A N/A

5. Aqua-Chem, Inc.

832-08651-000 09647 832-08651-000 09647 Coil, Distillate Solenoid Valve ASCO 120V AC #224071-001 SPD35 Ea. 1 $78.00 2 N/A Dry Storage N/A N/A N/A

6. Aqua-Chem, Inc.

805-07523-000 09647 805-07523-000 09647 Cleaning Chemical Container, Dry Compound, AC2

SULFAMIC

50LB. DRUM SPD35 Ea. 1 $141.00 2 2 Years Dry Storage N/A N/A N/A

LIST of MANUFACTURERS

NUMBER

INDENTURE

LEVEL

(OPTIONAL) MANUFACTURER'S or VENDOR'S NAME and ADDRESS

1. 09647 Aqua-Chem, Inc., Parts Department, P.O. Box 421, Milwaukee, WI 53201, (414) 359-0600

EQUIPMENT LOGISTICS INFORMATION LIST -- T-AKE DRY CARGO AMMUNITION SHIP Page: 1 Date: 1/31/2007

Text Box

CHAPTER 8

n50241

DISTILLING PLANT HULL NO. 471 -- SPD 35

TOOLS / MATLS REQ'ED FOR INSTALLATION

NUMBERNAME

RECOMMENDED

TYPE, SIZE,

VENDOR, SPEC or

OTHER

CHARACTERISTIC

S

UseOEM PART

NUMBER

OEM

CAGE

CODE

NOMENCLATURE / DESCRIPTION

COMPONENT

CHARACTERISTICS

SUPPLIER

CAGE CODE

UNIT

OF

ISSUE

QTYCOST

LEAD TIME

IN MONTHS

SHELF

LIFE

SPECIAL STORAGE

REQ'TS

SERIAL

NUMBER

VOLUME/

DIMENSIONSWEIGHT

1.

Aqua-Chem, Inc.

21. per hr.

CHECK

FLOW817-10450-00009647Distillate Flow Indicator21. per hr. 5"

KOBOLD DKB09647Ea.1$258.001N/AN/AN/A

21. per hr.

5" KOBOLD

DKB

N/A

2.

Aqua-Chem, Inc.

BrineN/A851-00238-00009647Brine Sight Glass

1/4" TKX2" DIA

NSN:6680-00-932-

09647Ea.1$15.351N/AN/AN/A

1/4" TKX2"

DIA NSN:6680-

00-932-0932

N/A

3.

Aqua-Chem, Inc.

CMPD 30"CHECK

PRESSURE850-08976-00009647Pressure GaugeCMPD 30"&15PS 1

SPAN LFC 21009647Ea.1$62.401N/AN/AN/A

CMPD

30"&15PS 1

SPAN LFC 210

N/A

4.

Aqua-Chem, Inc.

0-7 Barg.

1/4"

Bottom Mount

850-08970-00009647Pressure GaugePRESS 0-7 BARG.

ASHCRFT 1009SW09647Ea.1$94.301N/AN/AN/A

PRESS 0-7

BARG.

ASHCRFT

1009SW

N/A

5.

Aqua-Chem, Inc.

Liquid Filled

F to 250

F

CHECK

TEMP.937-07973-00009647Thermometer0

F to 250

F09647Ea.1$78.651N/AN/AN/A0

F to 250

FN/A

6.

Aqua-Chem, Inc.TOR SFD 35EJECTOR934-08455-00009647SONDEX EJECTORTOR SFD 3509647Ea.1$6,757.001N/AN/AN/ATOR SFD 35N/A

IMPORTANT NOTES:

The "Plant" is constructed for a seawater pressure of approx. 3 bar before educator (in ballast), and approx. 4 bar loaded.

Normally a chemical cleaning should be done 2 -3 times a year.

EQUIPMENT LOGISTICS INFORMATION LIST -- T-AKE DRY CARGO AMMUNITION SHIP Page: 2 Date: 1/31/2007 n50241 Line n50241 Text Box

CHAPTER 8

n50241

INSTALLATION, OPERATION, MAINTENANCE AND

REPAIR INSTRUCTIONS WITH PARTS LIST

COMMERCIAL MARINE CLOSE-COUPLED MAXUM

PUMPS

THIS MANUAL IS USEFUL FOR THE FOLLOWING PUMP SIZES:

1.5 X 1 X 8 4 X 3 X 6

1.5 X 1 X 6 6 X 4 X 13

2 X 1.5 X 13 6 X 4 X 10 2 X 1.5 X 10 6 X 4 X 8 2 X 1.5 X 8 6 X 6 X 13 2 X 1.5 X 6 6 X 6 X 10 3 X 1.5 X 10 8 X 6 X 20 3 X 1.5 X 8 8 X 6 X 16 3 X 1.5 X 6 8 X 6 X 13 3 X 2 X 13 8 X 6 X 10 3 X 2 X 10 10 X 8 X 20 3 X 2 X 8 10 X 8 X 16 3 X 2 X 6 10 X 8 X 13 4 X 3 X 13 12 X 10 X 20 4 X 3 X 10 12 X 10 X 13 4 X 3 X 8 14 X 12 X 20 14 X 12 X 16

DISTRIBUTION STATEMENT:

(To Be Determined By Buyer)

Chapter 9 ns505234

SERVICE RECORD PAGE

Service No. ____________________ Size and Type ________________ Make ___________________

Customer Order No. _________________________ Date Installed _______________________________

Installation

Date

Location

Application

PUMP RATING

Capacity (GPM) _________________________ Total Head (feet) ________________________________

Suction Pressure ________________________ Speed (RPM) ___________________________________

Impeller Diameter (inches) __________________________ Liquid ________________________________

PUMP MATERIALS

Casing ________________________________ Suction Cover ___________________________________

Motor Shaft ____________________________ Impeller ________________________________________

Adaptor _______________________________ Shaft Sleeve ____________________________________

MOTOR DATA

Manufacturer ______________________________ Serial No. ___________________________________

Horsepower _______________________________ Frame ______________________________________

Enclosure _________________________________ Volts _________________ Phase _______________

Hertz _____________________________________ RPM _________________

NOTES ON INSPECTION AND REPAIRS

INSPECTION

DATE

REPAIR TIME

REPAIRS

COST

REMARKS

i

TABLE OF CONTENTS

Chapter/Paragraph Page

SAFETY SUMMARY ................................. iii Live Circuits ........................................ iii Service or Adjustments......................... iii Resuscitation ....................................... iii

INTRODUCTION ...................................... v Scope ........................................ v Capabilities ........................................ v Performance Characteristics................. v Equipment Description ......................... v Power and Utility Data.......................... vi Environmental Data.............................. vi Equipment, Accessories and Documents Supplied .......................... vi Additional Equipment, Accessories and Documents Not Supplied.............. vi Tools, Materials and Test Equipment ........................................ vi Handling ........................................ vi Storage Requirements.......................... viii Safety Precautions ............................... viii

I PREPARATION FOR USE

AND INSTALLATION ......................... 1-1

1-1 Preparation ........................................ 1-1 1-1.1 Foundation................................... 1-1 1-1.2 Unpacking .................................... 1-1 1-2 Installation ........................................ 1-1 1-2.1 Tools Required ............................. 1-1 1-2.2 Site Information ............................ 1-1 1-2.3 Piping Information......................... 1-1 1-2.4 Installation Procedures .................. 1-1 1-2.5 Alignment ..................................... 1-2 1-3 Installation Checkout ........................... 1-2 1-3.1 Phase I – Installation, Inspection, and Pre-energizing Procedures ................................. 1-2 1-3.2 Phase 2 – Initial Turn-On and Preliminary Test.......................... 1-2 1-3.3 Phase 3 – Installation Verification Test.......................... 1-2 1-3.4 Test Procedure ............................. 1-2

2 OPERATION ....................................... 2-1

2-1 Introduction ........................................ 2-1 2-2 Theory of Operation............................ 2-1 2-3 Controls and Indicators ....................... 2-1 2-4 Operating Procedures ......................... 2-1 2-5 Operator’s Maintenance Instructions and Schedules .................................. 2-1

Chapter/Paragraph Page

3 PREVENTATIVE MAINTENANCE ........ 3-1

3-1 General Operating Checks .................. 3-1

4 TROUBLESHOOTING ......................... 4-1

4-1 Introduction ........................................ 4-1 4-2 Trouble Isolation and Testing............... 4-1 4-2.1 Malfunction................................... 4-1 4-2.2 Electrical Testing .......................... 4-1 4-2.3 Motor Voltage ............................... 4-1 4-3 Troubleshooting Procedures ................ 4-1

5. CORRECTIVE MAINTENANCE ............ 5-1

5-1 Adjustments and Alignments ............... 5-1 5-1.1 Performance Testing..................... 5-1 5-1.2 Hydrostatic Testing ....................... 5-1 5-2 Repair ........................................ 5-1

6 REPAIR ........................................ 6-1

6-1 Introduction ........................................ 6-1 6-2 Pump Repair ...................................... 6-1 6-2.1 Pump Disassembly ................... 6-1 6-2.2 Parts Inspection........................ 6-2 6-2.3 Pump Reassembly .................... 6-2 6-2.4 Wear Ring Replacement ............................ 6-3 6-2.5 Abrasive Separator Disassembly and Assembly ........................... 6-5 6-3 Motor Repair ...................................... 6-5 6-3.1 Motor Disassembly.................... 6-5 6-3.2 Motor Parts Inspection............... 6-6 6-3.3 Motor Ball Bearing Replacement ............................ 6-6 6-3.4 Motor Reassembly .................... 6-6

7 PARTS LIST....................................... 7-1

7-1 Introduction ........................................ 7-1 7-2 List of Manufacturers .......................... 7-1

8 FACTORY SERVICE ........................... 8-1

8-1 Introduction ........................................ 8-1 8-2 Parts Ordering.................................... 8-1

APPENDIX A.....................................Motor Manual

ILS Parts List ILS-1

Chapter 9 n50241 i ii

LIST OF TABLES

Number Title Page

1. Tools, Materials and Test Equipment ........................................ viii

2. Installation Materials ........................... 1-1

3. Initial Start Up..................................... 2-1

4. Normal Operation Start Up .................. 2-3

5. Normal Operation Shutdown................ 2-3

6. Emergency Operation ......................... 2-3

7. Differential Pressure Monitoring........... 2-4

8. Surface Inspection .............................. 2-4

9. Leakage Inspection............................. 2-4

Number Title Page

10 . Lubrication ........................................ 2-5

11. Motor and Bearing Temperature Inspection ........................................ 2-5

12. Pumping Unit Troubleshooting ............. 4-2

13. Pumping Unit Maintenance and Repair Standards ......................... 5-1

14. Pump Spare Parts .............................. 6-2

15. Pump Torque Values .......................... 6-2

16. Motor Spare Parts............................... 6-6

17. List of Manufacturers .......................... 7-1

LIST OF FIGURES

Number Title Page

1. Pumping Unit...................................... v

2. Pump .............................................. vii

3. Motor .............................................. vii

4. Dimensional Illustration ....................... ix

Number Title Page

5. Theory of Operation............................ 2-2

6. Performance Curve............................. 5-2 6-1. Proper Pinning of Pressed-In Composite Casing Ring ....................................... 6-4 FO-1. Sectional Drawing with Parts List ... FP-1 FO-2. Motor Drawing.............................. FP-3

Chapter 9 n50241 ii iii

SAFETY SUMMARY

The following are general safety precautions that are not related to any specified procedure and therefore, do not appear elsewhere in this publication. These are recommended precautions that personnel must understand and apply during many phases of opera-tion, maintenance and repair.

LIVE CIRCUITS. Operating personnel must always observe all safety regulations. Do not replace com-ponents or make adjustments inside the equipment with the high voltage supply “ON.” Under certain conditions, due to charges retained by capacitors, dangerous potentials may exist when the power con-trol is in the “OFF” position. To avoid casualties, al-ways remove power, remove discharge, and ground a circuit.

SERVICE OR ADJUSTMENTS. Under no circum-stances should any person reach into or enter the enclosure for the purpose of servicing or adjusting the equipment alone. Occasionally, maintenance, adjustments and repairs require more than one per-son; always work in the presence of person(s) capa-ble of rendering aid.

RESUSCITATION. Personnel working with or near high voltage areas should be familiar with modern methods of resuscitation. Refer to the Bureau of Medicine and Surgery for help finding the most cur-rent information about resuscitation.

Warnings appear throughout the text of this publica-tion and are cited here for quick reference as fol-lows:

When handling the pumping unit, do not ex-ceed the rated capacity of the hoisting equipment. Hoisting equipment should be capable of lifting 1500 pounds. Use of in-adequate hoisting equipment may result in serious injury or death to personnel and/or damage to the pumping unit. (Page 1-1)

Be sure to adequately support suction and discharge piping prior to disconnecting the pump assemblies. Failure to adequately support piping could result in serious injury or death to personnel and/or damage to equipment or parts. (Page 1-1, 4-1, 6-1, 6-3 and 6-5)

Before activating the pumping unit, make sure no one is performing adjustments or repairs on the unit. Serious injury or death to personnel could result if the power is turned

on. (Page 2-3)

In case of fire, turn off motor immediately and use a carbon dioxide extinguisher. If possible to approach motor, cover the motor with canvas. If available, turn on smothering steam. Inadequate fire control could result in serious injury or death to personnel or dam-age to equipment or parts. (Page 2-3)

To prevent injury or death to personnel, do not wear loose clothing around rotating equipment. (Page 2-4)

To prevent injury or death to personnel, do not service electrical equipment alone. The immediate presence of someone capable of rendering aid is required. All circuits not known to be dead must be considered live at all times. (Page 4-1)

To prevent serious injury or death to per-sonnel, do not operate testing equipment known to be in poor condition. (Page 4-1)

To prevent injury or death to personnel dur-ing hydrostatic testing, vent all air from cas-ing to eliminate risk of explosion. (Page 5-1)

Before attempting to disassemble the pump, the motor electrical power supply must be locked and tagged in the “OFF” position.

This prevents serious injury or death to per-sonnel. (Page 6-1 and 6-3)

Chapter 9 n50241 iii iv

Due to the weight (184 pounds) of the mo-tor, hoisting equipment is required. Fatal in-jury to personnel or damage to the motor could result if the weight of the motor is not properly controlled. (Page 6-5)

Due to the weight (40 pounds) of the rotor, a two-man lift or hoisting equipment is re-quired. Serious injury or death to personnel and/or damage to the rotor could result if dropped. (Page 6-6 and 6-7)

Do not allow heated bearings to come in contact with skin. Serious burns to person-nel could result if bearings heated 80-90o C (176-194o F) come into contact with the skin.

(Page 6-7)

Cautions appear throughout the text of this publica-tion and are cited here for quick reference as fol-lows:

CAUTION

Connect new piping lines so that no foreign matter such as dirt, chips, tools, etc., is in new piping, tank or return piping. Foreign matter drawn into the pump will damage parts or the entire unit. (Page 1-1)

CAUTION

Do not operate pumping unit without liquid in the pump casing because the impeller, wear rings, and/or mechanical seal will be dam-aged. (Page 2-3)

To prevent equipment damage, keep the in-terior and exterior of the equipment clean.

Dust and dirt tend to absorb oil or grease, forming a gum. Do not allow dirt and oil to accumulate, either inside or outside of the equipment. Dust may prevent heat dissipa-tion and restrict ventilating passages. This causes overheating and insulation break-down in the motor. (Page 2-4)

Composite parts should never be struck with a hard tool or foreign object during installa-tion. Excessive force should never be used during the installation of composite parts.

The use of pullers or similar extraction de-vices is prohibited for parts that are re-installed. Although CPC composite compo-nents are dimensionally stable to elevated temperatures, a direct flame should never be applied to these parts. (Page 6-1)

Use of a hoist with adequate capacity is rec-ommended when handling unit. Do not lift the complete pumping unit using the motor or lifting eyes. (Page vi, 6-1, 6-3, and 6-5)

Do not dynamic balance composite products by weight adjustment (ie., grinding off mate-rial or adding balancing weights such as set screws). If necessary, contact a representa-tive at Carver for assistance. (Page 6-3)

Protect motor internals from contacting con-taminants. Contaminants will reduce ball bearing life. (Page 6-6)

To avoid damage to motor windings and shaft bearings, brace rotor when bracket is removed. (Page 6-6)

Adequately support rotor and shaft assem-bly during disassembly and assembly in or-der to prevent damage to windings. (Page 6- 6 and 6-7)

To remove ball bearings, use government standard bearing puller, specification GGG- P-781, type 1, size 1 and puller attachment type XII, size 3. Inadequate use of tools may damage motor shaft. (Page 6-6)

Chapter 9 n50241 iv v

INTRODUCTION

SCOPE. This manual is designed to provide ade-quate instructions for the safe and efficient installa-tion, operation, and maintenance of the pump. Fail-ure or neglect to properly install, operate or maintain the pump may result in personal injury, property damage or unnecessary damage to the pump. The information, as presented, should improve your knowledge and understanding of the pump, thus upgrading the quality of pump maintenance and care.

The pumping unit may contain parts made of com-posite materials approved to NAVSEA drawing, 7226047. When used with a basic knowledge of pump assembly and sound maintenance practices, these instructions will ensure optimum life of the composite part and Improved Mean Time Between Failures (MTBF) of the pump.

Carver Pump Company (CPC) products are carefully engineered and manufactured and if properly in-stalled, maintained and operated will provide main-tenance free operation and long service life.

Specifications and operating limits should be re-corded on the service record page located in the front of this manual upon receipt of the pumping unit.

CAPABILITIES. The pump’s rated capacity may be found on the pump nameplate. The motor is used to convert electrical energy into mechanical energy.

For complete capabilities and limitations of the unit, refer to the performance curve, figure 6.

PERFORMANCE CHARACTERISTCS. For per-formance characteristics of the pump and motor, refer to the respective nameplate. The nameplate for the pump is located on the pump, and the nameplate for the motor is located on the motor.

EQUIPMENT DESCRIPTION. The pumping unit consists of a Carver centrifugal pump and electric motor. Refer to figure 1 for a general view of the pumping unit.

Pump. Refer to figure 2 for general location of pump parts. For specific parts information, refer to the pump sectional drawing, figure FO-1. The princi-pal features of the pump end portion of the pumping unit consists of the following:

Volute. The volute houses the impeller and wear ring and consists of the suction inlet, discharge vo-lute, and discharge nozzle. The backcover is held in place between the volute and the motor adaptor.

The volute is fastened to the motor adaptor using studs and nuts with locknuts.

Figure 1. Pumping Unit n50241 v vi

Impeller. The pump is equipped with an enclosed impeller. The impeller is keyed to the shaft by the impeller key and locked in place by the impeller nut.

The impeller washer fits between the impeller nut and the impeller. The impeller washer is positioned between the impeller washer gasket and the impeller washer o-ring.

Shaft Sleeve. The shaft sleeve protects the shaft and is positioned up against the impeller. The shaft sleeve o-ring prevents leakage around the motor shaft. The shaft sleeve gasket is located in front of the shaft sleeve. The rotating elements of the me-chanical seal are installed on the shaft sleeve.

Backcover. The backcover is held in place be-tween the volute and the frame adaptor. The back-cover is positioned in the volute bore by an o-ring, which is mounted in an o-ring groove located on the outer perimeter of the backcover. The backcover is designed to accommodate nearly all mechanical seals with seal accessories including double, tan-dem, and balanced versions, and packing rings.

Abrasive Separator. If the unit is equipped with an optional abrasive separator, a ¼-inch Outside Di-ameter (OD) tubing supplies fluid to the separator from the volute. The separator, by use of centrifugal effect, reduces the solids suspended in the fluid.

This cleaner fluid is then piped to the mechanical seal gland through tubing to cool, lubricate, and flush the mechanical seal faces. This cleaner fluid greatly increases mechanical seal life by reducing the abrasives (solids) in the liquid. The fluid contain-ing the solids, separated out by the abrasive separa-tor, is then piped to the suction head through the tubing.

Motor Adaptor. The motor adaptor has two paral-lel-machined faces. It provides a rigid connection between the motor and the volute. The machined rabbet connects, aligns, and positions the volute.

The stationary element of the mechanical seal is installed in the seal gland.

POWER AND UTILITY DATA. The electrical sys-tem power is supplied from the ship supply load cen-ter through a motor controller. A motor controller controls the circuit for the pump motor.

ENVIRONMENTAL DATA. To allow the pumping unit to operate properly, the following requirements are necessary:

a. Maximum ambient temperature of 122 o (50 o C) for motor.

b. Normal room ventilation for motor cooling.

c. Power supply of 440 volts, 3 phase and 60 hertz.

EQUIPMENT, ACCESSORI ES AND DOCUMENTS

SUPPLIED. The only equipment supplied is a Carver centrifugal pump with electric motor. There are no other equipment, accessories or documents supplied with this pumping unit other than this man-ual.

ADDITIONAL EQUIPMENT, ACCESSORIES AND

DOCUMENTS NOT SUPPLIED. Equipment not furnished with the basic equipment covered by this manual, but which attach or relate importantly to ba-sic equipment are as follows:

• motor controller for starting and stopping the electric motor

• foundation and foundation bolts for mounting the pumping unit

• suction, discharge, vent and drain valves to con-trol flow of fluid

• pressure gauges

See applicable manual for motor electric power sup-ply and Ship Information Book.

TOOLS, MATERIALS AND TEST EQUIPMENT.

Recommended on-board tools, materials and test equipment for the pumping unit is listed in table 1.

HANDLING.

CAUTION

When handling pumping unit, use a hoist with ade-quate capacity. Do not lift the complete pumping unit using the motor or lifting eyes.

Complete pumping unit must be handled with care.

Attach slings in a manner, which will distribute the load evenly avoiding slipping or shifting to occur.

Install and locate pump unit in accordance with fig-ure 4.

vi vii

Figure 2. Pump

Figure 3. Motor n50241 vii viii

STORAGE REQUIREMENTS. If the equipment is not immediately installed and operated, Carver Pump Company recommends rotating each shaft twelve revolutions at least once a month to prevent flat spots on ball bearings. This is also done to en-sure bearings are fully protected by periodic distribu-tion of fresh lubricant during the inoperative period.

NOTE

The pump and equipment, as shipped from Carver Pump Company, have adequate protection for short-term storage. If the equipment is not immediately installed and operated, store the equipment in a covered, clean, dry, well-ventilated location, free from vibrations, moisture, and rapid or wide varia-tions in temperature.

Composite parts should be kept in their protective shipping containers or packaging until the time of installation. Bubble wrap, poly-foam, or equivalent packaging is recommended to prevent damage to parts.

Consider a pumping unit to be in storage when:

a. The unit has been delivered to the job site and is waiting to be installed.

b. The unit has been installed but operation is delayed pending completion of construction.

c. There are long (30 days or more) periods between operating cycles.

d. The plant (or department) is shut down for periods longer than 30 days.

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 will be necessary to refurbish the pump.

Storage requirements vary depending on the length of storage, the climatic environment, and the equip-ment. For storage periods three months or longer, contact a representative from Carver Pump Com-pany for specific instructions. Improper storage will damage the equipment and will require non-warranty restoration and/or non-warranty product failures.

Check to make sure that the fluid pumped is clear and clean, free from foreign objects.

SAFETY PRECAUTIONS. Various federal, state and local laws 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.

CPC composite parts are safe to work with, and when conventional environmental safety practices are followed, will not adversely affect the health of personnel during servicing and repair operations.

CPC composite parts are non-toxic and pass the requirements for contaminant levels established un-der the Environmental Protection Agency’s National Primary Drinking Water Regulations (NPDWR). The toxilogical requirements are in accordance with NAVSEA Drawing, 803-7226047.

Table 1. Tools, Materials and Test Equipment Tools Materials Testing Equipment

Wrench set Brush Flowmeter Flashlight Towel Pressure gauges Impact wrench Grease (DOD-G-24508) Dial indicator Centigrade thermometer Parker Super O-Lube Micrometer Bearing puller Megger Grease gun viii ix

Figure 4. Dimensional Illustration n50241 ix

1-1

CHAPTER 1

PREPARATION FOR USE AND INSTALLATION

1-1 PREPARATION

1-1.1 Foundation. The foundation should be ready to accept the pumping unit with no further prepara-tion of the foundation necessary. The foundation must be capable of accommodating the pumping unit dimensions given in figure 4.

When handling the pumping unit, do not ex-ceed the rated capacity of the hoisting equipment. Hoisting equipment should be capable of lifting 1500 pounds. Use of in-adequate hoisting equipment may result in serious injury or death to personnel and/or damage to the pumping unit.

1-1.2 Unpacking. Remove pumping unit from wooden crate by disassembling crate with a claw hammer and/or crowbar. Unbolt pumping unit from floor of crate. Remove covering from flanges.

1-2 INSTALLATION

Skilled personnel in accordance with engineering standards should install the pump. Faulty installation will result in operating troubles and premature wear of parts.

1-2.1 Tools Required. Refer to figure 4 to install the pumping unit. Tools normally found in shipboard maintenance should be sufficient for installing the pumping unit. Refer to table 2 for special materials for installation.

Table 2. Installation Materials Material Quantity Purpose

Gasket 1 Suction flange Gasket 1 Discharge flange Foundation bolts 4 Grade 5 Lead wire 3 Electrical connection

1-2.2 Site Information. Install and locate the pump-ing unit in accordance with figure 4. The shipboard compartment containing each pumping unit shall accommodate the pumping dimensions given in fi g-ure 4. In addition, the overhead shall be capable of accommodating attached hoisting equipment for maintenance purposes.

1-2.3 Piping Information. The pump is shipped with flange covers to protect flange faces and to prevent foreign matter from entering pump. Flange covers should remain intact until discharge and suction pip-ing is connected to pump flanges. The pump should be installed as close as possible to the fluid to be pumped. A short direct suction pipe should be used to keep suction losses at a minimum. If possible, locate the pump so fluid will flow by gravity to the suction opening. The discharge piping should be direct with as few elbows and fittings as possible.

pump assemblies. Failure to adequately support piping could result in serious injury or death to personnel and/or damage to equipment or parts.

1-2.4 Installation Procedures. Install the pumping unit as follows:

a. Remove any rust preventative that may have been applied to the pumping unit prior to shipment.

b. Make sure the foundation is level. Bolt pump unit to foundation. Check that pump rotates freely.

Connect new piping lines so that no foreign matter such as dirt, chips, tools, etc., is in new piping, tank or return piping. Foreign matter drawn into the pump will damage parts or the entire unit.

c. Connect system suction and discharge pip-ing to respective pump flanges.

d. Connect any necessary auxiliary piping and gauge lines.

e. Turn motor shaft by hand to be sure it ro-tates freely. If necessary, recheck pipe con-nection for pipe strain.

f. Compare the motor nameplate data to sys-tem (ship) wiring plan to ensure that the power supply is the correct voltage, fre-quency and phase for the motor. Connect wiring to motor. Due to high voltage required to operate the pumping unit, personnel working with the equipment should be famil-iar with electrical safety practices and mod-ern methods of resuscitation.

1-2

g. Add wire terminals to wire and connection box.

h. Connection electrical power supply to motor.

i. Open system valves.

1-2.5 Alignment.

To keep the pump and motor properly aligned, shims are added to the foundation. Specific proce-dures for disassembly/reassembly of the pump and motor are addressed within chapter 6 of this manual.

1-3 INSTALLATION CHECKOUT

1-3.1 Phase 1 - Installation, Inspection, and Pre-energizing Procedures. Refer to table 1 for a list of required test equipment before starting the pumping unit for the first time. Use the following checklist for verification:

a. The pumping unit has been installed in the proper location and orientation. Piping has been installed according to plans and speci-fications and continuity exists in all intercon-nections.

b. Test equipment listed in table 1 is on board, and operating satisfactorily.

c. Equipment data is included in the Allowance Parts List (APL), which is on board, and the Coordinated Shipboard Allowance List (CO-

SAL).

d. All field changes, SHIPALTS and mandatory retrofits have been accomplished.

e. All installation and reference standards have been completed.

f. All rotating devices are free from obstacles.

g. There is access to the pumping unit for maintenance. Refer to figure 4.

h. All pre-energizing procedures have been accomplished.

i. It is safe to turn on the…