THRUSTREAM RANGE
Limited Coleford England
HORIZONTAL SPLIT CASE PUMPS
OPERATORS INSTRUCTIONS
THRUSTREAM
EXTENDED RANGE
Horizontal Split Case
Centrifugal Pumps
And Pump Sets
SPP Pumps Limited
Crucible Close
Mushet Industrial Park
Coleford, Glos
ENGLAND
RG31 7SP
Telephone:
+44 (0)1594 832 701
Fax:
+44 (0)1594 836 300
Document No: W12-005E
Revision No: 3
Revision Note No
Date Issued: August 2012
Produced at SPP Pumps
: R 39552
DECLARATION OF CONFORMITY
We
Of
SPP Pumps Limited
Crucible Close
Mushet Industrial Park
Coleford
Gloucestershire
England
GL16 8PS
Declare that:
Equipment:
Model/Type: Models TL to TV (As per the table on page 3)
Serial Number:
For pumps supplied with electric motors:
in accordance with the following Directives:
2006/42/EC The Machinery Directive
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.
HORIZONTAL SPLIT CASE CENTRIFUGAL PUMP
As shown on the Pump Nameplate
and its amending directives
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
Extended Thrustream Centrifugal Pumps
CONTENTS
Section Page
1. General Information & Safety Instructions 4
2. Transport Handling and Storage 4
3. General Description 5
4. Assembly and Installation 6
5. Commissioning and Operation 8
6. Maintenance and Service 10
6.1 Preparation for Maintenance 11
6.2 Repacking the Stuffing Box 11
6.3 Maintenance of Mechanical Seals 12
6.4 Bearing Lubrication 12
6.5 Bearing Replacement 12
6.6 Mechanical Seal Replacement 14
6.7 Pump Overhaul & Repairs 14
7. Faults and Remedial Action 19
8. Pump Details: 20
8.1 Typical Pump Section Single Stage 20
8.2 Parts Identification List Single Stage 21
8.3 Typical Pump Section Two Stage 22
8.4 Parts Identification List Two Stage 23
9. Metric Bolt Torque Recommendations 24
10. Spares & Service 28
Manufacturer’s Information (Where applicable)
Electric Motor Appendix I
Coupling Appendix II
Mechanical Seal Appendix III
Introduction
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.
Manual No/Rev
W12-005E / 3
The pump sizes covered by this manual are:
Extended Single Stage
Thrustream Range:
Size Pump Module
200/58
300/34
250/42
250/51
250/68
300/59
350/39
300/48
300/77
350/44
350/54
350/66
TR20A
TL30A
TN25A
TQ25A
TT25A
TR30A
TM35A
TP30A
TV30A
TN35A
TQ35A
TT35A
1E
1E
2E
2E
2E
2E
2E
3E
3E
3E
3E
3E
Extended Two Stage
Thrustream Range:
150/48-2
200/58-2
TP15T
TR20T
2T
3T
This manual covers the Extended Range of
Thrustream pumps that are built for use in the
horizontal position. For information on pumps built
for vertical applications, please refer to a separate
manual that can be obtained from SPP Pumps
Limited.
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
W12-005E / 3
Operators Instructions for Horizontal
Extended Thrustream Centrifugal Pumps
1. General Information and
Safety Instructions
The products supplied by SPP Pumps Ltd. have
been designed with safety in mind. Where hazards
cannot be eliminated, the risk has been minimised
by the use of guards and other design features.
Some hazards cannot be guarded against and the
instructions below MUST BE COMPLIED WITH for
safe operation. These instructions cannot cover all
circumstances: YOU are responsible for using safe
working practices at all times.
1.1 SPP Pumps Ltd. products are designed for
installation in designated areas, which are to
be kept clean and free of obstructions that
may restrict safe access to the controls and
maintenance access points.
1.7 Note any limits to the pump application
specified in the contract documentation.
Operation of the equipment outside these
limits will increase the risk from hazards noted
below and may lead to premature and
hazardous pump failure.
1.8 Clear and easy access to all controls, gauges
and dials etc. MUST be maintained at all
times. Hazardous or flammable materials
must NOT be stored in pump rooms unless
safe areas or racking and suitable containers
have been provided.
1.9 IMPROPER INSTALLATION, OPERATION
OR MAINTENANCE OF THIS SPP PUMPS
LTD PRODUCT COULD RESULT IN INJURY
OR DEATH.
A pump nameplate is fitted to each unit and
must not be removed. Loss of this plate could
make identification impossible. This in turn
could affect safety and cause difficulty in
obtaining spare parts. Should accidental loss
or damage occur, contact SPP Pumps Ltd.
immediately.
1.2 Access to the equipment should be restricted
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.
1.3 SPP Pumps Ltd. requires that all personnel
that are responsible for installation, operation
or maintenance of the equipment, have
access to and study the product instruction
manual BEFORE any work is done and that
they will comply with all local and industry
based safety instructions and regulations.
1.4 Ear defenders should be worn where the
specified equipment noise level exceeds
locally defined safe levels. Safety glasses or
goggles should be worn where working with
pressurised systems and hazardous
substances. Other personal protection
equipment must be worn where local rules
apply.
1.5 Do NOT wear loose or frayed clothing or
jewellery that could catch on the controls or
become trapped in the equipment.
1.6 Check and confirm that the manual is the
relevant copy by comparing the serial number
on the identification plate with that on the
manual.
1.10 Within the manual, safety instructions are
marked with safety symbols.
Hazard
This symbol refers to general mechanical
aspects of safety.
Hazard
This symbol refers to electrical safety.
ATTENTION
hazard to the pump itself, which in turn, could
cause a risk to personal safety.
This symbol gives warning of a
2. Transport Handling and
Storage Instructions
2.1 Transport
Horizontal Extended Thrustream pumpsets
are despatched fully assembled except where
stability or handling constraints require the
motor to be packed and delivered separately.
Pumps are protected against corrosion and
packed for transport by normal road, rail and
sea carriers.
2.2 Handling
Crushing Hazard
When lifting the pump unit, use lifting
equipment having a safe working load
rating suitable for the weight specified.
Use suitable slings for lifting any pump not
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
Extended Thrustream Centrifugal Pumps
Manual No/Rev
W12-005E / 3
The use of suitable forklift truck and four-chain
crane sling equipment is recommended but
locally approved equipment of suitable rating
maybe used.
Pumps are usually supplied on pallets for
handling by forklift truck, to lift from the pallet
the pump should be slung as shown.
When pumps are not in use, the pump shaft
should be rotated several turns, every six
weeks.
2.3.2 Long Term Storage
It is recommended that the pump is stored in a
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
pump or pumpset.
2.3 Storage
Shearing Hazard
Do NOT place fingers or hands etc. into
SPP Pumps Ltd. Thrustream Pumps are a
range of centrifugal pumps that are usually
supplied as pumpsets with electric motors but
can be supplied separately for customers to fit
to drivers of their own preference.
3.1. Pumps
the suction or discharge pipe outlets and
do NOT touch the impeller. If rotated this
may cause severe injury. To prevent ingress
of any objects, retain the protection covers or
packaging in place until removal is necessary
for installation. If the packaging or suction and
discharge covers are removed for inspection
purposes, replace afterwards to protect the
pump and maintain safety.
2.3.1 Temporary Storage for up to Six Weeks
If the pump is not to be used immediately, it
should be stored carefully in a horizontal
position, in a sheltered, dry location. Additional
rust preventative should be applied to all
The mechanical assembly comprises a rigid
shaft, supported by grease-lubricated ball
bearings at each end of the pump shaft. The
pump casing is fitted with wear rings and
houses a double entry shrouded type impeller
mounted on a stiff shaft. Some pumps in the
range are fitted with a pair of single side entry
impellers. The seal chamber is housed in the
casing inserts retained within the casing.
Some impellers may be fitted with wear rings if
required. When the top half casing is
removed, the bearing housings, inserts, shaft
and impeller assembly can be removed from
the bottom casing for maintenance without
disconnection of pipework.
unpainted carbon steel or cast iron parts. Fit
or retain in place the covers to the suction and
discharge flanges and all other pipe
connections. Rust preventative and flange
covers should not be removed until final
installation.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 5 of 28
The suction and discharge branch flanges are
positioned horizontally at 90 degrees to and
below the shaft centreline. The pump casings
allow for construction to suit different rotations.
Manual No/Rev
W12-005E / 3
Operators Instructions for Horizontal
Extended Thrustream Centrifugal Pumps
The standard pump is soft packed but the
option to fit internal component mechanical
seals or selected external cartridge
mechanical seals is provided to suit
customer’s requirements. These pumps are
normally supplied with a cast iron casing and
impeller but bronze may be supplied where
required. Other parts may be supplied in a
variety of materials to suit the pump
application.
In standard form, these pumps are designed
to pump liquids at temperatures up to 80oC.
Where pumps are needed to suit higher
temperatures, please refer to SPP Pumps Ltd.
Nameplate details are shown on the back
cover of this manual, full pump specification
can be supplied on a data sheet, if requested.
Note 1) The head specified is the Duty Head
generated by the pump only.
2) - Suction pressure must be included
when assessing the Maximum Working
Pressure.
event of a handling accident, carefully check
that the pump is not damaged before
installation and commissioning.
4.2 Preparation for Mounting
Before installation, check that the pump
mounting location is suitable for accepting the
pump. Refer to the certified General Assembly
drawing, for details of pump installation
dimensions.
4.3 Location of Pump
The pump should be located as near the liquid
source as practical, with adequate accessibility
for inspection and repair and sufficient
headroom for lifting tackle if necessary.
Where pumps are electric motor driven, power
source electrical characteristics should match
those shown on motor data plate. A qualified
electrical contractor should be used to make
the electrical connection.
3.2 Electric Motor Driven Pumpsets
Pumpsets are supplied mounted on a
substantial fabricated baseplate; the complete
assembly is of a rigid construction, being
intended for mounting on suitable foundations.
These pumpsets are supplied fitted with a
proprietary high efficiency electric motor
adequately sized for the duty specified. For
details of the motor supplied, refer to the
manufacturer’s instructions in Appendix I.
The proprietary flexible coupling has been
selected to meet the power transmission and
other operating requirements for the pumpset.
Coupling fitting and maintenance details are
given in the manufacturer’s instructions in
Appendix II.
4. Assembly and Installation
Shearing Hazard
Do NOT place fingers or hands etc. into
the suction or discharge pipe outlets and
do NOT touch the impeller, if rotated this
may cause severe injury. To prevent ingress
of any objects, retain the protection covers or
packaging in place until removal is necessary
for installation.
4.1 Initial Inspection for Damage
During transport and storage, accidental
damage to the pump may have occurred.
When the pump is to be installed, or in the
4.4 Foundations
The pump is to be mounted on a substantial
floor or plinth and secured with suitable
foundation bolts to minimise vibration. The
foundation must have a flat level surface and
be of sufficient depth to contain the foundation
bolts. The pump unit should be installed with
the flange faces set in a vertical position.
Packers may be placed under the baseplate
near the bolt holes to level the unit if the floor
is uneven. The foundation bolts should be
tightened and the shaft alignment checked
again before commissioning and putting the
pump into operation.
For full installation instructions and guidance
on the design of suitable foundations for
pumpsets refer to the SPP Guide to Pump
Installation, obtainable on request from SPP
Pumps Ltd.
4.5 Pump Preparation
Abrasion & Entrapment Hazard
Do NOT touch any moving or rotating
parts. Guards are provided to prevent
access to these parts, where they have
been removed for maintenance they MUST be
replaced before operating the equipment.
For soft packed pumps the packing rings and
related components are often supplied loose.
Ensure that the packing is installed as per
instructions in section 6.2 paragraphs 10 to
20.
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
Foundation Plinth
FLAT TOP REDUCER
Foundation Plinth
INCREASER
DISCHARGE
DISCHARGE
Check
Valve
Support
Extended Thrustream Centrifugal Pumps
Remove packaging but leave the flange
covers in place, check that impeller rotates
freely by hand by turning the shaft.
If the pump has been in storage, remove any
protective coatings. If the bearing housings
were filled with grease flush, and re-lubricate
the bearings.
Manual No/Rev
W12-005E / 3
into the pump. A screen or basket strainer
may also be required to hold back larger
items. These should be sized to maintain the
flow through them to below 0.6 m/s.
The suction pipe work must be flushed clean
to ensure that site debris is not drawn into the
pump when it is commissioned.
4.6 Suction Pipework
The run of suction pipework must be such that
air can NOT become trapped where it would
be drawn into the pump on starting. The bore
of the suction pipe is recommended to be one
or two sizes larger than the pump suction
branch and reducers if used must be eccentric
to eliminate the possibility of an air pocket
being formed.
CONCENTRIC REDUCER
WILL TRAP AIR IN THE
SUCTION PIPE
X
WILL NOT TRAP AIR IN
THE SUCTION PIPE
4.7 Discharge Pipework
The bore of the discharge pipe should ideally
be sized to ensure a flow velocity of 2.5 to 3
m/s is not exceeded. This is usually one size
larger than the discharge branch. Pipework
should be as short and straight as possible to
reduce friction head loss.
A non-return valve is usually fitted to prevent
the pump from excessive backpressure and
reverse rotation and a discharge valve is
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.
The suction and discharge pipework must be
independently supported and positioned such
that no excessive forces and moments are
exerted on the pump flanges.
CHECK
VALVE
VALVE
PIPE
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
fully airtight. A gradual rise in the suction
pipeline is recommended to prevent formation
of air pockets. If fitting a foot valve, it should
have a free area of one and a half times the
area of the suction pipe.
Where pumping water at temperatures above
70°C, care must be taken to ensure that
enough pressure is available at the impeller
entry to prevent vaporisation. Expansion
joints are recommended to prevent strain on
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
4.8 Guards
Page 7 of 28
Foundation Plinth
ATTENTION
Failure to support suction and
delivery pipework may result in
distortion of the pump casing, with the
possibility of early pump failure.
If guards have been removed to install packing
or to check mechanical seal connections, they
MUST be replaced to maintain safe operation
of the pump. Refer to the General
Arrangement drawing for specific fixing
methods for the guarding supplied.
MOTOR
MOTOR
MOTOR
Manual No/Rev
W12-005E / 3
Operators Instructions for Horizontal
Extended Thrustream Centrifugal Pumps
4.9 Coupling Alignment
To minimise the bearing loading and to
achieve full coupling and bearing life, it is
recommended that the shafts are aligned as
accurately as possible i.e. well below the
allowable misalignment of the coupling.
Refer to the coupling manufacturer’s
instructions or proceed generally thus:
1 Lateral Alignment
Mount a dial gauge on
the motor shaft or
coupling with the
PUMP
gauge running on the
outer-machined
surface of the pump
coupling. Turn the
motor shaft and note the total indicator
reading.
2 Angular Alignment
Mount a dial gauge on
the motor shaft or
coupling to run on a
PUMP
face of the pump
coupling as near the
outside edge as
possible. Turn the
motor shaft and note the total indicator
reading.
3 Confirm Lateral Alignment
Mount the dial gauge
on the pump shaft or
coupling with gauge
PUMP
running on the outermachined surface of
the motor coupling.
Turn the pump shaft in
the direction of pump
rotation, and note the total indicator reading.
4 Adjustment
For horizontal lateral adjustment move the
motor using the motor jacking screws provided
and for vertical and angular adjustment fit
shims between the motor feet and the
baseplate.
Note Poor alignment is a major factor contributing to
shortening of pump bearing and seal life. It is
recommended that alignment is checked
frequently and maintained at below 10% of the
manufacturer’s specified figure or 0.1mm.
As the pump and motor feet are accurately
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
faces. These should be checked for
cleanliness before assembly and before
resorting to using shims under the motor feet.
ATTENTION
Shaft alignment must be checked
again after the final positioning of
the pump unit and connection to pipework as
this may have disturbed the pump or motor
mounting positions.
4.10 Grouting
A space of about 25mm should be left
between the top surface of the foundation
plinth and the underside of the baseplate to
allow for grouting.
Recommended grouting should comprise one
part of cement to two parts of sand, with
sufficient water to produce a heavy creamy
consistency.
After the grout has dried, the alignment should
be checked before commissioning and putting
the pump into operation.
5. Commissioning and Operation
5.1 Commissioning Checks
These checks must be done after first
installation and after pump maintenance that
required removal of the rotating assembly.
Abrasion and Entrapment Hazard
Do NOT touch any moving or rotating
parts. Guards are provided to prevent
access to these parts, where they have
been removed for maintenance they MUST be
replaced before operating the equipment.
Check that the rotating assembly is free to
rotate by hand before connecting the power
supply. Also check that the piping system has
been properly connected with all joints
tightened and instrumentation is in position.
Check that the pump is primed. Pumps should
never be run dry as the pumped liquid acts as
a lubricant for the close running fits
surrounding the impeller. Dry running can
cause serious damage to the pump and
seals.
Prime the pump using an ejector, exhauster or
vacuum pump. If a foot valve is used in the
suction line the pump may be primed by
venting and filling the casing with liquid. Open
the air release valve to bleed any air trapped
in the seal housing, as the seal must be
lubricated and dry running often results in
premature seal failure.
Operators Instructions for Horizontal
Extended Thrustream Centrifugal Pumps
Disconnect the pump drive by removal of the
spacer from the coupling. Connect the
electrical supply to the pump unit. Momentarily
switch on motor and check direction of
rotation. This should match the direction of
rotation of the pump. For three phase electric
motors, if the direction of rotation is incorrect,
disconnect the supply and change over two of
the three supply phases. Replace the
coupling spacer.
5.2 Starting Procedure
BEFORE A THRUSTREAM SERIES PUMP IS
STARTED ALWAYS ENSURE THAT THE SUMP
IS FILLED TO THE CORRECT LEVEL WITH
LIQUID, AND THAT ANY LEVEL CONTROLS
ARE FUNCTIONING CORRECTLY.
Abrasion and Entrapment Hazard
Do NOT touch any moving or rotating
parts. Guards are provided to prevent
access to these parts, where they have
been removed for maintenance they MUST be
replaced before operating the equipment.
Check that the suction valve is open and that
the pump is primed.
Open the discharge valve to one quarter open
to prevent hydraulic lock from occurring.
Switch on the motor and allow it to build up to
full operating speed. Slowly open discharge
valve until the pump reaches the required duty
condition.
Check that the motor is not overloading, unit is
not vibrating or excessively noisy, the motor is
not overheating, and that the pump is
developing the correct flow and head
requirements.
If the pump is operating at its normal speed,
the pump should be shut down at once if any
of the following defects are found:
a) No liquid delivered.
b) Not enough liquid delivered.
c) Not enough pressure.
d) Loss of liquid after starting.
e) Vibration.
f) Motor runs hot.
g) Excessive noise from cavitation.
h) Pump overheating.
Recommended corrective action for these
faults is given in Section 7 Faults and
Remedial Action.
Manual No/Rev
W12-005E / 3
5.3 During Operation
Hot Surfaces Hazard
Do NOT touch surfaces that during normal
running will be sufficiently hot to cause
injury. These are marked with the HOT
warning symbol. Note that these surfaces will
remain hot after the pump has stopped:
allow sufficient time for cooling before
maintenance. Be cautious and note that other
parts of the pump may become hot if a fault is
developing.
Cold Conditions Hazard
Do NOT operate water pumps in
temperatures below freezing point,
without first checking that the pumped fluid is
not frozen and the pump is free to turn. Pumps
in these environments should be drained down
during inactivity and re-primed before starting.
Hazardous Noise
In addition to local or site regulations for
noise protection, SPP Pumps Ltd.
recommend the use of Personal Ear
Protection equipment in all enclosed pump
rooms and particularly those containing diesel
engines. Care must be taken to ensure that
any audible alarm or warning signal can still
be heard with ear defenders worn.
Hazardous Gases, Mists, Sprays and
Leaks
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.
Periodic Checks:
a) Pump Bearings:
Check the bearing temperatures do not
exceed 80°C as an increase may indicate the
early stages of bearing trouble.
b) Noise:
Listen for any unusual noise or an increase in
normal sound level.
This may result from:
i) Loose fasteners for guards and other
equipment.
ii) Air trapped in the pump i.e. the pump was
not fully primed.
iii) Cavitation.
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
Daily Checks: (Manned Installations)
Visually check pump for leaks.
Check for leaks
Renew as necessary
Three Monthly Maintenan
ce:
overfilled.
Six Monthly Maintenance:
bushes for wear.
tightness.
perfo
rmance falls below an acceptable level.
W12-005E / 3
c) Suction Gauge Reading:
If this is lower than normal, investigate and
check that valves in the suction pipework are
fully open or that the suction lift may have
increased.
d) Discharge Gauge Reading:
If this is lower than normal, check for a leak in
the associated pipework or that a valve in the
delivery line has been opened when normally
it is partially closed.
5.4 Stopping Procedure
Stop the motor then fully close the discharge
valve.
6. Maintenance and Service
6.1 General Introduction
SPP Pumps Ltd Thrustream Series pumps will
provide many years of trouble free service
when maintained in accordance with these
instructions. In the event of failure of the pump
it is recommended that SPP Pumps Ltd.
Service Department are called to investigate
and carry out repairs. The following
instructions are given to cover the main
elements of strip and rebuild but do NOT
include instructions for work that MUST be
done by an SPP Pumps Ltd. Service
Engineer.
The following hazards may arise during
maintenance work:
Fluid Pressure Jet Hazards
Check and ensure that the pump
operates at below the Maximum Working
Pressure specified in the manual or on the
pump nameplate and before maintenance,
ensure that the pump is drained down.
Hazardous Materials
Wear a suitable mask or respirator when
working with packing or gasket
components that contain fibrous material, as
these can be hazardous when the fibrous dust
is inhaled. Be cautious if other supplier's
components have been substituted for
genuine SPP Pumps Ltd parts as these may
then contain hazardous materials.
Hazardous Gases, Mists, Sprays and
Leaks
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
Operators Instructions for Horizontal
Extended Thrustream Centrifugal Pumps
Recommended Maintenance Schedule
INSPECTION REMARKS
Carefully check the
bearing housing for
any sign of
temperature rise.
Check the pump for
vibration.
For mechanical seals:
For soft packed pumps:
Adjust gland to
maintain slight
leakage and check
that gland drains
are clear.
Lubricate the pump
bearings with 1520g of grease.
Check coupling
alignment. Check
coupling pins and
Check holdingdown bolts for
OVERHAUL
An overhaul is to be carried out when pump
BEFORE ATTEMPTING ANY MAINTENANCE ON A
PUMP, PARTICULARLY IF IT HAS BEEN
HANDLING ANY FORM OF HAZARDOUS LIQUID,
ENSURE THAT THE UNIT IS SAFE TO WORK ON.
THE PUMP MUST BE FLUSHED THOROUGHLY
WITH A SUITABLE CLEANSER TO PURGE AWAY
ANY OF THE PRODUCT LEFT IN THE PUMP
COMPONENTS. THIS SHOULD BE CARRIED OUT
BY THE PLANT OPERATOR AND A CERTIFICATE
OF CLEANLINESS OBTAINED BEFORE
STARTING WORK. TO AVOID ANY RISK TO
HEALTH IT IS ALSO ADVISABLE TO WEAR
PROTECTIVE CLOTHING AS RECOMMENDED BY
THE SITE SAFETY OFFICER, ESPECIALLY WHEN
REMOVING OLD SEALS OR GASKETS THAT
MAY BE CONTAMINATED.
Page 10 of 28
Check the bearing housing
temperature with a suitable
thermometer & refer to Fault
Finding Chart in Section 7.
Maximum running temperature
is 80°°°°C(176°°°° F).
Refer to Fault Finding Chart in
Section 7.
When gland is fully compressed,
change or add more packing.
(Refer to Soft Packed Seal
maintenance instructions in
section 6.3).
Use Texaco Multifak All Purpose
EP2 grease or equivalent grease
to DIN 51825: KP2 K-30. Do not
overfill the bearing housing, as
the bearings will overheat if
Refer to maintenance instructions
adjust or renew parts as
necessary.
Tighten as necessary.
Operators Instructions for Horizontal
Packing Removal Procedure
46
51
50B
50F
50
46
51
Packing Preparation
SLEEVE
NO. OF
SQUARE
SECTION
LENGTH
Extended Thrustream Centrifugal Pumps
6.1 Preparation for Maintenance
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
equipment is available and that the work is
carried out in a clean area.
6.2 Repacking the Stuffing Box
Where a soft packed gland seal is fitted, it will
be necessary to replace the packing rings
periodically when the gland can no longer be
tightened to reduce leakage to the normal
level, or if the gland is overheating.
1 Close the suction & discharge valves and
release pressure from the casing, remove the
gland retaining nuts (50F) and pull the split
gland (50) clear of the stuffing box.
50X
Manual No/Rev
W12-005E / 3
4 Clean the sleeve, the bore of stuffing box, the
lantern ring and the split gland with a clean oily
cloth.
5 Check the sleeve for concentricity with the
stuffing box bore and that that the surface
under the packing rings is free from scores,
pitting or grooves.
6 Examine the gland for general condition and
replace if damaged.
If the packing is to be cut from a coil or long
length the size, number of rings and length is
thus:
Stuffing Box Data
PUMP
SHAFT
MODULE
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
DIA.
mm
PACKING SIZE
of ONE
mm
RING
mm
SIZE of
RING
ID/OD
mm / mm
RINGS
PER
BOX
7 Wrap the packing around a dummy shaft, of
the same diameter as the sleeve.
2 Remove the retainer (50X) and separate and
remove the two halves of the gland.
3 Carefully withdraw the old packing rings (51)
and lantern ring (46), using a pair of extractor
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
8 To assist in cutting rings, two guide lines
Page 11 of 28
parallel to the shaft axis and separated by a
distance equal to the packing section may be
drawn on the spiral.
Manual No/Rev
45
o
Repacking Procedure
KP2 K
-
30
As Supplied with
W12-005E / 3
9 Cut each ring from the spiral at an angle of 45°
10 Insert the first ring and tap it to the bottom of
11 Install the lantern ring(s) (46) in the proper
12. When the all the rings have been inserted, the
13. Slide the gland into the stuffing box and
14. Start the pump as per paragraph 5.2, allow
15. A soft packed gland must have slight steady
16. If gland leakage stops, the pump will overheat
17. If the pump overheats again, stop the pump
18. After the pump had been running for 10
19. Excessive gland pressure will cause damage
Operators Instructions for Horizontal
Extended Thrustream Centrifugal Pumps
by cutting off lubrication to the packing, and
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
diagonally across the guidelines.
leakage occurs but if maintenance is required,
the manufacturer's information is given in
Appendix IIl.
6.4 Bearing Lubrication
The ball bearings are supplied pre-loaded with
the stuffing box. Each following ring should be
installed in the same manner and positioned in
the stuffing box so that the "split" is advanced
120°.
position(s) to align with the seal lubrication
connection(s), allowing for movement of the
ring deeper into the box as the packing is
compressed.
appropriate grease. A grease nipple and V
ring seals are fitted to the bearing housing to
ensure that any surplus grease is trapped
inside the bearing housing.
It is important to know the weight of grease
delivered by each stroke your grease gun to
ensure application of the correct amount of
grease.
It is recommended that the drive end bearings
are topped up as per the Recommended
last packing ring should not protrude from the
stuffing box face.
ensure that it sits squarely against the last
packing ring. Fit the gland retainer (50X) and
the gland retaining nuts (50F) on the studs
(50A) and tighten evenly to finger pressure.
Maintenance Schedule in Section 6.
Recommended Grease Lubricant:
International
Standard
TEXACO MULTIFAK ALL
a new pump.
DIN 51825:
PURPOSE EP2
Note Greasing points may be provided for the
bearings on the electric motor fitted, refer to
pressure to increase to normal level and
ensure that air is not trapped in the pump
Appendix I for motor maintenance details.
casing.
6.5 Bearing Replacement
Ball bearings will provide satisfactory service
leakage, and this should start soon after the
pump reaches it’s normal operating pressure.
for their designed working life if they are
correctly lubricated and inspected at the
intervals shown in Section 6. - Recommended
Maintenance Schedule.
leading to seal damage or premature pump
failure. If overheating is detected, the pump
must be stopped and allowed to cool and
when restarted, gland leakage should start.
Bearing Specifications
Shaft Module Bearing Specification
1E 6214
2E 6218
restart it again, do not slacken the gland
retaining nuts.
3E 6220
2T 6411
3T 6218
minutes with steady leakage, tighten the gland
nuts by one sixth of a full turn. Continue to
adjust at 10-minute intervals, each time
evenly, by one sixth of a full turn, until leakage
is reduced to an acceptable level (30 drops
per minute minimum).
A suitable bearing puller is required for
removal of the bearings from the pump shaft.
If a puller is not available, a hammer and soft
metal drift may be used to tap evenly around
the face of the inner ring.
Exerting force on the outer ring of a ball
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
Drive End Bearing Replacement Procedure
Non-Drive End Bearing Replacement Procedure
Extended Thrustream Centrifugal Pumps
bearing can cause severe damage.
The work area and all tools used for bearing
replacement must be clean and free of dust
and grit to prevent contamination of a clean
bearing and new grease.
Ball bearings should not be dismantled.
ATTENTION
For pumps fitted with cartridge
mechanical seals:
Refer to the seal manufacturer’s instructions
in Appendix III and lock the seal before
removing the retaining nuts (52A) and sliding
the seals back from the face of the insert
(A/B53).
When replacing all the bearings, complete the
replacement of the drive end bearings
BEFORE commencing to replace the nondrive end bearings.
1. Remove the screws (64A) and slide the
bearing cap (64) along the shaft towards the
liquid thrower (72).
Manual No/Rev
W12-005E / 3
the bearing cap.
13. Heat the bearing (67) to approximately 1000C
(2120F) using bearing hotplate, induction
heater or oven. NOTE - Do not exceed 1200C
(2480F).
14. Slide the heated bearing onto the shaft to abut
the shoulder. Ensure that the bearing sits fully
and squarely against the shoulder.
15. Cool the bearing to room temperature and
pack both sides with two/three ounces of
recommended grease.
16. Coat the inside of the bearing housing (62)
with grease and slide into place over the
bearings.
17. If necessary use two screwed rods to pull the
bearing housing towards the bearing cap then
fit four of the screws (62A), tighten evenly to
pull the bearing housings into place, fit and
tighten the remaining screws.
18. Fit the bearing cap (64) to the bearing housing
(62) using screws (64A).
2. Remove the screws (62A and 53A) to free the
bearing housing (52) for removal.
3. Using a suitable puller, withdraw the bearing
housing from the shaft (71).
4. Using a suitable bearing puller on the inner
race, pull the bearing (67) off the shaft.
5. Clean the bearing thoroughly with an approved
cleaning fluid.
6. Dry the bearing with dry compressed air or
with a clean soft cloth by hand.
7. DO NOT SPIN A CLEAN DRY BEARING.
8. Inspect the bearing for wear, fractures, cracks,
corrosion or other damage, which may
necessitate replacement.
9. Lightly oil the bearing and wrap in greaseproof
paper to prevent contamination before
reassembly.
10. Check that the shaft, bearing cap and housing
are clean and undamaged.
11. It is recommended that new oil seals (64R)
are fitted when bearings are replaced to
ensure that contamination is prevented.
12. Slide the oil seal onto the shaft (71) wipe the
seal recess in the bearing cap (64) with
grease and set in position on the shaft against
19. Check that the shaft rotates freely by hand.
20. Secure bearing housing (62) to the insert
(B53) with screws (53A).
21. Fit the new oils seal (64) on the shaft to abut
against the bearing housing.
22. Where applicable refit and set the mechanical
seal as per the seal manufacturer’s
instructions in Appendix III.
1. Proceed as per the drive end bearing
replacement procedure, paragraphs 1 and 2.
2. Remove the cover plate (62Y) from the nondrive end bearing housing and using a suitable
puller, withdraw the bearing housing from the
shaft (71).
3. Using a suitable punch, flatten the lock washer
(75F) and remove the bearing locknut (75)
and the lock washer.
4. Replace the non-drive end bearing and as per
the drive end bearing replacement procedure,
paragraphs 4 to 16.
5. Place the locking washer (75F) onto the shaft
and screw on the bearing lock nut (75).
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
Mechanical Seal Replacement Procedure
Impeller Inspection Procedure
Preparation for Removal of the Rotating Assembly
W12-005E / 3
and lift the tab of the lock washer.
Operators Instructions for Horizontal
Extended Thrustream Centrifugal Pumps
the mechanical seal (52).
7. Fit the bearing housing as per the drive end
bearing replacement procedure, paragraphs
17 to 20.
8. Refit the cover plate (62Y).
6.6 Mechanical Seal Replacement
Mechanical seals will need replacement when
failure has occurred, they may not be replaced
without removal of the rotating assembly
unless the motor is demounted and the
coupling is removed from the pump shaft.
It is recommended that new mechanical seals
are fitted when conducting a full pump stripdown for overhaul to give maximum operating
life.
Refer to the seal manufacturer’s instructions
in Appendix III and lock the seal before
removing the retaining nuts (52A) and sliding
the seals back from the face of the insert
(A/B53).
1 Isolate the pump and drain the casing using
the air vent valves (308) and drain plugs (1P &
1M) provided.
2 Disconnect the seal flush pipe, remove the
four hexagon screws (52A) that retain the
mechanical seal, and slide the seal assembly
off the shaft.
3 Proceed as per the bearing replacement
instructions, paragraphs 1 to 10.
4 Remove the nuts (52F) from the studs (52A)
and withdraw the mechanical seal (52) from
the shaft (71).
5 Fit a new mechanical seal as per the
manufacturer’s instructions in Appendix III
6 Reconnect the seal flush pipe.
7 Proceed as per the bearing replacement
instructions, paragraphs 11 to 21.
6.7 Pump Overhaul and Repairs
Refer to a certified Pump Section drawing or
the typical cross section drawing in Section 8.
Note the hazards outlined in Section 6.
3 Remove the screws (62A) that retain the
bearing housings (62) to the top half casing
(A1).
4 Remove the nuts (1F) from the casing studs
(1B) securing the top half casing (A1) to the
bottom half casing (B1).
5 Press or tap out the dowels (1C).
6 Using a pair of pry bars in the slots provided
between the top and bottom casings, apply
pressure to break the gasket seal and lift the
top half casing (1A) off the bottom half casing
(1B).
7 If the top half casing is trapped between the
bearing housings, release the remaining
screws (62A) from the non-drive-end bearing
housing (62) and back it off by about 1mm.
5 Using the eyebolt and a suitable lifting device,
lift the top half casing (A1) clear of the
impeller, place to one side on a clean flat
surface.
6 At this stage, the impeller may be inspected
for damage or blocking and cleaning if
necessary.
To check the pump shaft (71) and impeller
(21) and to replace the wear rings (23) or soft
packed seal sleeves (B26 & B27), it is
necessary to remove the rotating assembly
from the bottom half casing.
Disconnect the motor coupling.
For pumps fitted with mechanical seals, refer
to the seal manufacturer’s instructions and
lock the seal before removing the retaining
screws (52A) and sliding the seals back from
the face of the insert (A/B53).
Provide a suitable lifting strap and support the
weight of the rotating assembly thus:
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
Removal of the Rotating Assembly Procedure
Min Max Min Max
TR20A, TL30A, TT25A,
TN25A, TQ25A, TR30A
TP30A, TV30A, TN35A
Procedure to Dismantle the Rotating Assembly
Cleaning and Inspection of Parts
Extended Thrustream Centrifugal Pumps
1. Remove the remaining screws (62A) that
retain the bearing housings (62) to the bottom
half casing (B1).
2. Tap the inserts (41/53) with a soft-faced
hammer to break the seal between the insert
and the bottom half casing (B1).
Manual No/Rev
W12-005E / 3
(75F) and remove the bearing locknut (75)
and the lock washer.
6. Using a suitable bearing puller on the inner
race of each bearing, pull the bearings (66 &
67) off the shaft.
7. Release the screws (72A) and remove the
liquid throwers (72) from the shaft.
3. Lift the rotating assembly clear of the bottom
half casing and support the shaft on suitable V
blocks with the impeller clear of the work
surface.
4 If necessary, remove the case wear ring
dowels (23A) from the bottom half casing
(B1).
5 With feeler gauges, check the clearance
between the case wear rings (23) and the
impellers (21), compare clearance with the
figures below.
Internal
TP15T & TR20T
& TM35A
& TQ35A
TT35A
Diametral
mm
0.440 0.651 0.220 0.325
0.440 0.659 0.220 0.330
0.460 0.689 0.230 0.345
0.460 0.549 0.230 0.275
Radial
mm
Note Increase in the wear ring clearance allows
increased internal leakage with resultant loss
of pump performance, head and efficiency.
When the clearance is double the original
clearance, it is recommended that new wear
rings are fitted. It is permissible to run the
pump with increased clearance due to wear
but the loss of pump efficiency will significantly
increase the pump running costs.
8. For pumps fitted with mechanical seals: Slide
the mechanical seal assemblies off the shaft
(71), remove the inserts (53) complete with
throttle bush (45) and set aside for inspection.
9. For pumps fitted with soft packed glands:
Slide the gland (50) off the end of the shaft
(71) and remove the inserts (53) complete
with packing rings (51) and lantern rings (46)
and set aside for inspection.
10. If not already removed, remove the case wear
rings (23) and set aside for inspection and
measurement.
For Clockwise pump construction:
11. 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:
12. 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.
Note Light tapping with a soft faced mallet may be
needed to free the impeller from the shaft, do
not damage the impeller if it is to be reused.
13. Using suitable pullers or levers, slide the
impeller (21) of the shaft (71).
1. Remove the screws (64A) and slide the
bearing cap (64) along the shaft towards the
liquid thrower (72).
2. Remove the screws (53A) to free the bearing
housing (52) for removal.
3. Using a suitable puller, withdraw the drive end
bearing housing from the shaft (71).
4. Remove the cover plate (62Y) from the nondrive end bearing housing and using a suitable
puller, withdraw the non-drive end bearing
housing from the shaft (71).
5. Using a suitable punch, flatten the lock washer
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
14. Scribe a line on the shaft to mark the position
of the locked sleeve or nut for reassembly.
15. Withdraw the impeller key (116) and unscrew
and remove the remaining sleeve or the
impeller nut.
1. Clean the bearings thoroughly with an
approved cleaning fluid, kerosene or white
spirit.
2. Dry the bearings with dry compressed air or
with a clean soft cloth by hand and by spinning
by hand. Confirm that the bearings rotate
smoothly without slackness.
Page 15 of 28
Manual No/Rev
Pump Reassembly
IMPELLER
DRIVE END IMPELLER
DIMN. B
IMPELLER
NON-DRIVE END IMPELLER
W12-005E / 3
3. DO NOT OVERSPIN A CLEAN DRY
BEARING.
4. Inspect the bearings for wear, fractures,
cracks, corrosion or other damage to the
running surfaces, which may necessitate
replacement.
5. Coat the bearings with rust preventive oil and
wrap in greaseproof paper.
Note: It is recommended that all ‘V’ rings, ‘O’ rings
and gaskets: are replaced by new parts during
an overhaul. If ‘O’ rings are to be reused they
should be left in place in their grooves and
protected from contamination by oil and dirt.
Operators Instructions for Horizontal
Extended Thrustream Centrifugal Pumps
approved coating for pumps used for potable
water.
15. Clean all threads with kerosene followed by
wire brushing, dry and wrap shaft threads with
protective adhesive tape.
16. If the unit is not to be reassembled
immediately, brush all bright iron and steel
surfaces with Texaco Rust Proof Compound L
or Rust Proof Compound Spray or a suitable
equivalent rust preventive fluid.
17. Protect all parts (especially mechanical seal
parts and faces) against loss, weather or
mechanical damage.
6. Remove all O-rings from their grooves and
discard where these are to be replaced.
7. Remove all grease and other deposits from all
other parts using suitable cleaning fluid and a
clean dry cloth.
8. Coat all unpainted carbon steel parts with a
light smear of oil to prevent rust.
9. Measure the inside diameter of the wear rings
and the outside diameter of the wear ring
surfaces on the impeller, calculate the
clearance and compare these with dimensions
in Section 6.7.
10. Mount the shaft between point centres or on
rollers, and place the stem of a dial indicator in
contact with the shaft. Set the indicator dial at
zero and turn the shaft slowly by hand.
Readings at any point A, B, C, D and E must
not vary more than 0.05mm (0.002").
11. For soft packed pumps: examine the shaft
sleeves for wear, replace the sleeve if it is
scored or has any visible surface damage.
12. If the shaft runs true within tolerance, remount
the shaft as in 2 but with the sleeve fitted in
position, and check the sleeves run-out at the
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
packing surface, to a maximum of 1.0mm
(0.04") below the initial diameter. Do not grind
reduce sleeve diameter in the throat bush
area unless scored. The surface finish of the
sleeve should be 20-30 C.L.A.
14. Scour any rust or scale from internal iron nonfitting surfaces and immediately repair or
renew any previous coating. Use WRC
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
6.8 Before reassembly:
1 Re-examine all old parts intended for re-fitting.
Worn, damaged or corroded parts should
either be re-conditioned or, if beyond this, be
discarded and replaced by new.
2 Ensure that all parts to be refitted (especially
new parts) are free from burrs, with screw
threads and abutting faces clean and free
from damage.
3 Examine 'O' and 'V' rings and renew if
showing wear, damage or deterioration.
1 Lightly smear the shaft (71) with clean good
quality grease or light oil.
For clockwise rotation:
KEY
DIMN. A
For counter-clockwise rotation:
NUT OR SLEEVE
NUT OR SLEEVE
KEY
Note The position of the impeller key and the locked
sleeve or impeller nut is governed by the
direction of rotation of the pump. For
clockwise pumps they are fitted at the drive
end of the shaft slot and for counter-clockwise
pumps they are at the non-drive end.
Page 16 of 28
Operators Instructions for Horizontal
Extended Thrustream Centrifugal Pumps
Where the location was not marked, please
refer to the pump section drawing supplied or
to SPP Pumps Ltd for dimensions A or B.
Manual No/Rev
W12-005E / 3
15. Slide the heated bearings onto the shaft to
abut the shoulder. Ensure that the bearings sit
fully and squarely against the shoulder.
2 Screw the locked impeller nut (B21) or sleeve
(A47) onto the shaft (71) to the marked
position. Turn the nut or sleeve to the nearest
slot to align with the keyway.
3 Place impeller key (116) into keyway and tap
the end right home under locked impeller nut
or sleeve.
4 Check the impeller for correct direction of
rotation and slide onto shaft.
5. Screw free impeller locking nut (A21) or
sleeve (B47) onto shaft to retain the impeller
against the locked impeller nut or sleeve.
6. Slide the casing wear rings (23) onto the
impeller.
7. Lightly grease and carefully fit new ‘O’ rings
(53R) to the inserts (A53 & B53).
8. Slide the inserts on to the shaft with the guide
vane at top position.
9. For soft packed pumps: Fit the packing (51),
lantern rings (46) and glands (50) as per
instructions in section 6.2.
10. Fit the liquid throwers (72) on the shaft and
secure with screws (72A).
11. For mechanical seals: Fit the throttle bushes
(45) onto shaft and slide them into position
inside the inserts.
12. Fit the mechanical seals to the shaft as per
the manufacturer’s instructions in Appendix III.
13. Fit new oil seals (64R) into the bearing caps
(63) and slide them on the shaft, ready for
assembly of the bearing housings.
16. Place the locking washer (75F) onto the shaft
and screw on the bearing lock nut (75).
17. Fit and tighten the bearing locknut to 300 Nm
and lift the tab of the lock washer.
18. Cool the bearings to room temperature and
pack both sides with two/three ounces of
recommended grease.
19. Coat the inside of the bearing housings (62)
with grease and slide into place over the nonbearings. 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).
22. Place the rotating assembly into the pump
casing bottom half (B1). Correct any
excessive ‘O’ ring twisting or buckling. Check
that the impeller is centralised in the casing
and that there are no rubs.
23. Install casing gasket (1U) with a light coat of
commercial cup grease on both gasket
surfaces. Carefully align the inner edge of the
gasket with the insert ‘O’ rings.
24. Lower the upper half casing (Al) into place and
install casing joint nuts (1F).
25. NOTE: When installing upper half casing,
make sure that the ‘O’ rings (53R) are not cut
or pinched and that the casing gasket is hard
against the ‘O’ rings.
26. Insert casing joint dowels (1C) and drive them
home. Tighten the joint nuts (1F) to the
specified torques
Thread Size lb/ft Nm
M16 120 160
M20 260 360
M24 440 600
27. Tighten the case screws in the following
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
2
4
6
8
7
5
10
11
Two Stage Pump Assembly Instructions
W12-005E / 3
3
Operators Instructions for Horizontal
Extended Thrustream Centrifugal Pumps
Note Light tapping with a soft faced mallet may be
needed to free the impeller from the shaft, do
not damage the impeller if it is to be reused.
12
9
1
a) Tighten the four 'corner' screws marked 1,
2, 3 and 4.
b) W ork outward along shaft axis toward the
stuffing boxes in opposite quarters
tightening screws in regions 5, 6, 7 and 8.
c) Work outward along the branch and in
opposite quarters tightening screws in
regions 9, 10, 11 and 12.
d) Repeat the whole sequence (a to d).
29. Check that the shaft turns freely by hand.
30. Top up the bearing lubrication by applying
several strokes with a grease gun.
31. The pump is now ready for re-coupling to the
motor and re-commissioning.
Note: Two stage pumps are similar in construction
to the single stage pump and instructions
relating to maintenance and repair apply
equally to both types.
The difference relates to the disassembly of
the two impellers (A21 & B21) and the
interstage plate (8).
Proceed to disassemble the rotating assembly
as for single stage pumps to paragraph 10:
1. Using suitable pullers or levers, slide the first
impeller (A21) of the shaft (71).
2. Withdraw the interstage plate (8) from the
impeller spacer (17) and check the condition
of the interstage neck bush (24) replace if
worn.
3. Tap and pull the other impeller (B21) off the
shaft with the impeller spacer (17).
4. Withdraw the impeller key (116) and unscrew
and remove the locked sleeve (A47) or the
impeller nut (B21).
Impeller re-assembly:
Proceed with shaft assembly as for single
stage pumps to paragraph 3.
1. Select the first impeller for assembly, check
the impeller for correct direction of rotation
and slide onto shaft to abut the locked sleeve
or nut.
2. Fit new O rings to each side of the impeller
spacer (17), slide on to the shaft and fit the
interstage plate (8) complete with its’ O ring,
ensuring that it is the correct way round to fit in
the pump casing.
3. Screw free impeller locking nut (A21) or
sleeve (B47) onto shaft to retain the impellers
against the locked impeller nut or sleeve.
4. Slide the casing wear rings (23) onto the
impeller.
5. Check that the dowels (8A) that retain the
interstage plate are correctly fitted.
Continue with pump re-assembly from
paragraph 7.
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
CAUSE
REMEDIAL ACTION
connected and receiving the full supply
Air leak in suction
Check each flange for suction draught,
evel or lower the pump.
CAUSE
REMEDIAL ACTION
Not enough head
ing with the
If voltage and frequency are lower than
Check impeller for damage, replace as
or options to
Extended Thrustream Centrifugal Pumps
7. Faults and Remedial Action
POTENTIAL FAULT OR DEFECT:
No liquid delivered.
Insufficient liquid delivered.
Liquid delivered at low pressure.
Loss of liquid after starting.
Pump not
primed.
Speed too low. Check that the motor is correctly
Excessive vibration.
Motor runs hotter than normal.
Excessive noise from pump cavitation.
PROBABLE CAUSES
Pump not primed.
Speed too low.
Speed too high.
Not enough head for hot liquid.
Air leak in suction pipework.
Air leak in mechanical seal.
Air or gas in liquid.
Discharge head too high (above rating).
Suction lift too high.
Inlet pipe not submerged enough.
Viscosity of liquid greater than rating
Liquid density higher than rating.
Insufficient nett inlet head.
Impeller plugged up or blocked.
Wrong direction of rotation.
Excessive wear ring clearance.
Damaged impeller.
Rotor binding.
Defects in motor.
Voltage and/or frequency lower than rating.
Foundation not rigid.
Misalignment of pump and driver.
Rotor out of balance.
Shaft bent.
Impeller too small.
Fill pump and suction pipe completely
with fluid.
Manual No/Rev
W12-005E / 3
for hot liquid.
Inlet pipe not
submerged
enough.
Liquid density
higher than
rating.
Insufficient nett
inlet head.
Impeller blocked. Dismantle pump and clean the
Wrong direction
of rotation.
Excessive wear
ring clearance.
Damaged
impeller.
Rotor binding. Check for shaft run out, and replace if
Defects in motor. Ensure that motor is adequately
Voltage and/or
frequency lower
than rating.
Foundation not
rigid.
Misalignment of
pump and driver.
Rotor out of
balance.
Shaft bent. Check shaft run-out and replace if
Impeller too
small.
Reduce the positive suction head by
raising the liquid level.
If the pump inlet cannot be lowered,
provide a baffle to smother the inlet
vortex and prevent air enter
liquid.
Refer to SPP Pumps Ltd. for guidance
to increase the size or power of the
motor or engine.
Increase the positive suction head by
lowering the pump or raising the liquid
level.
impeller.
Check driver rotation with the direction
arrow on the pump casing.
Replace the wear rings when the
clearance exceeds the maximum
tolerances.
Replace if damaged or vanes are
eroded.
necessary.
ventilated. Refer to manufacturers
instructions.
the motor rating, arrange for provision
of correct supply.
Ensure that the foundation bolts are
tight; check that foundations match
SPP Pumps Ltd. Recommendations.
Check shaft run-out and replace if
necessary.
necessary.
needed.
Refer to SPP Pumps Ltd. f
fit a larger impeller.
Speed too high. Check the motor voltage.
pipework
Air leak in
mechanical seal.
Air or gas in
liquid.
Discharge head
too high (above
rating).
Suction lift too
high.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
voltage also confirm that the supply
frequency is correct.
rectify as necessary.
Check all joints, plugs and flushing
lines, if fitted. Note that prolonged
running with air in the mechanical seal
will result in damage and failure of the
seal.
It may be possible to increase the
pump performance to provide
adequate pumping.
Check that valves are fully open and
for pipe friction losses. An increase in
pipe diameter may reduce the
discharge pressure.
Check for obstruction of pump inlet
and for inlet pipe friction losses.
Measure the static lift, if above rating,
raise the liquid l
Page 19 of 28
Manual No/Rev
W12-005E / 3
8. Pump Details:
8.1 Pump Cross Section Drawing – Single Stage Pump – Clockwise Rotation:
Operators Instructions for Horizontal
Extended Thrustream Centrifugal Pumps
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
As reqd.
Extended Thrustream Centrifugal Pumps
Manual No/Rev
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
A1 Casing Top Half 1
B1 Casing Bottom Half 1
1B Casing Stud 32
1C Casing Dowel 2
1CF Hexagon Nut Full Dowel 2
1CG Plain Washer Dowel 2
1F Hexagon Nut Full Casing 32
1L Casing Plug 1” BSP 7
1M Casing Plug ½” BSP 2
1U Casing Gasket 1
21 Impeller 1
22 Impeller Wear Ring 2
22A Set Screw – Impeller W ear Ring 6
23 Case W ear Ring 2
23A Dowel - Case Wear Ring 4
46 Lantern Ring 4
A47 Sleeve – Locked (Soft Packed) 1
B47 Sleeve – Free (Soft Packed) 1
47R O Ring – Sleeve - Outer 2
47S O Ring – Sleeve - Inner 2
50 Gland 2
50A Stud – Gland 4
50F Nut – Gland 4
50X Retainer - Gland 2
51 Packing 10
A53 Insert Soft Packed - Non Drive End 1
B53 Insert Soft Packed – Drive End 1
53A Screw –Hexagon Head 8
53R O Ring Insert 2
62 Bearing Housing 2
62A Screw – Bearing Housing 24
62Y Cap – N D E Bearing Housing 1
62YA Screw - Hex Headed 4
64 Cover – Bearing 2
64A Screw – Bearing Cover 8
66 Bearing Non-drive End 1
67 Bearing Drive End 2
Item Description Qty
71 Pump Shaft 1
72 Deflector – Water 2
72A Screw - Deflector 2
73 Eyebolt - Lifting (Not Shown) 2
75 Bearing Lock Nut 1
75X Bearing Lock Washer 1
A79 Spacer Ring - Inner 1
B79 Spacer Ring - Outer 1
105 Grease Nipple (Not Shown) 2
B106 Stud Coupling 4
A107 Pipe
108 Reducer 2
116 Key - Impeller 1
118 Key - Coupling 1
308 Air Vent Valve 1
308X Reducer 1
Parts for Pumps with Component Mechanical Seals:
A21F Nut - Impeller (Free) 1
B21F Nut - Impeller (Locked) 1
21R O Ring – Nut - Outer
52 Component Mechanical Seal 2
52A Stud 8
52F Nut 8
52G Washer 8
A53 Insert Mech. Seal - Drive End 1
B53 Insert Mech. Seal – Non Drive End 1
56 Cover - Mechanical Seal 2
56A Plug – Mech. Seal Cover 2
56U Gasket - Mech. Seal Cover 2
Replacement parts should be obtained from
SPP Pumps Ltd. Spares Department; use of
parts from unapproved suppliers will invalidate
the pump warranty. W hen ordering spare parts
please quote the pump serial number from the
pump identification plate.
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
W12-005E / 3
Operators Instructions for Horizontal
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
Extended Thrustream Centrifugal Pumps
Manual No/Rev
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
A1 Casing Top Half 1
B1 Casing Bottom Half 1
1A Casing Stud Varies
1B Casing Stud Varies
1C Casing Dowel 2
1CF Hexagon Nut Full Dowel 2
1CG Plain Washer Dowel 2
1F Hexagon Nut Full Casing Varies
1L Casing Plug 4
1M Casing Plug 2
1U Casing Gasket 1
8 Interstage Plate (Two Stage) 1
8A Dowel 1
8R O Ring – Interstage Plate 1
17 Impeller Spacer (Two Stage) 1
17R O Ring – Impeller Spacer 2
A21 Impeller (Two Stage) 1
B21 Impeller (Two Stage) 1
A21F Impeller Nut – Locked (Mech. Seal) 1
B21F Impeller Nut – Free (Mech. Seal) 1
22 Impeller Wear Ring (Where fitted) 2
22A Set Screw – Impeller W ear Ring 4
23 Case W ear Ring 2
23A Dowel Case Wear Ring 4
24 Interstage Neck Bush 1
24A Socket Set Screw – Neck Bush 2
45 Neck Ring 2
46 Lantern Ring 2 / 4
A47 Sleeve – Locked 1
B47 Sleeve – Free 1
47R O Ring – Sleeve - Outer 2
47S O Ring – Sleeve - Inner 2
50 Gland 2
51 Packing 5
53 Spacer Ring (Soft Packed) 2
A53 Insert 1
B53 Insert 1
53A Socket Capscrew 8
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
Item Description Qty
66 Bearing Non-drive End 1
67 Bearing Drive End 2
71 Pump Shaft 1
71 Oil Seal 1
73 Eyebolt 1
75 Bearing Lock Nut 1
75F Bearing Lock Washer 1
77 Shoulder Ring 1
79 Spacer Ring 1
105 Grease Nipple 2
A106 Elbow 90deg. 2
B106 Stud Coupling 4
C106 Tubular Piece 2
D106 Stud Coupling 2
116 Key - Impeller 1
118 Key - Coupling 1
A107 Pipe 2
B107 Pipe 2
308 Air Vent Valve 1
Parts for Pumps with Component Mechanical Seals:
A21F Nut - Impeller (Free) 1
B21F Nut - Impeller (Locked) 1
21R O Ring – Nut - Outer
52 Component Mechanical Seal 2
52A Stud 8
52F Nut 8
52G Washer 8
A53 Insert Mech. Seal - Drive End 1
B53 Insert Mech. Seal – Non Drive End 1
56 Cover - Mechanical Seal 2
56A Plug – Mech. Seal Cover 2
56U Gasket - Mech. Seal Cover 2
Replacement parts should be obtained from
SPP Pumps Ltd. Spares Department; use of
parts from unapproved suppliers will invalidate
the pump warranty. W hen ordering spare parts
please quote the pump serial number from the
pump identification plate.
Manual No/Rev
Approximate Torque (Nm) for Bolt Diameters:
M5 M6 M8 M10 M12 M16 M20 M24 M30 M36
W12-005E / 3
Operators Instructions for Horizontal
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.
Grade of Bolt
4.6
8.8
10.9
12.9
Note:
These torque figures are approximate, and for
special finishes or lubricants, washers or mating surfaces.
Bolt and Nut Grade Combinations
Grade of BOLT
Grade of NUT
Grade Identification
2.7 4.5 11 22 38 95 185 320 633 1110
6.9 11.7 28 56 98 244 476 822 1634 2855
9.4 15.9 38 77 134 332 646 1120 2223 3885
11.2 19.1 46.4 92 160 397 775 1342 2666 4660
un-plated
4.6 8.8 10.9 12.9
4 8 12 12
fasteners only. No allowance has been made for
Note: It is permissible to fit higher grade
nuts than recommended.
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
BS 3692 (ISO272, 4759/1). Grade
marking is mandatory, may also
have trade marks
NUTS - Grade 8
Indented marks as a clock face,
dot at 12.00, bar at 8.00,
indicates grade 8 nut.
High Strength Friction Grip Bolts & Nuts
BOLT
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
NUT
BOLT
Grade10.9
Page 24 of 28
NUT
Grade 12
Operators Instructions for Horizontal
First Lateral Check: …………… Angular Check: ………….. Confirmed Lateral Check: …………..
Extended Thrustream Centrifugal Pumps
Installation & Maintenance Record
Date Summary of maintenance & repairs done - replacement parts fitted etc:
Initial Alignment TIR readings:
Final Alignment TIR readings:
First Lateral Check: …………… Angular Check: ………….. Confirmed Lateral Check: …………..
Installed & Commissioned
Signed –
Commissioning Engineer
Manual No/Rev
W12-005E / 3
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
W12-005E / 3
Operators Instructions for Horizontal
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
Extended Thrustream Centrifugal Pumps
Manual No/Rev
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
SPP Pumps Ltd. Reading
Tel: +44(0)1594 832701
Fax
: +44(0)1594
836300
W12-005E / 3
Operators Instructions for Horizontal
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.
SPP Pumps Coleford,
ENGLAND RG31 7SP
Tel:++44(0)118 932 3123
ENGLAND
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
W12-005Erev0 1 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
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