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A Guide to Sustaining the Performance of

Pressure and Temperature Control Systems

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


Keep your
control
equipment
working

Sustained Performance Factors In plants where steam usage takes place at many different pressures,
pressure reduction allows the generation of steam at a single high pressure
In today’s competitive environment, and subsequent reduction to the desired pressure at the point of usage. This
with increasing energy costs,
industries want their steam systems enables economy of both, design – high pressure distribution pipelines are of
running at peak efficiency with least smaller bore – and operation, by reducing pressure at point-of-use thereby
down time. Process uptime depends reducing steam demand as well as improving process stability.
on the right steam at the right
quality, all the time.

Sustained performance depends on


three factors:
Design that enables maintenance,
not just performance and efficiency.

Selection and sizing that is


appropriate for current loads.

Operation and maintenance


practices that prevent failures.

A continuous improvement approach


covering all three factors is the only
way to achieve sustained high
performance over time. Steam Assets Should be Maintained for Sustained Performance

Despite exceptional product engineering and manufacturing, nothing lasts


> 90% Performance Rate
forever. All steam systems are vulnerable to issues such as corrosion,
buildup, and wear and tear, with time. With design, selection and sizing,
followed by scheduled maintenance and/or component replacement, these
problems can be avoided.
t
Disciplined continuous improvement
in Operation and Maintenance
practices can only go so far. Without
all three factors, shortened service
life problems will occur, impacting
plant-level and company-level
results, such as reliability, safety,
and energy efficiency.
Common Performance Issues Proper Operation and Maintenance Practices
Resolve Such Issues
Issues with non-functioning or unmaintainable systems
can affect the entire plant’s KRAs for process downtime, In a process plant, we observed that a pressure reducing
return on assets and efficiency. valve failed and the safety valve was stuck shut. This
resulted in the pressure exceeding safe operating levels
Process production issues due to steam pressure thereby damaging the equipment.
fluctuations, suboptimal pressure or ineffective
temperature control stability The safety valve was stuck shut and no drain
arrangement was made in the vent pipe which was
Poor quality steam hampering process oriented facing vertically upwards. Though this position
of the vent pipe is correct as per EHS guidelines, a drain
Steam loss through packing and valve gland leaks plug / valve should have been provided at the bottom of
the pipe. We suggested this modification in the vent pipe
Scaling, corrosion and erosion and after cleaning the safety valve, pressure relief was
established and the pressure reducing valve was
Reduced equipment reliability and life replaced.

Increased downtime / equipment repairs Note : Timely inspection and maintenance of the safety
valve would have prevented the failure and mitigated the
risk to personnel, equipment and production.

Poor Quality Instrument Air Causing Malfunction of


Pressure / Temperature Control Valves

During a site visit for chronic failure of a control valve,


the RCA (root cause analysis) revealed the presence of
moisture in the instrument air. This caused the
positioner, pilot valve and torque motor to fail
prematurely leading to malfunction of the control valve.

An air filter regulator was installed before the control


valve which resolved the issue of moisture removal from
the control air. This also resulted in streamlined and
trouble free operation of the control valve.

Poor Steam Quality and Presence of Foreign


Particles Cause Erosion and Damage the Seating
Area of Trim

Incorrectly conditioned steam directly supplied to the


pressure reducing valve results in poor steam quality
(poor dryness fraction) which in turn increases the
amount of corrosion.

Water droplets travelling at high steam velocities


alongwith foreign articles eroded the seating area of the
control valve trim.

After ensuring removal of the moisture by installing a


moisture separator before the control valve, the issue
was resolved. A strainer was also installed upstream to
protect it.
From I J Q
Boiler
Header Mainline Traps Boiler
(Drain) Pressure
3 1 3
Steam
P
4 4
G
D P

Best K
P O
E A B F
P
P
Practices to P
3
2
H L
3

Keep D
4
M
P
4

Pressure and 3 K
P O E A B F P

Temperature 4 P H L 5 8

Control K P
M P

Systems Up P
P E AC F O
H L 5
P

and Running M
P

P E AC F O P
7
H L 5
7 P
M

P E AC F O P
K K K

Pressure Control systems are vital Proper Sizing Proper Installation


for reducing steam pressure at the
point of use in process heat
applications. A. Prevent loss of precision from D. Ensure quality of steam coming
oversizing, where pressure drops into the unit by installing a
Pressure reducing valves should below the turndown range and moisture separator and strainer.
always be used in combination with
starvation from undersizing. E. Insulate components with
isolation and steam quality controls,
as with the Forbes Marshall B. Check that pressure reducing removable jackets instead of
Pressure Reducing Station stations are sized to between 15- fixed insulation so they do not
(FMPRS). 85% of operating range of trap moisture nor impede access
While some plants choose either pressure and flow parameters. to outdoor weather.
temperature or pressure control for PRS sizing should be rechecked F. Install valves upright. If not
steam in their process, the best in case of boiler change, plant possible, install at no more than
plants reduce pressure, then control expansions and process
temperature, giving them precise 45 deg from vertical.
process control and maximum modification. G. Keep at least 1.2 m in feedback
reliability. C. For temperature control valves, line downstream from PRV.
use similar guidelines: between H. Ensure quality of instrument air
Lines and fittings also play a role in
performance. 15-85% of range for steam for positioner and control valves
generation at plant. is maintained by installing an air
filter regulator.
Best Practices
E

From High Pressure PRS

3
P P 4

P
Steam System Asset
K
8 1 PRS - Direct Acting
8 P
P
6 2 PRS - PID Roboter Activated

3 Steam Pressure Monitoring Gauges


7 P L P N I
R 9 5 TCS - PID Controlled
O
6 TCS - On / Off

K 7 Temperature Monitoring Gauges

8 Steam Flow Metering

4 Syphon

9 Team

A-R Refer best practices given below


To Condensate Recovery System

Supervised Operation Preventive Maintenance Quick Response

I. Keep operating range N. Inspect and clean system Install hookups that permit online
between 40-60% of maximum components following maintenance, such as bypass and
boiler pressure for maximum maintenance schedules as isolation valves.
life. recommended in the product
J. Monitor and correct boiler water manual. Insulate components with removable
quality regularly to prevent O. Clean upstream and inbuilt traps jackets instead of fixed insulation so
corrosion. and strainers periodically. they do not trap moisture nor
K. Monitor the view glass and traps P. Operate and lubricate valves impede access.
regularly. periodically.
L. Monitor the quality of compressed Q. Check pipes and boiler corrosion Allow room for access to
air used to actuate control valves and water quality regularly as components for easy service.
to prevent moisture and fouling. sediment, acidity, and oxygen
M. Check calibration twice yearly, or can corrode condensate system
Keep a supply of precision-
after compressed air quality components.
engineered spare parts and
issues are found. R. Train all team members in replacements of critical items on
maintenance and repair hand.
procedures to be ready and
proactive and involve them in
repairs to keep skills fresh.
System Tips for Pressure/Temperature Control Reliability
Upstream assets, lines, and system-level factors in sustaining performance

From Boiler Header

Safety
Valve
Syphon

Y-Type Isolation
Strainer & Bypass Valves

Isotub
Air Vent
Diffuser

Compact Drain
Trap
Flowmeter
Plant Instrument Control Air
Distribution Heat Recovery
Header System
Vacuum
Breaker

Low Temperature
Process
TOFT
Circulation Module
Pump

SOPT
Module

To Condensate Recovery System

Sizing and Selection Installation Maintenance

Check boiler capacity and plant Shelter the unit from corrosive Inspect strainers and accessories
operating pressures. elements like rain, immersion, and before/after pressure reduction
chemicals. stations and process equipment
Select pressure reducing valves where steam is utilised.
with appropriate ratings. Allow easy access for maintenance
activity. This often reveals clogs and
Check sizing for the capacity your problems that affect the operation
plant is running at and the of the pressure reduction /
processes used. temperature control apparatus.

Guideline: Quality of steam influences life


and performance of these
Pressure turndown for 40:1 components.
pneumatic control
valve Check pipes and boiler corrosion
and water quality regularly as
Flow turndown for 40:1 sediment, acidity, and oxygen can
pneumatic control corrode condensate system
valve components.

Pressure turndown for 10:1


self-actuated pressure
reducing valve

Flow turndown for 4:1


self-actuated pressure
reducing valve
Safety Note: Check the Manual Before Engaging in Any Maintenance in this Booklet.

Read the safety notes in the product manual FIRST before installing/operating/maintaining the product. The
precautions listed in the manual are 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. See the manual for

System Reliability Tips


proper use and care.

Task Daily Monthly Quarterly Annually

Boiler House Ensure boiler is operated Ensure safety controls of Review non- Re-tighten electrical
in the correct pressure boiler systems are conformances and rectify. connections on boiler
band and plot the trend. working. Alternate standby Target focus on processes. controls, panels, meters,
Flag deviations. pumps. Maintain standby 1) Data discrepancy or fuel, feed water and ash
Ensure water quality. Flag systems ready for use. gaps in data. handling control systems.
deviations. 2) Establish critical Look for carbon build-up
Plot BWT profile. Flag components to be at connections and rectify.
deviations. maintained without
Check frequency and taking them off line.
quality of makeup water.

Lines, Moisture Carry out house keeping Ensure safety valves are Check insulation integrity Ensure calibration of
Separators and checks for leaks, functioning. and rectify. PG / TG.
Strainers vibrations, pressure / Ensure oil line strainers Ensure anti-corrosion
temperature gauge are clean. measures are intact –
readings. Flag deviations. Ensure MS drain and line paint, clamps etc.
traps are performing.
Flag deviations of load.

Process Plot distribution header Review changes in Ensure all auxiliary Ensure all PG, TG and
or local consumption operating requirements components – isolation sensors pertaining to
point pressure readings. if exceeding 80% or valves, traps, etc are steam utilities are
Flag deviations. below 40% of valve functional for critical calibrated.
Ensure instrument capacity. If deviation is equipment.
control air is maintained on a permanent basis, Lubricate valves.
at correct parameters. plan on resizing system.
Flag deviations. Ensure all isolation
Ensure electrical integrity valves are operational.
is maintained. Flag Lubricate as required.
deviations.

Corrosion in Pipelines Preventing Corrosion at the Source

Steam systems are also affected by scale, foaming, Optimum chemical dosing is critical.
carryover from boilers and corrosion.
Boiler water should be maintained at a pH of 10.1 to 11.
In a steam and condensate system, pipeline debris such Lower pH will cause rust and corrosion in the entire
as scale, rust, jointing compound, weld material and steam system.
other solids may find their way into the pipe line system.
These foreign particles mix with steam and get settled Dissolved oxygen should be scavenged either by
on the surfaces of internal components. Excess heating the water close to 100oC or by adding O2
dissolved oxygen in the steam and condensate lines scavenger chemicals in the boiler feed water.
leads to pitting corrosion.
Sodium sulphite can be fed into the boiler to prevent
pitting corrosion. However, excess sodium sulphite can
also cause an acidic condition.
Pressure Reducing Stations | Pressure Reducing Valves
Selection, Accessories and Maintenance

Forbes Marshall PID based


Pressure Control Valve
2

3
3
1

6
4 5 3

Forbes Marshall Roboter based


Pressure Control Valve

Component PID Robotor Pilot Clean Forbes Marshall Pilot Operated


Steam Pressure Reducing Valve
A. Hand wheel for manual
operation
B. Diaphragm chambers

C. Valve operational range


indication
D. Spindle sealing gland

E. Controller

F. Feedback pick up

Sr. No. Product Forbes Marshall Clean Steam


Pressure Reducing Valve
1. Moisture separator with trap

2. Pressure gauges with syphon and isolation valve


PMO: 7.6 barg

3. Isolation / bypass valve/s

4. Strainer

5. Pressure reducing valve

6. Safety valve SS316L

7. Clean steam pressure reducing valve


Maintaining Pressure Reducing Station (PRS)
Please refer to the maintenance schedule mentioned in the table below to undertake routine maintenance.
Sr. Parameters to be Checked Frequency for Checking Various Parameters
No.
Pressure Reducing Station Daily Weekly Monthly Quarterly Half-Yearly Annually
1 Clean strainer before pressure reducing station
2 Pressure gauge calibration
3 Safety relief valve testing
4 Cleaning and overhauling of safety relief valve
5 Feedback line cleaning

Maintenance
System Selection &
6 Draining of AFR
7 AFR filter cleaning
8 Check instrument air quality
Diaphragm Pilot Operated Pressure Daily Weekly Monthly Quarterly Half-Yearly Annually
Reducing Valve
1 Clean pilot valve strainer
2 Clean pilot valve chamber assembly kit
3 Check and clean main valve and main valve strainer
4 Check and clean main / pilot diaphragm
5 Clean SS tube and stud coupling with split pin
6 Pressure reducing valve overhauling and push rod
checking
Control Valve Daily Weekly Monthly Quarterly Half-Yearly Annually
1 Overhauling / checking / cleaning

Control Valve Actuator Daily Weekly Monthly Quarterly Half-Yearly Annually


1 Diaphragm and seal kit inspection
2 Actuator spring inspection
Control Valve Positioner Daily Weekly Monthly Quarterly Half-Yearly Annually
1 Pilot valve cleaning / checking
2 Calibration (zero / span)
3 Pressure / temperature gauge calibration
Robotor Daily Weekly Monthly Quarterly Half-Yearly Annually
1 Feedback line cleaning
2 Path restriction / response adjustment screw cleaning

Piston Valve Daily Weekly Monthly Quarterly Half-Yearly Annually


1 Manually operate the valve
2 Lubrication of piston valves
3 Visual inspection and cleaning of threads
Drain Trap Daily Weekly Monthly Quarterly Half-Yearly Annually
1 Manual operation of PC series valves
2 Strainer and internal cleaning of trap
3 Lubrication of valves
Clean Steam Pressure Reducing Valve Daily Weekly Monthly Quarterly Half-Yearly Annually
1 Clean all pipeline filters / strainers (remove elements
or screens to clean)
2 Clean all joints for leakage

Preventive Maintenance Guidelines


Before undertaking any maintenance on the product, it must be isolated from both the supply as well as the return line and any
pressure should be allowed to safely normalise to the atmosphere. The product should then be allowed to cool. With suitable
isolation, repairs can be carried out with the product on the line. When re-assembling, make sure that all joint faces are clean.
Once completed, open the isolation valves slowly and check for leaks.
Temperature Control System | Temperature Control Valve
Selection, Accessories and Maintenance

eValve

2 3

Ecotrol
6

3 5 4 3 1

Component eValve Ecotrol Piston


Actuated Valve
A. Hand wheel for manual operation

B. Diaphragm chambers

C. Valve operational range


indication
D. Spindle sealing gland

E. Controller Forbes Marshall Piston


Actuated Valve

Sr. No. Product

1. Moisture separator with trap

2. Pressure gauges with syphon and isolation valve

3. Isolation / bypass valve/s

4. Strainer

5. Temperature control valve

6. Positioner
Maintaining Temperature Control Systems (TCS)
Please refer to the maintenance schedule mentioned in the table below to undertake routine maintenance of
temperature control systems.

Sr. Parameters to be Checked Frequency for Checking Various Parameters


No.
Temperature Control System Daily Weekly Monthly Quarterly Half-Yearly Annually

1 Clean strainer before temperature control valve


2 Pressure / temperature gauge calibration
3 Safety relief valve testing
4 Cleaning and overhauling of safety relief valve
5 Draining of AFR
6 AFR filter cleaning
7 Check instrument air quality
8 Check / change temperature sensor thermowell oil
Control Valve Actuator Daily Weekly Monthly Quarterly Half-Yearly Annually
1 Diaphragm and seal kit inspection
2 Actuator spring inspection
Control Valve Daily Weekly Monthly Quarterly Half-Yearly Annually
1 Overhauling / checking / cleaning
Control Valve Positioner Daily Weekly Monthly Quarterly Half-Yearly Annually
1 Pilot valve cleaning / checking
2 Calibration (zero / span)
3 Pressure / temperature gauge calibration
Robotor Daily Weekly Monthly Quarterly Half-Yearly Annually
1 Feedback line cleaning
2 Path restriction / response adjustment screw cleaning
Piston Valve Daily Weekly Monthly Quarterly Half-Yearly Annually
1 Manually operate the valve
2 Lubrication of piston valve
3 Visual inspection and cleaning of internals
Drain Trap Daily Weekly Monthly Quarterly Half-Yearly Annually
1 Manual operating of PC series valves
2 Lubrication of valves
3 Strainer and internal cleaning of trap

Preventive Maintenance Guidelines


Before undertaking any maintenance on the product, it must be isolated from both the supply as well as the return
line and any pressure should be allowed to safely normalise to the atmosphere. The product should then be
allowed to cool. With suitable isolation, repairs can be carried out with the product on the line. When re-assembling,
make sure that all joint faces are clean. Once completed, open the isolation valves slowly and check for leaks.
Pressure Reducing Station (Pilot Operated) Asset Care
Troubleshooting

Failure Mode Possible Cause Remedy Skill


Responsibility
Downstream pressure Pressure adjustment bolt a. Rotate it clockwise slowly to set Operations
zero or too low loose the downstream pressure.
b. Allow stabilisation time and lock.
Main valve lift disturbed Check that pushrod lock nut is Operations
intact and in full tightened
condition. If the lock nut is loose,
there is a chance that the main
valve lift may be reduced and will
have to be readjusted.

Clogged control pipes a. Ensure pilot valve strainer, Maintenance


control pipe assembly and SS
hex coupling fixed to bottom
diaphragm chamber are clean.
If clogged, clean it properly.
b. Check the internal balancing
line for blockage.
Main diaphragms damaged If main diaphragms are Maintenance
permanently deformed or
punctured, replace them. Follow
OEM’s replacement schedule.

Jammed push rod Check if push rod is jammed in Maintenance


liner bush at lower position. Open
and clean. Replace if scored.
Downstream pressure Pressure adjustment bolt fully Rotate the pressure adjustment Operations
is equal to upstream tightened bolt anti-clockwise and loosen it
pressure completely. Set the downstream
pressure to zero and readjust the
required downstream pressure by
slowly rotating the pressure
adjustment bolt clockwise.

Downstream pressure not Check the pilot valve / main valve Operations
responding to adjustment bolt for leakages. To do so,
rotation a. Close the upstream isolation
valve
b. Loosen the pressure
adjustment bolt and set the
downstream pressure to zero
c. Remove the SS tubing from the
pilot valve chamber and centre
the T-joints
d. Open the upstream isolation
valve slowly and check for
steam leakage
e. If steam is escaping from the
pilot valve chamber, it means
the pilot valve is leaking
f. Clean the pilot valve or replace
it, if required
g. Steam escaping from the ‘T’
joint indicates that either the
main valve is leaking or the
main valve return spring is
broken
h. Clean and lap the main valve
head or replace the MV return
spring if found broken
Pressure Reducing Station (Pilot Operated) Asset Care
Troubleshooting

Failure Mode Possible Cause Remedy Skill


Responsibility
Downstream pressure Check the control orifice Clean it if found clogged Maintenance
is equal to upstream
pressure
Check pilot diaphragm Replace if found deformed or Maintenance
damaged

Hunting Sticking of push rod in the Check that the main valve push Maintenance
main valve chamber rod is not sticking. Open and
clean it
Check the outer surface of
the push rod. Replace if deformed

System Troubleshooting
Diaphragms over-stretched / If pilot diaphragms or main Maintenance
permanently deformed diaphragms are overstretched /
deformed, replace them

PRV sizing Set the PRV in no flow condition, Operations


i.e.; close all process valves. Now
apply full load to the PRV by
opening all the process valves. If
the downstream pressure drops
excessively during full load
condition but is maintained by
opening of bypass valve, it is likely
that the valve is undersized. In
such a case, replace the valve.
Refer the PRV sizing chart given
in the technical information sheet
or consult a Forbes Marshall
engineer for correct sizing of the
valve.

Check split pin (NRV) port Check the port is clean and the Maintenance
split pin is free to move
Pressure / Temperature Control Valve Asset Care
Troubleshooting

Failure Mode Possible Cause Remedy Skill


Responsibility
No flow at the outlet No flow at valve inlet Open all isolation valves in loop Operations

Flange protection cap may not Ensure that the flange Operations
have been removed protection covers are removed
before installation
Handwheel position Check hand-wheel position Operations
(For NC it should be open)

No signal to positioner (4-20mA) Check wire continuity and Maintenance


connections to the positioner and
correct if found wrong
Actuator diaphragm failed Replace the actuator diaphragms Maintenance

Actuator spring broken Replace the actuator spring Maintenance

Inadequate flow Insufficient air supply Supply inlet air pressure as stated Operations
in actuator manual / name plate

Blockage in the piping system / Check pipeline / strainer for Maintenance


upstream strainer blockage and clean it

Incorrect valve sizing / wrong Check valve sizing as per Operations


Kv value selection required parameters

Incorrect calibration of positioner Recalibrate the positioner with Maintenance


respect to 4-20mA

Actuator diaphragm failed Replace the actuator diaphragms Maintenance

Actuator spring broken Replace the actuator spring Maintenance

In-line valve leakage in Dirt / foreign particles in plug Check plug / seat assembly for Maintenance
closed condition seating area foreign particles, clean and lap it

Sealing area of plug and seat Replace plug and/or seat Maintenance
damaged

Closing force of the actuator too Check actuator diaphragm Maintenance


low condition and replace the
diaphragms if found damaged

Improper tightening of valve Apply correct torque along with Maintenance


bonnet bolts correct sequence as mentioned
in user manual
Improper calibration Recalibrate valve system (At Maintenance
(At 4mA: shut-off condition shift) 4mA : valve to be perfectly shut)

Leakage from stem seal / Chevron seal damaged Replace sealing kit Maintenance
Gland nut

Improper tightening of gland nut Apply correct torque while Maintenance


tightening gland nut as mentioned
in user manual
Pressure / Temperature Control Valve Asset Care
Troubleshooting

Failure Mode Possible Cause Remedy Skill


Responsibility

No movement of stem Chevron seal damaged Replace sealing kit Maintenance

Actuator stem damaged Replace the stem with bush Maintenance

Guide / gland bush damaged Replace guide / gland bush along Maintenance
with chevron set

Actuator diaphragm failed Replace the actuator diaphragms Maintenance

Actuator spring broken Replace the actuator spring Maintenance

Stem hunting Incorrect valve travel Check valve sizing as per required Operations
parameters

Positioner failure Check postioner condition Maintenance


(span and zero setting)

Improper tuning of PID controller Tune the PID controller of control Maintenance
valve

Valve opening completely Reversal in signal connections Reverse the signal polarity Maintenance
at start
Electro Pneumatic Positioners (Series 830/831 WP/EX)
Selection, Accessories and Maintenance

Positioner Electro Pneumatic Positioner 831-WP


(With Feedback)

Nomenclature / Model No. Electro Pneumatic Positioner 830-WP

8 3 0 - W P

83 Series Positioner

0 - Normal
1 - With Feedback Transmitter

Always "-"

Wp - Weather Proof IP66


Ex - Explosion Proof IIB & IIC

Maintaining Positioners
Please refer to the maintenance schedule mentioned in the table below to undertake routine maintenance of
positioners.
Sr. Parameters to be Checked Frequency for Checking Various Parameters
No.
Daily Weekly Monthly Quarterly Half-Yearly Annually
1 Clean the compressed air AFR (Air Filter Regulator)
2 Clean the compressed air dehumidifying system
3 Piston valve cleaning and checking
4 Positioner calibration
5 Gauge calibration

Preventive Maintenance
1. If the quality of the supply air is fouled, then the positioner may not operate normally. Moist air may damage the
pilot valve/ torque motor and cause positioner to malfunction / become defunct. The requirement for a quality air
supply can be found in the instrument society of America’s “Quality Standard for Instrument Air” (ISA-S7.3) or
BS 5967:Part 2. Basically, this standard calls for the following-
Particle Size – The maximum particle size in the air stream at the instrument should be no larger than 3µ
Dew Point – The dew point - at line pressure - should be at least 10 OC below the minimum temperature to
which any part of the instrument air system is exposed at any season of the year.
2. When the fixed orifice is clogged with carbon particles or others, remove the pilot valve auto / manual changeover
screw (built-in fixed aperture) and clean it by inserting a 0.2 wire (provided on the inside of the positioner cover)
into the aperture. If it is required to be replaced with a new one, stop the supply pressure and remove the stopper
screw of the pilot valve.
3. There should not be any air leakage from the tubing. Use pipe sealant sparingly, only on the male thread of the
tube fittings. A non-hardening sealant is strongly recommended.
Installation and Calibration
a. Check that the pneumatic pipes/ tubing are properly flushed.
b. Connect the wires from the controller, at the terminal block of the positioner. “+” & “-“ signs are printed at the
terminal block of the positioner for the ease of connection. The grounding terminal should also be connected.

1 2 3 4 5 6 Sr No. Part Name

1 Lift indicator

2 Link

3 Threaded pin

4 Stroke
scanning lever

5 Positioner
mounting
bracket

6 Positioner

c. Connect the feedback lever to the control valve’s link mounted on the valve’s lift indicator. Apply 50% signal (i.e.12
mA DC) and position the stroke scanning pin / positioner in such a way that the feedback lever is at 90O.
d. For best performance, the movement of the feedback lever should be between +15~200 to –15~200 from the 900

Positioners Asset Care


(horizontal position set at 50% signal). Please check that, while setting the full stroking angle, the feedback lever
should not foul with the stoppers provided near the feedback lever connection point on to the positioner.
e. Position the span lever as per the actuator function i.e. ATO (air to open) or ATC (air to close), as explained under.

ATC Actuator ATO Actuator

ATC ACTUATOR ATO ACTUATOR

Span Lever Fixing Screw

Lock Screw
Lock Screw

OUT2 OUT2
OUT1
OUT1

Span Lever Fixing Screw


SUP
SUP
AIR
AIR

To change the position of the span lever, the lock screw, should be loosened slightly, to avoid damage to the
feedback spring. After reorienting the lever to the desired position, the lock screw should be tightened carefully.
While changing the position of the span lever, take care not to stretch the feedback spring. OUT2 port is not to
be used, unless confirmed from works.
f. Apply, starting signal (4 mA) and turn the zero setting adjuster, to set the zero setting (clockwise rotation of the
adjusting wheel will increase the pneumatic supply to the actuator, to decrease the supply to actuator rotate the
adjuster in CCW direction).
g. Then apply 100% signal (20 mA), if the valve is not taking 100% stroke then slightly loosen the lock screw mounted
on the span lever, rotate the knob on the span lever to achieve the full stroke position. After setting the span, again
check the zero setting at 4mA and set if found disturbed. After setting, carefully tighten the lock screw of the span
lever.
Note : The positioner can be set in split range also (i.e. 4~12 mA or 12~20 mA), as described below-
Split range 4~12mA – Set zero at 4mA and span at 12mA for 100% valve travel. Recheck zero after setting span.
Correct, if found disturbed.
Split range 12~20mA - Set zero at 12mA and span at 20mA for 100% valve travel. Recheck zero after setting
span. Correct, if found disturbed.
Positioners Asset Care
Troubleshooting

Failure Mode Possible Cause Remedy Skill


Responsibility
No response when input Too low or no supply pressure Check supply pressure Operations
signal is applied

Wrong wiring of (+ve) and (-ve) Correct (+ve) and (-ve) Operations
terminals

Short or open circuit of torque Replace motor unit Maintenance


motor

Clogged nozzle Clean the nozzle with the help of Maintenance


wire provided in the positioner
cover or replace the motor unit
Loose or wrong setting of Correct the setting / tighten Operations
feedback lever

Valve operates only for Wrong orientation of span Correct to the required position Operations
0% and 100% signals i.e. switch
no response for
in-between signals and “A-M” screw is disturbed Fully tighten the “A -M” screw Operations
actuator operates only (it has two O rings)
to on or off position
Wrong connection of OUT1 Correct the pneumatic connection Operations
and OUT2 ports with respect to the position of
SPAN adjustment switch
Output pressure raised Leakage of A/M switch Tighten or replace O rings of Maintenance
and stays, does not come A/M switch
down
Wrong orientation of span Correct to the required position Operations
switch

Actuator diaphragm failed Replace the actuator diaphragms Maintenance


Positioners Asset Care
Troubleshooting

Failure Mode Possible Cause Remedy Skill


Responsibility

Output pressure is Clogged fixed orifice Clean the orifice with the help of Maintenance
operated by A/M switch wire provided in the positioner
only cover

Clogged nozzle Clean the nozzle with the help of Maintenance


wire provided in the positioner
cover or replace the motor unit

Disturbed compensation / Correct the positioning of Operations


stabiliser spring stabilizer spring

Downstream pressure Clogged fixed nozzle Clean the nozzle with the help of Maintenance
hunting wire provided in the positioner
cover or replace the motor unit

Incorrect linearity Wrong setting of feed back lever Readjust the setting of the Operations
feed back lever

Wrong zero, span adjustment Readjust the zero and span Operations

Supply pressure is unstable Check the air leakage from the Maintenance
pneumatic supply or replace the
air filter regulator

Loose pneumatic connections in Check and correct Operations


the actuator or positioner
Balance of Systems
Conditioning and Isolation

Steam going to a pressure / temperature control valve must be conditioned to avoid damages or sub-optimal
performance. This includes managing quality of steam, steam conditioning and positive isolations.

Strainer Moisture Separator

Isolation Valve (Piston Valve) Clean Steam Moisture Separator

Vacuum Breaker 1. Strainer of mesh 0.8mm perforation screen max.


2. Moisture separator to be flushed prior to
installation
3. Piston valves (3) per pressure reducing station
(PRS) and temperature control system (TCS)
4. Gland seals to be nipped up (ensure valve in
closed position only) when seen to weep
5. Lubrication oil (Molykote M30)
6. Loctite anti-seize threaded compound 767 high
performance conforms to ML-A-90-7-E
Maintenance Schedule

Sr. Parameters to be Checked Frequency for Checking Various Parameters


No.
Strainer Immediately Daily Weekly Monthly Quarterly Half-Yearly Annually

1 Clean the screen

Piston Valve Immediately Daily Weekly Monthly Quarterly Half-Yearly Annually

1 Manually operate the valve

2 Lubrication of piston valves

3 Visual inspection and cleaning of


threads
4 Refilling of loctite anti-seize (in
grease cap) for DN 15/20/25
Steam Trap Immediately Daily Weekly Monthly Quarterly Half-Yearly Annually

1 Test high pressure steam traps


(17.5 bar g and above)
2 Test medium pressure steam traps
(3.5 to 17.5 bar g)
3 Test low pressure steam traps

4 Repair / replace steam traps - when


testing shows leaks
5 Clean strainers of float traps

Accessories Asset Care


6 Clean internals of float traps

7 Clean internals / strainer of


thermodynamic trap
8 Clean internals of balanced
pressure trap
9 Visual inspection for leakages

10 Arresting leaks

11 Valve operation for PC series traps

Clean Steam Moisture Separator Immediately Daily Weekly Monthly Quarterly Half-Yearly Annually

1 Clean baffle plate

2 Clean and replace seal

Preventive Maintenance Guidelines


Before undertaking any maintenance on the product, it must be isolated from both the supply as well as the return
line and any pressure should be allowed to safely normalise to the atmosphere. The product should then be
allowed to cool. With suitable isolation, repairs can be carried out with the product on the line. When reassembling,
make sure that all joint faces are clean. Once completed, open the isolation valves slowly and check for leaks.
Strainers Asset Care
Troubleshooting

Failure Mode Possible Cause Remedy Skill


Responsibility
No flow through strainer Strainer screen is clogged with Flush inline drip leg and clean the Maintenance
rust or debris screen. If screen is rusted, replace
with a new screen
Increased pressure drop Screen is blocking up Clean or replace the screen Maintenance
across the strainer

Fluid leakage from Gasket deterioration or damage Replace gasket and tighten the Maintenance
strainer flange cap / bolts to the recommended
torque

Moisture Separators Asset Care


Troubleshooting

Failure Mode Possible Cause Remedy Skill


Responsibility
Not draining moisture Drip leg or drain trap assembly Remove the drain trap assembly Maintenance
blocked and flush the drip leg. Clean the
drain trap assembly
Steam leaking Flange gasket damaged Remove and replace the gasket Maintenance

Vacuum Breaker Asset Care


Troubleshooting

Failure Mode Possible Cause Remedy Skill


Responsibility

Steam leakage from cap Gasket worn out Replace gasket Maintenance /
and body joint Operation
Isolation Valves Asset Care
Troubleshooting

Failure Mode Possible Cause Remedy Skill


Responsibility
Inadequate flow rate at The piston valve is not Ensure the piston valve is Operation
outlet completely open completely open

Fluid leakage from end End connection is not tight Tighten the end connection with Maintenance /
connection proper torque for flange end and Operation
tighten the screwed end piston
valve
Fluid leakage from Sealing stack worn out For piston valve of sizes DN15-50 Maintenance /
bonnet and body if any leakage is observed through Operation
bonnet hole,
a. lose the valve till the
handwheel touches the bonnet
b. tighten all the nuts equally by
¼ turn until leakage stops.
c. If leakage does not stop
dismantle the valve replace the
seal stack.

Note: Never tighten nuts when


valve is in open condition.

Piston is damaged or corroded Check if piston is damaged due to Maintenance


scouring, corrosion of the piston
valve. If damaged, replace with
new piston kit.

Excessive force is Seizing of the piston valve Lubricate the piston valve using Maintenance
required to turn the Molykote M30 lubricating oil on a
handwheel quarterly basis. For sizes DN15-50
lubricate spindle through the hole
provided in the bonnet and spindle
threads and for sizes DN65-200
lubricate between the spindle and
threaded bush at the upper part of
bonnet and stem and also spindle
at the lower part of the bonnet.
Balance of Systems
Monitoring and Safety

Steam going to the process should be monitored for the correct pressure and in case of pressure overshoot,
excess pressure should be released to avoid process breakdown.

Safety (Open Bonnet Type) Relief Valve Safety Valve

Pressure Gauge Temperature Gauge

a. Safety valve discharge vent pipe should be routed to a safe location


b. Make a proper drain arrangement in the safety valve discharge vent pipe
c. Pressure gauges to be installed with an isolation valve and syphon
d. Temperature gauges in steam line / water lines to be installed alongwith the thermowell filled with oil
Maintaining Safety Relief Valves

Sr. Parameters to be Checked Frequency for Checking Various Parameters


No.
Strainer Daily Weekly Monthly Quarterly Half-Yearly Annually

1 Visual inspection for leakages

2 Testing of safety relief valve

3 Cleaning of internals

Safety Valve Asset Care


Troubleshooting

Failure Mode Possible Cause Remedy Skill


Responsibility
Valve leakage Check for spring range Refer to the spring ranges given Operations
in the user manual of the product
or contact a Forbes Marshall
engineer.

Steam leaking Valve seating surface dirty or It is sufficient to clean the seating Maintenance
damaged surfaces and reassemble. If the
seating surface is damaged, relap.
When reassembling, ensure all
foreign matter and scales are
cleared away from surrounding
components, all lapping paste
removed and seating surface
cleaned.
Not releasing the Check the pressure setting of a. It should be 10% above the Operations
pressure the valve working pressure of the system
b. Ensure spring range selected is
within the given range
Maintaining Pressure Gauges

Sr. Parameters to be Checked Frequency for Checking Various Parameters


No.
Strainer Daily Weekly Monthly Quarterly Half-Yearly Annually

1 Working condition

2 Visual (dirt, glass broken, dent or damages)

3 Pointer position (zero position and pointer shift)

4 Calibration

Pressure Gauges Asset Care


Troubleshooting

Failure Mode Possible Cause Remedy Skill


Responsibility
No indication in the Connection / inlet location Remove pressure gauge from Maintenance /
gauge choked or blocked mounting location and check the Operation
process connection / inlet location
for any choke or blockage
Steam Operated Pump Trap (SOPT)
Accessories, Installation and Maintenance

The Forbes Marshall Steam Operated Pump Trap (SOPT) is a pumping trap operated by steam and is used to
remove condensate from the process plant under all operating conditions including vacuum / stall.

Recommended SOPT installation diagram 1 50 NB Isolation Valve

2 50 NB Forbes Marshall FMSTR31


Air vent elevation
Strainer 0.8 Mesh
higher then steam inlet 3 40 NB Forbes Marshall Disk check valve
process
(FMDCV )
4 15 NB Forbes Marshall Screwed Strainer
(FMSTR51 ) Dutch Weave type
5 15 NB Forbes Marshall Piston valve
6 Pressure Gauge with syphon

(25 NB min)
7 15 NB Forbes Marshall Thermodynamic
trap
8 15 NB Forbes Marshall Soft seated Disc
check valve
9 15 NB Forbes Marshall Air vent

10 25 NB Forbes Marshall Piston Value

Dimensions (in mm) and Material Table

Sr.No Description Material

1 Base SG Iron ASTM A395 / EN-JS1025

2 Cover SG Iron ASTM A395 / EN-JS1025

3 Hex Head / Hex Socket Head ISO 4762 / ASTM A193 B7


Cap Screw M12

4 DN 40 FMDCV Stainless Steel

5 DN 40 #150 Flange ASTM A105

6 DN 15 Steam Inlet (Screwed BSPT) SG Iron ASTM A395 / EN-JS1025

7 DN 25 Steam Exhaust (Screwed BSPT) SG Iron ASTM A395 / EN-JS1025

8 Main Flange Gasket Graphite

9 Internal Mechanism Stainless Steel


Installation Guidelines
1. To prevent condensate backing up into the equipment being drained, the inlet pipework should be
sufficiently sized to accumulate at least 10 ltr of condensate during the pump’s discharge cycle.
2. A Y-type strainer with 0.8 mm perforation screen size to be fitted at the condensate inlet of the SOPT.
3. Recommended installation head from the base of the unit is 0.45 m
4. The motive steam inlet pipe should be at least 25m from the steam header and can be reduced to 15NB
when the motive steam pipework is close to 0.5m to the pump.
5. An air vent must be fitted at higher elevation than inlet to the process
6. The outlet piping should be sized to take into account the effects of flash steam at the heat exchanger’s full
load operating conditions.

Maintaining Steam Operated Pump Trap (SOPT)


Please refer to the maintenance schedule below to undertake routine maintenance of the SOPT

Sr. Parameters to be Checked Frequency for Checking Various Parameters


No.
Immediately Daily Weekly Monthly Quarterly Half-Yearly Annually

1 Cleaning of strainers

2 Visual inspection of leakages

3 Arresting leaks

4 Checking of SOPT

SOPT Asset Care


5 Repair SOPT when testing shows
leaks

6 Visual inspection of maintained


mechanism for damage and clean it
if required

7 Clean the inlet swing check valve,


sealing faces of the seat and flap

8 Clean the two outlet orifices to


ensure it is free from dirt and debris

Preventive Maintenance Guidelines


Before undertaking any maintenance on the product, it must be isolated from both the supply as well as the return
line and any pressure should be allowed to safely normalise to the atmosphere. The product should then be
allowed to cool. With suitable isolation, repairs can be carried out with the product on the line. When reassembling,
make sure that all joint faces are clean. Once completed, open the isolation valves slowly and check for leaks.
Steam Operated Pump Trap (SOPT) Asset Care
Troubleshooting

Failure Mode Possible Cause Remedy Skill


Responsibility
SOPT fails to No motive pressure Increase the motive supply pressure to Operation
operate on exceed total back pressure
start up
Inlet isolation valve maybe closed a. Check if inlet pipe is free from Maintenance
obstructions
b. Ensure isolation valve is open
Motive inlet and exhaust lines Ensure Motive = In, Exhaust = Out Operation
incorrectly connected

The rate of condensate produced Ensure the process being drained is Operation
by the process maybe very low operating correctly
causing the SOPT to have slower
cycles
Equipment flooded Blocked exhaust line a. Ensure balanced line is free from Maintenance
and SOPT stopped obstruction
cycling b. Check the balanced line for
waterlogging

Blocked condensate inlet line a. Inspect and clean the strainer mesh Maintenance
b. Check for blockages
Blocked condensate outlet line Inspect outlet line for blockages Maintenance

Damaged mechanism a. Ensure mechanism operates as Maintenance


shown in working principle section of
the user manual
b. Replace malfunctioning part
No motive steam available a. Ensure steam supply to SOPT is Operation
available and at the correct pressure
b. Ensure motive pressure exceeds
total backpressure
Steam Operated Pump Trap (SOPT) Asset Care
Troubleshooting

Failure Mode Possible Cause Remedy Skill


Responsibility
Equipment flooded Leaking motive inlet valve If SOPT body is hot, it indicates the Maintenance
and SOPT stopped SOPT mechanism is stuck on the
cycling discharge cycle.
a. Check mechanism for excessive
friction
b. Check motive inlet valve and spring
c. For correct operation, replace
malfunctioning part

Broken spring If SOPT body is cold, it indicates the Maintenance


SOPT mechanism is stuck on the filling
cycle.
a. Check the pump mechanism spring
b. Replace malfunctioning part

Equipment flooded SOPT is undersized for the Ensure system parameters agree with Operation
but SOPT appears application the custom sizing sheet / graph
to have normal
cycles
Chattering / banging Live steam entering discharge line a. Ensure steam traps draining the Maintenance
in SOPT discharge motive supply line are discharging to
line a non-flooded condensate return.
b. Ensure the condensate return is
adequately sized.

Chattering / banging Hydraulic pulsing of the inlet a. Reduce installation head to SOPT Operation
of SOPT inlet check check valve. b. Install throttling valve on SOPT
valve flap condensate inlet.
Compact Module-Two Orifice Float Trap (CMTOFT)
Maintenance and Accessories

Compact Module Two Orifice Float Trap (CMTOFT) and its Accessories

(3) (2)

(1)

Sr. No. Part


(5)

1 Inlet valve

(4) 2 Outlet valve

3 Bypass valve

4 Strainer

5 Trap monitor sensor port

(6) 6 Steam lock release

Available Options

Installation Guidelines
1. Determine the correct installation location/position and the direction of fluid flow.
2. Remove protective covers from all connections where appropriate, before installation.
3. If the trap is to discharge to atmosphere ensure it is to a safe place, the discharging fluid may be at a
temperature of 100°C (212°F).
4. The trap must be fitted with the float arm in a horizontal plane so that float arm rises and falls vertically
therefore the arrow on the name-plate point downwards as shown in the figure below.

Size: Code:

CMTOFT
PMO
PMX
PMA
TMO
5. The arrow on the casting should be in the direction of the flow (refer alongside). Arrow
on casting
6. Check for normal discharge pattern and leaks if any.
7. Typical installation of Compact Module Two Orifice Float Trap (CMTOFT)
steam utilising equipment.

Installation of Compact Module Two Orifice Float Trap [CMTOFT]

CMTOFT

Maintaining Compact Module Two Orifice Float Trap (CMTOFT)

Please refer to the maintenance schedule below to undertake routine maintenance of compact module two orifice
float traps.

Sr. Parameters to be Checked Frequency for Checking Various Parameters


No.
Immediately Daily Weekly Monthly Quarterly Half-Yearly Annually

1 Check CMTOFT

2 Repair / replace steam trap when


testing shows leaks
3 Clean strainers of CMTOFT

4 Clean internals of CMTOFT

5 Visual inspection for leakages

6 Arresting any other leaks

7 Operation of inlet, outlet and


bypass valves
CMTOFT Asset Care

Preventive Maintenance Guidelines


Before undertaking any maintenance on the product, it must be isolated from both the supply as well as the return
line and any pressure should be allowed to safely normalise to the atmosphere. The product should then be
allowed to cool. With suitable isolation, repairs can be carried out with the product on the line. When reassembling,
make sure that all joint faces are clean. Once completed, open the isolation valves slowly and check for leaks.
Compact Module Two Orifice Float Trap (CMTOFT) Asset Care
Troubleshooting

Skill
Failure Mode Possible Cause Remedy Responsibility

Not No condensate is discharged, Check the installation. Check the flow Installation
discharging and the surface temperature direction arrow on the cover casting and Team
at all of the trap is low the name plate arrow on the base casting.

Check for blockage in the strainer. Maintenance

If the actual differential pressure is higher Operation


than the design pressure, the steam trap
would have failed in closed position as the
float buoyancy will not be adequate to open
the valve seat.

Check for the valve and seat assembly Maintenance


for blockage

Check if the ball float is punctured. If so, Maintenance


replace it. Post replacement, check for
water hammering in process to avoid
recurrence.

No condensate is discharged, The trap is getting steam locked. Operation


and the surface temperature of Adjust the steam lock release setting
the trap is high by first dosing it fully and then opening it by
1/4th turn.

Leaking Live steam continuously Check the installation. The arrow on the name Installation
steam leaking through the outlet plate should point downwards. Team

Check valve and seat assembly for any


deposits and clean it. Maintenance

i) Clean and lap the seating area. Maintenance


ii) Lightly stamp an SS ball on the seating area.

Check for SLR leakage/setting check for Operation


air vent leakage.

Steam leakage from the Tighten the cover nuts and bolts to the Maintenance
mating faces of the base frame recommended torque.
and cover of steam trap
Check the gasket for any possible Maintenance
damage and replace it if required.
Compact Module Two Orifice Float Trap (CMTOFT) Asset Care
Troubleshooting

Skill
Failure Mode Possible Cause Remedy
Responsibility

Not Reduced condensate Check parameters and trap sizing. Operation


discharging carrying capacity The trap will not discharge enough condensate if
enough of the trap the actual size is less than the recommended
condensate size based on the condensate load.

Check for back pressure and corresponding Maintenance


discharge capacities as per the capacity charts.

i) Replace/repair the leaking and non-working


traps with working traps. The leaking traps may
create/increase the back pressure on the
working traps connected to the same return
line

ii) If there is more than one trap discharging


in a single condensate return line, then ensure
all the traps have an NRV installed on the outlet of
each trap

iii)Ensure all the by-pass valves are closed. If the


bypass valve is leaking or if it is kept open in
closed loop condition, it creates / increases back
pressure on the other working traps, connected to Operation
the same return line.

Flooding of condensate Check whether the inlet strainer is partially blocked.


Maintenance
Check thermostatic valve seat orifice for blockage.
If blocked, clean and lap.

Check main valve seat orifice for blockage.


If blocked, clean and lap.
Inventory for timely response and preventive
maintenance

Forbes Marshall engineers can advise on spares


based on our experience across industries. We
consider logistics, criticality of your downtime, and
your risk profile to help you decide how many spares
and replacements to have on hand. Always specify
that Forbes Marshall genuine spares should be used
in your plant, as they are precision engineered and
manufactured with care in our facilities.

Pressure Reducing Station with Pressure Reducing Stations with Electro Pneumatic
Pilot Operated Pressure Reducing Valve (PRS-PO) Positioner / Roboter Based Control Valve
(PRS-PID/ROB)
7
11
10 6
12 12 6 6
4 5 2 8
1 10
8 4 11
3 7 12 12
2 3 5
1
Steam Steam
Inlet Outlet

9 9

Components of PRS-PO Components of PRS-PID / Roboter


No. Component No. Component
1 FM Piston valve - inlet isolation 1 FM Moisture Separator
2 FM Piston valve - bypass 2 FM Piston valve - inlet isolation
3 FM Strainer 3 FM Strainer
4 FM Pilot operated pressure reducing valve 4 FM Control valve with electro pneumatic positioner/roboter
5 FM Piston valve - outlet isolation 5 FM Piston valve - outlet isolation
6 FM Safety relief valve 6 FM Safety relief valve
7 FM Piston valve - for pressure balancing 7 PID controller
8 FM Moisture separator 8 FM Piston valve - bypass
9 FM Pipeline connector for drain assembly 9 FM Pipeline connector for drain assembly
10 Pressure gauge 10 Pressure gauge - inlet
11 Pressure gauge 11 Pressure gauge - outlet
12 FM Piston valve for pressure gauge 12 FM Piston valve for pressure gauge

How to Order How to order


Example: Forbes Marshall Pressure Reducing Station Example: Forbes Marshall Pressure Reducing Station
(Pilot Operated) with FMPRV41 pilot operated with Arca control valve roboter based, PRS size inlet -
pressure reducing valve, FMPRS-PO size inlet - DN40 DN40 and outlet – DN 50 with set pressures inlet - 10
and outlet – DN 50 with set pressures inlet - 10 bar g bar (g) and outlet – 3 bar (g) for steam flow rates max.
and outlet – 3 bar g for steam flow rates 2000 kg/hr. 1200 kg/hr to Min. 200 kg/hr.

Note: Always specify inlet and outlet required set


Note: Always specify inlet and outlet required set pressures and Max – Min steam flowrates while
pressures and max – min steam flowrates while ordering ordering the PRS
the FMPRS-PO. This will help us in ensuring that you
have selected the correct size.
Forbes Marshall Available Spares
Pilot Operated Pressure Reducing Valve 1 Spring housing stud & nut kit (Steam/Air) 1/2
STEAM 2 Body lower bolt & nut kit 3
14 3 Main valve kit assembly with spring (Steam) 4,5,6,7
4 Main valve kit assembly with spring (Air) 8,9,10,11
21
18 12 5 Control pipe assembly kit (Steam / Air) 12 / 13
1,2 6 Pipe assembly kit (Steam / Air) 14 / 15
1
7 Main diaphragm kit 16
Pilot valve assembly

17 8 Pilot diaphragm kit 17


13 2 19 9 Pilot valve chamber assembly kit (Steam / Air) 18 / 19

Pilot valve assembly


10 Gasket kit 20
AIR 11 Pressure adjustment conical spring 21
15
20 STEAM 12 Main valve return spring kit 8
3
13 Repair kit (Steam) 1,2,12,19,
8 17,13,18,
4

5
9 9,15,22
10 16
6
22
14 Push rod assembly kit 22
11
7
How to Order Spares : Always order spares by using the
STEAM AIR
description given above and stating the size of the
pressure reducing valve

Forbes Marshall Available Spares for Actuator


Arca Control Valve with Actuator
1 Actuator Repair Kit consists of
a. Diaphragm plate 10
b. Diaphragm 13
c. Spindle 1
d. Spring 14
e. Bush 4
f. O-ring 6, 26, 28
g. Washer 22
h. Allen bolt
2 Diaphragm Kit consists of
a. Diaphragm 13
b. O-ring 6
c. Spindle bearing 1,5
3. Spring for actuator 14

How to Order Spares : Always order spares by using the


description given above and stating the size of the valve,
type, application number and OA no of actuator.
Air to Open

Available Spares for Control Valve Available Spares

1 Bonnet Sealing Kit consists of For Positioner


a. Body gasket 1 Pilot valve kit consisting of pilot valve, diaphragm and
b. Wiper ring spring
c. Gland packing 2 Electro-pneumatic positioner (specify one model)
d. Bottom ring
For Roboter
e. Slide bearing
1 Roboter spare kit consisting of O-ring, plain gasket,
f. Slotted nut roboter spring, clamp throttle, throttle pin, special screw,
g. Gland nut feedback pin, spring, guide tube, thrust ball bearing, allen
h. O-ring head screw
Just-in-Time Supply
Precision Engineered &

2 Trim kit (plug and seat)


2 Roboter - specify the pressure range and model
How to Order Spares : Always order spares by using the 3 Mounting bracket consisting of mounting bracket, dowel,
description given above and stating the size, type, lever, socket LH, socket RH, feedback, adjustable lever,
application no., and OA no. of the control valve feedback spring
4 Bellow

How to Order : For positioner, please specify the model


no.; for roboter, please specify model no., range,
application no., OA no. of control valve
Compact Module Thermodynamic Trap Available Spares
6
No. Spares Part No.
8

5
1 Spare Isolation Valve Internals Set (Sealing 3,4,9
Stack, Spacer, Stem-Piston)
31
7 2 DV Spare Kit ( Dome Nut, M6 Plain Washer, 3,4,5,6,8,9
5 27 M6 Hex Nut, Sealing stack,Spacer,Stem-Piston
32
11 12
26
3 Spare Sealing Stack for isolation valve and trap 4
2
3 25
bypass valve (DV1)
9 33
4 CMTD42M-F Top Cover Stud and Nut Set 30,31
34
4
40 30 5 15NB CMTD42M-F Seat, Disc 25,26
10
6 20NB CMTD42M-F Seat, Disc 25,26
15
4
3 7 CMTD42M-F Strainer Screen 28
16 1
14 8 CMTD42M-F Top Cover and Seat Gasket 32,33,34
5
17
5
36
21 9 Trap vent valve (DV2) and trap test valve (DV3) 6,8,18,19,20,22
6
8
18
22 Internals Set
20
19
23 28

37
5
How to Order Spares : Always order spares by using the
24
38 29 description given above and stating the size of the trap

Forbes Marshall Compact Module Available Spares


Two Orifice Float Trap
1 Main valve assembly with float 3,5,6,7,8,9,10
(4.5 / 10 / 15 bar g differential
pressure)
2 Valve maintenance kit 14,15,16,20,21,22,31
3 Valve sealing stack (pack of 15) 14
4 Valve stem piston (pack of 5) 15
5 Strainer screen 24
6 Air vent assembly 11
7 Cover and seat gasket 3,6
(pack of 5)

How to Order Spares : Always order spares by using the


description given above and stating the size, type of the
trap and pressure range

FIG-5

Steam Operated Pump Trap Available Spares


Sr. Description
No.
1. SOPT mechanism assembly kit
2. Gasket

Gasket kit Exhaust valve head 3. Exhaust valve head assembly kit
assembly Kit
4. Inlet valve seat assembly kit
Mechanism Inlet valve seat
Assembly Kit assembly kit 5. Trap valve head assembly kit
6. Trap seat assembly kit
7. Trap valve and trap seat kit
8. Inlet check valve assembly kit
9. Float assembly kit

Trap Valve Head Trap Seat Trap Valve and Inlet Check Valve Float
Assembly Kit Assembly Kit Trap Seat Assembly Kit Assembly Kit
Assembly Kit
How to Order Spares : Always order spares by using the
description given above and stating the size of the valve
Forbes Marshall Piston Isolation Valve Available Spares
1 Sealing ring kit 4,10,14
2 Piston kit 3,6
19
20 18 3 Handwheel kit 18
11 23 4 Bonnet stem seal kit 2,7,14
6
16 2 5 Sealing ring inserter tool kit
13
17 8
6 Sealing ring extractor tool kit
15 10
24 21
14 7 How to Order Spares : Always order spares by using the
12 description given above and stating the size of the valve
22
9
5
3
4
1

Forbes Marshall Safety Relief Valve Available Spares

1 Valve head and spindle kit 3,4,6


2 Spindle and lock nut kit 4,6
3 Spring and guide kit 7,8,9
4 Valve and seat kit 1,2,3
5 Spring kit 7
6 Adjustment bolt 11

How to Order Spares : Always order spares by using


the description given above and stating the size of the
valve.

Forbes Marshall Strainer Available Spares


Screen and Gasket kit 1, 2
Gasket kit 2

How to Order Spares : Always order spares by using


the description given above and stating the size of the
strainer.

2
Knowledge, Service, and Products
The Forbes Marshall Approach to Sustained Steam System Performance

Forbes Marshall Experience for Sustained Performance

As a Forbes Marshall customer, you’ll experience our total team approach to supporting your goals for reliability,
operational effectiveness, and risk management. In addition to our energy efficiency and improvement services, Forbes
Marshall’s Steam Asset Management engineers are backed by a company with decades of service and innovation. Our
visits to your plants allow us share our pride in serving your needs through knowledge, service and products.

Forbes Marshall is committed to helping customers achieve sustained performance of their steam utilities. Over several
visits, From Forbes Marshall, with our engineers working with your team, the overall system performance rate will
improve asset by asset and sustain at a high level.

Inspections Knowledge Actions, Plans, Parts

Our engineers inspect your steam Our people share knowledge to help We work with you to identify actions
system regularly, one sub-system you and your team learn how to to meet goals including repairs,
at a time, noting status and sustain performance, through the preventive maintenance schedules,
performance of critical Health Snapshot, tips and spot stocking, genuine Forbes Marshall
components including Forbes training. spares, and life-cycle planning.
Marshall products.
We have placed FM Depots around
India for direct and rapid supply of
common spares, to minimise your
time from order to installation.

Plant-level Key Result Area


Impacts

Reliability Excellence %
Process uptime

Operational Effectiveness
Fuel cost

Product and Process Quality


Quality of batches in continuous
processes 90%
Safety
Mean time to failure of critical items

Environmental Care
Water consumption and discharge

Capital Effectiveness Minimum


Service life management
t
Months
Steam Asset Management Visits
Learn More about Sustaining and Improving
Performance

Refer product manuals


Download our apps for Android, iOS
Visit us at www.forbesmarshall.com
Call your Forbes Marshall engineering team to
schedule training, audits and other services which will
help your plant reach its potential.

e-Connect Training

Onsite Training in Product Operation and


Maintenance

A critical aspect of sustaining performance depends on


the maintenance team’s preventive practices and
readiness to handle problems when they occur. Forbes
Marshall can conduct spot training with your team as
part of our regular visits, for example, hands-on
guidance for internal maintenance or trouble shooting for
products.

Forbes Marshall Training Courses

Mobile Apps Online Reference Material Forbes Marshall also provides in depth training at our
education facilities around India, where steam system
Product Hub SteamPedia professionals come to learn valuable skills and benefit
Product Manuals from our experienced steam and instrumentation experts
Technical Information Sheets in a classroom and laboratory setting.
Installation and Maintenance Tips

Forbes Marshall Depots for Genuine Spares and Components


Now at Your Doorstep

iginal
Or
Easy ordering process

Right components Genuine Easy Just-in-Time


Knowledge, Services, Products

for your steam spares Ordering delivery


application Process
Forbes Marshall helps customers keep their steam systems working to meet their goals.

Years of Service Installed Pressure Total Plant Audits Customer Visits


and Temperature Annually
Control Valves

70 75,000 6,000 150,000

Customer Quotes

“Installation of steam operated pump traps and temperature control valves on paddy dryers has resulted in maintaining
constant air temperature of the dryers, improvement in our product quality and reduction in rice grains broken by 0.5%”
Director, Rice Plant
Mainpuri, Uttar Pradesh

“Bypass valve opening has been completely eliminated in the plant. Without opening the bypass, temperature has been
achieved effectively and repeatedly… We are constantly monitoring the steam consumption in the plant with the help of
the vortex flowmeter. In case the consumption goes up, corrective action is taken immediately.”
Utilities manager, Solvent Extraction Plant
Gorakhpur, Uttar Pradesh, 2015

“Forbes Marshall Steam Systems Pvt Ltd has provided very well with the after-sales service and we are happy with the
services of FMSSPL.”
Manager, Brewery Plant
Uttar Pradesh, 2015

“After implementation of a sustained performance program at a refinery, steam trap performance rate went from 55.5%
to 98.7%, remaining above 95% for at least 6 months. “Forbes Marshall has executed the contract with thorough
professionalism and to our complete satisfaction.”
General Manager - Operations
Oil refinery
Maharashtra, 2009

“We are quite happy with the technical support from Forbes Marshall and recommend FM Boiler and products to all
steam users for sustaining and enhancing boiler efficiency”.
Chief Engineer
International hotel chain
Karnataka, 2013

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