Axially Split-case Large Capacity Custom Made . - Flowserve

TKL SCAxiallySplit-caseLarge CapacityCustom MadeCentrifugalWater Pumps

Pump DivisionCompany In 2004 Flowserve Pump Division (FPD) acquired Thompsons, KellyProfile & Lewis Pty. Ltd. (TKL) which was formed in 1987 by the merger oftwo long-established pump companies, Thompsons at Castlemaine(Vic) and Kelly & Lewis in Melbourne. FPD is a division of FlowserveCorporation of the USA, a global company manufacturing centrifugalpumps, mechanical seals and control valves, and with pumpoperations in many countries.These well-known TKL SCpumps are used extensivelyin Australia and the AsianPacific area for applicationsinvolving the transfer andboosting of large volumeflows of water, for watersupply, power station, andother industrial services.Project EngineeringFlowserve Pump Division isexperienced in theadministration and supply ofcomplete turnkey pumpmechanical and electricalinstallations. We undertakeerecting and commissioningwork with our fully qualifiedfield engineering staff.Package pumping projectswhich include the supply ofancillary items such asmotors, switchgear, valves,pipework, steelwork, etc., area specialty of the company.Test FacilitiesOur extensive testing facilitiesallow pumps to be set-up fortesting in closed loops, undersuction lift or with boosterpumps. Acceptance tests offinished pumps can becarried out in our testlaboratory to StandardsAustralia andInternational Standardsorganisation testingstandards. Outcome oftests are analysed bycomputer and fullytabulated results can beprovided.The main test area isequipped with flowmeasuring equipmentup to a maximumflow rate of7000 litres/secondand the electricalsupply is suitable forelectric motors up to4.1 MW at 6.6 kV, and3.7 MW at 11 kV.

Pump DivisionOperating RangeModel Testing50 HZ – TKL SC Pumps Flow to 5000 L/s(18000 m3/h) Head to 200 m (660 feet) Temperature to 150 C Working pressure to2500 kPa Power Range to 5000 kWand larger Flange branch sizes to1200 mm (48") and largerFlowserve Pump Divisionhas experience in designingmodel tests and developingprototypes (scale models) toprove performance prior tothe manufacture of a largepump. Of vital importanceare sump model studies toensure that an intakestructure has suitablehydraulic characteristics forthe pump suction, andmechanical stiffness tosupport the pumpmachinery.Quality AssuranceQuality control is applied toproduct design andmanufacturing. The Flowservequality assurance systemcomplies with the ISO9000Standard, and Flowserve iscertified by the AustralianDepartment of Defence as aaccredited supplier.Tests are carried out to: eliminate the formation ofair-entraining vortices confirm that air entrained atthe base of the sump wouldnot be be drawn into thepumps ensure uniform steadyeddy-free flow to the pumpintakes eliminate stagnant areaswhere silt could accumulate eliminate resonantmechanical vibrations inthe structureVOLUMETRIC FLOW RATE – USgpm300Range Chart800Over 50 differentTKL SC pumpsizes are availableto meet yourhydraulicrequirements.600500 6004008001000200030004000 5000 60008000 100002000030000 400006000080000 100000200050015004001000300TYPE SC – 60 Hz800200600500400300TYPE SC – 50 Hz8020060504010030Refer to Super-Titan 50 Hz rangefor selection in this 00500 6008001000200030004000 5000 60008000 10000VOLUMETRIC FLOW RATE – LITRES PER SECOND5010020030040050060080010002000VOLUMETRIC FLOW RATE – m3/h30004000 5000 60008000100002000030000TOTAL HEAD – FEET LIQUIDTOTAL HEAD – METRES LIQUID100

Pump DivisionTypical PumpSectionsConstructionThe TKL SC range of pumps isbuilt to well-proven designs inaccordance with recognisedindustry standards.Reliable operation is derivedfrom low velocities in dischargebranch and the shaft andbearings are sized for minimumdeflection and for low stresses.The pumps are axially split-case,single stage, double suctiondesign. The can be supplied inhorizontal or verticalconfiguration, and withrotation to suit a pumpstation layout. Doublevolute hydraulic designs areemployed to minimise radialshaft loads and to provide extracasing stiffness. Our currentdesigns incorporate manyimprovements in mechanicaland hydraulic characteristics.These include hydraulicefficiency exceeding 90%,increased suction lift capacity,extra large suction branch, wellproven stuffing box layout withthe option of mechanical sealsand advanced bearing design.Every TKL SC pump is customengineered to fit the duty andoperating conditions specifiedby the customer, and issubjected to a complete full loadtest before leaving our plant.There are many constructionand design features, and themajor ones are:balance. Internal surfacesare dressed as necessaryto give a smooth surfaceto passages and vanes.Optional open-typeimpeller for paper pulp.CasingBearingsAxially split-case, with suctionand discharge branches locatedin the lower half casing.Double volute design (not usedin all models) balances radialload and minimisesdeflection.Removal of upper halfcasing permits inspection,maintenance and withdrawal ofrotating element.Anti-friction bearings orsleeve bearings withspecial thrust bearing,either grease or oil ringlubricated to suit theoperating conditions andavailability of services.The bearing housings aredesigned to prevententrance of moisture ordirt and are provided withmonitoring connections.ImpellerEnclosed, double-suction withvane shapes to ensure goodsuction performance against lowN.P.S.H. values, and to ensuremaximum axial hydraulicWear RingsPumps are fitted withrenewable casing wearrings, and whenpreferred, the impellercan also be fitted withwear rings.Shaft and SleevesShaft sleeves withO-rings, fully protectshaft of ample size tooperate below first criticalspeed.Stuffing BoxesProvided as standardwith soft packing,removable lantern ringsand renewable stuffingbox throat bushings andgland adjustment. Thestuffing boxes can acceptalternative manufacturersmechanical seals inaccordance with dutyrequirements andcustomer preference.

MaterialsMaterials for the TKL SC pumps are chosen to suitthe specific application. Typical materials for normalduties are all iron, bronze fitted or all bronzeconstruction, with ni-resist, steel and stainless steelfor special conditions.Materials may be produced to Australian,International and American specifications.Stuffing BoxesMaybe of the conventionalsoft-packing type withadjustable glands arrangedfor either product, water orgrease sealing.Various alternativemechanical seals can befitted, and connections areprovided for productcirculation and/orother necessaryservicerequirements.Wear RingsSeveral populardesigns of casing andimpeller (optional)wear rings are shown.For high pressuresealing the throttlingsurface can bestepped, or groovedrather than continuous flat.BearingsJournal or sleevebearings are of thebush type,horizontal split andwhite metal lined.Residual endthrust is taken by adouble thrust bearingfitted in the nondrive end housing.Oil retention anddirt exclusion devices areincorporated. Lubricationis arranged to suit theoperating conditions andavailability of services.Applications Water Supply Waste water / Effluent treatment Heavy Industry / Steel Mills / Paper Mills General Industry / Sugar Mills / FertilizerPlants Power Generation Irrigation Systems Mining IndustryProjectsOverleaf are some of the projects undertaken byFlowserve Pump Division, and serve toillustrate the scope and diversity of TKL SCsplit-case pump installations.Flowserve puts into practice a philosophy offlexible product design which benefit thecustomer with optimum performance in theapplication concerned.

Pump DivisionThe TKL SC custom madesplit-case pumps are anextension to the standardSuper-Titan split-case pumprange pictured left and as shownon range chart page 3.However, smaller TKL SCpumps are also availableto suit applicationswhen engineeredpumps with specialrequirements areneeded.11 Sugerloaf Reservoir PumpingStation, VictoriaTransfer of reservoir water totreatment plant. Three1000/1200 SDS-DV pumps.Duty 4500 L/s at 54 m head.Driver 2800 kW at 735 r/min.➋ ➌➍2 Bayswater Power Station,New South WalesCondenser cooling watermake-up service. Three 400/450CL pumps. Duty 500 L/s at 90 mhead. Driver 630 kW at1480 r/min.3 Stones Road PumpingStation, QueenslandUpgrading of local water supplysystem. Three vertical 500/500CLW pumps. Duty 750 L/s at30 m head. Driver 280 kW at960 r/min.4 Haughton No. 1Pumping Station,QueenslandLarge scale irrigationwater pumping. Two1000/1400 CDV pumps.Duty 3500 L/s at 17 mhead. Driver 750 kW at495 r/min.

Pump Division1 Yering Gorge PumpingStation, Victoria3 Yallourn ‘W’ Stage 2Power Station, Victoria1Pumping water from theYarra river into theSugarloaf reservoir. Fourvertical 900/1050 SDS-DVpumps. Duty 2900 L/s at130 m head. Drivers4725-5250 kW at735-745 r/min.Main circulating waterpumps for delivering waterto the condensers of theassociated turbo/generatorunits. Four 1200/1350 SDSpumps. Duty 4675 L/s at24.5 m head. Driver1300 kW at 490 r/min.2 Mundaring Weir ‘B’Pumping Station –Kalgoorlie Pipeline,Western Australia4 North Pine PumpingStation, QueenslandWater supply to the city ofBrisbane. Four vertical600/750 C pumps. Duty1052 L/s at 54 m head.Driver 780 kW at960 r/min.First booster station inO’Connor pipeline toSwayers valley high levelstorage tank. Five 250x300GME pumps. Duty 300 L/sat 227 m head. Driver955 kW at 1485 r/min.➋ ➌➍

Pump Division1 Forrestfield PumpingStation, Western Australia2 Sepp Outfall Pumping Station,VictoriaMains booster duties forwater supply to Perth. Two375/400 SCO two stagepumps and two 300/350SDS-ML pumps in series.Duty 300 L/s at 82-170 mhead. Drivers 400-700 kWat 1480 r/min.Pumping reconditioned waterthrough a 9.6 km raising mainto a gravity outfall, discharginginto Bass Strait some 60 kmaway. Five 900/1050 SDS-DVpumps. Duty 2800 L/s at 76 mhead. Driver 2600 kW at400-600 r/min.1➋3 Apsley PumpingStation, QueenslandPumping fresh water toreservoirs supplyingBrisbane with watersupply. Two vertical350/400, two 500/500and two 750/750 SDSpumps. Duties 550-600-1500 L/s at 33-9-16 mhead. Drivers225-75-300 kW at980-750-750 r/min.4 Lloyd Street PumpingStation, QueenslandInterchanges waterbetween the North Pineand Mount Crosby sourceof supply. Three750/750 SDS-DV pumps.Duty 795 L/s at 10.7 mhead. Driver 275 kW at740 r/min.➌➍10

Pump Division1Yallourn ‘W’ Stage 1Power Station, VictoriaMain circulating waterpumps for delivering waterto the condensers of theassociated turbo/generatorunits. Four vertical1200/1350 SDS pumps.Duty 4300 L/s at 23 m head.Driver 1120 kW at 495 r/min.2 Lantana BoosterPumping Station, NewSouth WalesWater supply boosting fromthe Lantana reservoir to theForster reservoir in theManning District WaterSupply AugmentationScheme. One 400/450 CLand one 400/400 C pump.Duties 520 L/s at 89 m and490 L/s at 112 m head.Drivers all 800 kW at1475 r/min.➋1➌3 Happy Valley Stage 2 WaterFiltration Plant, SouthAustraliaPumping filtered water toreservoirs and holding tanksin outer Adelaide suburbs.➍Four 380/380 CW pumps.Duties 300-375 L/s at63-78 m head. Driver280/410 kW at 1480 r/min.Two 200/250 CHH and two350/400 SDS-DV pumps.Duties 208-375 L/s at140-195 m head. Drivers440/1250 kW at 1480 r/min.4 Woodman Point WaterTreatment Plant, WesternAustraliaThe pumps receive treatedsewage and pump theeffluent to Point Peron. Two1000/1100 C pumps.Duties 2800-3080 L/s at59-74 m head. Driver2800 kW at 990 r/min.