SPP Pumps Thrustream User Manual
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.
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