Forbes Marshall FLASHJET FJP25 Installation And Maintenance Manual

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Installation and Maintenance Manual

FLASHJET

Pump

FJP

FJP25

FJP

40-50-80-80X

Energy Conservation | Environment | Process Efficiency

www.forbesmarshall.com

Table of Contents

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Summary of Contents for Forbes Marshall FLASHJET FJP25

Page 1 Installation and Maintenance Manual FLASHJET Pump FJP25 40-50-80-80X Energy Conservation | Environment | Process Efficiency www.forbesmarshall.com...
Page 2: Table Of Contents
Table of Contents Preface ..................1 Important Safety Notes ............1 Brief Product Information ............4 Product Working Principle ............10 Installation Guidelines ............11 Start-up and Commissioning ..........13 Maintenance Guidelines ............13 Troubleshooting ..............21 Available Spares ..............23 Warranty Period ..............26 Forbes Marshall Flash Jet Pump...
Page 3: Preface
4. The correct installation and direction of fluid flow has to be determined. 5. Forbes Marshall products are not intended to resist external stresses, hence necessary precautions to be taken to minimize the same.
Page 4 2.6 Tools and consumables: Ensure you have appropriate tools and / or consumables available before starting the work. Use of original Forbes Marshall replacement parts is recommended. 2.7 Protective clothing: Consider for the requirement of any protective clothing for you/ or others in the vicinity for protection against hazards of temperature (high or low), chemicals, radiation, dangers to eyes and face, noise and falling objects.
Page 5: Brief Product Information
Brief Product Information: 3.1 Description: The Forbes Marshall Flash Jet Pump is an integrated solution of a pressure powered condensate pump operated by steam & a flash vessel. It is an innovative concept that enables the total recovery of flash steam & condensate simultaneously.
Page 6 30 litres for FJP40 / FJP50 / FJP80 55 litres for FJP80X Maximum steam consumption : 4.5 kg of steam per 1000 kg of condensate pumped. Note: For lower operating temperatures consult Forbes Marshall 3.4 Standard Accessories: Condensate recovery meter - 485 (CRM485R) and insulation jacket...
Page 7 Schematic FJP40/50/80/80X Model Approx. Dimensions Approx. Empty Weight 1.4m 0.71m 250 kg 0.77m FJP40 0.87m 1.4m 0.71m 270kg FJP50 0.85m FJP80 1.4m 0.75m 300 kg 0.95m FJP80X 2.2m 1.5m 0.77m 450 kg FMFJP...
Page 8 Schematic FJP25 Model Approx. Dimensions Approx. Empty Weight 1.28m 0.46m 175 kg FJP25 1.8m 0.74m...
Page 9 Exhaust valve seat Stainless Steel ASTM A276 Gr 304 Inlet valve stem Stainless Steel ASTM A276 Gr 431 Inlet valve seat Stainless Steel ASTM A276 Gr 304 Inlet valve spring Stainless Steel ASTM A276 Gr 316 Forbes Marshall Flash Jet Pump...
Page 10 FJP40 / FJP50 & FJP80 Fig 4 : Mechanism Detail of FJP40 / FJP50 & FJP80 FMFJP...
Page 11 FJP80X Fig 5 : Mechanism Detail Of FJP80X Forbes Marshall Flash Jet Pump...
Page 12 Maximum flash pressure :- 1.5 bar g Maximum back pressure :- 2 bar g maximum condensate pressure :- 10 bar g Total back pressure on FJP has to be more than the flash pressure for its working Recommended motive pressure = Total back pressure + 2 bar g Total Back pressure = {H * 0.1 bar g }+ FP bar g + LP bar g H= Height to which condensate is to be lifted in mtrs.
Page 13: Product Working Principle
The motive steam used to pump the condensate from pump body is recovered in the flash vessel when exhaust stroke takes place. This exhaust steam can be used along with flash steam from the flash outlet. Forbes Marshall Flash Jet Pump...
Page 14: Installation Guidelines
4. It is an advisable to install forbes marshall 15NB 100 mesh strainer, piston valve and a float trap as a drain trap before the steam inlet connection.
Page 15 The common condensate line should be sized to take care of connected condensate load of all the pumps. Forbes Marshall Flash Jet Pump...
Page 16: Startup And Commissioning
Startup and Commissioning: For trouble free operation of FJP, it is important that the single orifice float trap internals, pump internals & check valves are not subjected to dirt or other hard particles. Therefore, prior to bringing FJP in to operation, please ensure that the entire condensate piping circuit is thoroughly flushed.
Page 17 Inspect the float to ensure they are undamaged. Check all the pivot point to ensure they are moving freely. To refit the mechanism assembly Ensure the mechanism cover gasket is clean and free from debris. Forbes Marshall Flash Jet Pump...
Page 18 Carefully slide the new cover assembly into the pump body, whilst ensuring the new gasket is carefully aligned with the gasket faces and no parts of it are trapped or pinched outside the sealing areas. Refit the Base bolts ensuring they are sequentially tightened in opposing pairs, gradually increasing torque to 90-100 N m Carefully reconnect the motive steam supply and the exhaust lines to the connections.
Page 19 24 mm (A/F) Strainer assembly (M16 X 70mm) Box spanner 24 mm(A/F) Disc check valve (M16 X 130mm) Box spanner 24 mm (A/F) Condensate return connection Disc check valve (M16 X 130mm) Box spanner 24 mm (A/F) Forbes Marshall Flash Jet Pump...
Page 20 Size Part Component Tool used and Size Motive inlet and exhaust Valve Open Spanner 22 mm (A/F) Float Open Spanner 19 mm (A/F) Internal Mechanism Assembly Float Arm Bolt Open Spanner 10 mm (A/F) For Split Pin Assembly Nose Plier Reed switch assembly 4 No M8 studs;...
Page 21 7.3.5 Procedure to Maintain/Replace the springs: 1. Unscrew all eight nuts (3) present on the cover (1) and lift the cover and mechanism assembly from the pump body (15). 2. Arrange the whole assembly onto the vice such that the internals are placed on top and clamp the cover.
Page 22 Disc check valve (M16 X 130mm) Box spanner 24 mm (A/F) connection 7.5 Maintenance/Replacement Procedure : For FJP80X For a detailed maintenance/replacement procedure of the FJP80X Unit body internals, please refer to the instructions given in the subsequent sections; Forbes Marshall Flash Jet Pump...
Page 23 7.5.1Procedure to Maintain/Replace the whole FJP internal assembly: 1.Open the FJP door.Before carrying out any maintenance, remove all the connections to the pump cover (1). Isolate the pump body by closing the inlet isolation butterfly valve and the the ball provided on the exhaust line. Open the pump body drain to normalize any pressure within pump body to atmospheric pressure.
Page 24 4. Remove the washer and the springs from the linkage mechanism 5. Insert the new springs 6. Put the washer and split pins back 7. Reassemble the whole mechanism following steps 4 and 5 of section 7.3.1 Forbes Marshall Flash Jet Pump...
Page 25: Troubleshooting
7.5.6 Procedure to Maintain/Replace new set of O-rings: 1. Follow steps 1 and 2 of section 7.3.1 2. Unscrew the allen bolts present on the top of the cover. 3. Remove the motive inlet valve manifold . 4. Remove the old O rings and replace with the new ones. 5.
Page 26 Replace it if found damaged. j) Exhaust valve leaking j) Open the pump internals and clean it. Also check the setting of valve actuator disc and correct it if found disturbed. Forbes Marshall Flash Jet Pump...
Page 27: Available Spares
Failure Mode Possible Cause Remedy a) Check inlet Check Valve a) Lap the seat and if the problem persists replace FJP80X working, Check Valve overflows only during discharge. a) FJP under sized. a) Verify the rated capacity as per the capacity table. Install additional FJP as required.
Page 28 Gasket kit SPARE-405080PPPPU-GKIT Inlet valve kit SPARE-405080PPPPU-IVKIT Exhaust valve kit SPARE-405080PPPPU-EVKIT Float assembly SPARE-405080PPPPU-FKIT Spring assembly SPARE-405080PPPPU-SKIT Overflow trap gasket SPARE-FJP40-GKIT SOFT53 mechanism gasket 25NB gasket for exhaust assembly SOFT53 main valve assembly with float SPARE-50SOFT53-4.5MVKIT Forbes Marshall Flash Jet Pump...
Page 29 FJP80 Internals SPARE-405080PPPPU-MKIT Gasket kit SPARE-405080PPPPU-GKIT Inlet valve kit SPARE-405080PPPPU-IVKIT Exhaust valve kit SPARE-405080PPPPU-EVKIT Float assembly SPARE-405080PPPPU-FKIT Spring assembly SPARE-405080PPPPU-SKIT Overflow trap gasket SPARE-FJP80-GKIT SOFT53 mechanism gasket 25NB gasket for exhaust assembly SOFT53 main valve assembly with float SPARE-50SOFT53-4.5MVKIT 9.3 For FJP80X FJP80X Internals SPARE-MV55-MKIT...
Page 30: How To Specify
Always order spares by using the description given in the column headed “Available Spares” for this product. Warranty Period: As per ordering information and agreements in the contract A: Forbes Marshall Pvt. Ltd. Forbes Marshall International Pte. Ltd. 16A, Tuas Avenue 1, Opp. 106th Milestone, CTS 2220,...

This manual is also suitable for:

Flashjet fjp 40 Flashjet fjp 50 Flashjet fjp 80 Flashjet fjp 80x