TKL™ SCAxially Split-caseLarge CapacityCustom MadeCentrifugalWater Pumps

Pump Division

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 Standards

Australia andInternational Standardsorganisation testingstandards. Outcome oftests are analysed bycomputer and fullytabulated results can beprovided.

The main test area isequipped with flowmeasuring equipmentup to a maximum flow rate of7000 litres/second and the electricalsupply is suitable forelectric motors up to4.1 MW at 6.6 kV, and3.7 MW at 11 kV.

CompanyProfile

In 2004 Flowserve Pump Division (FPD) acquired Thompsons, Kelly& 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.

Pump Division

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.

Model TestingFlowserve 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.

Tests are carried out to:• eliminate the formation of

air-entraining vortices• confirm that air entrained at

the 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 structure

Operating Range50 HZ – TKL SC Pumps• Flow to 5000 L/s

(18000 m3/h)• Head to 200 m (660 feet)• Temperature to 150°C• Working pressure to

2500 kPa• Power Range to 5000 kW

and larger• Flange branch sizes to

1200 mm (48") and larger

VOLUMETRIC FLOW RATE – m3/h

VOLUMETRIC FLOW RATE – LITRES PER SECOND

VOLUMETRIC FLOW RATE – USgpm

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TYPE SC – 60 Hz

TYPE SC – 50 Hz

Refer to Super-Titan 50 Hz rangefor selection in this area.

Range ChartOver 50 differentTKL SC pumpsizes are availableto meet yourhydraulicrequirements.

Typical PumpSections

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 in

horizontal or verticalconfiguration, and withrotation to suit a pumpstation layout. Double

volute 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, well-proven 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:

Casing

Axially split-case, with suctionand discharge branches locatedin the lower half casing.Double volute design (not usedin all models) balances radial

load and minimisesdeflection.

Removal of upper halfcasing permits inspection,

maintenance and withdrawal ofrotating element.

Impeller

Enclosed, double-suction withvane shapes to ensure goodsuction performance against lowN.P.S.H. values, and to ensuremaximum axial hydraulic

balance. Internal surfacesare dressed as necessaryto give a smooth surfaceto passages and vanes.Optional open-typeimpeller for paper pulp.

Wear Rings

Pumps are fitted withrenewable casing wearrings, and whenpreferred, the impellercan also be fitted withwear rings.

Shaft and Sleeves

Shaft sleeves withO-rings, fully protectshaft of ample size tooperate below first criticalspeed.

Stuffing Boxes

Provided as standardwith soft packing,removable lantern ringsand renewable stuffingbox throat bushings andgland adjustment. Thestuffing boxes can acceptalternative manufacturersmechanical seals inaccordance with dutyrequirements andcustomer preference.

Bearings

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.

ConstructionThe TKL SC range of pumps isbuilt to well-proven designs inaccordance with recognisedindustry standards.

Pump Division

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 non-drive end housing.Oil retention anddirt exclusion devices areincorporated. Lubrication is arranged to suit theoperating conditions andavailability of services.

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.

Applications• Water Supply

• Waste water / Effluent treatment

• Heavy Industry / Steel Mills / Paper Mills

• General Industry / Sugar Mills / FertilizerPlants

• Power Generation

• Irrigation Systems

• Mining Industry

Projects Overleaf 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.

Applications• Water Supply

• Waste water / Effluent treatment

• Heavy Industry / Steel Mills / Paper Mills

• General Industry / Sugar Mills / FertilizerPlants

• Power Generation

• Irrigation Systems

• Mining Industry

Projects Overleaf 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 Division

1 Sugerloaf Reservoir PumpingStation, Victoria

Transfer 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.

2 Bayswater Power Station, New South Wales

Condenser cooling water make-up service. Three 400/450CL pumps. Duty 500 L/s at 90 mhead. Driver 630 kW at1480 r/min.

3 Stones Road PumpingStation, Queensland

Upgrading 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,Queensland

Large scale irrigationwater pumping. Two1000/1400 CDV pumps.Duty 3500 L/s at 17 mhead. Driver 750 kW at495 r/min.

The TKL SC custom made split-case pumps are anextension to the standardSuper-Titan™ split-case pumprange pictured left and as shown

on range chart page 3.However, smaller TKL SC

pumps are also availableto suit applicationswhen engineeredpumps with specialrequirements areneeded.

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Pump Division

1 Yering Gorge PumpingStation, Victoria

Pumping 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.

2 Mundaring Weir ‘B’Pumping Station –Kalgoorlie Pipeline, Western Australia

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.

3 Yallourn ‘W’ Stage 2Power Station, Victoria

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.

4 North Pine PumpingStation, Queensland

Water supply to the city ofBrisbane. Four vertical600/750 C pumps. Duty1052 L/s at 54 m head.Driver 780 kW at960 r/min.

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Pump Division

3 Apsley PumpingStation, Queensland

Pumping 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 at 980- 750-750 r/min.

4 Lloyd Street PumpingStation, Queensland

Interchanges 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.

2 Sepp Outfall Pumping Station,Victoria

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.

1 Forrestfield PumpingStation, Western Australia

Mains 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.

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Pump Division

1Yallourn ‘W’ Stage 1Power Station, Victoria

Main 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.

4 Woodman Point WaterTreatment Plant, WesternAustralia

The 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.

3 Happy Valley Stage 2 WaterFiltration Plant, SouthAustralia

Pumping filtered water toreservoirs and holding tanksin outer Adelaide suburbs. Four 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.

2 Lantana BoosterPumping Station, NewSouth Wales

Water 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.

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Pump Division

1 Elwick Booster PumpingStation, Tasmania

To extend the existingdomestic water supply toHobart. One 600/750 SDSpump. Duty 1157 L/s at80 m head. Driver 1175 kWwith variable speed to1000 r/min.

2 Bootawa Dam No. 2 PumpingStation, New South Wales

Raw water supply servicing theManning Water SupplyAugmentation Scheme via theWingham pipeline. Two 400/450CL pumps. Duty 770 L/s at 71 mhead. Driver 800 kW at1475 r/min.

3 Tarong PowerStation, Queensland

Condenser circulatingwater duties. Four1200/1400 SDS pumps.Duty 5100 L/s at 22 mhead. Driver 1300 kW at490 r/min.

4 South Dandalup Pump Station,Western Australia

Recharges (pump back)Lower South Dandalupdam with capturedspillway water. 700x800-850 SDS-DV pump. Duty1388 L/s at 209 m head.Driver 3500 kW at1489 r/min.

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Pump Division

treatment plant. One900x1100-890 CDV pump.Duty 2500 L/s at 40 mhead. Driver two speed1100 kW at 720 r/min and600 kW at 590 r/min.

3 Jugiong No. 1 PumpingStation, New South Wales

Upgrading of existing watersupply system nearGundagai. Two 375/400SDO two stage pumps. Duty380 L/s at 192 m head.Driver 850 kW at1485 r/min.

4 Monduran Dam PumpingStation, Queensland

The project suppliesirrigation water to the sugarcane industry in the drought-prone Bundaberg area. Three825/900 SDS-DV pumps.Duty 2570 L/s at 28 m head.Driver 750 kW at 728 r/min.

Back PageProspect Pumping Stations,New South Wales

Water supply Thornleighunits. Four 600/600 SC twostage pumps. Duty 980 L/sat 213 m head. Driver3000 kW at 1450 r/min.

1 Isis Main Pumping Station,Queensland

Water from the Burnett riveris pumped into a mainchannel for irrigation ofsugar cane fields in theBundaberg region. Twovertical 900/1000 CDVpumps. Duty 2500 L/s at70 m head. Driver 2000 kWat 895 r/min.

2 Hinze Dam PumpingStation, Queensland

Pumps water from HinzeDam to Molendinar Water

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ISO 9001 Lic 2685Standards Australia

Flowserve Pump DivisionA.B.N. 15 004 249 012

26 Faigh Street Mulgrave Victoria 3170 AustraliaTel +61 3 9562 0744 Fax +61 3 9562 2816Internet: www.tkl.com.au

For further information, sales, service or technical assistance,consult your telephone directory for nearest sales office:AUSTRALIA Adelaide Brisbane Melbourne Perth SydneyNEW ZEALAND Auckland ChristchurchTM – Trademark owned by Flowserve Pump DivisionAlteration Rights Reserved Publication TKL SC/2.1 February 2006 A

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