Forbes Marshall FMPP30 Manual

Pressure Pump with Insulation Jacket

FMPP30

Installation and Maintenance Manual

Energy Conservation | Environment | Process Efficiency www.forbesmarshall.com

1. Preface .................................................................................1

2. Important Safety Notes ........................................................1

3. Brief Product Information ....................................................3

4. Product Working Principle.....................................................10

5. Installation Guidelines .........................................................12

6. Startup and Commissioning ................................................14

7. Maintenance Guidelines .....................................................16

8. Troubleshooting ..................................................................19

9. Available Spares ................................................................21

10. Warranty Period ..................................................................21

Table of Contents

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. This symbol denotes CAUTION, WARNING or

DANGER.

Pressure Powered Pump Package Unit with IJ and CRM485R

Preface:

This manual is intended for anyone using, commissioning, servicing, or disposing the below

mentionedproductssafelyandefficiently.

PressurePumpInsulationJacket ,[FMPP30

Size: DN40 (1 ½”), DN50 (2”), DN80 (3”)

Importantsafetynotes:

Read this section carefully before installing/operating/maintaining the product. The

precautions listed in this manual are provided for personnel and equipment safety.

Furthermore, Forbes Marshall accepts no responsibility for accidents or damage

occurring as a result of failure to observe these precautions. Note that the product is

designedtoperformfornon-contaminatedfluidsonly.Acontaminationintheformof

chemical, foreign particle etc. can lead to problem with product performance and life

oftheproduct.

If these products in compliance with the operating instructions are, properly installed,

commissioned, maintained and installed by qualified personnel (refer Section 2.8) the safety

operationsoftheseproductscanbeguaranteed.Generalinstructionsfor proper use of toolsand

safetyofequipments,pipelineandplantconstructionmustalsobecompliedwith.

2.1 Intendeduse:

Check if the product is suitable for intended use/ application by referring to the installation

andmaintenanceinstructions,nameplatesandtechnicalinformationsheets

1. Theproduct issuitablefor useasdefinedinthetechnicalinformationsheet.Incasethe

need arises to use the product on any other fluid please contact Forbes Marshall for

assistance.

2. Checkforthesuitabilityinconformancetothelimitingconditionsspecifiedintechnical

informationsheetoftheproduct.

3. Thecorrectinstallationanddirectionoffluidflowhastobedetermined.

4. Forbes Marshall products are not intended to resist external stresses, hence necessary

precautionstobetakentominimizethesame.

2.2 AccessibilityandLighting:

Safeaccessibilityandworkingconditionsaretobeensuredpriortoworkingontheproduct.

2.3 Hazardousliquidsorgasesinthepipeline:

Contemplate what may have been in the pipe or is in the pipe and also for flammable

materials,substanceshazardoustohealth,extremesoftemperature.

PPPPU

2.4 Hazardousenvironmentandmedia:

The product has to be protected from hazardous environment and check to ensure that no

hazardousliquidsorgasespassthroughtheproduct.

2.5 Depressurizingofsystemsandnormalizingoftemperature:

Ensure isolation and safety venting of any pressure to the atmospheric pressure. Even if the

pressure gauge indicates zero, do not make an assumption that the system has been

depressurized.

Toavoiddangerofburnsallowtemperaturetonormalizeafterisolation.

2.6 Toolsandconsumables:

Ensure you have appropriate tools and / or consumables available before starting the work.

UseoforiginalForbesMarshallreplacementpartsisrecommended.

2.7 Protectiveclothing:

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

eyesandface,noiseandfallingobjects.

2.8 Permitstowork:

All work to be carried out under supervision of a competent person. Training should be

imparted to operating personnel on correct usage of product as per Installation and

Maintenance instruction. “Permit to work” to be complied with (wherever applicable), in

case of absence of this system a responsible person should have complete information and

knowledgeonwhatworkisgoingonandwhererequired,arrangetohaveanassistantwith

his primary goal and responsibility being safety. “Warning Notices” should be posted

wherevernecessary.

2.9 Handling:

There is a risk of injury if heavy products are handled manually. Analyze the risk and use

appropriatehandling method by takingintoconsiderationthetask,individual,the working

environmentandtheload.

2.10 Freezing:

Provision should be made to protect systems which are not self-draining, against frost

damage(inenvironmentwheretheymaybeexposedtotemperaturesbelowfreezingpoint)

tobemade.

2.11 Returningproducts:

CustomersandStockistareremindedthat,whenreturningproductstoForbesMarshallthey

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

environmentalrisk.

This information must be provided in writing including Health and Safety data sheets

relatingtoanysubstancesidentifiedashazardousorpotentiallyhazardous.

Pressure Powered Pump Package Unit with IJ and CRM485R

3. BriefProductInformation:

PPPPU

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.

3.2 Sizes and Pipe Connections:

SIZE : DN40, 50 and 80 pressure powered pump package unit.

Condensate inlet : vent flanged to class 150

Condensate outlet : use flange provided with pump

3.3 Limiting Conditions:

Note: For lower operating temperatures consult Forbes Marshall

Size Condensate Pump Vent Empty

(DN) inlet conn. (A) (DN) (DN) conn. weight

40 50 50 100 245kg

50 50 80 100 350kg

80 80 80 100 395kg

outlet

conn. (B) (DN)

PMA Maximum design pressure 8.7 bar g

TMA Maximum design temperature 220°C

Operating inlet motive pressure Steam / Compressed Air /

Pressurised gas 3 - 8.7 bar g (max)

Pump discharge per cycle 30 kg

Steam consumption 3 Kg of steam per

1000 Kg liquid pumped

Air consumption 22 SCF per 1000 Kg

liquid pumped

Minimum operating temperature 0°C

Figure 1 : Pressure Powered Pump Package Unit

4Pressure Powered Pump Package Unit with IJ and CRM485R

3.5 Standard Accessories:

Condensate recovery meter - 485 (CRM485R)

and insulation jacket

3.4 Operating Range:

Figure 2 : Detail of Pressure Powered Pump Package Unit with IJ and CRM485R

305

PPPPU

(305)

6Pressure Powered Pump Package Unit with IJ and CRM485R

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.

FP= Frictional pressure drop of discharge

LP=Line Pressure

2318

9(b)

9(a)

PPPPU

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(barg) Capacity(kg/hr)

Motive Back DN40 DN50 DN80

8.7 0 4090 6765 10355

1 3295 4655 6165

2 2980 3765 5090

3 2730 3605 3925

4 2405 3100 3495

8 0 4015 6680 10245

1 3260 4440 5830

2 2890 3660 4555

3 2475 2995 3770

4 2350 2645 2950

7 0 3935 6605 10135

1 3230 4195 5545

2 2830 3415 4440

3 2420 2930 3515

4 2195 2605 2855

6 0 3880 6365 9880

1 3115 3775 5210

2 2800 3270 4290

3 2325 2700 3425

4 2095 2195 2720

5 0 3830 6275 9605

1 3005 3705 5050

2 2635 3055 4140

3 2290 2505 3070

4 0 3705 5910 9175

0.5 3095 3885 5440

1 2835 3410 4460

2 2380 2705 3215

3 0 3525 5420 8090

0.5 2970 3540 4705

1 2570 2950 3675

8Pressure Powered Pump Package Unit with IJ and CRM485R

MOTIVE AIR

Pressure(barg) Capacity(kg/hr)

Motive Back DN40 DN50 DN80

6 0 4055 6360 9645

1 3835 5555 7925

2 3635 4845 6710

3 3335 4390 5765

4 3055 3815 4810

5 0 4060 6335 9605

1 3750 5485 7700

2 3555 4800 6460

3 3275 4130 5465

4 0 4110 6305 9555

0.5 3905 5590 8425

1 3680 5380 7550

2 3450 4520 6105

3 0 4060 6265 9500

0.5 3935 5695 8085

1 3610 5125 7085

Table of contents

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