Installation and Maintenance Manual

Duplex Pressure Powered Pump Package Unit with

Insulation Jacket and Condensate Recovery Meter
PPPPU-D

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

Table of Contents

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

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

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

4. Product Working Principle ...................................................9

5. Installation Guidelines ..........................................................10

6. Startup and Commissioning ................................................12

7. Maintenance Guidelines .....................................................13

8. Troubleshooting .................................................................17

9. Available Spares ................................................................19

10. Warranty Period ..................................................................20

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.

Duplex Pressure Powered Pump Package Unit with CRM485R and IJ

PPPPU-D 1
 2.3 Hazardous environment and media:
The product has to be protected from hazardous environment and check to ensure that no
hazardous liquids or gases pass through the product.
2.4 Depressurizing of systems and normalizing of temperature:
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.
To avoid danger of burns allow temperature to normalize after isolation.
2.5 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.
2.6 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
2.7 Permits to work:
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
knowledge on what work is going on and where required, arrange to have an assistant with
his primary goal and responsibility being safety. “Warning Notices” should be posted
wherever necessary.
2.8 Handling:
There is a risk of injury if heavy products are handled manually. Analyze the risk and use
appropriate handling method by taking into consideration the task, individual, the working
environment and the load.
2.9 Freezing:
Provision should be made to protect systems which are not self-draining, against frost
damage (in environment where they may be exposed to temperatures below freezing point)
to be made.
2.10 Product Disposal:
It is necessary to dispose this product only in accordance with local regulations at the
authorized, qualified collecting point specified for equipment’s and its parts—Please refer
the part details mentioned in the material table of this manual. Please follow all waste
disposal guidelines (Management & Handling) as published by local governing authorities in
India & abroad
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.
This information must be provided in writing including Health and Safety data sheets
relating to any substances identified as hazardous or potentially hazardous.

2 Duplex Pressure Powered Pump Package Unit with CRM485R and IJ

3.1 Description:
The Forbes Marshall Duplex Pressure Powered Pump Package Unit, PPPPU-D, is a duplex
positive displacement pump unit operated by steam, compressed air or pressurized gas.
The unit is specifically designed to pump hot condensate and liquids of specific gravity
1.0 down to 0.9. VENT A
INLET

B
INLET
A

Figure 1: Duplex Pressure Powered Pump Package Unit

3.2 Sizes and End Connections:
Size DN 80 (A) (C) (B)
Model Cond. Inlet (DN) Cond. Outlet (DN) Vent (DN)
PPPPU-D 80 50 80
Condensate inlet : vent flanged to ANSI Class 150
Condensate outlet : 150NB Class 150
3.3 Limiting Conditions:

PMA Maximum design pressure 8.7 bar g

TMA Maximum design temperature 220°C
Operating inlet motive pressure Steam / compressed air /pressurised gas
3-7 bar g (max.)
Pump discharge per cycle 30 kg
Steam consumption 3 kg of steam per 1000 kg
condensate pumped
Air consumption 22 SCF per 1000 Kg condensate pumped
Minimum operating temperature 0°C
Note: For lower operating temperatures consult Forbes Marshall

PPPPU-D 3
 600
12
300 3
2

15
6
5
13

2000
1944
17
10

490
4
1531

16
11 8 9 18 1 7
1033
14
146

211

1200
1173
1315

* Aprox assmbly wt - 670 kg

Sr. No. Part Material Standard

1 Shell Assembly Carbon Steel IS 3589
2 Receiver Assembly Carbon Steel IS 3589
3 Vent Connection Carbon Steel
4 Steam Inlet Line Carbon Steel IS 1239 CLASS C
5 Steam Inlet Line Strainer Cast Iron IS 210 FG 260
6 Steam Inlet Line Piston Valve Carbon Steel ASTM A 105
7 Ball Float Trap Cast Iron IS 210 FG 260
8 Disc Check Valve Stainless Steel
9 Condensate outlet Disc Check Valve Stainless Steel
10 Butterfly valve Cast Iron
11 Strainer Cast Iron IS 210 FG 260
12 Condensate inlet line Carbon Steel
13 Pump shell mechanism assembly Carbon Steel IS 3589
14 Drain line ball valve Cast Steel
15 Over flow line Carbon Steel IS 1239 Class C
16 Exhaust Pipe Bend Carbon Steel
17 CRM Sensor Assembly Stainless Steel
18 Steam Inlet Flange 50NB Class 150 Carbon Steel
19 Condensate outlet Flange 150NB Class 150 Carbon Steel

4 Duplex Pressure Powered Pump Package Unit with CRM485R and IJ

 22
3

1 2

12
23
13
18
17 14
6
19

15
21
16
7 1
8 10
4 9(a)
20
9(b)
5
11

Material

Sr. No. Description Material Standard Sr. No. Description Material Standard
1 Cover Cast Iron IS 210 Gr FG 260 12 Push Rod Stainless Steel ASTM A240
SS 304
2 Cover Gasket Synthetic Fibre AF154 13 Mechanism Cast Iron IS 210 FG 260
3 Stud and Nut M - 12 Carbon Steel - 14 Mechanism Stainless Steel SS304
Actuator
4 Inlet Valve Seat Stainless Steel ASTM A276 15 Body Carbon Steel IS 3589
SS 304
5 Inlet Valve Stem Stainless Steel ASTM A276 16 Float Stainless Steel ASTM A240
Type 304 SS 304
6 Inlet Valve Head Stainless Steel AISI 440 C 17 Linkage Stainless Steel ASTM A351
Mechanism CF 8
7 Inlet Seat Gasket Copper - 18 Push Rod Stainless Steel ASTM A351
Actuator CF 8
8 Exhaust Valve Stainless Steel ASTM A276 19 Spring Inconel -
SS 304
9(a) Exhaust Valve Stainless Steel ASTM A276 20 Plug 1/2”BSPT Forged ASTM A105
SS 304
Steel
9(b) Exhaust Stainless Steel ASTM A276 21 Check Valve Stainless Steel -
Valve Head SS304
10 Exhaust Seat Copper - 22 Flow-temp Sensor Stainless Steel -
Gasket
11 Valve Stainless Steel ASTM A276 23 Sensor Float Stainless Steel ASTM A240
Actuator Disc SS 304 SS 304

PPPPU-D 5
 3.4 Operating Range:

3.5 Standard Accessories:

Condensate recovery meter - 485 (CRM485R)
Insulation Jacket (IJ-PPPPU-D)

3.6 How to Select and Size:

From the inlet pressure, back pressure and filling head conditions given below select the
pump size which meets the capacity requirements of the applications.
Select optional extras as required.
Back pressure is the lift height (H) in mts x 0.1 plus bar (g) in return line plus downstream
piping friction pressure drop in bar (g) at the lesser of six times the actual flow rate or 340 lit /
min

6 Duplex Pressure Powered Pump Package Unit with CRM485R and IJ

3.7 Capacity of each pump (kg/hr):
When installed with recommended filling head above top of pump: 305 mm. For liquid
specific gravity (0.9 to 1).

MOTIVE STEAM MOTIVE AIR

Pressure (bar g) Capacity Pressure (bar g) Capacity
Motive Back (Kg/hr) Motive Back (Kg/hr)
8.7 1 12330 6 1 15850
2 10180 2 13420
3 7850 3 11530
4 6990 4 9620
8 1 11660 5 1 15400
2 9110 2 12920
3 7540 3 10930
4 5900 4 0.5 16850
7 1 11090 1 15100
2 8880 2 12210
3 7030 3 0.5 16170
4 5710 1 14170
6 1 10420
2 8580
3 6850
4 5440
5 1 10100
2 8280
3 6140
4 0.5 10880
1 8920
2 6430
3 0.5 9410
1 7350

PPPPU-D 7
 3.8 Capacity Multiplying Factors for Other Filling Heads:

Filling Head mm DN 80
152 0.84
305 1.0
610 1.08
914 1.20

3.9 Example:

Condensate Load 6000kg/hr

Steam/Air pressure available for operating pump 5.0 Bar g
Vertical lift from pump to return piping 9m
Pressure in return piping (piping friction negligible) 1.72 Bar g
Filling head on pump 0.3048 mtr.

Solution:
1. In duplex unit condensate load on each pump =3000kg/hr
2. Calculate ‘h’, the total lift or back pressure against which the
condensate must be pumped
=(9mx0.1)+1.72
=2.62 bar g
3. From capacity table with 5.0 bar g operating Inlet pressure
and 3.0 bar g back pressure, each pump has capacity of
3070 kg/hr
4. From this, the duplex unit handles condensate load
6140 kg/hr for given operating conditions.

Note from capacity factor charts:

Pump capacity if filling head is 0.610 mtr.
=1.2 x1725 =2070 kg /hr

8 Duplex Pressure Powered Pump Package Unit with CRM485R and IJ

PPPPU-D 9
 Flash Steam

4
5

Condensate
Inlet

1 3 Condensate Line

INLET
VENT A
B
INLET
A
6

10 Duplex Pressure Powered Pump Package Unit with CRM485R and IJ

 INLET
VENT A
B
INLET
A
6

PPPPU-D 11
 Flash
Steam
Outlet

Condensate Intlet

Condensate Outlet

Drain
Line

12 Duplex Pressure Powered Pump Package Unit with CRM485R and IJ

NO. PARAMETERS TO BE CHECKED FREQUENCY FOR CHECKING VARIOUS PARAMETERS

Duplex Pressure Powered Pump Package Unit / Half

A Daily Weekly Monthly Quarterly Annually.
Forbes Marshall Flash Vessel Yearly
1 Clean strainer of motive media line Y

2 Clean condensate inlet strainer Y

Visual inspection and cleaning of complete set of
3 Y
internals
4 Condensate pump chamber draining Y
5 Inlet / Exhaust valve leakage testing Y
6 DCV Cleaning Y
7 Operate motive line valve Y
8 Operate Condensate inlet valve Y
9 Lubrication of piston valves Y
10 Pr. Gauge calibration Y
11 Checking of PPPPU-D motive pressure Y
12 Checking of flash steam pressure in Flash Vessel Y
13 Cleaning of motive line trap internals Y
14 Cleaning of steam trap internals Y
15 Visual inspection for leakages Y
16 Arresting leaks Y
17 Checking of float trap SLR setting Y
Cleaning of strainer between Forbes Marshall
18 Y
Flash Vessel and pump
19 Check air quality(in case motive media is air) Y
20 Visual inspection of Safety relief valve Y
21 Overhauling and cleaning of safety relief valve Y

PPPPU-D 13
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 80 Internal Mechanism Assembly Bush assembly and stop bolt Box Spanner 13 mm (A/F)

Stopper bracket bolt Box spanner 8 mm (A/F)

Float Arm Bolt Open Spanner 10 mm (A/F)

For Split Pin Assembly Nose Plier

Read switch assembly 4 No M6 studs; M6 X

Ring spanner 10 mm (A/F)
4mm nuts
DN 80 External Assembly Internal assembly cover (M12 X 50) Open spanner 18 / 19 mm (A/F)

Motive inlet and exhaust hose pipe connection Pipe wrench

Butterfly valve (M16 X 120mm) Box spanner 24 mm (A/F)

Condensate inlet connection Strainer assembly (M16 X 70mm) Box spanner 24 mm(A/F)
DN 80
Disc check valve (M16 X 130mm) Box spanner 24 mm (A/F)
Condensate return
Disc check valve (M16 X 130mm) Box spanner 24 mm (A/F)
connection

14 Duplex Pressure Powered Pump Package Unit with CRM485R and IJ

PPPPU-D 15
16 Duplex Pressure Powered Pump Package Unit with CRM485R and IJ
Failure
Possible Cause Remedy
Mode

a) Open valves to supply motive steam

a) Motive steam supply closed. pressure to condensate in the pump
shell.

b) Motive line strainer chocked. b) Clean the strainer.

c) Open condensate inlet valve and

c) Condensate inlet line closed allow condensate to flow in
pumping chamber.

d) Condensate line strainer chocked d) Clean the strainer.

e) Open all discharge line valves to

e) Condensate discharge line closed allow free discharge from pump to
Pump destination.
stops
working f) Check motive and back pressure.
f) Motive pressure insufficient to
Adjust motive pressure to 2barg
overcome back pressure
more than total back pressure.

g) Float punctured g) Replace the float.

h) Check the direction of the Check

h) Correct it if found wrong.
Valve

i) It means motive steam inlet valve is

i) Steam coming out continuously from leaking- open the internals and
exhaust line clean the inlet valve. Replace it if
found damaged.

j) Open the pump internals and clean

it. Also check the setting of valve
j) Exhaust valve leaking
actuator disc and correct it if found
disturbed.

PPPPU-D 17
 Failure Mode Possible Cause Remedy

Pump
working,
a) Lap the seat and if the problem
overflows a) Check inlet Check Valve
persists replace Check Valve
only during
discharge.

a) Verify the rated capacity as per the

a) Pump under sized capacity table. Install additional
pump as required.

b) Clean the strainer. Ensure all valves

b) Inlet strainer partially choked
are fully open.

c) Motive line strainer partially c) Clean the strainer and ensure inlet
choked. valve is fully open.

d) Check the steam trap installed after

d) Live steam reaching in pump
the Flash Vessel or process traps (if
receiver and receiver is
there is no Flash Vessel), for leakage
pressurized.
and rectify it.

e) Make sure that receiver is vented to

Pump e) Receiver vent line is closed.
atmosphere as recommended.
working,
continuously
overflows f) Check motive pressure setting and
maximum back pressure during
f) Insufficient motive pressure to
operation. Compare with capacity
achieve rated capacity.
table and increase motive pressure
as required.

g) Outlet check valve stuck open or g) Open the check valve and clean it or
leaking replace it if found damaged.

h) Motive isolation valve partially h) Check and ensure that motive

closed. isolation valve is fully open.

i) Condensate return line size should

i) Condensate return line size lesser
be equal to or greater than pump
than pump discharge.
discharge line.

18 Duplex Pressure Powered Pump Package Unit with CRM485R and IJ

 6

SPARES PART NO. SPARE CODES

SPARE KIT FOR PPPPU-D INTERNALS 10 SPARE-PPPPU-MKIT

SPARE KIT FOR GASKET SET (SET OF 5) 1,2,3 SPARE-PPPPUD-GKIT

SPARE KIT FOR PPPPU-D INLET VALVE SEAT AND HEAD

4,5 SPARE-PPPPUD-IVKIT
ASSEMBLY

SPARE KIT FOR PPPPU-D EXHAUST VALVE SEAT AND

6,7 SPARE-PPPPUD-EVKIT
HEAD ASSEMBLY

FLOAT ASSEMBLY 8 SPARE-PPPPUD-FKIT

SPARE KIT FOR PPPPU-D SPRING ASSEMBLY(SET OF 2) 9 SPARE-PPPPUD-SKIT

How to Order:
Example : DN 80 Duplex Pressure Powered Pump Package Unit PPPPU-D

How to Order Spares:

Always order spares by using the description given in the column headed “Available
Spares” in user manual for this product.

PPPPU-D 19
20 Duplex Pressure Powered Pump Package Unit with CRM485R and IJ
PPPPU-D 21
Disclaimer:
This information is strictly proprietary and legally privileged. All contents herein shall be the property of Forbes
Marshall Pvt Ltd and having protection under the intellectual property rights. No part of this information or data may
be distributed or disclosed in any form to any third party. 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. Khed, Dist, Pune 410 501. Tel: +91(0)2135 393400
Sales: Opp 106th Milestone, Bombay Pune Road, Kasarwadi,
Pune 411034 Tel.: +91 (0)20 39858555
CIN No: U28996PN1985PTC037806

Email : seg@forbesmarshall.com www.forbesmarshall.com

Doc# FMSS/0418/UM-PPPPU-D/R1