Contents
2
ContaCts
sales and administration
1420 Lakeview Arlington Business Park Theale, Reading Berkshire RG7 4SA Tel: +44 (0) 118 932 3123 Fax: +44 (0) 118 932 3302 Manufacturing Centre Crucible Close Mushet Industrial Park Coleford
Gloucestershire GL16 8PS Email: [email protected] Tel: +44(0)1594 832701 Fax: +44(0)1594 836300
UK service Centre Contact Directory Western service Centre
Tufthorn Avenue, Coleford Gloucestershire England GL16 8PJ
Email: [email protected] Tel: +44 (0) 1594 832701 Fax: +44 (0) 1594 810043
north West service Centre
Metrology House Dukinfield Road Hyde England SK14 4PD Email: [email protected] Tel: +44 (0) 161 366 7309 Fax: +44 (0) 161 366 8849
scottish service Centre
137 Deerdykes View Cumbernauld G68 9HN Email: [email protected] Tel: +44 (0) 1236 455035 Fax: +44 (0) 1236 455036
southern service Centre
Unit 1 Stanstead Road Boyatt Wood Industrial Estate Eastleigh, Hampshire England SO50 4RZ
Email: [email protected] Tel: +44 (0) 2380 616004 Fax: +44 (0) 2380 614522
northern Ireland service Centre
Unit 2 Oak Bank Channel Commercial Park Queens Road, Queens Island Belfast Northern Ireland BT3 9DT Email: [email protected] Tel: +44 (0) 2890 469802 Fax: +44 (0) 2890 466152
For Service support outside of office hours please call +44 (0) 8443 759662
Contents
3
France
SPP Pumps 2 rue du Chateau d’eau 95450 US
France
Email: [email protected] Tel: +33 (0) 1 30 27 96 96 Fax: +33 (0) 1 34 66 07 33
north and south america
2905 Pacific Drive Norcross GA 30071 U.S.A. Email: [email protected] Tel: +1(770) 409 3280 Fax: +1(770) 409 3290 www.spppumpsusa.com Middle East
SPP Pumps Limited (Middle East) P O Box 61491, Jebel Ali Dubai
United Arab Emirates Email: [email protected] Tel: +971 (0) 4 8838 733 Fax: +971 (0) 4 8838 735
asia
SPP Pumps Limited (Asia) 152 Beach Road Gateway East #05 - 01 to 04 Singapore 189721 Email: [email protected] Tel: +(65) 6576 5725 Fax: +(65) 6576 5701 south africa SPP Pumps (South Africa) Cnr Horne St & Brine Ave Chloorkop Ext 23 Kemptonpark Gauteng R.S.A 1619 Email: [email protected] Tel: +27(0)11 393 7177 / 71792 Italy SPP Italy Via Watt, 13/A 20143 Milano Email: [email protected] Tel: +(0039) 02 58111782 Fax: +(0039) 02 58111782 Mobile: +(0039) 346 3204457 Poland Email: [email protected] netherlands SPP Pumps Limited Klerkenveld 7 NL-4704 SV Roosendaal The Netherlands E-mail: [email protected] Tel: +31(0)165743053 Contents 3 4
4 Czech Republic Email: [email protected] Tel: +420 775 656 110 Russia Email: [email protected] Tel: +420 775 656 110 Parent Company
Kirloskar Brothers Limited “YAMUNA” Plot No 98 (3-17), Baner 411045 Pune India Tel: +91 20 2721 4444 www.kirloskarpumps.com Contents 3 4
5
UsEFUl WEbsItEs
tRaDE assoCIatIons:
British Pump Manufacturers Association (BPMA) www.bpma.org.uk
Construction Equipment Association (CEA) www.coneq.org.uk
Fire Protection Association (FPA) www.thefpa.co.uk
British Automatic Sprinkler Association www.basa.org.uk
European Fire Sprinkler Network www.eurosprinkler.org Energy Industries Council www.the-eic.com Pump Centre www.pumpcentre.com
REgUlatoRy aUthoRItIEs:
Factory Mutual (FM) www.fmglobal.com Underwriters Laboratories www.ul.comLoss Prevention Certification Board www.brecertification.co.uk National Fire Protection Association www.nfpa.org
Pump Distributors Association www.the-pda.com Pumps-Directory www.pumps-directory.com Usef Ul Websites Usef Ul W bsites Contents 3 4
7 ContEnts Introduction to sPP ...8 -15 Manufacturing ...9 Test Facility ...9 SPP Divisions ... 10 SPP International ... 15
Fire Protection and Approval Standards ... 16
Pump specification & operation ...17 – 42 Data Required When Buying Pumps ...19
Dimensions of Cast Iron Flanges to BS EN 109221 ...21
Dimensions of Cast Iron Flanges to ASME/ANSI B16.1 ...24
Dimensions of Steel Flanges to ASME/ANSI B16.5 ...26
Pump Installation ... 28
Pump Operation ... 28
Faults and Remedial Action ... 29
Vibration Tolerance ... 31
Condition Monitoring ... 33
Flow Estimation Methods ... 34
Application Do’s and Don’ts ... 39
hydraulic Design Data ...43 – 68 Pressure (bar) vs Head (m of Water) ...44
Calculation of Head for Pump Selection ... 46
Autoprime Pumping Terms ... 49
Friction Loss for Water Hazen-Williams Formula, C=140) ...51
Resistance in Fittings ... 54
Quantities Passed by Pipes at different Velocities ...55
Recommended Maximum Flow through Valves (l/s) ...55
Water Discharged by Round Spray Holes in thin walled Pipes Under Different Pressures ...56
Net Positive Suction Head (NPSH) ... 57
Maximum Suction Lift with Barometric Pressure at Different Altitudes ...59
Liquid Viscosity and its Effect on Pump Performance ...60
Approximate Viscosity Conversion Schedule .... 62
Test Tolerances and Different Standards ... 64
Velocity head Correction ...69 – 78 Electrical Design Data ...79 – 84 Average Efficiencies and Power Factors of Electric Motors ...80
Approximate Full Load Speeds (RPM) of AC Motors ...82
Starting AC Motors ... 83
Whole life Cost ...85 – 90 Whole Life Cost Principles and Pump Design ...86
Features of a Low Life-Cycle cost centrifugal pumps ...88
Energy ...91 – 94 Conversion Factors ...95 – 105 Conversion Factor Tables ...96
Vacuum Technical Data ... 100
Product / Application Charts ... 101
notes ...106
Contents
8
“For Where it Really Matters”
For more than 130 years SPP Pumps has been a leading manufacturer of centrifugal pumps and associated systems. A global principal in design, supply and servicing of pumps, pump packages and equipment for a wide range of applications and industry sectors.
SPP pumps and systems are installed on all continents providing valuable high integrity services for diverse industries, such as oil and gas production, water and waste water treatment, power generation, construction, mines and for large industrial plants.
Major applications include water treatment & supply, sewage & waste water treatment, fire protection, and mobile pumps for rental sectors, for which our low life cost and environmental considerations are fundamental design priorities. Assessed to OHSAS 18001:2007 LPCB reg. no 111 Contents 3 4
9 ManUFaCtURIng
SPP requires the highest standards of manufacturing excellence from its facilities around the world. This is crucial to the on-going growth and development of the company. At the main manufacturing facility located in the UK, SPP set the highest standards attainable in the industry for quality and reliability.
SPP distinguishes its product split between pre-engineered standard products and fully customised equipment engineered and packaged to order. The extensive manufacturing and testing capabilities reflect this wide and diverse product range.
To ensure efficient use of production resources, an ERP manufacturing planning system is utilised. Assembly areas are segregated into the main product groups; standard pumps, industrial fire pumps, contractors pumps and engineered products. The machine shop is planned in cell layout with individual cells specialising in types, or ranges of components. CNC machines are linked by a DNC system allowing programming to be carried out on the machine or offline.
Lean manufacturing principles ensure that SPP are always focused on continuous improvement to support their ‘Right First Time’ philosophy. Customers are always welcome to visit the facility, either during manufacturing or when equipment is on test.
tEst FaCIlIty
Testing, including witness testing, of all SPP’s range of pumps is performed at SPP’s own extensive in-house test facility. The main test area has a 1.4 million litre test tank with a depth of 6 metres. It can test pressures up to 50 bar, flows up to 2000 l/s and powers up to 800kW at 6.6kV, 400kW at 415V and 400kW at 60Hz. Generators can be used for higher powers or voltages.
Contents
10
Pumps for water supply, water/waste water treatment, industrial processes and general pumping service.
SPP has an extensive range of products suitable for a variety of applications. From end suction DIN24255 (EN 733:1995) through to vertical turbine, split case and sewage pumps, SPP has reliable and well proven products to offer. lowest life Cycle Cost series
SPP’s recognises the increasing emphasis on whole life cost when evaluating pumping schemes, for the twenty-first century. This has lead to the development of their Lowest Life-Cycle Cost Series of split case, vertical turbine, dry well sewage pumps and solides diverters.
SPP is the world’s leading specialist manufacturer of quality fire protection pump packages. Unrivalled experience in design and manufacture together with advanced testing and accreditation ensures the utmost in equipment reliability.
SPP fire pumps comply with the demanding requirements of the LPCB, FM and UL approval standards and meet all the requirements of NFPA 20.
WatER
FIRE
Contents
11 SPP is a world leader in the design and manufacture of pumping equipment for both onshore and offshore applications. In-house expertise ensures compliance with all applicable specifications and regulations. SPP has also established quality assurance and document control business systems allied to the needs of the major oil and gas contractors and end users.
SPP is the packager as well as the pump manufacturer and takes full unit responsibility for the complete scope of supply.
The SPP Autoprime range is a proven, versatile and comprehensive product range suitable for use in a variety of applications worldwide. The Autoprime pumps are primarily sold to rental organisations, contractors, utility companies, open cast mining companies and municipalities providing a durable solution. Continual investment in market-led research and development ensure that the products are designed to meet market requirements and legislation, providing significant benefits and solutions to owners and users alike.
oIl & gas
DEWatERIng
Contents
12
stanDaRD PRoDUCts
The SPP standard pump product range has been expertly designed to enable you to fit them to any of your existing DIN Standard Pump Applications. SPP’s excellent modular pump design allows interchangeability across the range and with the ability to use standard shaft motors, gives much more flexibility in terms of maintenance, stock holding and material options. SPP Standard pumps can also be used for a variety of new pump application needs.
InDUstRy
This is the largest market sector spanning chemical, pharmaceutical, power and general industry, including manufacturing processes such as foundries, rolling mills, boiler houses and water reclamation.
The main pumping equipment is largely electrically driven such as: • End suction / SH & SHL non clog along with current distribution offering • KPD for chemical process
• Split case units • RKB multistage • Vertical turbines
Contents
13 tRansFoRMER oIl PUMPs
SPP’s transformer oil pump range is designed and manufactured to the highest quality standards. SPP have been producing transformer oil pumps for more than sixty years. Life expectancy in many cases has exceeded forty years. Applications include oil circulation in the following: power transmission, distribution and electric traction locomotive transformers.
EnERgy
Through the use of proven systems and techniques, the Energy Division offers a complete energy saving package that can be applied equally to new projects and existing installations. The new division offers the following services: Energy Audits, Customer Training, Energy Management, Surveys/reports/ analysis and recommendations. By monitoring and/or analysing the actual requirement of the installation and comparing this with the specifications of the equipment installed, SPP can make recommendations that can reduce running costs (eg: power requirements), minimise maintenance costs (eg: parts/servicing and downtime) and improve plant reliability (eg: upgraded material specifications).
Contents
14
EngInEERIng sERVICEs
At SPP we are committed to providing the very best in customer support. We have built our reputation by providing a fast, cost effective service whilst maintaining continually high standards of workmanship and quality. With strategically located service centres in the UK and around the world, help is never far away. Each service centre is fully equipped to offer a comprehensive range of equipment repair and refurbishment techniques. Our support is available 24 hours a day, and is only ever a phone call away.
SPP supports our customers around the globe through our extensive network of field service engineers. SPP field service engineers have thousands of hours of experience, backed by intensive product and applications training. Whatever your technical support requirement, we can help you get the best performance from our equipment in your application. Field service engineers can provide: • Equipment installation and commissioning
• Preventative maintenance • Equipment repair and upgrades • Product training
On SPP and other manufacturers’ pumps.
SPP are proud to be a chosen partner by SKF Bearings in the UK. This has led to all SPP service centres being the only UK approved SKF Certified Rebuilder of pumps. SPP also works with SKF globally and is the first port of call for SKF customers needing pump repairs and services.
Contents
15 sPP IntERnatIonal
SPP is a truly global company with the main R&D
, manufacturing and
test facilities centr
ally located in the UK and local sites in the United
States, India, Fr ance , South Africa, Singapor e, Dubai,
Italy and Poland.
SPP Locations Appro ved Ser vice Pro viders Contents 3 4
16
FIRE PRotECtIon aPPRoVal stanDaRDs
SPP has one of the widest ranges of approved and listed equipment in the world complying with the demanding requirements of the UL and FM approval standards and meeting all the requirements of NFPA 20. Along with these approvals, SPP’s fire products are also approved for use in many other markets such as Europe, The Far East, The Middle East and Africa. Although many pump companies can offer equipment ‘designed to’ the various locally applicable fire rules and regulations, only a very select few have had their pumps subjected to the stringent performance and reliability tests of specialist fire approval laboratories.
Being the first to achieve fire pump approval and listing by the internationally recognised Loss Prevention Certification Board the company today has more pumps approved by the LPCB than any other manufacturer.
Contents
17
PUMP sPECIFICatIon
anD oPERatIon
Contents
19
sECtIon 1
Data REQUIRED WhEn bUyIng PUMPs Fundamentals
number required. nature of service.
Whether continuous or intermittent. Performance
Capacity (State whether total or per unit). total head or pressure to be developed.
suction lift (including friction), inlet pressure or head, or nPsh available. (State range of any variation in above items. Otherwise, send sketch or give full details of lifts and pipe runs including lengths, bores, materials and class of pipes and number and nature of bends, valves etc.).
Pumped Medium
nature of liquid (if other than cold, clean water).
Values or ranges of actual pumping temperature with corresponding specific gravities, viscosities (if greater than for water) and vapour pressures. Any corrosive and/or abrasive properties.
Nature, proportion and maximum size of any solids content.
Driver nature of driver.
If driver to be supplied, give full specification.
If electric motor, state electricity supply details, any speed restriction. Whether lining-up and connecting free issue driver required. Details of starting equipment and/or other accessories required system of control if automatic.
PUMP sPECIFIC at Ion an D oPER at Ion se Cti ON 1 Contents 3 4
20 other Data
If required to run in parallel with other units. Is it to be self-priming with suction lift. Pump type and arrangement. Fixed or portable.
Horizontal or vertical shaft.
Whether close-coupled, dry well, wet well or borehole (if vertical). Borehole diameter or any other space restrictions.
If baseplate and coupling required.
Constructional / material specification required. Site conditions:
If altitude above 150m.
If ambient temperature above 30º C. If to work outdoors.
Type of drive:
Direct or indirect (i.e. coupling, gearbox or V belt). Direction of rotation (if restricted).
Official tests/inspection, packing and shipping requirements. Tender receipt/material despatch date required.
Any other significant information.
Items printed in bold are minimum requirements for quotation of any standard horizontal pump. All other items, so far as they apply, are necessary for the correct execution of all orders and quotations other than standard horizontal pumps.
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21
sECtIon 2
DIMEnsIons oF Cast IRon FlangEs to bs En 1092 Pumps and Fittings
noM. DIa.
FlangE RaIsED FaCE bolts DRIllIng nECK
D b d4 Fmax DIa. no d2 k d3 r 10 75 12 33 2 M10 4 11 50 20 3 15 80 12 38 2 M10 4 11 55 26 3 20 90 14 48 2 M10 4 11 65 34 4 25 100 14 58 3 M10 4 11 75 44 4 32 120 16 69 3 M12 4 14 90 54 5 40 130 16 78 3 M12 4 14 100 64 5 50 140 16 88 3 M12 4 14 110 74 5 65 160 16 108 3 M12 4 14 130 94 6 80 190 18 128 3 M16 4 19 150 110 6 100 210 18 144 3 M16 4 19 170 130 6 125 240 20 174 3 M16 8 19 200 160 6 150 265 20 199 3 M16 8 19 225 182 8 200 320 22 254 3 M16 8 19 280 238 8 250 375 24 309 3 M16 12 19 335 284 10 300 440 24 363 4 M20 12 23 395 342 10 350 490 24 415 4 M20 12 23 445 392 10 400 540 24 463 4 M20 16 23 495 442 10 450 595 24 518 4 M20 16 23 550 494 12 500 645 24 568 4 M20 20 23 600 544 12 600 755 24 667 5 M24 20 28 705 642 12 700 860 24 772 5 M24 24 28 810 746 12 800 975 24 878 5 M27 24 31 920 850 12 900 1075 24 978 5 M27 24 31 1020 950 12 1000 1175 24 1078 5 M27 28 31 1120 1050 12 BS EN 1092 TABLE PN6
notE - All dimensions listed below are in millimetres
se Cti ON 2 PUMP sPECIFIC at Ion an D oPER at Ion Contents 3 4
22
BS EN 1092 TABLE PN10
noM. DIa.
FlangE RaIsED FaCE bolts DRIllIng nECK
D b d4 Fmx DIa. no d2 k d3 r
notE: FoR noMInal sIZEs 10 - 150 UsE Pn16 tablE
200 340 26 266 3 M20 8 23 295 246 8 250 395 28 319 3 M20 12 23 350 298 10 300 445 28 370 4 M20 12 23 400 348 10 350 505 30 429 4 M20 16 23 460 408 10 400 565 32 480 4 M24 16 28 515 456 10 450 615 32 530 4 M24 20 28 565 502 12 500 670 34 582 4 M24 20 28 620 559 12 600 780 36 682 5 M27 20 31 725 658 12 700 895 40 794 5 M27 24 31 840 772 12 800 1015 44 901 5 M30 24 34 950 876 12 900 1115 46 1001 5 M30 28 34 1050 976 12 1000 1230 50 1112 5 M33 28 37 1160 1080 12 1200 1455 56 1328 5 M36 32 41 1380 1292 12 1400 1675 62 1530 5 M39 36 44 1590 1496 12 1600 1915 68 1750 5 M45 40 50 1820 1712 12 1800 2115 70 1950 5 M45 44 50 2020 1910 15 2000 2325 74 2150 5 M45 48 50 2230 2120 15 2200 2550 78 - - M52 52 56 2440 2320 20 BS EN 1092 TABLE PN16 noM. DIa.
FlangE RaIsED FaCE bolts DRIllIng nECK
D b d4 Fmx DIa. no d2 k d3 r 10 90 14 41 2 M12 4 14 60 28 3 15 95 14 46 2 M12 4 14 65 32 3 20 105 16 56 2 M12 4 14 75 40 4 25 115 16 65 3 M12 4 14 85 50 4 32 140 18 76 3 M16 4 19 100 60 5 40 150 18 84 3 M16 4 19 110 70 5 50 165 20 99 3 M16 4 19 125 84 5 65 185 20 118 3 M16 4 19 145 104 6 80 200 22 132 3 M16 8 19 160 120 6 100 220 24 156 3 M16 8 19 180 140 6 125 250 26 186 3 M16 8 19 210 170 6 150 285 26 211 3 M20 8 23 240 190 8 200 340 30 266 3 M20 12 23 295 246 8 250 405 32 319 3 M24 12 28 355 296 10 300 460 32 370 4 M24 12 28 410 350 10 350 520 36 429 4 M24 16 28 470 410 10 400 580 38 480 4 M27 16 31 525 458 10 450 640 40 548 4 M27 20 31 585 516 12 500 715 42 609 4 M30 20 34 650 576 12 600 840 48 720 5 M33 20 37 770 690 12 700 910 54 794 5 M33 24 37 840 760 12 800 1025 58 901 5 M36 24 41 950 862 12 Contents 3 4
23 BS EN 1092 TABLE PN25
noM. DIa.
FlangE RaIsED FaCE bolts DRIllIng nECK
D b d4 Fmx DIa. no d2 k d3 r 10 90 16 41 2 M12 4 14 60 28 3 15 95 16 46 2 M12 4 14 65 32 3 20 105 18 56 2 M12 4 14 75 40 4 25 115 18 65 3 M12 4 14 85 50 4 32 140 20 76 3 M16 4 19 100 60 5 40 150 20 84 3 M16 4 19 110 70 5 50 165 22 99 3 M16 4 19 125 84 5 65 185 24 118 3 M16 8 19 145 104 6 80 200 26 132 3 M16 8 19 160 120 6 100 235 28 156 3 M20 8 23 190 142 6 125 270 30 186 3 M24 8 28 220 162 6 150 300 34 211 3 M24 8 28 250 192 8 200 360 34 274 3 M24 12 28 310 252 8 250 425 36 330 3 M27 12 31 370 304 10 300 485 40 389 4 M27 16 31 430 364 10 350 555 44 448 4 M30 16 34 490 418 10 400 620 48 403 4 M33 16 37 550 472 10 450 670 50 548 4 M33 20 37 600 520 12 500 730 52 609 4 M33 20 37 660 580 12 600 845 56 720 5 M36 20 41 770 684 12 700 960 56 820 5 M39 24 44 875 780 12 800 1085 56 928 5 M45 24 50 990 882 12 se Cti ON 2 PUMP sPECIFIC at Ion an D oPER at Ion BS EN 1092 TABLE PN40 noM. DIa.
FlangE RaIsED FaCE bolts DRIllIng nECK
D b d4 Fmx DIa. no d2 k d3 r 10 90 16 41 2 M12 4 14 60 28 3 15 95 16 46 2 M12 4 14 65 32 3 20 105 18 56 2 M12 4 14 75 40 4 25 115 18 65 3 M12 4 14 85 50 4 32 140 20 76 3 M16 4 19 100 60 5 40 150 20 84 3 M16 4 19 110 70 5 50 165 22 99 3 M16 4 19 125 84 5 65 185 24 118 3 M16 8 19 145 104 6 80 200 26 132 3 M16 8 19 160 120 6 100 235 28 156 3 M20 8 23 190 142 6 125 270 30 186 3 M24 8 28 220 162 6 150 300 34 211 3 M24 8 28 250 192 8 200 375 40 284 3 M27 12 31 320 254 8 250 450 46 345 3 M30 12 34 385 312 10 300 515 50 409 4 M30 16 34 450 378 10 350 580 54 465 4 M33 16 37 510 432 10 400 660 62 535 4 M36 16 41 585 498 10 450 685 62 560 4 M36 20 41 610 522 12 500 755 62 615 4 M39 20 44 670 576 12 Contents 3 4
24
asME/ansI b16.1 – 125lb – RATING – CAST IRON
250lb – RATING – CAST IRON
notE - All dimensions listed below are in inches
DIMEnsIons oF Cast IRon FlangEs to asME/ansI b16.1 BS EN 1092 TABLE PN63
noM. DIa.
FlangE RaIsED FaCE bolts DRIllIng nECK
D b d4 Fmx DIa. no d2 k d3 r 40 170 28 84 3 M20 4 23 125 77 5 50 180 28 99 3 M20 4 23 135 87 5 65 205 28 118 3 M20 8 23 160 112 6 80 215 31 132 3 M20 8 23 170 122 6 100 250 33 156 3 M24 8 28 200 142 6 125 295 37 184 3 M27 8 31 240 174 6 150 345 39 211 3 M30 8 34 280 208 8 200 415 46 284 3 M33 12 37 345 267 8 250 470 50 345 3 M33 12 37 400 322 10 300 530 57 409 4 M33 16 37 460 382 10 350 600 61 465 4 M36 16 41 525 438 10 400 670 65 535 4 M39 16 44 585 490 10 200 360 34 274 3 M24 12 28 310 252 8 250 425 36 330 3 M27 12 31 370 304 10 300 485 40 389 4 M27 16 31 430 364 10 350 555 44 448 4 M30 16 34 490 418 10 400 620 48 403 4 M33 16 37 550 472 10 Contents 3 4
25 asME/ansI b16.1 – 250lb RATING – CAST IRON
noM. DIa.
FlangE bolts DRIllIng sPotFaCE
DIaMEtER hUb D b DIa. no d2 k d3 r 1 4.88 0.69 0.62 4 0.75 3.50 1.25 2.06 0.13 1 1/4 5.25 0.75 0.62 4 0.75 3.88 1.25 2.50 0.13 1 1/2 6.12 0.81 0.75 4 0.88 4.50 1.50 2.75 0.13 2 6.50 0.88 0.62 8 0.75 5.00 1.25 3.31 0.25 2 1/2 7.50 1.00 0.75 8 0.88 5.88 1.50 3.94 0.25 3 8.25 1.12 0.75 8 0.88 6.62 1.50 4.62 0.25 3 1/2 9.00 1.19 0.75 8 0.88 7.25 1.50 5.25 0.25 4 10.00 1.25 0.75 8 0.88 7.88 1.50 5.75 0.25 5 11.00 1.38 0.75 8 0.88 9.25 1.50 7.00 0.25 6 12.50 1.44 0.75 12 0.88 10.62 1.50 8.12 0.25 8 15.00 1.62 0.88 12 1.00 13.00 1.63 10.25 0.25 10 17.50 1.88 1.00 16 1.12 15.25 1.88 12.62 0.25 12 20.50 2.00 1.12 16 1.25 17.75 2.13 14.75 0.25 14 23.00 2.12 1.12 20 1.25 20.25 2.13 16.25 0.25 16 25.50 2.25 1.25 20 1.38 22.50 2.25 18.38 0.25 18 28.00 2.38 1.25 24 1.38 24.75 2.25 20.75 0.25 20 30.50 2.50 1.25 24 1.38 27.00 2.25 23.00 0.38 24 36.00 2.75 1.50 24 1.62 32.00 2.75 27.25 0.38 30 43.00 3.00 1.75 28 2.00 39.25 34.00 34.00 0.38 se Cti ON 2 PUMP sPECIFIC at Ion an D oPER at Ion
ASME/ANSI B16.1 – 125lb RATING – CAST IRON
noM. DIa.
FlangE bolts DRIllIng sPotFaCE
DIaMEtER hUb D b DIa. no d2 k d3 r 1 4.25 0.44 0.50 4 0.62 3.12 1.00 1.94 0.12 1 1/4 4.62 0.50 0.50 4 0.62 3.50 1.00 2.31 0.12 1 1/2 5.00 0.56 0.50 4 0.62 3.88 1.00 2.56 0.12 2 6.00 0.62 0.62 4 0.75 4.75 1.25 3.06 0.25 2 1/2 7.00 0.69 0.62 4 0.75 5.50 1.25 3.56 0.25 3 7.50 0.75 0.62 4 0.75 6.00 1.25 4.25 0.25 3 1/2 8.50 0.81 0.62 8 0.75 7.00 1.25 4.81 0.25 4 9.00 0.94 0.62 8 0.75 7.50 1.25 5.31 0.25 5 10.00 0.94 0.75 8 0.88 8.50 1.50 6.44 0.25 6 11.00 1.00 0.75 8 0.88 9.50 1.50 7.56 0.25 8 13.50 1.12 0.75 8 0.88 11.75 1.50 9.69 0.25 10 16.00 1.19 0.88 12 1.00 14.25 1.62 11.94 0.25 12 19.00 1.25 0.88 12 1.00 17.00 1.62 14.06 0.25 14 21.00 1.38 1.00 12 1.12 18.75 1.88 15.38 0.25 16 23.50 1.44 1.00 16 1.12 21.25 1.88 17.50 0.25 18 25.00 1.56 1.12 16 1.25 22.75 2.12 19.62 0.25 20 27.50 1.69 1.12 20 1.25 25.00 2.12 21.75 0.38 24 32.00 1.88 1.25 20 1.38 29.50 2.25 26.00 0.38 30 38.75 2.12 1.25 28 1.38 36.00 2.25 - 0.38 Contents 3 4
26 noM.
DIa.
FlangE RaIsED FaCE bolts DRIllIng sPotFaCE
DIaMEtER hUb D b d4 Fmax no DIa. d2 k d3 r 1/2 3.50 0.44 - - 4 1/2 0.62 2.38 1.00 1.19 0.12 3/4 3.88 0.50 - - 4 1/2 0.62 2.75 1.00 1.50 0.12 1 4.25 0.56 2.00 1/16 4 1/2 0.62 3.12 1.00 1.94 0.12 1 1/4 4.62 0.62 2.50 1/16 4 1/2 0.62 3.50 1.00 2.31 0.12 1 1/2 5.00 0.69 2.88 1/16 4 1/2 0.62 3.88 1.00 2.56 0.12 2 6.00 0.75 3.62 1/16 4 5/8 0.75 4.75 1.25 3.06 0.25 2 1/2 7.00 0.88 4.12 1/16 4 5/8 0.75 5.50 1.25 3.56 0.25 3 7.50 0.94 5.00 1/16 4 5/8 0.75 6.00 1.25 4.25 0.25 3 1/2 8.50 0.94 5.50 1/16 8 5/8 0.75 7.00 1.25 4.81 0.25 4 9.00 0.94 6.19 1/16 8 5/8 0.75 7.50 1.25 5.31 0.25 5 10.00 0.94 7.31 1/16 8 3/4 0.88 8.50 1.50 6.44 0.25 6 11.00 1.00 8.50 1/16 8 3/4 0.88 9.50 1.50 7.56 0.25 8 13.50 1.12 10.62 1/16 8 3/4 0.88 11.75 1.50 9.69 0.25 10 16.00 1.19 12.75 1/16 12 7/8 1.00 14.25 1.62 12.00 0.25 12 19.00 1.25 15.00 1/16 12 7/8 1.00 17.00 1.62 14.38 0.25 14 21.00 1.38 16.25 1/16 12 1 1.12 18.75 1.88 15.75 0.25 16 23.50 1.44 18.50 1/16 16 1 1.12 21.25 1.88 18.00 0.25 18 25.00 1.56 21.00 1/16 16 1 1/8 1.25 22.75 2.12 19.88 0.25 20 27.50 1.69 23.00 1/16 20 1 1/8 1.25 25.00 2.12 22.00 0.38 24 32.00 1.88 27.25 1/16 20 1 1/4 1.38 29.50 2.25 26.12 0.38 DIMEnsIons oF stEEl FlangEs to asME/ansI b16.5
ASME/ANSI B16.5 – 150lb RATING - STEEL
notE - All dimensions listed below are in inches asME/ansI b16.5 – 150lb – RATING - STEEL
– 300lb – RATING - STEEL
Contents
27 noM.
DIa. FlangED b RaIsED FaCEd4 Fmax noboltsDIa. DRIllIngd2 k sPotFaCE DIaMEtER d3hUbr
1/2 3.75 0.56 1.38 1/16 4 1/2 0.62 2.62 1.00 1.50 0.12 3/4 4.62 0.62 1.69 1/16 4 5/8 0.75 3.25 1.25 1.88 0.12 1 4.88 0.69 2.00 1/16 4 5/8 0.75 3.50 1.25 2.12 0.12 1 1/4 5.25 0.75 2.50 1/16 4 5/8 0.75 3.88 1.25 2.50 0.12 1 1/2 6.12 0.81 2.88 1/16 4 3/4 0.88 4.50 1.50 2.75 0.12 2 6.50 0.88 3.62 1/16 8 5/8 0.75 5.00 1.25 3.31 0.25 2 1/2 7.50 1.00 4.12 1/16 8 3/4 0.88 5.88 1.50 3.94 0.25 3 8.25 1.12 5.00 1/16 8 3/4 0.88 6.62 1.50 4.62 0.25 3 1/2 9.00 1.19 5.50 1/16 8 3/4 0.88 7.25 1.50 5.25 0.25 4 10.00 1.25 6.19 1/16 8 3/4 0.88 7.88 1.50 5.75 0.25 5 11.00 1.38 7.31 1/16 8 3/4 0.88 9.25 1.50 7.00 0.25 6 12.50 1.44 8.50 1/16 12 3/4 0.88 10.62 1.50 8.12 0.25 8 15.00 1.62 10.62 1/16 12 7/8 1.00 13.00 1.62 10.25 0.25 10 17.50 1.88 12.75 1/16 16 1 1.12 15.25 1.88 12.62 0.25 12 20.50 2.00 15.00 1/16 16 1 1/8 1.25 17.75 2.12 14.75 0.25 14 23.00 2.12 16.25 1/16 20 1 1/8 1.25 20.25 2.12 16.75 0.25 16 25.50 2.25 18.50 1/16 20 1 1/4 1.38 22.50 2.25 19.00 0.25 18 28.00 2.38 21.00 1/16 24 1 1/4 1.38 24.75 2.25 21.00 0.25 20 30.50 2.50 23.00 1/16 24 1 1/4 1.38 27.00 2.25 23.12 0.38 24 36.00 2.75 27.25 1/16 24 1 1/2 1.62 32.00 2.75 27.62 0.38
ASME/ANSI B16.5 – 300lb RATING - STEEL
*NOTE:
The standard for Ductile Iron flanges is ASME/ANSI B16.42 150lb and 300lb rating. They are dimensionally the same as ASME/ANSI B16.5 including the raised face. The standard for Copper Alloy flanges is ASME/ANSI B16.24 150lb and 300lb rating. They are dimensionally the same as ASME/ANSI B16.5 except they are FLAT FACE.
se Cti ON 2 PUMP sPECIFIC at Ion an D oPER at Ion Contents 3 4
28
sECtIon 3
PUMP InstallatIon
Fixed pumps must be securely anchored to firm foundations. Pumps must be accurately levelled with shafts, coupling faces and flange faces truly horizontal or vertical (as appropriate). The pump and driver shafts should be truly in line in all senses and checks and requisite adjustments should be made by means of wedges and shims both in initial setting-up and after grouting in and tightening down.
Foreign matter must be prevented from ingress to liquid openings, bearings, etc., and external pipe-bores ensured clean before connecting. Pipework must be brought up to pump orifices, and independently supported, so as not to impose any weight or strain on the pump when connected. Make sure at all stages that the pump will turn freely. For fuller particulars see specific instructions as supplied with pumps.
sECtIon 4
PUMP oPERatIon
SPP’s Field service engineers can provide a full commissioning service for a wide range of pumps. Contact your local SPP office for details
• Check all guards are fitted correctly before starting the pump • Make sure pump will turn freely
• Check driver and pump rotations agree, with driver uncoupled • Make sure bearings are adequately charged with clean lubricant • Check stuffing boxes are packed and correctly adjusted
• Make sure any external lubricating, cooling, sealing, etc., services and connections are turned on and operative
• Make sure pump is effectively primed before starting up
• Check that pump runs without undue overheating, noise or vibration: otherwise refer to detailed operating instructions for possible defects and rectify accordingly
• On no account must a pump be allowed to continue running unprimed, or with a closed discharge valve
• On no account should a pump be regulated by closing a valve on the suction side
Contents
Potential Fault or Defect:
No liquid delivered. Insufficient liquid delivered. Liquid delivered at low pressure. Loss of liquid after starting. Excessive vibration.
Motor runs hotter than normal.
PRobablE CaUsEs
• Pump not primed.
• • • Speed too low.
• • Speed too high. • • • • • 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.
• Not enough head for hot liquid. • • • • • Inlet pipe not submerged enough.
• • • Viscosity of liquid greater than rating. • Liquid density higher than rating. • • • • • Insufficient nett inlet head.
• • • Impeller blocked.
• • • Wrong direction of rotation. • • Excessive impeller clearance.
• • • Damaged impeller.
• Rotor binding. • Defects in motor.
• Voltage and/or frequency lower than rating. • Lubricating grease or dirty oil or contaminated. • Foundation not rigid.
• • • Misalignment of pump and driver.
• Bearing worn.
• • Rotor out of balance. • • • Shaft bent.
• Impeller too small.
sECtIon 5
Excessive noise from pump cavitation. Pump bearings run hotter than normal.
29 FaUlts anD REMEDIal aCtIon
SPP’s service division can carry out fault identification and rectification on a wide range of pumps. Contact your local SPP office for details se Cti ON 3/4/5 PUMP sPECIFIC at Ion an D oPER at Ion Contents 3 4
30
CAUSE REMEDIAL ACTION
Pump not primed. Fill pump and suction pipe completely with fluid.
Speed too low. Check that the motor is correctly connected and receiving the full supply voltage also confirm that the supply frequency is correct.
Speed too high. Check the motor voltage.
Air leak in suction pipework. Check each flange for suction draught, rectify as necessary. Air leak in mechanical seal.
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.
Air or gas in liquid. It may be possible to increase the pump performance to provide adequate pumping.
Discharge head too high (above rating).
Check that valves are fully open and for pipe friction losses. An increase in pipe diameter may reduce the discharge pressure.
Suction lift too high.
Check for obstruction of pump inlet and for inlet pipe friction losses. Measure the static lift, if above rating, raise the liquid level or lower the pump.
Not enough head for hot liquid. Reduce the positive suction head by raising the liquid level. Inlet pipe not submerged
enough.
If the pump inlet cannot be lowered, provide a baffle to smother the inlet vortex and prevent air entering with the liquid.
Viscosity of liquid greater than rating.
Refer to SPP Pumps Ltd for guidance to increase the size or power of the motor or engine.
Liquid density higher than rating.
Refer to SPP Pumps Ltd for guidance to increase the size or power of the motor or engine.
Insufficient nett inlet head. Increase the positive suction head by lowering the pump or raising the liquid level.
Impeller blocked. Dismantle the pump and clean the impeller.
Wrong direction of rotation. Check driver rotation with the direction arrow on the pump casing. Excessive impeller clearance. Replace the impeller when clearance exceeds the maximum adjustment. Rotor binding. Check for shaft deflection, check and replace bearings if necessary. Defects in motor. Ensure that motor is adequately ventilated. Refer to manufacturers’
instructions. Voltage and/or frequency lower than rating.
If voltage and frequency are lower than the motor rating, arrange for provision of correct supply.
Lubricating grease or oil dirty or contaminated.
Dismantle the pump, clean the bearings, reassemble the pump and fill with new grease or oil.
Foundation not rigid. Ensure that the foundation bolts are tight, check that foundations match SPP Pumps Ltd recommendations.
Misalignment of pump and
driver. Realign the pump and driver as specified.
Bearings worn. Remove the bearings, clean and inspect for damage and wear, replace as necessary.
Rotor out of balance. Check impeller for damage, replace as necessary. Shaft bent. Check shaft run-out and replace if necessary. Impeller too small. Refer to SPP Pumps Ltd for options to fit a larger impeller. SPP’s service division can carry out fault identification and rectification on a wide range of pumps. Contact your local SPP office for details
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31
sECtIon 6
VIbRatIon tolERanCE
In every pump there are dynamic forces of hydraulic or mechanical origin that will inevitably lead to a certain level of vibration. To maintain the integrity of the pump unit and associated equipment the level of vibration must be kept within certain limits.
acceptance Criteria
The following table defines the maximum allowable level of vibration measured in mm/s RMS overall velocity during a factory acceptance test. It should be noted that the factory acceptance test is not necessarily an accurate representation of the vibration on site, when the unit is grouted in with permanent pipe supports etc.
Pump Classes
Class 1 pumps will only include those that have been designed in full accordance with A.P.I. 610, for use in critical applications. None of the standard ranges of SPP fall into this class and pumps that meet it are only available on an engineered to order basis.
Class 2 pumps will include all SPP general purpose industrial designs apart from those specifically identified as class 3 below.
Class 3 pumps shall include any pumps with less than three impeller vanes, split case pumps of the “through bore” type and any unit driven by a diesel engine of four or more cylinders. (Refer to SPP Engineering for units driven by engines of three or less cylinders).
application / Class Class 1 Class 2 Class 3
Continuous operation over the preferred operating range
3.0 4.7 7.1
Continuous operation over the allowable operating range
3.9 5.6 9.0
Intermittent operation over the allowable operaing range Not applicable 9.0 13.0 se Cti ON 6 PUMP sPECIFIC at Ion an D oPER at Ion Contents 3 4
32 Method
Vibration measurements will be made on the pump bearing housings, as close as is practical to the bearing positions.
For each bearing position two measurements will be taken perpendicular to the pump rotation axis. In addition an axial measurement will be taken at the thrust bearing position.
The measurements will be of velocity, overall RMS values, in mm/s. In order to reliably achieve the stated acceptance limits the pump must be rigidly restrained, aligned to the driver within the coupling makers recommendations, operating without cavitation or air entrainment. Pipe work must be arranged to provide straight uniform flow into the pump and be connected and anchored so as avoid strains and resonance.
SPP’s field service engineers can undertake vibration analysis. Contact your local SPP office for details
Contents
33
sECtIon 7
ConDItIon MonItoRIng
In order to minimise the ownership costs of capital equipment, it is critical for the user to monitor and maintain the equipment once installed. Failure to do so will impact both on the mechanical integrity and economic performance of the installed equipment.
Early diagnosis of potential equipment failure can result in considerable repair cost savings and crucially a reduction in unplanned downtime. Monitoring of pump energy consumption and system efficiency will bring visibility to pump wear, operating efficiency and highlight any system irregularities. All of these factors will help minimise energy consumption and reduce operating costs.
The SPP condition monitoring systems can provide this level of security by detecting, analysing and evaluating key equipment performance. These include the following:
• Performance/Efficiency degradation • Bearing vibration levels
• Bearing element damage • Bearing operating temperatures • Driver alignment condition • Residual unbalance • Cavitation
The system provides considerable flexibility in the display and use of the diagnostic output. The options include web based user configurable dashboard for live and trend data, automatic notification of alerts by text or email and local download of data to PC for detailed evaluation.
se Cti ON 7 PUMP sPECIFIC at Ion an D oPER at Ion Contents 3 4
34
sECtIon 8
FloW EstIMatIon MEthoDs
Many pumping systems are fitted with permanently installed flowmeters which enable a reasonably accurate measurement of system flow to be obtained. Where permanent flowmeters are not installed, it is often possible to use external clamp-on meters, insertion meters or thermodynamic testing equipment to determine system flow. However, it is not always practical to use these devices – either for financial reasons or system layout constraints – and where this is the case, alternative indirect methods need to be used for estimating system flow.
There are a number of methods available to enable an estimation of flow to be made in the field. Each of these methods requires some form of knowledge of the system or the pump, and all have inherent inaccuracies of varying degrees. However, in the absence of any more accurate flow measuring apparatus, these can be the only alternatives available.
There are four main indirect methods of determining pump flow in the field: • Pressure method
• Power method • Drop test
• Suction pressure measurement
The Pressure and Power methods require the use of the pump curve, whilst the drop test requires sump geometry and level details.
PREssURE MEasUREMEnt
This is the more accurate and simplest of the four methods, requiring suction and delivery pressure gauge readings, a copy of the pump performance curve at the correct operational speed and knowledge of the impeller diameter. Determine the differential head across the pump by subtracting the suction head from the discharge head. Then use the pump performance curve to obtain the pump flow at the measured head and impeller diameter. For example, if the suction head is measured as 3m and the discharge head as 63m, the pump differential head is 60m. Using the pump manufacturers original test curve for the pump, the flow can be estimated as 150 l/s.
Contents
35 Over time, a pump’s Flow/Head curve will change as wear occurs within the pump. Therefore, the accuracy of this method will tend to reduce as the pump gets older. However, this will remain a more accurate method than the others detailed below.
Where existing installed site gauges are used, it should be remembered that their accuracy may be far from ideal.
Remember that the pump Q/H curve is based on differential head, normally pumping water with an SG of 1. If the site liquid being pumped has an SG other than 1, SG correction should be applied to the site pressure readings to match the performance curve being used.
PoWER MEasUREMEnt
Power meters are rarely available on site, but amps (I) and volts (V) are commonly displayed at the control panel. These readings can be used to calculate power, although this also requires motor efficiency and power factor data - which will need to be estimated if motor manufacturers information is not available.
Power (kW) = (1.732 x I x V x eff x pf)/1000
Using this equation, the pump power can be calculated and from this, the flow can be read off the pump curve.
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36
Reading across the power scale on the pump manufacturers curve, the flow at this absorbed power can be obtained – 150 l/s in this example.
As mentioned above, a pump’s Flow/Head curve and efficiency curve will change as wear occurs within the pump. This will affect the pump’s power curve and therefore, as with the pressure measurement method, accuracy will tend to reduce as the pump gets older.
It should also be remembered that the installed instruments from which readings are taken may themselves be inaccurate, as it is unlikely that they will not have been calibrated to any significant accuracy since their original installation.
As an alternative to the above calculation, taking a simple current ratio (actual current/full load current) and applying it to the motor rated power can give a reasonable estimation of the motor output power. In the above example, assuming a 132kW motor with a full load current of 230A, this method would result in a duty power of (165/230)*132 = 95kW, and a resultant flow of around 135 l/s.
For example, if the current is read as 165A, the voltage as 400V and motor efficiency and pf from manufacturers’ data are 95% and 0.92 respectively, the calculated power becomes: Power = (1.732 x 400 x 165 x 0.95 x 0.92)/1000 = 100kW Contents 3 4
37 Although the power method can be used very effectively in situations where a quick approximate on site estimate is required, it should not be applied to high specific speed pumps such as vertical turbine or mixed flow pumps, whose power curves can follow significantly different rules.
DRoP tEst
This is the least accurate method, and requires knowledge of sump dimensions and levels. It is often used on sewage pump installations, where sump emptying occurs over a relatively short period of time.
In this method, the time taken for a pump to lower the sump level over a known depth is recorded. The volume of liquid pumped is then calculated based on the sump level change and the sump area, and is divided by the time taken to arrive at a volume flow rate.
For example, if a sump has dimensions of 4m x 3m, and the level is reduced by 1m over a time period of 10 minutes, the average pump flow is (4 x 3 x 1)/10 = 1.2 m3/min, or 72 m3/h
This method has a number of inherent inaccuracies:
• During the drop test, it is likely that flow will continue to enter the sump. This will affect the result – the extent of the effect will depend upon the rate of inflow in proportion to the outflow.
• The sump may not have a uniform section, making volume calculation less accurate.
• As the level is lowered, the total head on the pump changes which will affect the pump output. Any resultant calculation will only give an average flow over the range of heads.
• Measurement of pumped depth may be difficult if there is no installed measuring equipment.
sUCtIon PREssURE MEasUREMEnt
In most pumping stations, it is possible to obtain a pressure reading on the suction side of the pumps. The velocity and friction head components of this reading can be used to estimate the flow. To use this method, it is necessary to know the pressure drop on the pump suction (static suction pressure - operational suction pressure), the type and number of pipe fittings up to the pressure measurement point and fittings diameter. An estimation of the fittings friction (K) factor is also required.
se Cti ON 8 PUMP sPECIFIC at Ion an D oPER at Ion Contents 3 4
38
Convert the suction pressure drop (P in kPA) into a head drop (Zd in meters) using the equation:
Zd = P x 0.102 sg
(note that this Zd calculation will change depending on your site measured units) Obtain a total K factor for the suction fittings up to the measurement point. Assuming there are no significant straight pipe losses in the suction, the following equation can then be used to determine the flow velocity:
Zd = V2 x (1+K)
2g
Once the velocity is known, the flow rate can be calculated using the suction diameter. This method can be adapted to suit a wide variety of suction and pump configuration and the available locations for pressure measurement.
Although there are potential inaccuracies in determining K factors and internal diameters, careful use of this method can allow the velocity to be estimated to within a few percent.
ConClUsIon
There is no single simple and accurate method of determining flow in systems where installed meters are not present, or where the use of alternative temporary flow metering equipment cannot be fitted. Instead there are a number of methods that can be utilised to obtain an approximate pumping rate, which in many cases may be sufficient for the purposes required.
All these methods have limitations and inherent inaccuracies. Where these methods need to be employed, it is worthwhile applying at least two methods to get comparative results.
Contents
39 39
sECtIon 9
aPPlICatIon Do’s anD Don’ts suction & Delivery Piping
Ensure that bolt grouting or chemical anchors are allowed to dry thoroughly before connecting any pipework.
Note that fire pumpsets have regulatory requirements for piping and these must be strictly observed. Refer to the appropriate standard for details. Both suction and discharge piping should be supported independently and close to the pump so that no strain is transmitted to the pump when the flange bolts are tightened. Use pipe hangers or other supports at intervals necessary to provide support. When expansion joints are used in the piping system, they must be installed beyond the piping supports closest to the pump.
Install piping as straight as possible, avoiding unnecessary bends. Where necessary, use 45º or long sweep 90º bends to decrease friction losses.
Eccentric Reducer on a Split Case Pump
Typical End Suction Pump Piping Installation se Cti ON 9 PUMP sPECIFIC at Ion an D oPER at Ion Contents 3 4
40
Make sure that all piping joints are airtight. Where reducers are used, eccentric or ‘flat top’ reducers are to be fitted in suction lines and concentric or straight taper reducers in discharge lines. The length of eccentric reducers should be about four times the pump suction diameter. Undulations in the pipe runs are also to be avoided. Failure to comply with this may cause the formation of air pockets in the pipework and thus prevent the correct operation of the pump and measuring equipment.
The suction pipe should be as short and direct as possible, and should be flushed clean before connecting to the pump. For suction lift applications, it is advisable to use a foot valve. Horizontal suction lines must have a gradual rise to the pump. If the pumped fluid is likely to contain foreign matter then a filter or coarse strainer should be fitted to prevent ingress to the pump.
The discharge pipe is usually preceded by a non-return valve or check valve and a discharge gate valve. The check valve is to maintain system pressure in case of stoppage or failure of the driver. The discharge valve is used to prevent back flow when shutting down the pump for maintenance.
CoUPlIng alIgnMEnt
Periodical checks of shaft alignments should be undertaken and if necessary adjusted accordingly. In order to maintain the warranty status of your SPP pump it is recommended to take out an SPP preventative maintenance contract. SPP’s field service engineers have extensive experience in pump and coupling alignment. Refer to the pump and coupling
instruction manuals for details of shaft alignment procedures and tolerances or proceed generally thus: a) Lateral Alignment
Mount a dial gauge on the motor shaft or coupling with the gauge running on the outer-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 to the
outside diameter as possible. Turn the motor shaft and note the total indicator reading at top & bottom and each side.
Contents
41 c) Confirm Lateral Alignment
Mount the dial gauge on the pump shaft or coupling with the gauge running on the machined outer 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 to the coupling manufacturer’s specifications.
note:
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 driver mounting positions.
EngInE DRIVEn PUMPs
Air is required for combustion and cooling purposes, with air and radiator cooled engines in particular needing large volumes of air for cooling. Inlet and outlet apertures, suitably sized and positioned to prevent air recirculation, must be provided in the pump house structure. It is recommended that a low level vent be matched by a high level vent in the opposite wall.
Exhaust runs should be as short as possible. Small bore pipe and/or excessive length will cause backpressure on the engine, reducing engine performance and therefore pump output.
Engine driven fire pumps should not be left unattended whilst undertaking weekly test runs. The run-to-crash design of fire pump engines makes it essential to that they are commissioned by experienced personnel to avoid permanent damage. SPP offers fixed price fire pump commissioning services
PRE-CoMMIssIonIng ChECK
If SPP Pumps Ltd is contracted to carry out the commissioning, the following check list shows items to be completed before the commissioning engineer arrives.
sPP CoMMIssIonIng sERVICEs
SPP use qualified engineers to maintain approved systems, warranty and approved parts. se Cti ON 9 PUMP sPECIFIC at Ion an D oPER at Ion Contents 3 4
42
ChECK lIst
1 Installation:
• Mounting plinths comply with instructions for size, construction and location
• The baseplate has been accurately levelled and adequately supported. This prevents distortion and makes achievable the final shaft alignment to within manufacturers specification
• The fixing bolts are grouted as instructed and tightened to the required torque
• The shaft alignment has been checked and set to within the stated tolerances.
2 Suction and delivery pipework is adequately supported and NEGLIGIBLE forces are transmitted to the pump casing.
3 Where applicable, all drain, minimum flow, and test pipelines are fitted, together with valves gauges and flow meters.
4 The diesel engine exhaust has been fitted in line with recommendations. 5 The engine fuel tank is filled with sufficient fuel.
6 Batteries are filled and charged in accordance with the manufacturer’s instructions.
7 All wiring to controls and to remote alarm panels is completed in line with appropriate regulations & power supplies are connected.
8 The area is clear of all builders’ material and rubbish to allow access to the pumps.
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43
hyDRaUlIC
DEsIgn Data
Contents
44
sECtIon 10
PREssURE (
bar
) Vs hEaD (m
oF WatER)bar 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0.00 0.00 1.02 2.04 3.06 4.08 5.10 6.12 7.14 8.16 9.18 1.00 10.19 11.22 12.24 13.26 14.28 15.30 16.32 17.33 18.35 19.37 2.00 20.39 21.41 22.43 23.45 24.47 25.49 26.51 27.53 28.55 29.57 3.00 30.59 31.61 32.63 33.65 34.67 35.69 36.71 37.73 38.75 39.77 4.00 40.79 41.81 42.83 43.85 44.87 45.89 46.91 47.93 48.95 49.97 5.00 50.99 52.00 53.02 54.04 55.06 56.08 57.10 58.12 59.14 60.16 6.00 61.18 62.20 63.22 64.24 65.26 66.28 67.30 68.32 69.34 70.36 7.00 71.38 72.40 73.42 74.44 75.46 76.48 77.50 78.52 79.54 80.56 8.00 81.58 82.60 83.62 84.64 85.65 86.67 87.69 88.71 89.73 90.75 9.00 91.77 92.97 93.81 94.83 95.85 96.87 97.89 98.91 99.93 100.95 10 20 30 40 50 60 70 80 90 100 bar 101.97 203.94 305.91 407.88 509.85 611.82 713.79 815.76 917.73 1019.70 metres Contents 3 4
45 ExaMPlE
Find the metres head of water (1.0 s.g.) equivalent of 54.76 bar
From bottom two lines: 50.00 bar = 509.85m
Select ‘4 bar’ line in first column and read along to figure under 0.7 in top line, hence:
4.70 bar = 47.93m
For 0.06 bar, read under 0.6 top line: hence 6.12m dividing both figures by 10:
0.06 bar = 0.612m
thus by addition 54.76 bar = 558.392m
note:
For liquids with specific gravities differing from 1.0, answer must be divided by actual specific gravity to obtain head in metres of liquid.
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46
sECtIon 11
CalCUlatIon oF hEaD FoR PUMP sElECtIon
To fulfill a pumping duty a pump must develop sufficient head and meet the suction conditions. The total head of a system must take into account the difference in liquid levels at inlet and outlet, friction in the pipes, surface pressure (or in some cases vacuum) on inlet and outlet and the velocity of the fluid at discharge. The following diagram and example explains how to calculate the system head taking all these factors into account.
• hd = total discharge head • hsd = discharge static head
• hpd = discharge surface pressure head • hfd = discharge friction head • hvd = discharge velocity head
System head = total discharge head - total suction head
H = hd – hs
The total discharge head is made from four separate heads:
hd = hsd + hpd + hfd + hvd
Contents
47 The total suction head consists of four separate heads
hs = hss + hps - hfs - hvs • hs = total suction head • hss = suction static head
• hps = suction surface pressure head • hfs = suction friction head
• hvs = suction velocity head
Example
Calculate the total head of the following pump system. The total friction through suction pipes and fittings is equivalent to 1m head and through delivery pipes and fittings is equivalent to 10m head.
The header tank and discharge pipe is open to atmosphere at sea level.
The suction velocity head is 0.1m and the discharge velocity head is 0.5m
Pumped fluid is cold clean water.
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48
First we calculate the total delivery head, hsd and hss – from the diagram we can see that the discharge static head is 40m and the suction static head is 5m hpd –
millimeters of mercury x = meters of liquid
pressure at sea level is approx. 760mm Hg, specific gravity of cold clean water
is 1, so 760 x 0.014/1 = 10.6m
so hpd is 10.6m, the header tank is also open to atmosphere so hps is also 10.6m hd = hsd + hpd + hfd + hvd = 40 + 10.6 + 10 + 0.5 = 61.1 m hs = hss + hps - hfs - hvs = 5 + 10.6 - 1 - 0.1 = 14.5 m
Total system head H = hd – hs
= 61.1 – 14.5
= 46.6 m
note:
Gauge readings need correcting for height of gauge mounting. For this purpose it is important that pressure gauges should be full of liquid. Where a vacuum gauge is used for a suction lift, the gauge pipe should be left empty and correction made from the point of connection, not from the gauge itself.
0.014 specific gravity
Contents
49 aUtoPRIME PUMPIng tERMs
head
“Total Head from all Causes” is the combination of both “Total Suction Head and “Total Discharge Head”.
When static heights are kept to a minimum and pipework of the correct size for the pump is used, performance will be maintained and running costs minimised.
Suction head will be affected by changes in liquid viscosity and specific gravity and in the vapour pressure resulting from increased liquid temperature.
net Positive suction head (nPsh)
NPSHr: minimum liquid head (pressure) required by the pump at the impeller to pump the liquid, this is determined by the pump design. NPSHa: minimum liquid head (pressure) available from the atmosphere to deliver the liquid to the impeller for pumping.
Example:
NPSHa (Available) 10.5 m
less Static Lift 3.0 m
Friction & Vapour Loss 1.5 m
NPSHr (Required) 2.0 m
therefore leaving for suction lift 4.0 m
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50
tyPICal sUCtIon lIFt ConFIgURatIon
AUTOPRIME TOTAL HEAD FROM ALL CAUSES Total Discharge Head Discharge Hose Friction Static Delivery Head Static Suction Lift Suction Hose Friction Contents 3 4
51
sECtIon 12
FRICtIon loss FoR WatER (m/100m) In sMooth anD nEW UnCoatED stEEl PIPEs (haZEn-WIllIaMs FoRMUla, C=140) NB Figures assume actual bores exactly equal to nominal bores. See following notes regarding corrections for actual bores of commercial pipes differing from nominal bores. l/s bore 20(3/4) 25(1) 0.1 0.83 0.28 32(1 3/4) - -0.2 3.0 1.0 0.30 40(1 1/2) -0.5 16.4 5.5 1.66 0.56 50(2) 1 65(2½) 20.0 6.0 2.0 0.68 1.5 0.4 80(3) 12.7 4.3 1.45 2 0.68 0.25 21.6 7.3 2.5 3 1.45 0.53 100(4) 15.5 5.2 4 2.5 0.90 0.30 26.4 8.9 5 3.8 1.36 0.46 125(5) 13.4 6 5.2 1.9 0.64 0.22 18.8 7 6.9 2.5 0.84 0.29 150(6) 8 8.9 3.2 1.10 0.37 0.15 9 11.1 4.0 1.36 0.46 0.19 10 13.4 4.9 1.66 0.55 0.23 12 175(7) 6.9 2.3 0.78 0.32 14 0.20 9.1 3.1 1.04 0.43 16 0.26 11.7 4.0 1.33 0.55 18 0.32 200(8) 4.9 1.65 0.68 20 0.39 0.20 6.0 2.0 0.83 25 0.59 0.31 9.0 3.0 1.25 30 0.83 0.43 225(9) 4.3 1.76 35 1.10 0.58 0.32 5.7 2.3 40 1.41 0.74 0.42 7.3 3.0 45 1.76 0.92 0.52 250(10) 3.7 50 2.1 1.11 0.63 0.38 4.5 60 3.0 1.56 0.88 0.53 6.3 70 4.0 2.1 1.17 0.70 300(12) 80 5.1 2.7 1.50 0.90 0.37 90 6.3 3.3 1.87 1.12 0.46 100 4.0 2.3 1.36 0.56 120 5.6 3.2 1.90 0.78 140 7.5 4.2 2.5 1.04 160 5.4 3.2 1.33 180 6.7 4.0 1.65 200 8.2 4.9 2.0
Nominal and actual bores of pipes in mm width with nominal inch equivalents.
se Cti ON 12 hy DR aU lIC DE sIgn D at a Contents 3 4
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For other types of pipe, multiply foregoing figures as below, for pipes in smooth and new condition.
Galvanised iron 1.33
Uncoated cast iron 1.23
Coated cast iron, wrought iron, coated steel 1.07
Coated spun iron 1.04
Smooth pipe (lead, brass, copper, stainless steel, glass, plastic) 0.88
Friction losses are affected to an even greater degree by deviations of actual bore from the standard dimensions represented in the foregoing table. To correct for actual bore, multiply also by
(D/d)4.87
Where D = Standard (nominal) bore. d = Actual internal diameter.
Multiplying factors for grey iron pipes to BS 4622 (both sand mould cast and spun): ductile iron pipes to BS 4772: and uPVC pipes to BS 3505 taking into account the corrections both for type of pipe and for actual bore, are as follows on the next page.
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