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Summary of Contents for TLV PowerTrap GP5C
- Page 1 172-65637MA-05 (GP5C PowerTrap) 8 June 2020 GP5C Copyright © 2020 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 Open System Piping (Steam System Example) ............9 Installation Procedure ..................... 10 Sizing the Condensate Receiver ................14 Maintenance Space and Tolerance Angle for Installation 15 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 Be sure to use only the recommended components when CAUTION 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
There are two types of delivery systems (piping methods): the closed system and the open system. The PowerTrap GP5C you have purchased is a suitable model for the open system. -
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 (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 Condensate Screwed GP5C Inlet/Outlet Connection* JIS 10K Rc(PT) JPI 150 Rc(PT) ASME 150 NPT PN16 Rc(PT) Rc(PT) *Exhaust outlet, motive medium inlet Motive Medium Inlet Exhaust Outlet Plug and all plugs Screw: Screw: Condensate Inlet Flange: 1 in Condensate Outlet Screw/Flange: 1 in Repair Kit Maintenance... -
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: Installation Procedure
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... - Page 12 pressure reducing valve and the PowerTrap. The set pressure of the pressure reducing valve should be equal to or greater than 0.05 MPa (7 psi, 0.5 bar) higher than the back pressure [Pb]. When the pumping capacity of the PowerTrap is insufficient for the set motive pressure, increase the set pressure even further.
- Page 13 easy maintenance. Be sure to provide the necessary maintenance space for PowerTrap disassembly and repair (see “Maintenance Space and Tolerance Angle for Installation”). (8) Condensate Receiver [Dh] and Filling Head [A] Please refer to “Sizing the Condensate Receiver”. The size and vent pipe aperture are determined by (a) the amount of flash steam in the in-flowing condensate (pumped medium) and (b) the amount of pumped medium held back while the PowerTrap is discharging.
- Page 14 (generally 25 mm (1 in) or smaller) • Do not install loop seal on the vent pipe Contact TLV if neither 1) nor 2) above can be installed. 172-65637MA-05 (GP5C PowerTrap) 8 Jun 2020...
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Page 15: Sizing The Condensate Receiver
Sizing the Condensate Receiver When selecting the receiver for the GP5C, select from among the following steps: (1) Determine the amount of flash steam Flash Steam (There may be a case that the flash steam hardly generates when the cold condensate is being pumped): Amount of flash steam Fs = Q ... -
Page 16: Maintenance Space And Tolerance Angle For Installation
Vented Receiver Table - 1 Flash Steam Receiver Vent Line Flash Steam Receiver Vent Line up to ~ Diameter Diameter up to ~ Diameter Diameter kg/hour mm (in) mm (in) lb/hour (Length: 1 m) (Length: 3.5 ft) Vented Receiver Table - 2 Amount of Receiver Diameter Amount of... -
Page 17: 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 CAUTION 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 18: Periodic Inspection And Diagnosis
and the start of the next discharge cycle.) 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: = 5,350/Q Q = 5,350/T Q: amount of inflowing pumped medium (kg/h) = 11,888/Qp = 11,888/T... -
Page 19: 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. ・Repairs or disassembly of the piping, adjustment and valve opening/ closing should be carried out only by trained maintenance personnel. -
Page 20: Replacement Parts
Replacement Parts The following replacement parts are available from TLV. Parts are not available individually, only together in kits. (See “Configuration”) Dimensions: mm (in) 1. Cover Gasket 2. Seal Set 3. Float 100 (3 139 (5 O-ring: 4 pcs. PTFE Gasket: 3 pcs. -
Page 21: Recommended Tools List For Disassembly/Reassembly
Recommended Tools List for Disassembly/Reassembly Tool Tool Name Step Used Torque Wrench (Ratchet) 0 – 100 Nm 1,2,3,4,5,6 (0 – 73 lbfft) Sockets Distance across flats = S 3,4,6 13 mm ( 19 mm ( 22 mm ( Extension Bar L = 150 mm (5 Offset Wrench 13 mm (... -
Page 22: Before Removing/Reattaching
1. Before Removing/Reattaching Discharge the condensate from the body before removing parts. Part Disassembly Reassembly • Using an adjustable wrench, slowly loosen the plug to release • Wrap threads with Plug 3 – 3.5 turns of sealing pressure and discharge fluid, take care to avoid being burned by fluid discharge. -
Page 23: Removing/Reattaching The Snap-Action Unit
3. Removing/Reattaching the Snap-action Unit Part Disassembly Reassembly • Using a 13 mm ( • Coat the bolt threads with anti-seize. Hex Bolts ) socket wrench, (M8 2 pcs)/ • Be sure to reinsert spring washers. slowly loosen the two bolts that are holding •... -
Page 24: Removing/Reattaching Each Unit
4. Removing/Reattaching Each Unit Part Disassembly Reassembly • Replace with a new O-ring • Remove bolts with a 13 mm Intake-Exhaust ) socket • Replace with a new gasket if damaged. Valve Seat/ wrench. Bolt (M8 2 pcs)/ • Coat O-ring with heatproof grease and •... -
Page 25: 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. ・Repairs or disassembly of the piping, adjustment and valve opening/ closing should be carried out only by trained maintenance personnel. -
Page 26: 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 27: Causes And Corrective Measures
Causes and Corrective Measures Category Cause Procedure • Slowly open the valve, using the proper procedure 1. The valve on the motive A valve on medium supply pipe is Check valves around the PowerTrap. If they are open, the pipeline closed check other valves on pipes connected to the is closed... - Page 28 Category Cause Procedure • Air-locking or vapor-locking has occurred. The exhaust pipe 1. The exhaust is Faulty piping abnormal is connected to the receiver, but the pumped medium may 2. The condensate inlet not be exchanged for the medium inside the PowerTrap for pipe is too small the following reasons: 3.
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Page 29: 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 30: Service
Service For Service or Technical Assistance: Contact your TLV representative or your TLV office. In Europe: Tel: [49]-(0)7263-9150-0 Daimler-Benz-Straße 16-18, 74915 Waibstadt, Germany Fax: [49]-(0)7263-9150-50 Tel: [44]-(0)1242-227223 Star Lodge, Montpellier Drive, Cheltenham, Gloucestershire, GL50 1TY, U.K. Fax: [44]-(0)1242-223077 Tel: [33]-(0)4-72482222 Parc d’Ariane 2, bât.
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