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Summary of Contents for Forbes Marshall FMPP30
- Page 1 Installation and Maintenance Manual Pressure Pump with Insulation Jacket FMPP30 Energy Conservation | Environment | Process Efficiency www.forbesmarshall.com...
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Page 2: Table Of Contents
Table of Contents Preface .................1 Important Safety Notes ............1 Brief Product Information ............3 Product Working Principle.............10 Installation Guidelines ............12 Startup and Commissioning ..........14 Maintenance Guidelines .............16 Troubleshooting ..............19 Available Spares ..............21 Warranty Period ..............21 PLEASE NOTE - Throughout this manual this cautionary symbol is used to describe a potential damage or injury that might occur if the safety considerations are overlooked. -
Page 3: Preface
The product is suitable for use as defined in the technical information sheet. In case the need arises to use the product on any other fluid please contact Forbes Marshall for assistance. - Page 4 2.11 Returning products: Customers and Stockist are reminded that, when returning products to Forbes Marshall they must provide information on any hazards and the precautions to be taken due to contamination residues or mechanical damage which may present a health, safety or environmental risk.
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Page 5: Brief Product Information
Brief Product Information: 3.1 Description: The Forbes Marshall Pressure Powered Pump Package Unit, PPPPU, is a positive displacement pump unit operated by steam, compressed air or pressurized gas designed to pump hot condensate. Figure 1 : Pressure Powered Pump Package Unit 3.2 Sizes and Pipe Connections:... - Page 6 3.4 Operating Range: 3.5 Standard Accessories: Condensate recovery meter - 485 (CRM485R) and insulation jacket Figure 2 : Detail of Pressure Powered Pump Package Unit with IJ and CRM485R Pressure Powered Pump Package Unit with IJ and CRM485R...
- Page 7 PPPPU...
- Page 8 9(a) 9(b) 3.6 How to Select and Size: Select the pump size according to the capacity requirement of the application from the inlet, back pressure and filling head conditions given in the table below. Back pressure (h) = [H X 0.1 bar g] + FP bar g + LP bar g where H=height to which condensate is to be lifted in mtrs.
- Page 9 3.7 Capacity kg/hr.: When installed with recommended filling head above top of pump :- 305 mm. For liquid specific gravity (0.9 to 1) MOTIVE STEAM Pressure (bar g) Capacity (kg/hr) Motive Back DN 40 DN 50 DN 80 4090 6765 10355 3295 4655...
- Page 10 MOTIVE AIR Pressure (bar g) Capacity (kg/hr) Motive Back DN 40 DN 50 DN 80 4055 6360 9645 3835 5555 7925 3635 4845 6710 3335 4390 5765 3055 3815 4810 4060 6335 9605 3750 5485 7700 3555 4800 6460 3275 4130 5465 4110...
- Page 11 3.8 Capacity Multiplying Factors for Other Filling Heads Filling Head DN40 DN50 Dn80 0.84 1.08 1.35 1.35 1.20 3.9 Capacity Multiplying Factors for Motive Gas Supplies % Back pressure vs. Motive pressure BP/ MP) 1.04 1.06 1.08 1.10 1.12 1.15 1.18 1.23 1.28...
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Page 12: Product Working Principle
Product Working Principle: Note: For this section refer to Figure 4 A PPPPU unit consists of a receiver (1), Inlet Isolation valve (2), Strainer (3), a body shell (4) containing a float mechanism which operates a set of motive steam / air inlet (5) and exhaust valves (6) and inlet (7) &... - Page 13 As the float (16) continues to rise, the mechanism link (17) is engaged which increases tension in the springs (19). When the float (16) has risen to its upper tripping position, the linkage mechanism (17) snaps upward over center. The energy in the springs (19) is released as the push rod (18) is moved upward, to simultaneously open the motive steam inlet valve (5) and close the exhaust valve (9A).
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Page 14: Installation Guidelines
©. Most important is that reservoir must be vented to atmosphere. This is to ensure free flow of condensate under gravity to the pump. It is recommended to install PPPPU along with a Forbes Marshall Flash vessel arrangement, if condensate flashing is expected when exposed to atmosphere. - Page 15 5.1 Care to be taken while routing the condensate pump discharge line: (Refer to Fig. 6) The outlet line size should be equal to or more than pump outlet flange size provided with pump. As far as possible, the discharge line should have minimum bends. Ideally the condensate pump discharge line should be lifted immediately after the pump to the maximum elevation in the circuit and then to be connected to feed water tank with a downward slope.
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Page 16: Startup And Commissioning
Startup and Commissioning: It is recommended to install Forbes Marshall PPPPU along with a Flash vessel arrangement, if condensate flashing is expected when exposed to atmosphere. For trouble free operation of PPPPU, it is important that the single orifice float trap internals, pump internals & check valves are not subjected to dirt or other hard particles. - Page 17 6.2 Flushing Procedure in the absence of a Forbes Marshall Flash Vessel (Refer Figure 9) Wherever process condensate is directly connected to pump receiver & Forbes Marshall flash vessel module is not part of PPPPU, open the pump condensate strainer cap (3) &...
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Page 18: Maintenance Guidelines
Maintenance Guidelines: Before undertaking any maintenance on the product it must be isolated from both supply line and return line and any pressure should be allowed to safely normalize to atmosphere. The product should then be allowed to cool. After suitable isolation repairs can be carried out with the product in the line. - Page 19 7.2 Tool Kit: To carry out any maintenance of the PPPPU use the tools mentioned in the table below. Size Part Component Tool used and Size Motive inlet and exhaust Valve Open Spanner 26 mm (A/F) Float Mechanism Open Spanner 19 mm (A/F) Push Rod and Lock Nut Open Spanner 17 mm (A/F) DN 40 / 50...
- Page 20 7.3.2 Procedure to Maintain/Replace float assembly: 1. Follow steps 1 to 3 of section 7.3.1 2. Unscrew the float (16) from the float arm using appropriate spanner. 3. Screw the new float using Loctite 272 adhesive onto the threads. 4. Insert the whole assembly inside the pump body as described in steps 7 and 8 of section 7.3.1 7.3.3 Procedure to Maintain/Replace Exhaust valve seat &...
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Page 21: Troubleshooting
Troubleshooting: If the expected performance is unachievable after installation of the Pressure Powered Pump Pacakage Unit, check the following points for appropriate corrective measures. Failure Mode Possible Cause Remedy a) Open valves to supply motive a) Motive supply closed pressure to pump b) Motive line strainer chocked b) Clean the strainer c) Open condensate inlet valve and... - Page 22 Failure Mode Possible Cause Remedy Pump working, a) Lap the seat and if the problem overflows only during a) Check inlet Check Valve persists replace Check Valve discharge. a) Verify the rated capacity as per a) Pump under sized. the capacity table. Install additional pump as required.
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Page 23: Available Spares
Available Spares: Figure 9: Available Spares for PPPPU SPARES PART NO. SPARE CODES SPARE KIT FOR PPPPU INTERNALS SPARE-405080PPPPU-MKIT SPARE KIT FOR GASKET SET (SET OF 5) 1,2,3 SPARE-405080PPPPU-GKIT SPARE KIT FOR PPPPU INLET VALVE SEAT AND SPARE-405080PPPPU-IVKIT SPARE KIT FOR PPPPUEXHAUST VALVE SEAT SPARE-405080PPPPU-EVKIT FLOAT ASSEMBLY SPARE-405080PPPPU-FKIT... - Page 24 Any dissemination, use, review, distribution, printing or copying is strictly prohibited, if you are not the intended recipient or user of this information. Forbes Marshall Pvt Ltd Manufacturing: B-85, Phase II Chakan Indl Area, Sawardari, Chakan Tal.
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