LIQUI-MOVER PUMP HANDBOOK pptx

LIQUI-MOVER ® PUMP HANDBOOK Kadant Johnson Inc., 805 Wood Street, Three Rivers, MI 49093 USA 269-278-1715 fax: 269-279-5980 www.kadant.com LMP Handbook-4002 What is a Liqui-Mover ® Pump? A Liqui-Mover pump is a positive displacement pressure powered pump with a minimum of moving parts. The pumping action is accomplished using a positive pressure to push the liquid from the pump tank into the return line. The Liqui-Mover pump can handle high temperature and high pressure condensate without difficulty. Liqui-Mover pumps are available in nine sizes. They are available in many configurations, from individual components that are field assembled to complete packaged systems ready for connection to field piping. A basic Liqui-Mover pump consists of a receiver/reservoir, pump tank, 3-way motive valve, inlet and outlet check valves, level control, and various other fittings. How a Liqui-Mover Pump Works In describing “How a Liqui-Mover Pump Works”, it is advantageous to look at the overall operation, and then break it down into smaller operations for a better understanding. Condensate from the equipment being drained enters the receiver/reservoir tank and flows down the fill line into the pump tank. When the predetermined high level is reached in the pump tank, the level control sys- tem sends out a signal, which causes the 3-way motive valve to cycle. When the 3-way valve cycles, the equalizing line between the receiver/reservoir and the pump tank is closed off and a regulated motive pres- sure is admitted into the pump tank. This motive pressure is confined above the condensate in the pump tank and its effect is to move the condensate out of the pump tank and into the return line. When the con- densate reaches a predetermined low level, the level control sends another signal, causing the 3-way valve to revert to its original position. The residual motive pressure remaining in the pump tank will flow through the equalizing line, into the receiver/reservoir, enabling the pressures in the two tanks to equalize with each other. When this is complete, the flow of condensate from the receiver/reservoir to the pump tank will start again. The cycle will now repeat. See below for more details of each stage of the cycle: STAGE ONE: During the fill cycle, fluid flows from the receiving chamber (A) through the inlet check valve (B) into the pumping chamber (C). The 3-way valve (D) is open between the pumping chamber and the receiving chamber, equalizing the pressure between them through the equalizing line (E). STAGE TWO: When the level control (F) senses that the pumping chamber is full, the 3-way valve energizes to admit the motive pressure into the pumping chamber (C). The inlet check valve (B) prevents backflow into the fill line. The discharge cycle begins when pressure inside the pumping chamber is greater than in the discharge line. The discharge check valve (G) opens and fluid flows into the discharge line. During this cycle, incoming condensate is stored in the receiver. STAGE THREE: Once the level control (F) senses the pumping chamber has emptied, the 3- way valve (D) de-energizes, shutting off the motive pressure, and opening the vent port in the valve. This equalization cycle allows the pumping chamber (C) and the receiving chamber (A) to equalize in pressure, and the fill cycle begins again. Installation Preparation For ease of future maintenance, the Liqui-Mover pump should be installed with the check valve side of the pump tank most accessible. Normally the motive inlet and the condensate discharge connections are on the left when facing the check valves. If a Johnson receiver is supplied, the replaceable sacrificial anode is also installed and removed from this end. On ERC and FAC (pneumatic operated 3-way valve) units, the control air is located on the right when facing the check valves. Refer to the enclosed assembly drawing for addi- tional information. Setting the Unit On LOOO models, the pump tank has (4) holes for mounting to the floor. On LROO models, you will also need to install a Johnson supplied receiver. The receiver is held in saddles with ‘U’ bolts supported by (4) pipes on floor flanges. The floor flanges have mounting holes for attachment to the floor. On LRFP models, the entire base of the frame should be supported. Mounting holes can be drilled through the frame base for attachment to the floor. All tanks should be installed level. Piping On LROO and LRFP models, the Johnson supplied receiver will normally have (3) top connections for: con- densate inlet, atmospheric vent, and pressure gauge. For ‘closed systems’ (no atmospheric vent), an air eliminator and safety relief valve will need to be installed. On LOOO models, the condensate is piped direct- ly to the inlet check valve from an existing receiver or pipe accumulator. The motive pressure (normally steam or compressed air) is piped to the 3-way valve through a strainer and a pressure reducing valve. The strainer is supplied on LRFP models. Compressed air of at least 55 psig should be piped to the pilot valve through a filter/regulator/lubricator on ERC and FAC models. The pilot valve and the filter/regulator/lubricator are supplied with the unit. For LROO and LOOO models, friction loss through the piping should be kept to a minimum. Therefore, pipe reducers should not be used and pipe runs kept to a minimum. All hand valves should be full port if at all possible. Electrical Connect the electrical service to the on/off switch located on the door of the electrical enclosure per the instruction label located near the switch. The electrical voltage must be the same as the rating of the level control relay and the valve, unless a step-down transformer has been supplied. NOTE: An on/off switch is not standard on NEMA 7 units. Pressure Reducing Valve Installation A pressure reducing valve (PRV) should be installed in the motive pressure line to regulate how fast the Liqui-Mover pump discharges the condensate out of the pump tank. When properly adjusted, the discharge time should not be less than 20 seconds. A longer discharge time is acceptable, so long as the Liqui-Mover pump can keep up with the incoming condensate load. Normally the motive pressure setting will be approx- imately 20 psig higher than the back pressure to achieve a 20 second discharge time. Here are some guidelines to be followed when installing a PRV in conjunction with a Liqui-Mover pump: 1. Never install a PRV immediately adjacent to the 3-way motive valve. The shock caused by the sudden opening and closing of the motive 3-way valve will ultimately damage the PRV. We rec- ommend a distance of 20-25 feet between the PRV and the 3-way valve, where the pipe size is the same as the 3-way valve connection. A larger diameter pipe of a shorter length that has an equivalent volume is also acceptable. The PRV should be sized by a pressure reducing valve manufacturer or representative. 2. A safety relief valve should be installed downstream of the PRV to prevent over-pressurization at the 3-way valve. The safety relief valve should be sized by a safety relief valve manufactur- er or representative. 3. When steam is the motive pressure, a drip trap, dirt leg, and strainer should be installed ahead of the PRV. The drip trap should not be piped to the Liqui-Mover pump, unless the receiver is vented. When compressed air is the motive pressure, a liquid drainer, dirt leg, and strainer should be installed ahead of the PRV. The liquid drainer should not be piped to the Liqui-Mover pump. 4. The piping from the PRV outlet to the 3-way valve inlet should be sized to minimize the pres- sure drop under ‘flow conditions’. 5. A throttling valve should be installed immediately ahead of the 3-way motive valve so it can be used in conjunction with the PRV to adjust the Liqui-Mover pump discharge time. Typically the throttling valve is a globe valve. The above sketch is for reference only. Always consult with the PRV and safety relief valve manufacturer or representative for proper sizing and application of their products. Motive Supply Header - Steam or Compressed Air Safety Relief Valve (Piped to safe location) Dirt Leg Y Strainer Drip Trap(Steam) or Liquid Drainer(Air Motive) PRV Equalization Line To Receiver / Condensate Header To Liqui-Mover Pump Throttle Valve (Globe) 3-Way Valve 20´ – 25´ Printed on 12/15/2008 at 11:41:12 AM Property of Kadant Johnson - Confidential Installation Diagram for Liqui-Mover Pump with Compressed Motive Safety Relief Valve (When Needed) This Connection Required For Liqui-Mover Pumps Having a Pneumatic Operated 3-Way Valve (ERC and FAC units) Regulator w/ Gage Filter w/ Auto Drain Motive - Compressed Air Supply Liqui-Mover Pump To 1/4" NPT Air Inlet Connection of Liqui-Mover Pump Throttle Valve (Globe) To Motive Inlet of Liqui-Mover Pump 1. This is the recommended piping for a Liqui-Mover pump with compressed motive. 2. The air should be clean, dry and regulated so that the Liqui-Mover pump discharges in the recommended time. 3. The above parts furnished by customer. NOTE: 1. The above sketch is for reference only. 2. Additional isolation hand valves may be added as required for maintenance purposes. 3. Globe valves should be used where flow restriction is required. 4. Gate valves should be used where minimal flow restriction is required. 5. For proper PRV installation, see manufacturers installation instructions. Start-Up Instructions 1. On Liqui-Mover pumps that are not pre-piped, inspect the inlet and outlet check valves for proper flow direction. Refer to the Liqui-Mover pump assembly drawing and parts list. 2. If the receiver and/or pump tank contains sub-cooled condensate, this needs to be drained prior to start-up. 3. On ERC and FAC units, open the compressed air line to the filter/regulator/lubricator and set the air pressure to 55 psig, minimum. 4. On ERC and ERS units, turn on the electrical power. 5. Open the motive steam or compressed air supply to the PRV and set the pressure to approx- imately 20 psig higher than the back pressure. The throttling (globe) valve should be closed. 6. Open all remaining isolation (hand) valves, except the isolation valve ahead of the inlet check valve (fill line). 7. Once condensate in seen in the receiver, slowly open the isolation valve in the fill line and watch for condensate to fill the pump tank. 8. When the 3-way motive valve energizes, slowly open the throttling (globe) valve ahead of the 3-way motive valve. This will allow the pump tank to discharge. 9. After a few discharge cycles, you will be able to fully open the throttling valve and set the motive pressure to achieve a 20-25 second discharge time using the PRV. 10. The unit is now in service. Discharged Condensate Equalize Line Drip Trap - Steam Liquid Drainer - Air Strainer Globe Valve PRV Motive Supply Check Valve Outlet Check Valve Receiver May Be JoCo ASME Labeled Receiver, Existing Receiver, Oversized Pipe Header, or Etc. 3-Way Motive Valve Pumping Tank Control Panel Vent Line Incoming Condensate Inlet Check Valve TYPICAL INSTALLATION SKETCH CV3S-1000 Series with 4-Way Pilot Valve Port 3 (Motive In) Port 2 (Equalize) Port 1 (Common) A B IN A EXB Filter/Regulator/Lubricator Solenoid Pilot Valve 4-Way Port 2 (Equalize) Port 3 (Motive In) Port 1 (Common) BEX A IN B A Solenoid Pilot Valve 4-Way Filter/Regulator/Lubricator CV3S-100 Series with 3-Way Pilot Valve 3 2 1 Filter/Regulator/Lubricator Motive In Equalize Common Solenoid Pilot Valve 3-Way 3 1 2 Motive In Equalize Common Solenoid Pilot Valve 3-Way Filter/Regulator/Lubricator Pilot De-Energized Pilot Energized Pilot De-Energized Pilot Energized Coil Voltage Freq. Coil No. Approx. Current Fuse Service JOCO Fuse No. Size (Amps) (Amps) Inrush Sealed B4 120 60 31 5.6 0.54 0.8 Cont. CSE175-3025-03 B4 240 60 32 2.8 0.27 0.5 Cont. CSE175-3025-08 B4 240 50 32-50 2.8 0.27 0.5 Cont. CSE175-3025-08 C4 120 60 595 12.7 1.00 1.25 Cont. CSE175-3025-04 C4 240 60 596 6.4 0.50 0.8 Cont. CSE175-3025-03 C4 240 50 596-50 6.4 0.50 0.8 Cont. CSE175-3025-03 D7 120 60 61 12.0 1.04 1.4 Cont. CSE175-3025-05 D7 240 60 62 6.0 0.53 0.8 Cont. CSE175-3025-03 D7 240 50 62-50 6.0 0.53 0.8 Cont. CSE175-3025-03 D3 120 60 71 20.0 1.82 2.50 Cont. CSE175-3025-06 D3 240 60 72 10.0 0.92 1.25 Cont. CSE175-3025-04 D3 240 50 72-50 10.0 0.92 1.25 Cont. CSE175-3025-04 D4 120 60 81 33.5 4.57 6.0 Int. * CSE175-3025-07 D4 240 60 82 16.8 2.35 3.0 Int. * CSE175-3025-09 D4 240 50 82-50 16.8 2.35 3.0 Int. * CSE175-3025-09 Int. * : Intermittent service - solenoid energized not over 45% of the time and not longer than 1/2 hour at one time Fuses manufactured by: Gould Shawmut TR XX R Bussman FRN-R-XX (Replace X's with Fuse Amps) Reference Johnson Drawing A37786 Johnson Solenoid Coil and Fuse Specification Sheet Troubleshooting Contents General Troubleshooting General ERC and ERS Troubleshooting ERC Troubleshooting ERS Troubleshooting FAC Troubleshooting Preventative Maintenance Check List Preventative Maintenance Check List Additional For FAC Ceramic Electrode Plugs Electrode Lengths 8300 Series Relay Installation and Maintenance Intrinsically Safe Relay Installation and Maintenance [...]...Page 1 - General Troubleshooting LMTSO387-03 GENERAL TROUBLESHOOTING OF LIQUI-MOVER PUMPS OBSERVATION 1 Liqui-Mover pump fails to fill PROBABLE CAUSE REMEDY 1 Increase in liquid level in receiver, possible flood in receiver Obstruction in fill line, valve closed, inlet check valve backwards Inspect... Receiver flooding Restriction in vent line, 3-Way Valve assembly out of adjustment 3 Liqui-Mover pump fills very rapidly 1 Unit cycling almost normally, receiver flooding Defective check valve in discharge line Inspect discharge line check valve and and/or fill line Possible back flow to fill line check valve Refer to Liqui-Mover pump Assembly and Parts List Drawing 4 Noise in or at fill line check valve 1... Leave Resistor to 16, Remove 15-16 Remove Resistor to 16 Response Lamp Off Lamp On Lamp On Lamp Off THE JOHNSON LIQUI-MOVER PUMP CERAMIC ELECTRODE PLUGS PREVENTIVE MAINTENANCE TO: All Sales Personnel SUBJECT: ELECTRODE PLUGS The Ceramic Electrode Plugs supplied with Johnson Liqui-Mover pumps, are by the nature of their material, fragile While it is true that they can operate at high temperatures and... freely only 30 degrees If all appears proper, replace the wisker valve Refer to Dwg A-97-19-4-17, Pg 3 LIQUI-MOVER PUMP PREVENTATIVE MAINTENANCE CHECK LIST HOW OFTEN 6 Months CHECK REFERENCE Check electrodes for build up of foreign matter With build up, poor conductivity may occur creating erratic pumping behavior Remove cap on electrode holder Remove electrode plugs, this will also remove electrodes... FAC LIQUI-MOVER PUMP PREVENTATIVE MAINTENANCE CHECK LIST HOW OFTEN 1 Month CHECK REFERENCE 1 Oiler Level Should deliver (1) drop per week Adjustment screw 2 Blow down or clean as required Air Filter – Main 3 Air Filter – Secondary (Located on Control Head) 6 Months Blow down or clean as required 1 Remove 1-1/2˝ drain plug and flush Flush External Float Housing These items in addition to standard Liqui-Mover. .. OBSERVATION PROBABLE CAUSE REMEDY 1 3-Way Valve erratic Operates from one level only 1 Condensate level in Liqui-Mover pump at one level Electrode wires reversed Poor ground connection Refer to Relay Troubleshooting Section 2 3-Way Valve erratic Operates from low level only 1 Condensate level in LiquiMover pump at low level Electrode plugs shorted Electrode plug grounded Holding contact bad Refer to Relay... may be less than anticipated A 2-Way Controlled Valve may be required in discharge line 4 3-Way Motive Valve will not See observation under specific ERS deenergize or ERC Troubleshooting Section 2 Liqui-Mover pump fills too slow See specific remedy 1 No liquid level in receiver Load to unit not as great as anticipated No action required 2 Receiver flooding Obstruction or restriction in fill line Inspect... in Power failure Inspect for supply voltage Refer to Relay Troubleshooting Section 5 Relay will not pull in 2 3-Way Valve will not deenergize (open motive side – close vent side) 1 Relay pulls in Liqui-Mover pump flooded Replace fuse Refer to Valve Section Electrode circuit or relay malfunction Refer to Relay Troubleshooting Section 1 Relay drops out Receiver flooding Packing nut too tight Back off packing... not drop out Receiver flooding Electrode holder wet or dirty, probe or wire grounded Refer to Relay Troubleshooting Section 3 Relay will not drop out Receiver flooding Electrodes shorted Inspect Liqui-Mover pump chamber for debris Refer to Relay Troubleshooting Section 4 Relay drops out Receiver flooding 3-Way Steam Valve Assembly jammed Inspect 3-Way Solenoid Valve Assembly for obstruction, dirt, or... in liquid level in receiver, possible flood in receiver, increase in receiver pressure 3-Way Valve Assembly out of adjustment Inspect 3-Way Valve Assembly Refer to Valve Section 3 Receiver empty Liqui-Mover pump level fluctuating Receiver pressure greater than pressure in discharge line If unit has been in operation for a period of time without problems, check for traps blowing through If new installation . Handbook- 4002 What is a Liqui-Mover ® Pump? A Liqui-Mover pump is a positive displacement pressure powered pump with a minimum of moving parts. The pumping action. Air Supply Liqui-Mover Pump To 1/4" NPT Air Inlet Connection of Liqui-Mover Pump Throttle Valve (Globe) To Motive Inlet of Liqui-Mover Pump 1. This