Related Manuals for TLV PowerTrap GP10F
Summary of Contents for TLV PowerTrap GP10F
- Page 1 172-65378MA-03 (GP10F PowerTrap) 23 April 2019 GP10F Copyright © 2019 by TLV CO., LTD. All rights reserved...
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Page 2: Table Of Contents
Contents Introduction ................2 Safety Considerations ............3 General Description ..............5 Application ........................5 Operation ................6 Specifications ................7 Configuration .................7 Installation ................8 Open System* Piping (Steam System Example) ............8 Installation Procedure ....................9 Sizing the Condensate Receiver/Reservoir ............... 12 Installing Several PowerTrap Units in Parallel ............16 Installation and Maintenance Space ........17 Operation and Periodic Inspection ........18 Operation ........................ -
Page 3: Introduction
If detailed instructions for special order specifications or options not contained in this manual are required, please contact TLV for full details. This instruction manual is intended for use with the model(s) listed on the front cover. -
Page 4: Safety Considerations
• The three types of cautionary items above are very important for safety: be sure to observe all of them as they relate to installation, use, maintenance and repair. Furthermore, TLV accepts no responsibility for any accidents or damage occurring as a result of failure to observe these precautions. - Page 5 CAUTION When disassembling or removing the product, wait until the internal pressure equals atmospheric pressure and the surface of the product has cooled to room temperature. Disassembling or removing the product when it is hot or under pressure may lead to discharge of fluids, causing burns, other injuries or damage.
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Page 6: General Description
General Description Install properly and DO NOT use this product outside the recommended operating pressure, temperature and other specification ranges. CAUTION Improper use may result in such hazards as damage to the product or malfunctions which may lead to serious accidents. Local regulations may restrict the use of this product to below the conditions quoted. -
Page 7: Operation
Operation Take measures to prevent people from coming into direct contact with product outlets. Failure to do so may result in burns or other injury from CAUTION the discharge of fluids. (1) When condensate flows from the condensate inlet pipe through the inlet check valve into the body of the unit, the air in the body escapes through the exhaust valve (which equalizes the internal pump pressure to the pressure of the condensate source) and the float rises, as shown in (1) below. -
Page 8: Specifications
Specifications Install properly and DO NOT use this product outside the recommended operating pressure, temperature and other specification ranges. CAUTION Improper use may result in such hazards as damage to the product or malfunctions which may lead to serious accidents. Local regulations may restrict the use of this product to below the conditions quoted. -
Page 9: Installation
NOTE: This sketch is for explanation purposes only and is not intended as an installation design. * Consult with TLV for closed system piping. 172-65378MA-03 (GP10F PowerTrap) 23 Apr 2019... -
Page 10: Installation Procedure
(3) Pressure Reducing Valve on the Motive Medium Supply Piping: • When the motive medium pressure is greater than the maximum allowed for the particular PowerTrap model used (see “Specifications”), install a TLV COS/COSR series pressure reducing valve in order to reduce the motive medium pressure to the PowerTrap. - Page 11 The check valve on the inlet pipe in particular should be installed right next to the PowerTrap. • Only TLV check valves (CK3MG) should be used; proper discharge capacity cannot be guaranteed with other check valves. 172-65378MA-03 (GP10F PowerTrap) 23 Apr 2019...
- Page 12 (6) Valves on the Various Pipes • In order to ensure the proper discharge capacity, use full bore ball valves or gate valves on the pumped medium inlet and outlet lines as well as on the motive medium supply and exhaust lines. If it is necessary to reduce the velocity of the motive medium supply, a needle valve can be used.
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Page 13: Sizing The Condensate Receiver/Reservoir
Make sure to install vent pipe to lead to a safe place • Do not install loop seal on the vent pipe Contact TLV if neither 1) nor 2) above can be installed. (8) Velocity at Outlet Piping The PowerTrap uses the motive medium supply pressure to push the pumped medium out of the trap. - Page 14 condensate receiver set pressure (P : specific enthalpy (kJ/kg) (Btu/lb) vaporization (latent heat of steam) at condensate receiver set pressure (P b) Determine the vent pipe diameter according to the amount of flash steam in Vented Receiver Table - 1 shown on the next page. c) Determine the overflow pipe diameter (D , refer to the figure below).
- Page 15 Vented Receiver Table - 1 (For atmospheric, open system installations) Receiver Flash Steam Vent Line Flash Steam Receiver Vent Line Diameter up to ~ Diameter up to ~ Diameter Diameter (Length:3.5 ft) (Length: 1 m (3.5 ft)) kg/hour (in) lb/hour (in) 1½...
- Page 16 (2) When flash steam is not involved (For closed systems) Condensate Determining the reservoir diameter and length Reservoir based on the amount of condensate: Reservoir Table (For equalized, closed system installations) PowerTrap Amount of Amount of Pumped Pumped Reservoir Diameter (mm) & Length (m) Reservoir Diameter (in) &...
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Page 17: Installing Several Powertrap Units In Parallel
• Installing Several PowerTrap Units in Parallel Refer to the figure below as a general guide for the piping when several PowerTrap units are to be installed after the same pumped medium inlet pipe. The size of the pumped medium inlet pipe, return line and exhaust pipe manifold is determined by the number of PowerTrap units installed. -
Page 18: Installation And Maintenance Space
Installation and Maintenance Space The maintenance space shown in the figure below should be provided to enable disassembly, inspection and replacement of the PowerTrap. 500 mm (20”) 1500 mm (~60”) BE CAREFUL to install a union in the exhaust piping in a position that will allow the Cover Unit to be lifted straight up from the Body. -
Page 19: Operation And Periodic Inspection
Operation and Periodic Inspection • After all piping work has been completed in accordance with the specific piping system designed when the decision to utilize the WARNING PowerTrap was made, check once again to make sure that all pipe connections have been tightened, gaskets have been inserted where needed and all parts are securely installed. -
Page 20: Periodic Inspection And Diagnosis
e) The PowerTrap operation is normal if it cycles intermittently; first exhausting the motive medium to fill with pumped medium, then taking in motive medium to force the pumped medium out. • The interval of operation will vary greatly depending on the amount of pumped medium inflow, the temperature, the motive medium (steam or gas) and the motive pressure. - Page 21 (2) Disassembly Inspection • Refer to the “Disassembly/Reassembly” section. • As a general rule, this inspection should be performed at least once every 2 years. • When inspecting the interior of the unit, check the following items: a) Make sure the push rod does not catch on anything during snap-action (the up- down movement of the push rod) and moves smoothly as the float rises and falls.
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Page 22: Disassembly/Reassembly
Disassembly/Reassembly NEVER apply direct heat to the float. The float may explode due to increased internal pressure, causing accidents leading to serious injury WARNING or damage to property and equipment. Use hoisting equipment for heavy objects (weighing approximately 44 lb (20 kg) or more). -
Page 23: Recommended Tools List For Disassembly/Reassembly
Recommended Tools List for Disassembly/Reassembly Step Tool Name Tool Used 1 Torque Wrench (Ratchet) 80 to 180 N⋅m (58 to 130 lbf⋅ft) 2 Sockets Distance across flats = S ”) → 160 N⋅m (115 lbf⋅ft) 17 mm ( 19 mm (¾”) →80 N⋅m (58 lbf⋅ft) ”) →160 N⋅m (115 lbf⋅ft) 27 mm (1 38 mm (1½”) →160 N⋅m (115 lbf⋅ft) -
Page 24: Removing/Reattaching The Cover Unit
1. Removing/Reattaching the Cover Unit Prepare a new cover gasket for replacement before beginning this step. Part Disassembly Reassembly Drain Plug • Using an adjustable wrench, slowly loosen plug to release • Wrap threads with 3 (if present) pressure and discharge fluid; take care to avoid being to 3.5 turns of sealing burned by fluid discharge. -
Page 25: Removing/Reattaching The Float
2. Removing/Reattaching the Float It is not necessary to remove the float if only the intake (motive medium) and exhaust valves are to be serviced or replaced. It is not always necessary to replace the float when replacing the snap-action unit. The float should be replaced only when there are irregularities such as damage to its exterior or condensate found inside the float. -
Page 26: Removing/Reinstalling The Exhaust Valve
4. Removing/Reinstalling the Exhaust Valve Part Disassembly Reassembly Exhaust • Using needle-nose pliers, remove the split pin • Reverse the steps to reassemble. Valve from one side of the connecting pin; remove the • Use a new split pin if the old one exposed flat washer. -
Page 27: Removing/Reinstalling The Motive Medium Intake Valve And Valve Seat
6. Removing/Reinstalling the Motive Medium Intake Valve and Valve Seat The following procedure can be used to remove and replace the intake (motive medium) valve without first removing the cover of the PowerTrap. Part Disassembly Reassembly Plug • Using a 38 mm (1½ in) socket wrench, •... -
Page 28: Checking/Adjusting The Gap Between The Push Plate And The Motive Medium Intake Valve
7. Checking/Adjusting the Gap between the Push Plate and the Motive Medium Intake Valve It is necessary to inspect the gap to determine whether adjustment is necessary only when installing a new snap-action unit or an overhauled snap-action unit (from this or another PowerTrap). -
Page 29: Troubleshooting
Troubleshooting NEVER apply direct heat to the float. The float may explode due to increased internal pressure, causing accidents leading to serious injury WARNING or damage to property and equipment. DO NOT OPERATE the PowerTrap with piping disconnected. When it is absolutely necessary to operate with a portion of the outlet piping CAUTION removed in order to examine an operational failure, open the motive... -
Page 30: Types Of Failure And Their Causes
Types of Failure and their Causes Detailed explanations of the meanings of the numbers listed in the “Types of Failure” column are found in the “Causes and Corrective Measures” table. PowerTrap Does Not Operate PowerTrap Operates 172-65378MA-03 (GP10F PowerTrap) 23 Apr 2019... -
Page 31: Causes And Corrective Measures
Causes and Corrective Measures Category Cause Procedure 1. The valve on the motive - Slowly open the valve, using the proper A valve on medium supply pipe is closed procedure the pipeline 2. The valve on the exhaust is closed pipe is closed 3. - Page 32 Category Cause Procedure 1. The exhaust is abnormal - Air binding or vapor locking has occurred; in the Faulty case of a closed system, the exhaust pipe is piping connected to the reservoir, but the pumped medium may not be exchanged for the medium inside the PowerTrap for the following reasons: (1) There is a U-shaped pipe between the exhaust port and the receiver...
- Page 33 Category Cause Corrective Measure 1. Dirt or scale is caught in the - The operating medium that has been supplied Faulty pumped medium inlet check is leaking from the inlet check valve, preventing check valve valve or the valve is worn or the pressure inside the trap from increasing;...
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Page 34: Product Warranty
One year following product delivery. 2. Warranty Coverage TLV CO., LTD. warrants this product to the original purchaser to be free from defective materials and workmanship. Under this warranty, the product will be repaired or replaced at our option, without charge for parts or labor. -
Page 35: Service
Service For Service or Technical Assistance:Contact your TLV representative or your TLV office. In North America: 13901 South Lakes Drive, Charlotte, NC 28273-6790, U.S.A. Tel: [1]-704-597-9070 Fax: [1]-704-583-1610 In Mexico and Latin America: Av. Jesús del Monte 39-B-1001, Col. Hda. de las Palmas, Huixquilucan, Edo. de México, 52763, Mexico...
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