TLV PowerTrap GP10F Instruction Manual Download Page 3 | Manualshive

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172-65378MA-03 (GP10F PowerTrap) 23 Apr 2019

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Introduction

Thank you for purchasing the TLV PowerTrap.

This product has been thoroughly inspected before being shipped from the
factory. When the product is delivered, before doing anything else, check the
specifications and external appearance to make sure nothing is out of the
ordinary. Also be sure to read this manual carefully before use and follow the
instructions to be sure of using the product properly.

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. It is necessary not only for installation, but for subsequent maintenance,
disassembly/reassembly and troubleshooting. Please keep it in a safe place for
future reference.

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Summary of Contents for PowerTrap GP10F

Page 1: ...172 65378MA 03 GP10F PowerTrap 23 April 2019 GP10F Copyright 2019 by TLV CO LTD All rights reserved ...

Page 2: ...pection and Diagnosis 19 Disassembly Reassembly 21 Recommended Tools List for Disassembly Reassembly 22 1 Removing Reattaching the Cover Unit 23 2 Removing Reattaching the Float 24 3 Removing Reattaching the Snap action Unit 24 4 Removing Reinstalling the Exhaust Valve 25 5 Removing Reinstalling the Exhaust Valve Seat 25 6 Removing Reinstalling the Motive Medium Intake Valve and Valve Seat 26 7 Ch...

Page 3: ...nary Also be sure to read this manual carefully before use and follow the instructions to be sure of using the product properly 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 It is necessary not only for installat...

Page 4: ...ER WARNING or CAUTION item DANGER Indicates an urgent situation which poses a threat of death or serious injury WARNING Indicates that there is a potential threat of death or serious injury CAUTION Indicates that there is a possibility of injury or equipment product damage WARNING NEVER apply direct heat to the float The float may explode due to increased internal pressure causing accidents leadin...

Page 5: ...r the discharge of fluids Do not use excessive force when connecting threaded pipes to the product Over tightening may cause breakage leading to fluid discharge which may cause burns or other injury Use only under conditions in which no freeze up will occur Freezing may damage the product leading to fluid discharge which may cause burns or other injury Use only under conditions in which no water h...

Page 6: ... Trap Equip ment Reservoir Power Trap Equip ment Steam Trap Steam Trap Power Trap Equip ment Receiver Discharge to Atmosphere Condensate Recovery line Venting Pipe Exhaust Pipe Overflow Pipe Equip ment Steam Trap Steam Trap Power Trap Equip ment Receiver Discharge to Atmosphere Condensate Recovery line Venting Pipe Exhaust Pipe Overflow Pipe Benefits No need for external steam trap GT model featur...

Page 7: ... by the motive medium causes the internal pressure in the unit to become greater than the back pressure The inlet check valve closes and the outlet check valve is pushed open thus discharging the condensate in the unit through the outlet pipe as shown in 2 below 3 As a result of the condensate in the unit being discharged the water level in the unit drops and the float descends When the float reac...

Page 8: ...um Operating Pressure Valve No Nominal Diameter Motive Medium Pressure Range 0 03 to 1 05 MPaG 5 to 150 psig Max Allowable Back Pressure 0 05 MPa 7 psi less than motive medium pressure used Maximum allowable pressure PMA and maximum allowable temperature TMA are PRESSURE SHELL DESIGN CONDITIONS NOT OPERATING CONDITIONS Valve No is displayed for products with options This item is omitted from the n...

Page 9: ...m Example P2 If water hammer due to steam backflow in the condensate recovery line is expected installation of a check valve vertically and as close as possible to the recovery line is recommended TLV COS COSR Pressure Reducing Valve TLV CV10 Pressure Control Valve P1 Steam using Equipment Steam Trap When the rise in piping to the condensate recovery line is 30 m 100 ft or further from GP10F insta...

Page 10: ...non condensable gasses such as air or nitrogen When the motive medium is steam if the application will require that the equipment be shut down non operating for periods of 2 months or longer install piping connecting the motive medium supply line to the receiver being sure to install a drip leg on the motive medium supply line and a steam trap in the drip leg between where it branches to go to the...

Page 11: ...at a point just above where the exhaust pipe exits the unit body Figure 1 b For Open and Closed Systems Add piping connecting the exhaust pipe to the pumped medium inlet pipe between the reservoir and the strainer being sure to install a check valve on the piping to prevent backflow of condensate from the pumped medium inlet pipe to the exhaust pipe Figure 2 When the exhaust piping height exceeds ...

Page 12: ...ttom of the PowerTrap from grade to the bottom of the receiver reservoir The standard filling head is 1070 mm 42 in When an installation calls for a lower filling head a filling head of less than 1070 mm 42 in is allowable However the minimum filling head is 860 mm 33 in For open systems If venting flash steam to a high area an overflow pipe must be installed to discharge condensate to a safe area...

Page 13: ...re to push the pumped medium out of the trap The GP10F can discharge approximately 30 liters 7 9 gallons of pumped medium for each discharge operation The amount of time required for each discharge operation will be between 3 and 30 seconds depending on the back pressure and the motive medium pressure This means that the instantaneous flow through the pumped medium outlet pipe during the discharge...

Page 14: ...ermine the minimum condensate receiver diameter Dcr refer to the figure below by selecting the largest value among those from i ii and iii based on a condensate receiver length of 1 m i is the overflow pipe diameter multiplied by 3 or more ii is the minimum receiver diameter according to the amount of flash steam in Vented Receiver Table 1 shown on the next page iii is the minimum receiver diamete...

Page 15: ... 6 125 5 500 350 14 1000 14 6 150 6 700 400 16 1400 16 8 200 8 800 450 18 1600 18 8 200 8 1000 500 20 2000 20 8 200 8 1100 500 20 2200 20 10 250 10 1400 550 22 2800 22 10 250 10 1500 600 24 3000 24 10 250 10 Vented Receiver Table 2 For atmospheric open system installations Amount of Condensate kg hour Receiver Diameter Length 1 m 3 5 ft mm in Amount of Condensate lb hour Receiver Diameter Length 3...

Page 16: ... 0 1 3 0 6 4000 6 5 4 0 1 5 3000 2 0 0 9 0 5 5000 5 0 2 5 4000 1 2 0 7 6000 5 5 2 5 1 5 5000 1 4 0 8 0 5 7000 6 5 3 0 1 5 6000 1 7 1 0 0 6 8000 3 5 2 0 7000 2 0 1 2 0 7 9000 4 0 2 5 1 5 8000 1 3 0 8 10000 4 5 2 5 1 5 9000 1 5 0 9 12000 5 0 3 0 2 0 10000 1 7 1 0 14000 6 0 3 5 2 5 16000 6 5 4 0 2 5 18000 4 5 3 0 20000 1 5 1 5 NOTE Reservoir length can be reduced by 50 when the motive pressure Pm div...

Page 17: ...e TLV GP10F Pumped Medium Inlet Pipe Pumped Medium Return Line Receiver TLV GP10F TLV GP10F Exhaust Pipe Exhaust Pipe Motive Medium Supply Motive Medium Supply Medium Return main line Filling Head NOTE This sketch is for explanation purposes only and is not intended as an installation design Overflow Pipe Exhaust Pipe Manifold Number of PowerTrap Units Installed Pumped Medium Inlet Pipe Size Pumpe...

Page 18: ...ce shown in the figure below should be provided to enable disassembly inspection and replacement of the PowerTrap 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 500 mm 20 1500 mm 60 500 mm 20 1500 mm 60 400 mm 15 ...

Page 19: ...pheric 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 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...

Page 20: ...pumped medium inlet valve pumped medium outlet valve valve on exhaust pipe 3 Whenever any type of malfunction is suspected in the PowerTrap refer to the Troubleshooting section Periodic Inspection and Diagnosis There are two types of periodic inspection the visual inspection and the disassembly inspection 1 Visual Inspection As a general rule this inspection should be performed at least once every...

Page 21: ... valves move up and down smoothly The gap between the stem of the closed intake motive medium valve and the push plate should be within the specified range 2 mm 0 3 mm 0 079 0 012 in The exhaust valve will have some movement when open but should be stable when closed c Make sure the float is not damaged and has not filled with water d Make sure all nuts and bolts are properly installed and fastene...

Page 22: ...urns or other injury CAUTION Use the procedures on the following pages to remove components Use the same procedures in reverse to reassemble Installation inspection maintenance repairs disassembly adjustment and valve opening closing should be carried out only by trained maintenance personnel In cases where sufficient maintenance space has been provided for see Installation and Maintenance Space m...

Page 23: ...1 16 160 N m 115 lbf ft 38 mm 1 160 N m 115 lbf ft 6 1 5 6 S 3 Extension Bar L 150 mm 6 6 4 Open end Torque Wrench 60 to 100 N m 44 to 73 lbf ft 22 mm 100 N m 73 lbf ft 22 mm 60 N m 44 lbf ft 3 7 5 Offset Wrench 19 mm 22 mm 27 mm 1 1 16 1 3 5 6 Adjustable Wrench L 300 mm 12 max span 34 mm 1 1 7 7 Needle Nose Pliers 2 4 6 1 N m 10 kg cm NOTE If drawings or other special documentation were supplied ...

Page 24: ...to a torque of 80 N m 58 lbf ft Cover Unit NOTE All internal components are attached to the cover unit Disconnect the motive medium supply piping and the exhaust piping from the cover unit utilize unions in the piping if present Make sure to secure sufficient space above the cover unit to allow it to be lifted straight up The cover unit weighs 12 7 kg 28 lb take any appropriate measures to assist ...

Page 25: ... Washer Split Pin Connecting Pin Flat Washer 3 Removing Reattaching the Snap action Unit It is not necessary to remove the float before removing the snap action unit When working with the snap action unit take care not to pinch fingers etc Part Disassembly Reassembly Cover Unit Support Flat Washer Spring Washer Bolt Flat Washer Snap action Unit Exhaust Valve Exhaust Valve Bolts Using a 22 mm in op...

Page 26: ...y are wound around the connection pin Exhaust Valve Important Split Pin Flat Washer Flat Washer Exhaust Valve Split Pin Connecting Pin Push Plate Snap action Unit If the snap action unit is being reinstalled without being overhauled DO NOT loosen the holder nuts on the push plate see step 7 5 Removing Reinstalling the Exhaust Valve Seat Part Disassembly Reassembly Exhaust Valve Seat Using a 27 mm ...

Page 27: ... if damaged Screen Remove with needle nose pliers Replace with new if damaged Motive Medium Intake Valve Seat Using a 17 mm 21 32 in socket wrench with an extension bar loosen the valve seat Using needle nose pliers grasp and remove the valve seat Using needle nose pliers insert the valve seat Tighten to a torque of 160 N m 115 lbf ft Motive Medium Intake Valve Seat Gasket Remove gasket with needl...

Page 28: ...s the no go lip The valve is free to move vertically so be certain to hold the base of the gauge flush with the push plate and do not force the gauge past the no go lip Go No go Section Section Adjusting the gap between the push plate and the motive medium intake valve When a snap action unit that has been removed from the cover is reinstalled without being overhauled do not loosen the holder nuts...

Page 29: ...llation inspection maintenance repairs disassembly adjustment and valve opening closing should be carried out only by trained maintenance personnel CAUTION When the desired performance is not attained with the system in many cases it is due to the following 1 Loose chips from pipe cutting and tapping welding scraps or sealant which catch in the intake valve motive medium or check valve and prevent...

Page 30: ...ous flowing sound from the exhaust pipe NO YES NO NO YES NO NO YES NO NO YES Has pumped medium accumulated in the receiver reservoir and backed up in the equipment Is there any abnormal noise from the check valves Is there any abnormal noise from the pumped medium outlet pipe Is steam escaping from the exhaust pipe or reservoir receiver Is there a continuous flowing sound from the motive medium su...

Page 31: ... medium recovery line The motive medium pressure must be about 0 05 MPa 7 psi higher than the back pressure see 2 in the Installation Procedure section 2 Insufficient motive medium If the motive medium supply pipe is too small change to a larger size pipe the pipe should be at least 20 mm in 3 The pumped medium inlet pressure exceeds the back pressure see G 1 When the pumped medium inlet pressure ...

Page 32: ...eedle valve or one with a small Cv value The pipe and stop valve size must be increased to the design pipe size and a full bore ball valve or gate valve must be used E Faulty PowerTrap 1 Dirt or scale is caught in the motive medium intake valve or the valve is worn 2 Dirt or scale is caught in the exhaust valve or the valve is worn 3 The snap action unit is obstructed by dirt or scale or its opera...

Page 33: ...the unit operates to grow shorter and reducing its discharge capacity Disassembly and inspection is required 3 The pumped medium inlet or outlet check valves have been installed in the wrong direction Correct the installation so that the check valve is facing the right way to allow the desired flow of pumped medium 4 The pumped medium inlet or outlet check valves are too small The pumped medium fl...

Page 34: ...maged or defaced nor does it apply in the following cases 1 Malfunctions due to improper installation use handling etc by other than TLV CO LTD authorized service representatives 2 Malfunctions due to dirt scale rust etc 3 Malfunctions due to improper disassembly and reassembly or inadequate inspection and maintenance by other than TLV CO LTD authorized service representatives 4 Malfunctions due t...

Page 35: ...e 2 bât C 290 rue Ferdinand Perrier 69800 Saint Priest France Tel 33 0 4 72482222 Fax 33 0 4 72482220 In Oceania Unit 8 137 145 Rooks Road Nunawading Victoria 3131 Australia Tel 61 0 3 9873 5610 Fax 61 0 3 9873 5010 In East Asia 36Kaki 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 ...

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