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THRUSTREAM RANGE

HORIZONTAL SPLIT CASE PUMPS


OPERATORS INSTRUCTIONS

THRUSTREAM
EXTENDED RANGE
Horizontal Split Case
Centrifugal Pumps
And Pump Sets

SPP Pumps Limited Telephone: Document No: W12-005E


Crucible Close Revision No: 3
Mushet Industrial Park +44 (0)1594 832 701 Revision Note No: R 39552
Coleford, Glos Date Issued: August 2012
Fax:
ENGLAND Produced at SPP Pumps
RG31 7SP +44 (0)1594 836 300 Limited Coleford England
DECLARATION OF CONFORMITY

We SPP Pumps Limited

Of Crucible Close
Mushet Industrial Park
Coleford
Gloucestershire
England
GL16 8PS
Declare that:

Equipment: HORIZONTAL SPLIT CASE CENTRIFUGAL PUMP


Model/Type: Models TL to TV (As per the table on page 3)
Serial Number: As shown on the Pump Nameplate
For pumps supplied with electric motors:
in accordance with the following Directives:
2006/42/EC The Machinery Directive and its amending directives
2006/95/EC Low Voltage Directive
have been designed and manufactured to the following specifications:
EN 809:1998+A1:2009 Pumps & Pump Units for Liquids - Safety Requirements
EN 12100:2003 Parts 1 and 2 - Safety of Machinery
EN 60204-1:2006 Safety of Machinery - Electrical Equipment

We hereby declare that the equipment named above has been designed to comply with the relevant sections
of the above referenced specifications. The units comply with all essential requirements of the Directive.

For pumps supplied without motors:


We hereby declare that this equipment is intended to be incorporated into, or assembled with other machinery
to constitute relevant machinery to comply with the essential health and safety requirements of the Directive.

The machinery covered by this declaration must NOT be put into service until the relevant machinery into which
it is to be incorporated has been declared in conformity with the provisions of the Directive.

Signed:
Name: John Hollins
Position: Engineering Manager - Authorised to sign on behalf of SPP Pumps Limited
Mushet Industrial Park, Crucible Close, Coleford, Gloucestershire, GL16 8PS
Date: 25 February 2010

W12-005E

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 2 of 28
Operators Instructions for Horizontal Manual No/Rev
Extended Thrustream Centrifugal Pumps W12-005E / 3

CONTENTS The pump sizes covered by this manual are:


Section Page Extended Single Stage
1. General Information & Safety Instructions 4 Thrustream Range:

2. Transport Handling and Storage 4 Size Pump Module

3. General Description 5 200/58 TR20A 1E


4. Assembly and Installation 6
300/34 TL30A 1E
5. Commissioning and Operation 8
250/42 TN25A 2E
6. Maintenance and Service 10
6.1 Preparation for Maintenance 11 250/51 TQ25A 2E
6.2 Repacking the Stuffing Box 11 250/68 TT25A 2E
6.3 Maintenance of Mechanical Seals 12
300/59 TR30A 2E
6.4 Bearing Lubrication 12
350/39 TM35A 2E
6.5 Bearing Replacement 12
6.6 Mechanical Seal Replacement 14 300/48 TP30A 3E
6.7 Pump Overhaul & Repairs 14 300/77 TV30A 3E
7. Faults and Remedial Action 19
350/44 TN35A 3E
8. Pump Details: 20
8.1 Typical Pump Section Single Stage 20 350/54 TQ35A 3E

8.2 Parts Identification List Single Stage 21 350/66 TT35A 3E


8.3 Typical Pump Section Two Stage 22 Extended Two Stage
8.4 Parts Identification List Two Stage 23 Thrustream Range:
9. Metric Bolt Torque Recommendations 24 150/48-2 TP15T 2T
10. Spares & Service 28 200/58-2 3T
TR20T
Manufacturer’s Information (Where applicable)
Electric Motor Appendix I This manual covers the Extended Range of
Thrustream pumps that are built for use in the
Coupling Appendix II horizontal position. For information on pumps built
Mechanical Seal Appendix III for vertical applications, please refer to a separate
manual that can be obtained from SPP Pumps
Introduction Limited.

This manual gives the safety, installation, operation


and maintenance instructions for pumps in the SPP
Pumps Ltd Thrustream Extended range of
horizontal split case centrifugal pumps for general
water and industrial use.

Thrustream pumps are identified by their pump


designation and by their size code, the first number
is the delivery branch diameter and the second
number is the nominal diameter of the impeller in
centimetres.

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 3 of 28
Manual No/Rev Operators Instructions for Horizontal
W12-005E / 3 Extended Thrustream Centrifugal Pumps

1. General Information and


Safety Instructions 1.7 Note any limits to the pump application
specified in the contract documentation.
Operation of the equipment outside these
The products supplied by SPP Pumps Ltd. have
limits will increase the risk from hazards noted
been designed with safety in mind. Where hazards
below and may lead to premature and
cannot be eliminated, the risk has been minimised
hazardous pump failure.
by the use of guards and other design features.
Some hazards cannot be guarded against and the 1.8 Clear and easy access to all controls, gauges
instructions below MUST BE COMPLIED WITH for and dials etc. MUST be maintained at all
safe operation. These instructions cannot cover all times. Hazardous or flammable materials
circumstances: YOU are responsible for using safe must NOT be stored in pump rooms unless
working practices at all times. safe areas or racking and suitable containers
have been provided.
1.1 SPP Pumps Ltd. products are designed for
installation in designated areas, which are to 1.9 IMPROPER INSTALLATION, OPERATION
be kept clean and free of obstructions that OR MAINTENANCE OF THIS SPP PUMPS
may restrict safe access to the controls and LTD PRODUCT COULD RESULT IN INJURY
maintenance access points. OR DEATH.

A pump nameplate is fitted to each unit and 1.10 Within the manual, safety instructions are
must not be removed. Loss of this plate could marked with safety symbols.
make identification impossible. This in turn
could affect safety and cause difficulty in Hazard
obtaining spare parts. Should accidental loss This symbol refers to general mechanical
or damage occur, contact SPP Pumps Ltd. aspects of safety.
immediately.
Hazard
1.2 Access to the equipment should be restricted This symbol refers to electrical safety.
to the personnel responsible for installation,
operation and maintenance and they must be
trained, adequately qualified and supplied with
the appropriate tools for their respective tasks. ATTENTION This symbol gives warning of a
hazard to the pump itself, which in turn, could
1.3 SPP Pumps Ltd. requires that all personnel cause a risk to personal safety.
that are responsible for installation, operation
or maintenance of the equipment, have
access to and study the product instruction 2. Transport Handling and
manual BEFORE any work is done and that Storage Instructions
they will comply with all local and industry
based safety instructions and regulations. 2.1 Transport

Horizontal Extended Thrustream pumpsets


1.4 Ear defenders should be worn where the
are despatched fully assembled except where
specified equipment noise level exceeds
stability or handling constraints require the
locally defined safe levels. Safety glasses or
motor to be packed and delivered separately.
goggles should be worn where working with
pressurised systems and hazardous
Pumps are protected against corrosion and
substances. Other personal protection
packed for transport by normal road, rail and
equipment must be worn where local rules
sea carriers.
apply.
2.2 Handling
1.5 Do NOT wear loose or frayed clothing or
jewellery that could catch on the controls or Crushing Hazard
become trapped in the equipment. When lifting the pump unit, use lifting
1.6 Check and confirm that the manual is the equipment having a safe working load
relevant copy by comparing the serial number rating suitable for the weight specified.
on the identification plate with that on the Use suitable slings for lifting any pump not
manual. provided with lifting points.

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 4 of 28
Operators Instructions for Horizontal Manual No/Rev
Extended Thrustream Centrifugal Pumps W12-005E / 3

The use of suitable forklift truck and four-chain When pumps are not in use, the pump shaft
crane sling equipment is recommended but should be rotated several turns, every six
locally approved equipment of suitable rating weeks.
maybe used.
2.3.2 Long Term Storage
Pumps are usually supplied on pallets for
handling by forklift truck, to lift from the pallet It is recommended that the pump is stored in a
the pump should be slung as shown. clean dry place that is not subject to a wide
temperature variation. Pack the bearings with
the specified grease and periodically inspect
the bearing housings to ensure that they are
free from damp and moisture. Leave the
covers for the suction and discharge flanges in
place or replace with suitable covers to
prevent ingress of dirt or moisture. Rotate the
shaft several turns monthly, to distribute the
grease and prevent pitting of bearing surfaces.

If storage in the open cannot be avoided,


cover the pump with a tarpaulin sheet, but
allow dry air to circulate around the pump.

For special protection of electric motors and


mechanical seals, refer to the manufacturer’s
instructions in Appendix l & III.

2.3.3 Exposed or Extreme Conditions Storage

For exposed storage or extreme variants in


atmospheric or environmental conditions,
please refer to SPP Pumps Ltd.

3. General Description
Pump weight is shown on the general
arrangement drawing supplied with each SPP Pumps Ltd. Thrustream Pumps are a
pump or pumpset. range of centrifugal pumps that are usually
supplied as pumpsets with electric motors but
2.3 Storage can be supplied separately for customers to fit
to drivers of their own preference.
Shearing Hazard
Do NOT place fingers or hands etc. into 3.1. Pumps
the suction or discharge pipe outlets and
do NOT touch the impeller. If rotated this The mechanical assembly comprises a rigid
may cause severe injury. To prevent ingress shaft, supported by grease-lubricated ball
of any objects, retain the protection covers or bearings at each end of the pump shaft. The
packaging in place until removal is necessary pump casing is fitted with wear rings and
for installation. If the packaging or suction and houses a double entry shrouded type impeller
discharge covers are removed for inspection mounted on a stiff shaft. Some pumps in the
purposes, replace afterwards to protect the range are fitted with a pair of single side entry
pump and maintain safety. impellers. The seal chamber is housed in the
casing inserts retained within the casing.
2.3.1 Temporary Storage for up to Six Weeks Some impellers may be fitted with wear rings if
required. When the top half casing is
If the pump is not to be used immediately, it removed, the bearing housings, inserts, shaft
should be stored carefully in a horizontal and impeller assembly can be removed from
position, in a sheltered, dry location. Additional the bottom casing for maintenance without
rust preventative should be applied to all disconnection of pipework.
unpainted carbon steel or cast iron parts. Fit
or retain in place the covers to the suction and The suction and discharge branch flanges are
discharge flanges and all other pipe positioned horizontally at 90 degrees to and
connections. Rust preventative and flange below the shaft centreline. The pump casings
covers should not be removed until final allow for construction to suit different rotations.
installation.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 5 of 28
Manual No/Rev Operators Instructions for Horizontal
W12-005E / 3 Extended Thrustream Centrifugal Pumps

The standard pump is soft packed but the event of a handling accident, carefully check
option to fit internal component mechanical that the pump is not damaged before
seals or selected external cartridge installation and commissioning.
mechanical seals is provided to suit
customer’s requirements. These pumps are 4.2 Preparation for Mounting
normally supplied with a cast iron casing and
impeller but bronze may be supplied where Before installation, check that the pump
required. Other parts may be supplied in a mounting location is suitable for accepting the
variety of materials to suit the pump pump. Refer to the certified General Assembly
application. drawing, for details of pump installation
dimensions.
In standard form, these pumps are designed
o
to pump liquids at temperatures up to 80 C. 4.3 Location of Pump
Where pumps are needed to suit higher
temperatures, please refer to SPP Pumps Ltd.
The pump should be located as near the liquid
source as practical, with adequate accessibility
Nameplate details are shown on the back for inspection and repair and sufficient
cover of this manual, full pump specification headroom for lifting tackle if necessary.
can be supplied on a data sheet, if requested.

Note 1) The head specified is the Duty Head Where pumps are electric motor driven, power
generated by the pump only. source electrical characteristics should match
2) - Suction pressure must be included those shown on motor data plate. A qualified
when assessing the Maximum Working electrical contractor should be used to make
Pressure. the electrical connection.

3.2 Electric Motor Driven Pumpsets 4.4 Foundations

Pumpsets are supplied mounted on a The pump is to be mounted on a substantial


substantial fabricated baseplate; the complete floor or plinth and secured with suitable
assembly is of a rigid construction, being foundation bolts to minimise vibration. The
intended for mounting on suitable foundations. foundation must have a flat level surface and
be of sufficient depth to contain the foundation
These pumpsets are supplied fitted with a bolts. The pump unit should be installed with
proprietary high efficiency electric motor the flange faces set in a vertical position.
adequately sized for the duty specified. For Packers may be placed under the baseplate
details of the motor supplied, refer to the near the bolt holes to level the unit if the floor
manufacturer’s instructions in Appendix I. is uneven. The foundation bolts should be
tightened and the shaft alignment checked
The proprietary flexible coupling has been again before commissioning and putting the
selected to meet the power transmission and pump into operation.
other operating requirements for the pumpset.
Coupling fitting and maintenance details are For full installation instructions and guidance
given in the manufacturer’s instructions in on the design of suitable foundations for
Appendix II. pumpsets refer to the SPP Guide to Pump
Installation, obtainable on request from SPP
Pumps Ltd.
4. Assembly and Installation
Shearing Hazard 4.5 Pump Preparation
Do NOT place fingers or hands etc. into Abrasion & Entrapment Hazard
the suction or discharge pipe outlets and Do NOT touch any moving or rotating
do NOT touch the impeller, if rotated this parts. Guards are provided to prevent
may cause severe injury. To prevent ingress access to these parts, where they have
of any objects, retain the protection covers or been removed for maintenance they MUST be
packaging in place until removal is necessary replaced before operating the equipment.
for installation.
For soft packed pumps the packing rings and
4.1 Initial Inspection for Damage related components are often supplied loose.
Ensure that the packing is installed as per
During transport and storage, accidental instructions in section 6.2 paragraphs 10 to
damage to the pump may have occurred. 20.
When the pump is to be installed, or in the

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 6 of 28
Operators Instructions for Horizontal Manual No/Rev
Extended Thrustream Centrifugal Pumps W12-005E / 3

Remove packaging but leave the flange into the pump. A screen or basket strainer
covers in place, check that impeller rotates may also be required to hold back larger
freely by hand by turning the shaft. items. These should be sized to maintain the
flow through them to below 0.6 m/s.
If the pump has been in storage, remove any
protective coatings. If the bearing housings The suction pipe work must be flushed clean
were filled with grease flush, and re-lubricate to ensure that site debris is not drawn into the
the bearings. pump when it is commissioned.

4.6 Suction Pipework 4.7 Discharge Pipework

The run of suction pipework must be such that The bore of the discharge pipe should ideally
air can NOT become trapped where it would be sized to ensure a flow velocity of 2.5 to 3
be drawn into the pump on starting. The bore m/s is not exceeded. This is usually one size
of the suction pipe is recommended to be one larger than the discharge branch. Pipework
or two sizes larger than the pump suction should be as short and straight as possible to
branch and reducers if used must be eccentric reduce friction head loss.
to eliminate the possibility of an air pocket
being formed. A non-return valve is usually fitted to prevent
the pump from excessive backpressure and
CONCENTRIC REDUCER reverse rotation and a discharge valve is
WILL TRAP AIR IN THE
SUCTION PIPE usually fitted for isolation purposes to allow for
inspection and maintenance on the pump.

Where adverse suction conditions may cause


the pump to lose its prime, the use of an
external automatic priming device, such as a
vacuum pump, is recommended.

X Foundation Plinth
The suction and discharge pipework must be
independently supported and positioned such
that no excessive forces and moments are
FLAT TOP REDUCER
exerted on the pump flanges.
WILL NOT TRAP AIR IN
THE SUCTION PIPE CHECK DISCHARGE DISCHARGE
INCREASER VALVE VALVE PIPE

Foundation Plinth Check


Valve
Foundation Plinth Support

Bends in the suction pipeline should be as


large as possible, the pipe made as short and
as straight as possible and all joints must be Failure to support suction and
fully airtight. A gradual rise in the suction ATTENTION delivery pipework may result in
pipeline is recommended to prevent formation distortion of the pump casing, with the
of air pockets. If fitting a foot valve, it should possibility of early pump failure.
have a free area of one and a half times the
area of the suction pipe. 4.8 Guards
If guards have been removed to install packing
Where pumping water at temperatures above or to check mechanical seal connections, they
70°C, care must be taken to ensure that MUST be replaced to maintain safe operation
enough pressure is available at the impeller of the pump. Refer to the General
entry to prevent vaporisation. Expansion Arrangement drawing for specific fixing
joints are recommended to prevent strain on methods for the guarding supplied.
the pump casing.

An appropriate fine strainer is recommended


to prevent foreign matter from being drawn

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 7 of 28
Manual No/Rev Operators Instructions for Horizontal
W12-005E / 3 Extended Thrustream Centrifugal Pumps

4.9 Coupling Alignment faces. These should be checked for


cleanliness before assembly and before
To minimise the bearing loading and to resorting to using shims under the motor feet.
achieve full coupling and bearing life, it is
recommended that the shafts are aligned as ATTENTION Shaft alignment must be checked
accurately as possible i.e. well below the again after the final positioning of
allowable misalignment of the coupling. the pump unit and connection to pipework as
this may have disturbed the pump or motor
Refer to the coupling manufacturer’s mounting positions.
instructions or proceed generally thus:
4.10 Grouting
1 Lateral Alignment A space of about 25mm should be left
between the top surface of the foundation
Mount a dial gauge on plinth and the underside of the baseplate to
the motor shaft or allow for grouting.
PUMP
coupling with the
gauge running on the Recommended grouting should comprise one
outer-machined part of cement to two parts of sand, with
surface of the pump MOTOR sufficient water to produce a heavy creamy
coupling. Turn the consistency.
motor shaft and note the total indicator
reading. After the grout has dried, the alignment should
be checked before commissioning and putting
2 Angular Alignment the pump into operation.

Mount a dial gauge on


the motor shaft or
5. Commissioning and Operation
PUMP
coupling to run on a
face of the pump 5.1 Commissioning Checks
coupling as near the
outside edge as MOTOR These checks must be done after first
possible. Turn the installation and after pump maintenance that
motor shaft and note the total indicator required removal of the rotating assembly.
reading.
Abrasion and Entrapment Hazard
3 Confirm Lateral Alignment Do NOT touch any moving or rotating
parts. Guards are provided to prevent
Mount the dial gauge access to these parts, where they have
on the pump shaft or been removed for maintenance they MUST be
coupling with gauge PUMP replaced before operating the equipment.
running on the outer-
machined surface of Check that the rotating assembly is free to
the motor coupling. rotate by hand before connecting the power
Turn the pump shaft in MOTOR supply. Also check that the piping system has
the direction of pump been properly connected with all joints
rotation, and note the total indicator reading. tightened and instrumentation is in position.
4 Adjustment Check that the pump is primed. Pumps should
never be run dry as the pumped liquid acts as
For horizontal lateral adjustment move the a lubricant for the close running fits
motor using the motor jacking screws provided surrounding the impeller. Dry running can
and for vertical and angular adjustment fit cause serious damage to the pump and
shims between the motor feet and the
seals.
baseplate.
Prime the pump using an ejector, exhauster or
Note Poor alignment is a major factor contributing to vacuum pump. If a foot valve is used in the
shortening of pump bearing and seal life. It is suction line the pump may be primed by
recommended that alignment is checked venting and filling the casing with liquid. Open
frequently and maintained at below 10% of the the air release valve to bleed any air trapped
manufacturer’s specified figure or 0.1mm. in the seal housing, as the seal must be
lubricated and dry running often results in
As the pump and motor feet are accurately premature seal failure.
machined, any discrepancy may be due to
foreign matter between any of the mating
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 8 of 28
Operators Instructions for Horizontal Manual No/Rev
Extended Thrustream Centrifugal Pumps W12-005E / 3

Disconnect the pump drive by removal of the 5.3 During Operation


spacer from the coupling. Connect the
electrical supply to the pump unit. Momentarily Hot Surfaces Hazard
switch on motor and check direction of Do NOT touch surfaces that during normal
rotation. This should match the direction of running will be sufficiently hot to cause
rotation of the pump. For three phase electric injury. These are marked with the HOT
motors, if the direction of rotation is incorrect, warning symbol. Note that these surfaces will
disconnect the supply and change over two of remain hot after the pump has stopped:
the three supply phases. Replace the allow sufficient time for cooling before
coupling spacer. maintenance. Be cautious and note that other
parts of the pump may become hot if a fault is
5.2 Starting Procedure developing.

Cold Conditions Hazard


BEFORE A THRUSTREAM SERIES PUMP IS
Do NOT operate water pumps in
STARTED ALWAYS ENSURE THAT THE SUMP
temperatures below freezing point,
IS FILLED TO THE CORRECT LEVEL WITH
LIQUID, AND THAT ANY LEVEL CONTROLS without first checking that the pumped fluid is
ARE FUNCTIONING CORRECTLY. not frozen and the pump is free to turn. Pumps
in these environments should be drained down
during inactivity and re-primed before starting.
Abrasion and Entrapment Hazard
Do NOT touch any moving or rotating Hazardous Noise
parts. Guards are provided to prevent In addition to local or site regulations for
access to these parts, where they have noise protection, SPP Pumps Ltd.
been removed for maintenance they MUST be recommend the use of Personal Ear
replaced before operating the equipment. Protection equipment in all enclosed pump
rooms and particularly those containing diesel
Check that the suction valve is open and that engines. Care must be taken to ensure that
the pump is primed. any audible alarm or warning signal can still
be heard with ear defenders worn.
Open the discharge valve to one quarter open
to prevent hydraulic lock from occurring. Hazardous Gases, Mists, Sprays and
Switch on the motor and allow it to build up to Leaks
full operating speed. Slowly open discharge Be aware of the hazards relating to the
valve until the pump reaches the required duty pumped fluid, especially the danger from
condition. inhalation of noxious and toxic gases, skin and
eye contact or penetration. Obtain and
Check that the motor is not overloading, unit is understand the hazardous substance
not vibrating or excessively noisy, the motor is (COSHH) data sheets relating to the pumped
not overheating, and that the pump is fluid and note the recommended emergency
developing the correct flow and head and first aid procedures.
requirements.
Periodic Checks:
If the pump is operating at its normal speed,
the pump should be shut down at once if any a) Pump Bearings:
of the following defects are found: Check the bearing temperatures do not
exceed 80°C as an increase may indicate the
a) No liquid delivered. early stages of bearing trouble.
b) Not enough liquid delivered.
b) Noise:
c) Not enough pressure. Listen for any unusual noise or an increase in
d) Loss of liquid after starting. normal sound level.
e) Vibration.
f) Motor runs hot. This may result from:
i) Loose fasteners for guards and other
g) Excessive noise from cavitation. equipment.
h) Pump overheating. ii) Air trapped in the pump i.e. the pump was
not fully primed.
Recommended corrective action for these
iii) Cavitation.
faults is given in Section 7 Faults and
Remedial Action. iv) Small solids in the liquid.

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 9 of 28
Manual No/Rev Operators Instructions for Horizontal
W12-005E / 3 Extended Thrustream Centrifugal Pumps

c) Suction Gauge Reading: Recommended Maintenance Schedule


If this is lower than normal, investigate and INSPECTION REMARKS
check that valves in the suction pipework are
fully open or that the suction lift may have Daily Checks: (Manned Installations)
increased. Visually check pump for leaks.
Carefully check the Check the bearing housing
bearing housing for temperature with a suitable
d) Discharge Gauge Reading:
any sign of thermometer & refer to Fault
If this is lower than normal, check for a leak in temperature rise. Finding Chart in Section 7.
the associated pipework or that a valve in the Maximum running temperature
delivery line has been opened when normally is 80°°C(176°° F).
it is partially closed.
Check the pump for Refer to Fault Finding Chart in
vibration. Section 7.
5.4 Stopping Procedure
For mechanical seals:
Stop the motor then fully close the discharge Check for leaks Renew as necessary
valve. For soft packed pumps:
Adjust gland to When gland is fully compressed,
maintain slight change or add more packing.
6. Maintenance and Service leakage and check (Refer to Soft Packed Seal
that gland drains maintenance instructions in
are clear. section 6.3).
6.1 General Introduction
Three Monthly Maintenance:
SPP Pumps Ltd Thrustream Series pumps will Lubricate the pump Use Texaco Multifak All Purpose
provide many years of trouble free service bearings with 15- EP2 grease or equivalent grease
when maintained in accordance with these 20g of grease. to DIN 51825: KP2 K-30. Do not
overfill the bearing housing, as
instructions. In the event of failure of the pump the bearings will overheat if
it is recommended that SPP Pumps Ltd. overfilled.
Service Department are called to investigate
and carry out repairs. The following Six Monthly Maintenance:
instructions are given to cover the main Check coupling Refer to maintenance instructions
elements of strip and rebuild but do NOT alignment. Check adjust or renew parts as
coupling pins and necessary.
include instructions for work that MUST be
bushes for wear.
done by an SPP Pumps Ltd. Service Check holding- Tighten as necessary.
Engineer. down bolts for
tightness.
The following hazards may arise during
maintenance work:
OVERHAUL
An overhaul is to be carried out when pump
performance falls below an acceptable level.
Fluid Pressure Jet Hazards
Check and ensure that the pump
operates at below the Maximum Working
BEFORE ATTEMPTING ANY MAINTENANCE ON A
Pressure specified in the manual or on the
pump nameplate and before maintenance, PUMP, PARTICULARLY IF IT HAS BEEN
ensure that the pump is drained down. HANDLING ANY FORM OF HAZARDOUS LIQUID,
ENSURE THAT THE UNIT IS SAFE TO WORK ON.
Hazardous Materials THE PUMP MUST BE FLUSHED THOROUGHLY
Wear a suitable mask or respirator when WITH A SUITABLE CLEANSER TO PURGE AWAY
working with packing or gasket ANY OF THE PRODUCT LEFT IN THE PUMP
components that contain fibrous material, as COMPONENTS. THIS SHOULD BE CARRIED OUT
these can be hazardous when the fibrous dust BY THE PLANT OPERATOR AND A CERTIFICATE
is inhaled. Be cautious if other supplier's OF CLEANLINESS OBTAINED BEFORE
components have been substituted for STARTING WORK. TO AVOID ANY RISK TO
genuine SPP Pumps Ltd parts as these may HEALTH IT IS ALSO ADVISABLE TO WEAR
then contain hazardous materials. PROTECTIVE CLOTHING AS RECOMMENDED BY
THE SITE SAFETY OFFICER, ESPECIALLY WHEN
Hazardous Gases, Mists, Sprays and REMOVING OLD SEALS OR GASKETS THAT
Leaks MAY BE CONTAMINATED.
Be aware of the hazards relating to the
pumped fluid, especially the danger from
inhalation of noxious and toxic gases, skin and
eye contact or penetration. Obtain and
understand the hazardous substance
(COSHH) data sheets relating to the pumped
fluid and note the recommended emergency
and first aid procedures.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 10 of 28
Operators Instructions for Horizontal Manual No/Rev
Extended Thrustream Centrifugal Pumps W12-005E / 3

6.1 Preparation for Maintenance 46 51


Electric Shock & Accidental
Starting Hazard
ISOLATE the equipment before
any maintenance work is done.
Switch off the mains supply, remove fuses,
apply lock-outs where applicable and affix
suitable isolation warning signs to prevent
inadvertent re-connection.

During maintenance personnel should be


aware of the risks of inhaling dangerous
fumes or vapours.

No special tools are required for pump


dismantling and re-assembly. However, it is
important to ensure the suitable lifting 4 Clean the sleeve, the bore of stuffing box, the
equipment is available and that the work is lantern ring and the split gland with a clean oily
carried out in a clean area. cloth.

6.2 Repacking the Stuffing Box 5 Check the sleeve for concentricity with the
Where a soft packed gland seal is fitted, it will stuffing box bore and that that the surface
be necessary to replace the packing rings under the packing rings is free from scores,
periodically when the gland can no longer be pitting or grooves.
tightened to reduce leakage to the normal
level, or if the gland is overheating. 6 Examine the gland for general condition and
replace if damaged.
Packing Removal Procedure
Packing Preparation
1 Close the suction & discharge valves and
release pressure from the casing, remove the If the packing is to be cut from a coil or long
gland retaining nuts (50F) and pull the split length the size, number of rings and length is
gland (50) clear of the stuffing box. thus:

Stuffing Box Data


46 51 50 PACKING SIZE
SIZE of NO. OF
50X PUMP SLEEVE
SHAFT DIA. SQUARE
LENGTH
of ONE
RING RINGS
SECTION ID/OD PER
MODULE mm RING mm / mm BOX
mm
mm
1E 100 12.5 354 100/125 5
2E 120 12.5 416 120/145 5
3E 140 15.0 487 140/170 5
2T 85 12.5 290 85/110 5
3T 120 12.5 416 120/145 5

7 Wrap the packing around a dummy shaft, of


the same diameter as the sleeve.

50B
50F
2 Remove the retainer (50X) and separate and
remove the two halves of the gland.
8 To assist in cutting rings, two guide lines
parallel to the shaft axis and separated by a
3 Carefully withdraw the old packing rings (51) distance equal to the packing section may be
and lantern ring (46), using a pair of extractor
drawn on the spiral.
tools of the correct size placed on opposite
sides of the pump shaft (71).

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 11 of 28
Manual No/Rev Operators Instructions for Horizontal
W12-005E / 3 Extended Thrustream Centrifugal Pumps

by cutting off lubrication to the packing, and


o
45 the packing will burn and damage the sleeve.

6.3 Maintenance of Mechanical Seals

Generally no maintenance is required on


mechanical seals. They should be replaced if
leakage occurs but if maintenance is required,
the manufacturer's information is given in
9 Cut each ring from the spiral at an angle of 45° Appendix IIl.
diagonally across the guidelines.
6.4 Bearing Lubrication
Repacking Procedure
The ball bearings are supplied pre-loaded with
10 Insert the first ring and tap it to the bottom of
appropriate grease. A grease nipple and V
the stuffing box. Each following ring should be
ring seals are fitted to the bearing housing to
installed in the same manner and positioned in
ensure that any surplus grease is trapped
the stuffing box so that the "split" is advanced
inside the bearing housing.
120°.
It is important to know the weight of grease
11 Install the lantern ring(s) (46) in the proper
delivered by each stroke your grease gun to
position(s) to align with the seal lubrication
ensure application of the correct amount of
connection(s), allowing for movement of the
grease.
ring deeper into the box as the packing is
compressed.
It is recommended that the drive end bearings
are topped up as per the Recommended
12. When the all the rings have been inserted, the
Maintenance Schedule in Section 6.
last packing ring should not protrude from the
stuffing box face.
Recommended Grease Lubricant:
International DIN 51825:
13. Slide the gland into the stuffing box and
Standard KP2 K-30
ensure that it sits squarely against the last
packing ring. Fit the gland retainer (50X) and As Supplied with TEXACO MULTIFAK ALL
the gland retaining nuts (50F) on the studs a new pump. PURPOSE EP2
(50A) and tighten evenly to finger pressure.
Note Greasing points may be provided for the
14. Start the pump as per paragraph 5.2, allow bearings on the electric motor fitted, refer to
pressure to increase to normal level and Appendix I for motor maintenance details.
ensure that air is not trapped in the pump
casing.
6.5 Bearing Replacement
15. A soft packed gland must have slight steady Ball bearings will provide satisfactory service
leakage, and this should start soon after the for their designed working life if they are
pump reaches it’s normal operating pressure. correctly lubricated and inspected at the
intervals shown in Section 6. - Recommended
16. If gland leakage stops, the pump will overheat Maintenance Schedule.
leading to seal damage or premature pump
failure. If overheating is detected, the pump Bearing Specifications
must be stopped and allowed to cool and Shaft Module Bearing Specification
when restarted, gland leakage should start.
1E 6214
17. If the pump overheats again, stop the pump 2E 6218
restart it again, do not slacken the gland 3E 6220
retaining nuts. 2T 6411
3T 6218
18. After the pump had been running for 10
minutes with steady leakage, tighten the gland
A suitable bearing puller is required for
nuts by one sixth of a full turn. Continue to
removal of the bearings from the pump shaft.
adjust at 10-minute intervals, each time
If a puller is not available, a hammer and soft
evenly, by one sixth of a full turn, until leakage
metal drift may be used to tap evenly around
is reduced to an acceptable level (30 drops
the face of the inner ring.
per minute minimum).
Exerting force on the outer ring of a ball
19. Excessive gland pressure will cause damage
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 12 of 28
Operators Instructions for Horizontal Manual No/Rev
Extended Thrustream Centrifugal Pumps W12-005E / 3

bearing can cause severe damage. the bearing cap.


13. Heat the bearing (67) to approximately 1000C
The work area and all tools used for bearing 0
(212 F) using bearing hotplate, induction
replacement must be clean and free of dust
heater or oven. NOTE - Do not exceed 1200C
and grit to prevent contamination of a clean 0
(248 F).
bearing and new grease.

Ball bearings should not be dismantled. 14. Slide the heated bearing onto the shaft to abut
the shoulder. Ensure that the bearing sits fully
For pumps fitted with cartridge and squarely against the shoulder.
ATTENTION
mechanical seals:
Refer to the seal manufacturer’s instructions 15. Cool the bearing to room temperature and
in Appendix III and lock the seal before pack both sides with two/three ounces of
removing the retaining nuts (52A) and sliding recommended grease.
the seals back from the face of the insert
(A/B53). 16. Coat the inside of the bearing housing (62)
with grease and slide into place over the
When replacing all the bearings, complete the bearings.
replacement of the drive end bearings
BEFORE commencing to replace the non- 17. If necessary use two screwed rods to pull the
drive end bearings. bearing housing towards the bearing cap then
fit four of the screws (62A), tighten evenly to
Drive End Bearing Replacement Procedure pull the bearing housings into place, fit and
tighten the remaining screws.
1. Remove the screws (64A) and slide the
bearing cap (64) along the shaft towards the 18. Fit the bearing cap (64) to the bearing housing
liquid thrower (72). (62) using screws (64A).

2. Remove the screws (62A and 53A) to free the 19. Check that the shaft rotates freely by hand.
bearing housing (52) for removal.
20. Secure bearing housing (62) to the insert
3. Using a suitable puller, withdraw the bearing (B53) with screws (53A).
housing from the shaft (71).
21. Fit the new oils seal (64) on the shaft to abut
4. Using a suitable bearing puller on the inner against the bearing housing.
race, pull the bearing (67) off the shaft.
22. Where applicable refit and set the mechanical
5. Clean the bearing thoroughly with an approved seal as per the seal manufacturer’s
cleaning fluid. instructions in Appendix III.

6. Dry the bearing with dry compressed air or


with a clean soft cloth by hand. Non-Drive End Bearing Replacement Procedure

7. DO NOT SPIN A CLEAN DRY BEARING. 1. Proceed as per the drive end bearing
replacement procedure, paragraphs 1 and 2.
8. Inspect the bearing for wear, fractures, cracks,
corrosion or other damage, which may 2. Remove the cover plate (62Y) from the non-
necessitate replacement. drive end bearing housing and using a suitable
puller, withdraw the bearing housing from the
9. Lightly oil the bearing and wrap in greaseproof shaft (71).
paper to prevent contamination before
reassembly. 3. Using a suitable punch, flatten the lock washer
(75F) and remove the bearing locknut (75)
10. Check that the shaft, bearing cap and housing and the lock washer.
are clean and undamaged.
4. Replace the non-drive end bearing and as per
11. It is recommended that new oil seals (64R) the drive end bearing replacement procedure,
are fitted when bearings are replaced to paragraphs 4 to 16.
ensure that contamination is prevented.
5. Place the locking washer (75F) onto the shaft
12. Slide the oil seal onto the shaft (71) wipe the and screw on the bearing lock nut (75).
seal recess in the bearing cap (64) with
grease and set in position on the shaft against 6. Fit and tighten the bearing locknut to 300 Nm

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 13 of 28
Manual No/Rev Operators Instructions for Horizontal
W12-005E / 3 Extended Thrustream Centrifugal Pumps

and lift the tab of the lock washer. the mechanical seal (52).

7. Fit the bearing housing as per the drive end 3 Remove the screws (62A) that retain the
bearing replacement procedure, paragraphs bearing housings (62) to the top half casing
17 to 20. (A1).

8. Refit the cover plate (62Y). 4 Remove the nuts (1F) from the casing studs
(1B) securing the top half casing (A1) to the
6.6 Mechanical Seal Replacement bottom half casing (B1).

Mechanical seals will need replacement when 5 Press or tap out the dowels (1C).
failure has occurred, they may not be replaced
without removal of the rotating assembly 6 Using a pair of pry bars in the slots provided
unless the motor is demounted and the between the top and bottom casings, apply
coupling is removed from the pump shaft. pressure to break the gasket seal and lift the
It is recommended that new mechanical seals top half casing (1A) off the bottom half casing
are fitted when conducting a full pump strip- (1B).
down for overhaul to give maximum operating
life. 7 If the top half casing is trapped between the
bearing housings, release the remaining
screws (62A) from the non-drive-end bearing
Refer to the seal manufacturer’s instructions housing (62) and back it off by about 1mm.
in Appendix III and lock the seal before
removing the retaining nuts (52A) and sliding 5 Using the eyebolt and a suitable lifting device,
the seals back from the face of the insert lift the top half casing (A1) clear of the
(A/B53). impeller, place to one side on a clean flat
surface.
Mechanical Seal Replacement Procedure
1 Isolate the pump and drain the casing using 6 At this stage, the impeller may be inspected
the air vent valves (308) and drain plugs (1P & for damage or blocking and cleaning if
1M) provided. necessary.

2 Disconnect the seal flush pipe, remove the To check the pump shaft (71) and impeller
four hexagon screws (52A) that retain the (21) and to replace the wear rings (23) or soft
mechanical seal, and slide the seal assembly packed seal sleeves (B26 & B27), it is
off the shaft. necessary to remove the rotating assembly
3 Proceed as per the bearing replacement from the bottom half casing.
instructions, paragraphs 1 to 10.
Preparation for Removal of the Rotating Assembly
4 Remove the nuts (52F) from the studs (52A)
and withdraw the mechanical seal (52) from Disconnect the motor coupling.
the shaft (71).
5 Fit a new mechanical seal as per the For pumps fitted with mechanical seals, refer
manufacturer’s instructions in Appendix III to the seal manufacturer’s instructions and
lock the seal before removing the retaining
6 Reconnect the seal flush pipe. screws (52A) and sliding the seals back from
7 Proceed as per the bearing replacement the face of the insert (A/B53).
instructions, paragraphs 11 to 21.
Provide a suitable lifting strap and support the
6.7 Pump Overhaul and Repairs weight of the rotating assembly thus:
Refer to a certified Pump Section drawing or
the typical cross section drawing in Section 8.
Note the hazards outlined in Section 6.

Impeller Inspection Procedure

1 Isolate the pump and drain the casing using


the air vent valves (308) and drain plug (1M)
provided.

2 Remove the seal lubrication pipes (A107) from


the inserts (53) for soft packed pumps or from

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 14 of 28
Operators Instructions for Horizontal Manual No/Rev
Extended Thrustream Centrifugal Pumps W12-005E / 3

Removal of the Rotating Assembly Procedure (75F) and remove the bearing locknut (75)
and the lock washer.
1. Remove the remaining screws (62A) that
retain the bearing housings (62) to the bottom 6. Using a suitable bearing puller on the inner
half casing (B1). race of each bearing, pull the bearings (66 &
67) off the shaft.
2. Tap the inserts (41/53) with a soft-faced
hammer to break the seal between the insert 7. Release the screws (72A) and remove the
and the bottom half casing (B1). liquid throwers (72) from the shaft.

3. Lift the rotating assembly clear of the bottom 8. For pumps fitted with mechanical seals: Slide
half casing and support the shaft on suitable V the mechanical seal assemblies off the shaft
blocks with the impeller clear of the work (71), remove the inserts (53) complete with
surface. throttle bush (45) and set aside for inspection.

4 If necessary, remove the case wear ring 9. For pumps fitted with soft packed glands:
dowels (23A) from the bottom half casing Slide the gland (50) off the end of the shaft
(B1). (71) and remove the inserts (53) complete
with packing rings (51) and lantern rings (46)
5 With feeler gauges, check the clearance and set aside for inspection.
between the case wear rings (23) and the
impellers (21), compare clearance with the 10. If not already removed, remove the case wear
figures below. rings (23) and set aside for inspection and
measurement.
Diametral Radial
Internal mm mm For Clockwise pump construction:
Clearances Min Max Min Max
TR20A, TL30A, TT25A, 11. Using a suitable ‘C’ spanner, unscrew and
0.440 0.651 0.220 0.325
TP15T & TR20T remove the non-drive end sleeve (B47) on a
TN25A, TQ25A, TR30A soft packed pump or impeller nut (A21) when
0.440 0.659 0.220 0.330
& TM35A a mechanical seal is fitted.
TP30A, TV30A, TN35A
0.460 0.689 0.230 0.345
& TQ35A For Counter Clockwise pump construction:
TT35A 0.460 0.549 0.230 0.275
12. Using a suitable ‘C’ spanner, unscrew and
Note Increase in the wear ring clearance allows remove the drive end sleeve (A47) on a soft
increased internal leakage with resultant loss packed pump or impeller nut (B21) when a
of pump performance, head and efficiency. mechanical seal is fitted.
When the clearance is double the original
clearance, it is recommended that new wear Note Light tapping with a soft faced mallet may be
rings are fitted. It is permissible to run the needed to free the impeller from the shaft, do
pump with increased clearance due to wear not damage the impeller if it is to be reused.
but the loss of pump efficiency will significantly
increase the pump running costs. 13. Using suitable pullers or levers, slide the
impeller (21) of the shaft (71).
Procedure to Dismantle the Rotating Assembly
14. Scribe a line on the shaft to mark the position
1. Remove the screws (64A) and slide the of the locked sleeve or nut for reassembly.
bearing cap (64) along the shaft towards the
liquid thrower (72). 15. Withdraw the impeller key (116) and unscrew
and remove the remaining sleeve or the
2. Remove the screws (53A) to free the bearing impeller nut.
housing (52) for removal.
Cleaning and Inspection of Parts
3. Using a suitable puller, withdraw the drive end
bearing housing from the shaft (71). 1. Clean the bearings thoroughly with an
approved cleaning fluid, kerosene or white
4. Remove the cover plate (62Y) from the non- spirit.
drive end bearing housing and using a suitable
puller, withdraw the non-drive end bearing 2. Dry the bearings with dry compressed air or
housing from the shaft (71). with a clean soft cloth by hand and by spinning
by hand. Confirm that the bearings rotate
5. Using a suitable punch, flatten the lock washer smoothly without slackness.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 15 of 28
Manual No/Rev Operators Instructions for Horizontal
W12-005E / 3 Extended Thrustream Centrifugal Pumps

3. DO NOT OVERSPIN A CLEAN DRY approved coating for pumps used for potable
BEARING. water.

4. Inspect the bearings for wear, fractures, 15. Clean all threads with kerosene followed by
cracks, corrosion or other damage to the wire brushing, dry and wrap shaft threads with
running surfaces, which may necessitate protective adhesive tape.
replacement.
16. If the unit is not to be reassembled
5. Coat the bearings with rust preventive oil and immediately, brush all bright iron and steel
wrap in greaseproof paper. surfaces with Texaco Rust Proof Compound L
or Rust Proof Compound Spray or a suitable
Note: It is recommended that all ‘V’ rings, ‘O’ rings equivalent rust preventive fluid.
and gaskets: are replaced by new parts during
an overhaul. If ‘O’ rings are to be reused they 17. Protect all parts (especially mechanical seal
should be left in place in their grooves and parts and faces) against loss, weather or
protected from contamination by oil and dirt. mechanical damage.

6. Remove all O-rings from their grooves and 6.8 Before reassembly:
discard where these are to be replaced.
1 Re-examine all old parts intended for re-fitting.
7. Remove all grease and other deposits from all Worn, damaged or corroded parts should
other parts using suitable cleaning fluid and a either be re-conditioned or, if beyond this, be
clean dry cloth. discarded and replaced by new.

8. Coat all unpainted carbon steel parts with a 2 Ensure that all parts to be refitted (especially
light smear of oil to prevent rust. new parts) are free from burrs, with screw
threads and abutting faces clean and free
9. Measure the inside diameter of the wear rings from damage.
and the outside diameter of the wear ring
surfaces on the impeller, calculate the 3 Examine 'O' and 'V' rings and renew if
clearance and compare these with dimensions showing wear, damage or deterioration.
in Section 6.7.
Pump Reassembly
10. Mount the shaft between point centres or on
rollers, and place the stem of a dial indicator in 1 Lightly smear the shaft (71) with clean good
contact with the shaft. Set the indicator dial at quality grease or light oil.
zero and turn the shaft slowly by hand.
Readings at any point A, B, C, D and E must For clockwise rotation:
not vary more than 0.05mm (0.002").
IMPELLER DRIVE END IMPELLER
KEY NUT OR SLEEVE

DIMN. A
11. For soft packed pumps: examine the shaft
sleeves for wear, replace the sleeve if it is
scored or has any visible surface damage. For counter-clockwise rotation:

12. If the shaft runs true within tolerance, remount NON-DRIVE END IMPELLER
the shaft as in 2 but with the sleeve fitted in NUT OR SLEEVE IMPELLER
position, and check the sleeves run-out at the KEY
packing contact positions. Indicator readings
must not vary more than 0.08mm (0.003").
13. The sleeve can be re-ground to provide a new
DIMN. B
packing surface, to a maximum of 1.0mm
(0.04") below the initial diameter. Do not grind
reduce sleeve diameter in the throat bush Note The position of the impeller key and the locked
area unless scored. The surface finish of the sleeve or impeller nut is governed by the
sleeve should be 20-30 C.L.A. direction of rotation of the pump. For
clockwise pumps they are fitted at the drive
14. Scour any rust or scale from internal iron non- end of the shaft slot and for counter-clockwise
fitting surfaces and immediately repair or pumps they are at the non-drive end.
renew any previous coating. Use WRC
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 16 of 28
Operators Instructions for Horizontal Manual No/Rev
Extended Thrustream Centrifugal Pumps W12-005E / 3

Where the location was not marked, please 15. Slide the heated bearings onto the shaft to
refer to the pump section drawing supplied or abut the shoulder. Ensure that the bearings sit
to SPP Pumps Ltd for dimensions A or B. fully and squarely against the shoulder.

2 Screw the locked impeller nut (B21) or sleeve 16. Place the locking washer (75F) onto the shaft
(A47) onto the shaft (71) to the marked and screw on the bearing lock nut (75).
position. Turn the nut or sleeve to the nearest
slot to align with the keyway. 17. Fit and tighten the bearing locknut to 300 Nm
and lift the tab of the lock washer.
3 Place impeller key (116) into keyway and tap
the end right home under locked impeller nut 18. Cool the bearings to room temperature and
or sleeve. pack both sides with two/three ounces of
recommended grease.
4 Check the impeller for correct direction of
rotation and slide onto shaft. 19. Coat the inside of the bearing housings (62)
with grease and slide into place over the non-
bearings. If necessary use two screwed rods
to pull the bearing housing towards the
bearing cap.

20. Secure the bearing housings (62) to the insert


(A53 & B53) with four socket capscrews (53A)

21. Check and install the dowel pins (23A) in the


bottom half casing (B1) to locate the case
wear rings (23).
5. Screw free impeller locking nut (A21) or 22. Place the rotating assembly into the pump
sleeve (B47) onto shaft to retain the impeller casing bottom half (B1). Correct any
against the locked impeller nut or sleeve. excessive ‘O’ ring twisting or buckling. Check
that the impeller is centralised in the casing
6. Slide the casing wear rings (23) onto the and that there are no rubs.
impeller.
23. Install casing gasket (1U) with a light coat of
7. Lightly grease and carefully fit new ‘O’ rings commercial cup grease on both gasket
(53R) to the inserts (A53 & B53). surfaces. Carefully align the inner edge of the
gasket with the insert ‘O’ rings.
8. Slide the inserts on to the shaft with the guide
vane at top position. 24. Lower the upper half casing (Al) into place and
install casing joint nuts (1F).
9. For soft packed pumps: Fit the packing (51),
lantern rings (46) and glands (50) as per 25. NOTE: When installing upper half casing,
instructions in section 6.2. make sure that the ‘O’ rings (53R) are not cut
or pinched and that the casing gasket is hard
10. Fit the liquid throwers (72) on the shaft and against the ‘O’ rings.
secure with screws (72A).
26. Insert casing joint dowels (1C) and drive them
11. For mechanical seals: Fit the throttle bushes home. Tighten the joint nuts (1F) to the
(45) onto shaft and slide them into position specified torques
inside the inserts.
Thread Size lb/ft Nm
12. Fit the mechanical seals to the shaft as per M16 120 160
the manufacturer’s instructions in Appendix III. M20 260 360
M24 440 600
13. Fit new oil seals (64R) into the bearing caps
(63) and slide them on the shaft, ready for 27. Tighten the case screws in the following
assembly of the bearing housings. sequence:

14. Heat the bearings (66 & 67) to approximately


1000C (2120F) using bearing hot-plate,
induction heater or oven. NOTE:- Do not
exceed 1200C (2480F).

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 17 of 28
Manual No/Rev Operators Instructions for Horizontal
W12-005E / 3 Extended Thrustream Centrifugal Pumps

8 6 Note Light tapping with a soft faced mallet may be


3 2 needed to free the impeller from the shaft, do
not damage the impeller if it is to be reused.

12 10 1. Using suitable pullers or levers, slide the first


impeller (A21) of the shaft (71).

2. Withdraw the interstage plate (8) from the


9 11 impeller spacer (17) and check the condition
of the interstage neck bush (24) replace if
worn.
1 4
7 3. Tap and pull the other impeller (B21) off the
5 shaft with the impeller spacer (17).
a) Tighten the four 'corner' screws marked 1,
4. Withdraw the impeller key (116) and unscrew
2, 3 and 4.
and remove the locked sleeve (A47) or the
impeller nut (B21).
b) Work outward along shaft axis toward the
stuffing boxes in opposite quarters
Impeller re-assembly:
tightening screws in regions 5, 6, 7 and 8.
Proceed with shaft assembly as for single
c) Work outward along the branch and in
stage pumps to paragraph 3.
opposite quarters tightening screws in
regions 9, 10, 11 and 12.
1. Select the first impeller for assembly, check
the impeller for correct direction of rotation
d) Repeat the whole sequence (a to d).
and slide onto shaft to abut the locked sleeve
or nut.
29. Check that the shaft turns freely by hand.
2. Fit new O rings to each side of the impeller
30. Top up the bearing lubrication by applying spacer (17), slide on to the shaft and fit the
several strokes with a grease gun. interstage plate (8) complete with its’ O ring,
ensuring that it is the correct way round to fit in
31. The pump is now ready for re-coupling to the the pump casing.
motor and re-commissioning.
3. Screw free impeller locking nut (A21) or
Two Stage Pump Assembly Instructions sleeve (B47) onto shaft to retain the impellers
against the locked impeller nut or sleeve.
Note: Two stage pumps are similar in construction
to the single stage pump and instructions 4. Slide the casing wear rings (23) onto the
relating to maintenance and repair apply impeller.
equally to both types.
5. Check that the dowels (8A) that retain the
The difference relates to the disassembly of interstage plate are correctly fitted.
the two impellers (A21 & B21) and the
interstage plate (8). Continue with pump re-assembly from
paragraph 7.
Proceed to disassemble the rotating assembly
as for single stage pumps to paragraph 10:

For Counter Clockwise pump construction:

16. Using a suitable ‘C’ spanner, unscrew and


remove the non-drive end sleeve (B47) on a
soft packed pump or impeller nut (A21) when
a mechanical seal is fitted.

For Counter Clockwise pump construction:

17. Using a suitable ‘C’ spanner, unscrew and


remove the drive end sleeve (A47) on a soft
packed pump or impeller nut (B21) when a
mechanical seal is fitted.

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 18 of 28
Operators Instructions for Horizontal Manual No/Rev
Extended Thrustream Centrifugal Pumps W12-005E / 3

7. Faults and Remedial Action CAUSE REMEDIAL ACTION


Not enough head Reduce the positive suction head by
POTENTIAL FAULT OR DEFECT: for hot liquid. raising the liquid level.
No liquid delivered.
Inlet pipe not If the pump inlet cannot be lowered,
Insufficient liquid delivered.
submerged provide a baffle to smother the inlet
Liquid delivered at low pressure. enough. vortex and prevent air entering with the
Loss of liquid after starting. liquid.
Excessive vibration.
Liquid density Refer to SPP Pumps Ltd. for guidance
Motor runs hotter than normal. higher than to increase the size or power of the
Excessive noise from pump cavitation. rating. motor or engine.
PROBABLE CAUSES Insufficient nett Increase the positive suction head by
 Pump not primed. inlet head. lowering the pump or raising the liquid
   Speed too low. level.
  Speed too high. Impeller blocked. Dismantle pump and clean the
     Air leak in suction pipework. impeller.
  Air leak in mechanical seal. Wrong direction Check driver rotation with the direction
    Air or gas in liquid. of rotation. arrow on the pump casing.
    Discharge head too high (above rating). Excessive wear Replace the wear rings when the
 Suction lift too high. ring clearance. clearance exceeds the maximum
 Not enough head for hot liquid. tolerances.
     Inlet pipe not submerged enough. Damaged Replace if damaged or vanes are
   Viscosity of liquid greater than rating impeller. eroded.
 Liquid density higher than rating. Rotor binding. Check for shaft run out, and replace if
     Insufficient nett inlet head. necessary.
   Impeller plugged up or blocked. Defects in motor. Ensure that motor is adequately
   Wrong direction of rotation. ventilated. Refer to manufacturers
  Excessive wear ring clearance. instructions.
   Damaged impeller. Voltage and/or If voltage and frequency are lower than
 Rotor binding. frequency lower the motor rating, arrange for provision
 Defects in motor. than rating. of correct supply.
 Voltage and/or frequency lower than rating. Foundation not Ensure that the foundation bolts are
 Foundation not rigid. rigid. tight; check that foundations match
 
SPP Pumps Ltd. Recommendations.
Misalignment of pump and driver.
 Rotor out of balance. Misalignment of Check shaft run-out and replace if
  Shaft bent.
pump and driver. necessary.
 Impeller too small. Rotor out of Check impeller for damage, replace as
balance. necessary.
Shaft bent. Check shaft run-out and replace if
CAUSE REMEDIAL ACTION
needed.
Pump not Fill pump and suction pipe completely
primed. with fluid. Impeller too Refer to SPP Pumps Ltd. for options to
small. fit a larger impeller.
Speed too low. Check that the motor is correctly
connected and receiving the full supply
voltage also confirm that the supply
frequency is correct.
Speed too high. Check the motor voltage.
Air leak in suction Check each flange for suction draught,
pipework rectify as necessary.
Air leak in Check all joints, plugs and flushing
mechanical seal. lines, if fitted. Note that prolonged
running with air in the mechanical seal
will result in damage and failure of the
seal.
Air or gas in It may be possible to increase the
liquid. pump performance to provide
adequate pumping.
Discharge head Check that valves are fully open and
too high (above for pipe friction losses. An increase in
rating). pipe diameter may reduce the
discharge pressure.
Suction lift too Check for obstruction of pump inlet
high. and for inlet pipe friction losses.
Measure the static lift, if above rating,
raise the liquid level or lower the pump.

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 19 of 28
Manual No/Rev Operators Instructions for Horizontal
W12-005E / 3 Extended Thrustream Centrifugal Pumps

8. Pump Details:
8.1 Pump Cross Section Drawing – Single Stage Pump – Clockwise Rotation:

Differences for Mechanical Seals:

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 20 of 28
Operators Instructions for Horizontal Manual No/Rev
Extended Thrustream Centrifugal Pumps W12-005E / 3

8.2 Single Stage Pump Parts Identification List - (Numbers as shown on cross section drawing)
Note: Pump construction may vary slightly between the different pump sizes within each type, it is important
to refer to the specific pump section drawing and to quote the pump serial number when ordering
parts to ensure that the correct part is supplied in the original material of construction.

Item Description Qty Item Description Qty


A1 Casing Top Half 1 71 Pump Shaft 1
B1 Casing Bottom Half 1 72 Deflector – Water 2
1B Casing Stud 32 72A Screw - Deflector 2
1C Casing Dowel 2 73 Eyebolt - Lifting (Not Shown) 2
1CF Hexagon Nut Full Dowel 2 75 Bearing Lock Nut 1
1CG Plain Washer Dowel 2 75X Bearing Lock Washer 1
1F Hexagon Nut Full Casing 32 A79 Spacer Ring - Inner 1
1L Casing Plug 1” BSP 7 B79 Spacer Ring - Outer 1
1M Casing Plug ½” BSP 2 105 Grease Nipple (Not Shown) 2
1U Casing Gasket 1 B106 Stud Coupling 4
21 Impeller 1 A107 Pipe As reqd.
22 Impeller Wear Ring 2 108 Reducer 2
22A Set Screw – Impeller Wear Ring 6 116 Key - Impeller 1
23 Case Wear Ring 2 118 Key - Coupling 1
23A Dowel - Case Wear Ring 4 308 Air Vent Valve 1
46 Lantern Ring 4 308X Reducer 1
A47 Sleeve – Locked (Soft Packed) 1
Parts for Pumps with Component Mechanical Seals:
B47 Sleeve – Free (Soft Packed) 1
A21F Nut - Impeller (Free) 1
47R O Ring – Sleeve - Outer 2
B21F Nut - Impeller (Locked) 1
47S O Ring – Sleeve - Inner 2
21R O Ring – Nut - Outer
50 Gland 2
52 Component Mechanical Seal 2
50A Stud – Gland 4
52A Stud 8
50F Nut – Gland 4
52F Nut 8
50X Retainer - Gland 2
52G Washer 8
51 Packing 10
A53 Insert Mech. Seal - Drive End 1
A53 Insert Soft Packed - Non Drive End 1
B53 Insert Mech. Seal – Non Drive End 1
B53 Insert Soft Packed – Drive End 1
56 Cover - Mechanical Seal 2
53A Screw –Hexagon Head 8
56A Plug – Mech. Seal Cover 2
53R O Ring Insert 2
56U Gasket - Mech. Seal Cover 2
62 Bearing Housing 2
62A Screw – Bearing Housing 24 Replacement parts should be obtained from
62Y Cap – N D E Bearing Housing 1 SPP Pumps Ltd. Spares Department; use of
62YA Screw - Hex Headed 4 parts from unapproved suppliers will invalidate
the pump warranty. When ordering spare parts
64 Cover – Bearing 2 please quote the pump serial number from the
64A Screw – Bearing Cover 8 pump identification plate.
66 Bearing Non-drive End 1
67 Bearing Drive End 2

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 21 of 28
Manual No/Rev Operators Instructions for Horizontal
W12-005E / 3 Extended Thrustream Centrifugal Pumps

8.3 Pump Cross Section Drawing –Two Stage Pump – Clockwise Rotation.

Differences for Component Mechanical Seals:

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 22 of 28
Operators Instructions for Horizontal Manual No/Rev
Extended Thrustream Centrifugal Pumps W12-005E / 3

8.4 Two Stage Pump Parts Identification List - (Numbers as shown on cross section drawing)

Note: Pump construction may vary slightly between the different pump sizes within each type, it is important
to refer to the specific pump section drawing and to quote the pump serial number when ordering
parts to ensure that the correct part is supplied in the original material of construction.

Item Description Qty Item Description Qty


A1 Casing Top Half 1 66 Bearing Non-drive End 1
B1 Casing Bottom Half 1 67 Bearing Drive End 2
1A Casing Stud Varies 71 Pump Shaft 1
1B Casing Stud Varies 71 Oil Seal 1
1C Casing Dowel 2 73 Eyebolt 1
1CF Hexagon Nut Full Dowel 2 75 Bearing Lock Nut 1
1CG Plain Washer Dowel 2 75F Bearing Lock Washer 1
1F Hexagon Nut Full Casing Varies 77 Shoulder Ring 1
1L Casing Plug 4 79 Spacer Ring 1
1M Casing Plug 2 105 Grease Nipple 2
1U Casing Gasket 1 A106 Elbow 90deg. 2
8 Interstage Plate (Two Stage) 1 B106 Stud Coupling 4
8A Dowel 1 C106 Tubular Piece 2
8R O Ring – Interstage Plate 1 D106 Stud Coupling 2
17 Impeller Spacer (Two Stage) 1 116 Key - Impeller 1
17R O Ring – Impeller Spacer 2 118 Key - Coupling 1
A21 Impeller (Two Stage) 1 A107 Pipe 2
B21 Impeller (Two Stage) 1 B107 Pipe 2
A21F Impeller Nut – Locked (Mech. Seal) 1 308 Air Vent Valve 1
B21F Impeller Nut – Free (Mech. Seal) 1
Parts for Pumps with Component Mechanical Seals:
22 Impeller Wear Ring (Where fitted) 2
A21F Nut - Impeller (Free) 1
22A Set Screw – Impeller Wear Ring 4
B21F Nut - Impeller (Locked) 1
23 Case Wear Ring 2
21R O Ring – Nut - Outer
23A Dowel Case Wear Ring 4
52 Component Mechanical Seal 2
24 Interstage Neck Bush 1
52A Stud 8
24A Socket Set Screw – Neck Bush 2
52F Nut 8
45 Neck Ring 2
52G Washer 8
46 Lantern Ring 2/4
A53 Insert Mech. Seal - Drive End 1
A47 Sleeve – Locked 1
B53 Insert Mech. Seal – Non Drive End 1
B47 Sleeve – Free 1
56 Cover - Mechanical Seal 2
47R O Ring – Sleeve - Outer 2
56A Plug – Mech. Seal Cover 2
47S O Ring – Sleeve - Inner 2
56U Gasket - Mech. Seal Cover 2
50 Gland 2
51 Packing 5 Replacement parts should be obtained from
53 Spacer Ring (Soft Packed) 2 SPP Pumps Ltd. Spares Department; use of
A53 Insert 1 parts from unapproved suppliers will invalidate
the pump warranty. When ordering spare parts
B53 Insert 1 please quote the pump serial number from the
53A Socket Capscrew 8 pump identification plate.
53F Spring Washer 8
53R O Ring Insert 2
61 Support Frame 2
61A Hexagon Headed Screw 8
61F Plain Washer 8
A62 Bearing Housing Non-drive End 1
A62L Plug Bearing Housing N.D.E 1
B62 Bearing Housing Drive End 1
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 23 of 28
Manual No/Rev Operators Instructions for Horizontal
W12-005E / 3 Extended Thrustream Centrifugal Pumps

9. Standard Metric Nut and Bolt Torque Recommendations


This information is for reference only. The user must check that the torque figures listed here are applicable to
the fasteners used. Nuts and bolts should be neither under nor over tightened.
Approximate Torque (Nm) for Bolt Diameters:
Grade of Bolt
M5 M6 M8 M10 M12 M16 M20 M24 M30 M36
4.6 2.7 4.5 11 22 38 95 185 320 633 1110
8.8 6.9 11.7 28 56 98 244 476 822 1634 2855
10.9 9.4 15.9 38 77 134 332 646 1120 2223 3885
12.9 11.2 19.1 46.4 92 160 397 775 1342 2666 4660

Note: These torque figures are approximate, and for un-plated fasteners only. No allowance has been made for
special finishes or lubricants, washers or mating surfaces.

Bolt and Nut Grade Combinations


Grade of BOLT 4.6 8.8 10.9 12.9 Note: It is permissible to fit higher grade
Grade of NUT 4 8 12 12 nuts than recommended.

Grade Identification

BOLTS & NUTS - Grade 4.6


BS4190 (ISO272, 885, 888 & 4759/1). Grade marking is optional.
Normally there will be no mark other than the 'M' thus:

BOLTS - Grade 8.8 NUTS - Grade 8


BS 3692 (ISO272, 4759/1). Grade Indented marks as a clock face,
marking is mandatory, may also dot at 12.00, bar at 8.00,
have trade marks indicates grade 8 nut.

High Strength Friction Grip Bolts & Nuts


BOLT NUT BOLT NUT
Grade10.9 Grade 12

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 24 of 28
Operators Instructions for Horizontal Manual No/Rev
Extended Thrustream Centrifugal Pumps W12-005E / 3

Installation & Maintenance Record


Date Summary of maintenance & repairs done - replacement parts fitted etc:
Initial Alignment TIR readings:
First Lateral Check: …………… Angular Check: ………….. Confirmed Lateral Check: …………..
Final Alignment TIR readings:
First Lateral Check: …………… Angular Check: ………….. Confirmed Lateral Check: …………..
Installed & Commissioned Signed –
Commissioning Engineer

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 25 of 28
Manual No/Rev Operators Instructions for Horizontal
W12-005E / 3 Extended Thrustream Centrifugal Pumps

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 26 of 28
Operators Instructions for Horizontal Manual No/Rev
Extended Thrustream Centrifugal Pumps W12-005E / 3

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 27 of 28
Manual No/Rev Operators Instructions for Horizontal
W12-005E / 3 Extended Thrustream Centrifugal Pumps

10. SPARES & SERVICE


SPP Pumps operate a comprehensive Spares and Service support network throughout the world, and can be
contacted as follows:

SPARES & SERVICE Telephone: +44 (0)1189 323 123


For spare parts, supply only. ask for - Spares Dept.

For breakdowns, spare parts and on-site fitting, pump installation and
commissioning, and service contracts. ask for - Service Dept.

For breakdowns outside office hours. Telephone : +44 (0)1189 323 123

Spares & Service Office


SPP Pumps Limited General Fax line: +44 (0)1189 323 302
1420 Lakeview
Arlington Business Park
Reading, Berkshire Direct Fax line: +44 (0)1189 303 259
RG7 4SA
ENGLAND

Copies of this manual are available from the SPP Pumps Limited Spares & Service Department by quoting
the manual reference number and revision number.

You may enter details from your pump nameplates here for quick reference.

SPPSPP
Pumps Ltd.
Pumps Reading
Coleford,
ENGLAND RG31 7SP
ENGLAND
Tel: +44(0)1594932
Tel:++44(0)118 832701
3123

SPP Pumps Limited


SPP Pumps Limited
Crucible Close, Mushet Industrial Park,
Reading ENGLAND RG31 7SP
Coleford, Gloucestershire, ENGLAND,
Tel: ++44(0)1189 323123
GL16 8PS
Tel: +44(0)1594 832701
Fax: ++44(0)1189 323302
Fax: +44(0)1594 836300

W12-005Erev01 SPP Exd.Thrustream Manual 23/08/2012

Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 28 of 28