SPP Pumps Unistream User Manual
UNISTREAM RANGE
Limited Coleford England
CENTRIFUGAL PUMP
OPERATORS INSTRUCTIONS
Unistream Pumps
SPP Pumps Limited
Crucible Close
Mushet Industrial Park
Coleford
Gloucestershire
GL16 8PS
Telephone:
+ 44 (0)1594 832 701
Fax:
+ 44 (0)1594 836 300
Document No: W21-002E
Revision No: 10
Revision Note No
Date Issued: August 2012
Produced at SPP Pumps
: Windchill
DECLARATION OF CONFORMITY
We
Of
SPP Pumps Limited
Crucible Close
Mushet Industrial Park
Coleford
Gloucestershire
GL16 8PS
Declare that:
Equipment:
Model/Type:
Serial Number:
For pumps and pumpsets:
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 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 drivers:
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.
CENTRIFUGAL PUMP
UNISTREAM RANGE
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, Coleford, Gloucestershire, England, GL16 8PS
Date: 25 February 2010
W21-002E
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 2 of 24
Operators Instructions for
Unistream Centrifugal Pumps
CONTENTS
Section ........................................................ Page
1 General Information & Safety
Instructions ............................................ 3
2 Transport Handling and Storage ........... 4
3 General Description ............................... 5
4 Assembly and Installation ...................... 5
5 Commissioning and Operation .............. 7
6 Maintenance and Service ...................... 9
7 Faults and Remedial Action ................. 14
8 Pump Details: ...................................... 14
8.1 Pump Dimensions & Weights ........... 15
8.2 Pump Sections and Parts Lists ......... 15
8.3 Pump Connections ........................... 20
9 Additional Information .......................... 22
10 Bolt Torque Recommendations ........... 23
11 Spares and Service ............................. 24
Manufacturers Information:
(Where applicable)
Seal & Seal System .......................... Appendix I
Coupling .......................................... Appendix II
Electric Motor .................................. Appendix III
Introduction
This manual gives the safety, installation, operation
and maintenance instructions for pumps in the SPP
Pumps UNISTREAM range of horizontal, end
suction, centrifugal pumps for general and
industrial use
Pumps may be identified by the SPP Pumps code
typically in the form 'KP04E' or by the Equivalent
Standard pump code typically in the form '40/26'.
This manual applies to the following pump types:
Pump Size Code Type Suffix Letter
SIZE
Code
KP03 32 32/** B 125 **/13
KP04 40 40/** C 160 **/16
KP05 50 50/** D 200 **/20
KP06 65 65/** E 250 **/26
KP08 80 80/** F 315 **/32
KP10 100 100/** G 400 **/40
KP12 125 125/** V X Y These pumps are.
KP15 150 150/** & Z non-standard
Delivery
Branch
Dia.
mm.
Standard
Size
Code
TYPE
Suffix
Nominal
Impeller
Dia.
mm.
Standard
Size
Suffix
Use this table to convert the pump type code into
the equivalent standard code to obtain information
for your pump from the manual. Note, for pump
types AV03N, KP08V & Y, KP10X & Y, KP12X & Z,
& KP15Y, please refer to separate manuals W21003E and W21-004E
Manual No/Rev
W21-002E / 10
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.
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.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 3 of 24
Manual No/Rev
Sling here for lifting
Sling
W21-002E / 10
Operators Instructions for
Unistream Centrifugal Pumps
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.
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
This symbol gives
warning of a hazard to the
pump itself, which in turn, could cause a risk
to personal safety.
Pumps supplied on
pallets may be lifted
by forklift truck, to lift
from the pallet the
pump should be
slung as shown.
Pump weight is
shown on the
General Arrangement
drawing.
Pumpsets fitted with lifting eyebolts must be
lifted using suitable four chain lifting
equipment thus
complete pumpset
Eyebolt for
lifting motor
alone
2.3 Storage
2.3.1 Temporary Storage for up to Six Weeks
2. Transport Handling and
Storage Instructions
2.1 Transport
Unistream pumps are despatched fully
assembled but for overseas orders the
lubricating oil in the bearing housing is
drained. 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.
The use of suitable forklift truck and fourchain crane sling equipment is
recommended but locally approved
equipment of suitable rating maybe used.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 4 of 24
If the pump unit 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 unpainted carbon steel or
cast iron parts, and should not be removed
until final installation.
2.3.2 Long Term Storage
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. If the
packaging or suction and discharge covers
are removed for inspection purposes,
replace afterwards to protect the pump and
maintain safety.
Fill the bearing housing with recommended
oil to ensure that the shaft and bearings
remain rust free. Remove the gland,
packing rings and lantern ring, cover metallic
parts with rust preventative and wrap all
Operators Instructions for
Unistream Centrifugal Pumps
parts for storage with the pump.
The pump shaft should be rotated by hand at
least five turns every six weeks. For special
protection of the coupling and electric motor,
where applicable, refer to the manufacturers'
instructions in the relevant appendix.
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. for special
storage instructions to suit the conditions
applicable.
3. General Description
SPP Pumps Ltd. Unistream Pumps are a
range of horizontal centrifugal pumps that
comply with Pump Standard DIN24255. The
materials of construction can be either all
iron or iron with bronze fittings.
Manual No/Rev
W21-002E / 10
the pump only.
(2) Suction pressure must be included when
assessing the Maximum W orking Pressure.
3.2 Long Coupled Pumpsets
These pumpsets are supplied with
baseplate, coupling and electric motors,
specified to meet the pump duty and
customer requirements. Baseplates are
usually of the SPP Pumps Ltd. steel plate
design but fabricated baseplates may be
supplied to meet additional requirements.
A proprietary flexible coupling is fitted, this
has been selected to meet the power
transmission and other operating
requirements for the pumpset. Coupling
details are given in the manufacturers
instructions in Appendix II.
For details of the motor supplied, refer to the
manufacturer's instructions in Appendix III.
3.1 Pumps
The mechanical assembly comprises a rigid
shaft, supported by oil-lubricated bearings
with a double shrouded type impeller
mounted in a removable bearing housing
assembly. This is attached to an end suction
volute casing fitted with wear ring(s). The
bearing housing, shaft and impeller
assembly can be withdrawn from the volute
for maintenance without disconnection of
pipework.
The discharge branch is positioned vertically
opposite the main pump mounting feet, an
additional mounting foot is fitted at the outer
bearing position for stability.
The complete assembly is of a rigid
construction, being intended for mounting on
suitable baseplate with electric or other
motor driver. A suitable coupling is required
to transmit the rotational drive between
pump and motor. A spacer coupling can be
fitted to allow the removal of the pump
rotating assembly without disconnecting
pipework and removal of the motor.
The shaft is sealed with a soft packed gland
for fire pump applications.
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
event of a handling accident, carefully
check that no damage has been sustained
by the pump before installation and
commissioning.
4.2 Preparation for Mounting
Before installation, check that the pump
mounting location is suitable for accepting
the pump unit. Refer to Section 8, for details
of pump installation dimensions or to a
certified General Arrangement Drawing
when available.
Nameplate details are shown on the back
cover, full pump specification can be
supplied on a data sheet, if requested.
Note (1) Head specified is the Duty Head generated by
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 5 of 24
Manual No/Rev
W21-002E / 10
Operators Instructions for
Unistream Centrifugal Pumps
4.3 Pump Preparation
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.
Remove packaging but leave the flange
covers in place, check that impeller rotates
freely by hand by turning the shaft.
4.4 Pump Installation
c) Confirm Lateral Alignment
Mount the dial
gauge on the pump
shaft or coupling
with the gauge
running on the
machined diameter
of the motor
coupling. Turn the pump shaft and note the
total indicator reading.
d) Adjustment
The motor must be shimmed and re-
positioned to align the shafts within the
coupling manufacturer's specifications.
It is recommended that the pump unit is
fitted to the baseplate before fitting the motor
and coupling. The distance between shaft
ends should be established to suit the
coupling by reference to the manufacturer's
instructions.
4.5 Shaft Alignment
To minimise the side load on the bearings
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:
a) Lateral Alignment
Mount a dial gauge
on the motor shaft
or coupling with the
gauge running on
the machined
diameter of the
pump coupling. Turn the motor shaft and
note the total indicator reading.
b) Angular Alignment
Mount a dial gauge
on the motor shaft
or coupling to run
on a face of the
pump coupling as
near the outside
diameter as
possible. Turn the motor shaft and note
the total indicator reading.
e) Alternative Method
If a dial gauge is not available, callipers or
taper gauge may be used to measure the
distance between the coupling flanges at
four points around the circumference and a
straight edge used to check the lateral
alignment of the outer flange diameters.
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.
ATTENTION
If hot liquids (above
80°C) are being
pumped, alignment should be checked and
reset with the pump and motor at their
normal operating temperature. If this is not
possible, SPP Pumps Ltd. can supply
estimated initial offset figures to suit
extreme operating temperatures.
4.6 Suction Pipework
The run of suction pipework must be such
that air can NOT become trapped where it
would be sucked into the pump on starting.
The bore of 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.
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. If fitting a foot valve, it
should have a free area of one and a half
times the area of the suction pipe.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 6 of 24
UNISUC02.CDR
UNIPIP02.CDR
Unacceptable Suction Pipework
Trapped Air
Unsupported Pipe
Operators Instructions for
Unistream Centrifugal Pumps
Preferred Pipework
Suction Valve
Manual No/Rev
W21-002E / 10
Discharge Pipe
Discharge
Valve
Check Valve
Increaser
Eccentric
Reducer
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.
An appropriate fine strainer is recommended
to prevent foreign matter from being drawn
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.
4.7 Discharge Pipework
The bore of the discharge pipe should 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 back pressure and
reverse rotation and a discharge valve is
usually fitted to regulate the flow and allow
for inspection and maintenance on the
pump.
The suction and discharge pipework must be
independently supported and positioned
such that no excessive forces and moments
are exerted on the pump flanges.
ATTENTION
Failure to support suction
and delivery pipework
may result in distortion of the pump casing,
with the possibility of early pump failure.
Suction Pipe
4.8 Foundations
The baseplate must be secured to
substantial foundations with suitable
foundation bolts to minimise vibrations. A
space of approximately 25mm should be left
between the baseplate and the foundations
for grouting. After the grouting has dried, the
foundation bolts should be tightened and the
shaft alignment checked again 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
requires 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.
If the gland packing has been removed for
storage, this must be replaced as described
in Section 6.2.3 - Re-packing.
Check the level of the oil in the bearing
housing is at the level mark on the sight
glass on the side of the bearing housing.
Refer to Section 6.4 - Bearing Lubrication.
If the shaft sealing is by gland packing, the
packing should be relatively slack and check
that the gland (45.2) is free.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 7 of 24
Manual No/Rev
W21-002E / 10
Operators Instructions for
Unistream Centrifugal Pumps
If the stuffing box is supplied with cooling
water or the mechanical seal is supplied with
clean water flush, check that the water
supply is turned on.
ATTENTION
Failure to supply the
stuffing box or mechanical
seal with cooling or flush water may result in
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.
damage and premature failure of the pump.
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
Check that the motor is not overloading, unit
is not vibrating or excessively noisy, bearings
or gland packing are not overheating, and
that the pump is developing the correct flow
and head requirements.
tightened and instrumentation is in position.
ATTENTION
Check that the pump is
primed. Pumps should
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:
never be run dry as the pumped liquid acts
as a lubricant for the close running fits
surrounding the impeller and damage will be
incurred.
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.
Connect the electrical supply to the pump
unit. Momentarily switch on motor and check
direction of rotation. This should be such that
the pump assembly turns clockwise when
viewed on the driven end. For three phase
electric motors, if direction of rotation is
incorrect, disconnect the supply and change
over two of three supply wires.
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.
5.2 During Operation
Hot Surfaces Hazard
Do NOT touch surfaces that
After the first 200 hours running from new,
change the bearing lubricating oil. Refer to
Section 6.4 - Bearing Lubrication.
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
5.1 Starting Procedure
has stopped, allow sufficient time for
cooling before maintenance. Be cautious
BEFORE A UNISTREAM 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.
Before starting, check the level of oil in the
bearing housing is at the level mark on the
sight glass on the side of the bearing
housing. Refer to Section 6.4 - Bearing
Lubrication.
Check that the suction valve is open and that
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 8 of 24
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
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