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Summary of Contents for TLV PowerTrap GT5C
- Page 1 172-65473MA-03 (GT5C PowerTrap) 17 July 2019 GT5C 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 ..............8 Installation ................9 Steam System Example ................... 9 Installation Procedure ..................... 11 Sizing the Condensate Reservoir Pipe ..............13 Maintenance Space and Tolerance Angle for Installation 14 Operation and Periodic Inspection ........ -
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 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 Be sure to use only the recommended components when repairing the product, and NEVER attempt to modify the product in any way. Failure to observe these precautions may result in damage to the product and burns or other injury due to malfunction or the discharge of fluids.
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Page 6: General Description
Application PowerTrap GT5C can be used as a standard steam trap, and also has an integrated pumping function that can eliminate and pump out condensate even if condensate cannot be discharged due to very low supply steam pressure because of reduced load in the steam using equipment (this phenomenon is referred to in this document as ‘stall’). -
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 float rises and the main valve of the trap unit is open as shown in (A) 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: Configuration
Configuration Exhaust Outlet Plug Motive Medium Inlet Condensate Outlet Condensate Inlet Repair Kit *¹ Snap Maintenance Parts Float Action Spring Body Cover ✔ Gasket Gaskets, etc. ✔ Seal set Cover Bolt Nameplate ✔ Float ✔*² Snap-Action Unit ✔ Snap Action Spring ✔... -
Page 10: Installation
Installation 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 11 2. Installation Example for Increasing Pump Discharge Capacity The pumping discharge capacity can be increased by raising the filling head [A]. Refer to the latest GT5C data sheet for the discharge capacity on each filling head and “Sizing of the Condensate Reservoir Pipe” at the end of this section for the size of condensate inlet pipe [Si] (length of Dh).
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Page 12: Installation Procedure
Installation Procedure Installation, inspection, maintenance, repairs, disassembly, adjustment and valve opening/closing should be carried out only by trained maintenance personnel. (1) Pumped Medium: Fluids that can be discharged through the PowerTrap are limited to steam condensate. PowerTraps that have been specially constructed for other specific fluids are not limited by this restriction. - Page 13 When the motive medium pressure [Pm] is greater than 0.5 MPaG (75 psig, 5 barg), install a TLV pressure reducing valve (such as the DR20) in order to reduce the motive medium pressure to the PowerTrap. In order to prevent the pressure from rising at dead end shut off, be sure to install a relief valve between the pressure reducing valve and the PowerTrap.
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Page 14: Sizing The Condensate Reservoir Pipe
(5) 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 [Vi] and outlet lines [Vo]. Be sure to install blowdown valve [Vb]. A bellows sealed valve is recommended, due to the lack of leakage from the gland and easy flow rate adjustment. -
Page 15: Maintenance Space And Tolerance Angle For Installation
100 (4) Unit: mm (in) 100 (4) Tolerance Angle for Installation The product should be inclined no more than 3°. Make sure the body is installed with the raised TLV lettering on the body horizontal. 172-65473MA-03 (GT5C PowerTrap) 17 Jul 2019... -
Page 16: 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 17: Periodic Inspection And Diagnosis
The relation between the interval of operation T (seconds) and the amount of inflowing pumped medium (Q or Q ) can be roughly determined using the following formula: = 5,000/Q Q = 5,000/T Q: amount of inflowing pumped medium (kg/h) = 11,111/Qp = 11,111/T : amount of inflowing pumped medium (lb/h) -
Page 18: 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 20 kg (44 lb) or more). Failure to do so may result in back strain or other CAUTION injury if the object should fall. -
Page 19: Recommended Tools List For Disassembly/Reassembly
Recommended Tools List for Disassembly/Reassembly Tool Name Step Used Tool Torque Wrench (Ratchet) 0 – 100 Nm 1,2,3,4,5,6 (0 – 73 lbfft) Sockets Distance across flats = S 13 mm (½”) 3,4,6 19 mm (¾”) 22 mm ( ") Extension Bar ... -
Page 20: Before Removing/Reattaching
1. Before Removing/Reattaching Discharge the condensate from the body before removing parts. Part Disassembly Reassembly • Discharging condensate is carried out with the intake • Wrap threads with 3 Plug – 3.5 turns of sealing (motive medium), exhaust, inlet and outlet piping still connected to the unit. -
Page 21: Removing/Reattaching The Body From/To The Cover
2. Removing/Reattaching the Body from/to the Cover Prepare a new, replacement cover gasket before beginning this step. Cover Bolts • Using a 19 mm (¾”) socket wrench, loosen each bolt • Reverse steps in slowly one turn in an alternating diagonal pattern. disassembly. - Page 22 Part Disassembly Reassembly • Remove the intake-exhaust valve by • Reattach the intake-exhaust valve by Intake- Exhaust rotating it 90º. rotating it 90º. • Remove the coil spring. • Reattach the coil spring. Valve • Remove the float and the float holder •...
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Page 23: Removing/Reattaching Each Unit
4. Removing/Reattaching Each Unit Part Disassembly Reassembly • Remove bolts with a 13 mm (½” ) socket • Replace with a new O-ring Intake-Exhaust • Replace with a new gasket if it is Valve Seat/ wrench. • Remove the intake-exhaust valve seat Bolt/Snap Ring damaged. -
Page 24: Removing/Reattaching Of Air Vent Unit
5. Removing/Reattaching of Air Vent Unit Part / Step Disassembly Reassembly • Remove the spring clip with • Make sure that the check valve (a small steel Spring Clip/ X-element/ your fingers. ball) in the air vent valve seat can open and •... -
Page 25: Positioning Adjustment Of The Trap Valve
6. Positioning Adjustment of the Trap Valve Adjustment of the trap valve position is required if leakage occurs from the trap valve or a gap between the orifice and the trap valve exists. Item Procedure • Install the snap action unit assembled with the motive intake valve and the trap Installation of Snap valve (the float is not yet attached) to the cover assembled with the trap valve... -
Page 26: 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 27: 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. ≤ P Pump is in the correct operating condition when P (equipment pressure P is equal to or lower than back pressure P... -
Page 28: Causes And Corrective Measures
Causes and Corrective Measures Category Cause Procedure • Slowly open the valve, using the proper procedure 1. The valve on the A valve on motive medium supply Check valves around the PowerTrap. If they are the pipeline pipe is closed open, check other valves on pipes connected to is closed 2. - Page 29 Category Cause Procedure • Air-locking or vapor-locking has occurred. The exhaust 1. The exhaust is Faulty abnormal pipe is connected to the reservoir (inlet pipe), but the piping 2. The pumped pumped medium may not be exchanged for the medium inlet pipe is medium inside the PowerTrap for the following too small reasons:...
- Page 30 Category Cause Corrective Measure • The operating medium that has been supplied is 1. Dirt or scale is Faulty caught in the leaking from the inlet check valve, preventing the check valve pumped medium pressure inside the trap from increasing; as a result, inlet check valve or the pumped medium is not discharged the valve is worn or...
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Page 31: Replacement Parts
Replacement Parts The following replacement parts kits are available from TLV. Parts are not available individually, only together in kits. Dimensions: mm (in) 1. Cover Gasket 2. Seal Set 3. Float (5½) Float O-ring 4 pcs. PTFE Gasket 3 pcs. -
Page 32: 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 33: Service
Service For Service or Technical Assistance: Contact your TLV representative or your TLV office. In East Asia: 36 Kaki Bukit Place, #02-01/02, Singapore 416214 Tel: [65]-6747 4600 Fax: [65]-6742 0345 Room 5406, No. 103 Cao Bao Road, Shanghai, China 200233 Tel: [86]-21-6482-8622 Fax: [86]-21-6482-8623 No.16, Jalan MJ14, Taman Industri Meranti Jaya, 47120 Puchong, Selangor, Malaysia...
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