LIQUI-MOVER PUMP HANDBOOK pptx

Abasic Liqui-Mover pump consists of a receiver/reservoir, pump tank, 3-way motive valve, inlet and outletcheck valves, level control, and various other fittings.. When the predetermined

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

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 intothe return line The Liqui-Mover pump can handle high temperature and high pressure condensate withoutdifficulty

Liqui-Mover pumps are available in nine sizes They are available in many configurations, from individualcomponents that are field assembled to complete packaged systems ready for connection to field piping Abasic Liqui-Mover pump consists of a receiver/reservoir, pump tank, 3-way motive valve, inlet and outletcheck 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 thenbreak 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 lineinto 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, theequalizing 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 pumptank 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 throughthe equalizing line, into the receiver/reservoir, enabling the pressures in the two tanks to equalize with eachother When this is complete, the flow of condensate from the receiver/reservoir to the pump tank will startagain 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.

Preparation

For ease of future maintenance, the Liqui-Mover pump should be installed with the check valve side of thepump tank most accessible Normally the motive inlet and the condensate discharge connections are on theleft when facing the check valves If a Johnson receiver is supplied, the replaceable sacrificial anode is alsoinstalled and removed from this end On ERC and FAC (pneumatic operated 3-way valve) units, the controlair 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 saddleswith ‘U’ bolts supported by (4) pipes on floor flanges The floor flanges have mounting holes for attachment

con-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 psigshould be piped to the pilot valve through a filter/regulator/lubricator on ERC and FAC models The pilotvalve 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, pipereducers should not be used and pipe runs kept to a minimum All hand valves should be full port if at allpossible

Electrical

Connect the electrical service to the on/off switch located on the door of the electrical enclosure per theinstruction label located near the switch The electrical voltage must be the same as the rating of the levelcontrol 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 theLiqui-Mover pump discharges the condensate out of the pump tank When properly adjusted, the dischargetime should not be less than 20 seconds A longer discharge time is acceptable, so long as the Liqui-Moverpump 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 thesudden 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 reducingvalve 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 isvented 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 sure drop under ‘flow conditions’

pres-5 A throttling valve should be installed immediately ahead of the 3-way motive valve so it can beused in conjunction with the PRV to adjust the Liqui-Mover pump discharge time Typically thethrottling valve is a globe valve

The above sketch is for reference only Always consult with the PRV and safety relief valve manufacturer orrepresentative for proper sizing and application of their products

Motive Supply Header - Steam or Compressed Air

Safety Relief Valve (Piped to safe location)

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 therecommended time

3 The above parts furnished by customer

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

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 imately 20 psig higher than the back pressure The throttling (globe) valve should be closed

approx-6 Open all remaining isolation (hand) valves, except the isolation valve ahead of the inlet checkvalve (fill line)

7 Once condensate in seen in the receiver, slowly open the isolation valve in the fill line andwatch for condensate to fill the pump tank

8 When the 3-way motive valve energizes, slowly open the throttling (globe) valve ahead of the3-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 themotive pressure to achieve a 20-25 second discharge time using the PRV

10 The unit is now in service

Discharged Condensate

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 EX B

Filter/Regulator/Lubricator Solenoid Pilot Valve

4-Way

Port 2 (Equalize)

Port 3 (Motive In)

Pilot De-Energized Pilot Energized

Pilot De-Energized Pilot Energized

Coil Voltage Freq Coil No Approx Current Fuse Service JOCO Fuse No.

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

Preventative Maintenance Check List

Preventative Maintenance Check List Additional For FACCeramic Electrode Plugs

Electrode Lengths

8300 Series Relay Installation and Maintenance

Intrinsically Safe Relay Installation and Maintenance

Page 1 - General Troubleshooting LMTSO387-03

1 Liqui-Mover pump fails to fill 1 Increase in liquid level in

receiver, possible flood in receiver.

Obstruction in fill line, valve closed, inlet check valve backwards.

Inspect fill line for closed valve, inlet check valve in reverse, or obstruction

in fill line Refer to Assembly & Parts List Drawing.

2 Increase 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.

be greater than anticipated Back pressure may be less than anticipated.

A 2-Way Controlled Valve may be required in discharge line.

4 3-Way Motive Valve will not deenergize.

See observation under specific ERS

or ERC Troubleshooting Section.

See specific remedy.

2 Liqui-Mover pump fills too

slow.

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 fill line for partially closed

valve or defective check valve.

Inspect fill line for proper size fittings and pipe Refer to Assembly and Parts List Drawing for specific unit.

Page 2 - General Troubleshooting LMTSO387-03

3 Receiver flooding Restriction in vent line, 3-Way Valve

assembly out of adjustment.

Inspect vent line for partially closed valve, proper size fittings and pipe Refer to Assembly and Parts List Drawing Inspect 3-Way Valve Assembly Refer to Valve Section.

3 Liqui-Mover pump fills very

Inspect discharge line check valve and fill line check valve Refer to

Assembly and Parts List Drawing.

4 Noise in or at fill line check

valve.

1 Vibration and water hammer

at fill line check valve.

Cold condensate Inspect for cold condensate Throttle

flow control valve, ahead of 3-Way Motive Valve Assembly Refer to Assembly and Parts List Drawing, and start-up procedure.

5 Liqui-Mover pump discharges

very rapidly.

1 Water hammer in discharge line.

Motive pressure too high Throttle flow control valve or install

pressure reducing valve See start-up procedure.

2 Receiver flooding, rise in receiver pressure during discharge.

Defective check valve in fill line, discharging condensate back into receiver.

Inspect fill line check valve Refer to Assembly and Parts List Drawing.

6 Liqui-Mover pump discharge

cycle too long.

1 Possible receiver flooding, discharge time greater than

30 seconds.

Flow control valve throttled too much No action required, if receiver not

flooding If receiver flooding, adjust flow control valve for discharge of

20 - 25 seconds (approx.).

Page 3 - General Troubleshooting LMTSO387-03

2 Receiver flooding Discharge time greater than 30 seconds.

Restriction or increase of back pressure in discharge line.

Inspect discharge line for partially closed valve(s), obstructions or change in pressure A pressure increase may require adjustment of flow control valve to reduce discharge time Inspect discharge check valve.

3 No motive pressure flow.

4 3-Way Motive Valve noisy Condensate in motive supply line Inspect motive supply line for

condensate Check drip trap Refer to Assembly and Parts List Drawing.

5 Receiver pressure increase during discharge.

3-Way Valve out of adjustment, leakage into receiver.

Refer to Valve Section.

6 3-Way Motive Valve will not deenergize.

See observation under specific Relay Section.

See specific remedy.

Page 4 - ERC or ERS Troubleshooting LMTSO387-03

GENERAL ERC & ERS TROUBLESHOOTING

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 Mover pump at low level.

Liqui-Electrode plugs shorted Liqui-Electrode plug grounded Holding contact bad.

Refer to Relay Troubleshooting Section.

3 3-Way Valve erratic 1 Condensate level can be high

or low.

Moisture in electrode holder Dirty electrodes Cracked or broken electrode plug.

Refer to Relay Troubleshooting Section.

Page 5 - ERC Troubleshooting LMTSO387-03

TROUBLESHOOTING – ERC UNITS

(w/Electrodes-Relay-Cylinder Operated Valves)

1 3-Way Cylinder Operated Valve

will not cycle on (closed

motive side – open vent side).

1 Relay pulls in Air pilot shifts.

Packing nut too tight Back-off packing nut Refer to Valve

Air pilot valve Check wiring, check for voltage to

pilot coil Check air pressure (55 psig minimum).

4 Relay will not pull in Power failure Refer to Relay Troubleshooting

Section.

5 Relay will not pull in Electrode circuit or relay malfunction Refer to Relay Troubleshooting

Section.

2 3-Way Cylinder Operated Valve

will not cycle off (open motive

side – closed vent side).

1 Relay drops out Air pilot shifts.

Packing nut too tight Back-off packing nut Refer to Valve

Section.

2 Relay drops out Air pilot not shifting.

Air supply or air pilot valve Check for proper air pressure Inspect

relay contacts for being welded together If okay, repair or replace pilot valve.

3 Relay drops out Air pilot shifts Receiver flooding.

3-Way Cylinder Valve Assembly jammed.

Inspect 3-Way Cylinder Valve Assembly for obstruction, dirt or foreign debris Refer to Valve Section.

4 Relay will not drop out.

3 3-Way Cylinder Operated Valve

cycles On–Off erratically.

1 Relay does not follow erratic valve operation.

Air supply fluctuating Inspect air supply for fluctuations Air

pilot requires 55 psig minimum.