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172-65318MA-04 (GP10/GT10/GP14/GT14 PowerTrap) 23 Nov 2018

34

Troubleshooting

NEVER apply direct heat to the float. The float may explode due to

increased internal pressure, causing accidents leading to serious injury

or damage to property and equipment.

WARNING

DO NOT OPERATE the PowerTrap with piping disconnected. When it is

absolutely necessary to operate with a portion of the outlet piping

removed in order to examine an operational failure, open the motive

medium and condensate inlet valves slowly, standing a safe distance

from the open pipe section until the safety of this action is confirmed.

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.

CAUTION

Installation, 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 them from
closing/operating properly.

(2) Changes in the amount of condensate inflow, motive pressure or back pressure that

are in excess of the original design.

Since successful operation of the PowerTrap system depends on proper design and
installation of the system, investigate the entire system to locate the source of problems
when they occur. When no source can be identified, inspect the PowerTrap and take
whatever action is necessary.

Determining the Problem from the Symptoms

Use the “Types of Failure and their Causes” table on the following page to determine the
cause of the problem from the type of abnormality that has occurred. Apply the corrective
measures listed in the “Causes and Corrective Measures” table on pages 36 - 38.

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Содержание GP10

Страница 1: ...172 65318MA 04 GP10 GT10 GP14 GT14 PowerTrap 23 November 2018 GP10 GT10 GP14 GT14 Copyright 2018 by TLV CO LTD All rights reserved ...

Страница 2: ...st for Disassembly Reassembly 25 1 Removing Reattaching the Body from to the Cover 26 2 Removing Reattaching the Float 27 3 Removing Reattaching the Baffle 27 4 Removing Reattaching the Snap action and Lever Units 28 5 Removing Reinstalling the Exhaust Valve and Exhaust Valve Seat 29 5a Checking Adjusting the Gap between the Push Plate and Intake Valve Motive Medium 30 6 Removing Reinstalling the ...

Страница 3: ...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 mai...

Страница 4: ... 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 leading to serious injury or damage to property and equipment CAUTION Install properly and DO NOT use this product outside the recommended operating pressure temperatur...

Страница 5: ...uid 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 hammer will occur The impact of water hammer may damage the product leading to fluid discharge which may cause burns or other injury Take measures t...

Страница 6: ...lanned for installation Type of System Closed System Open System System Overview Equip ment Reservoir Condensate Recovery Line Exhaust Pipe Power Trap Equip ment Reservoir Condensate Recovery Line Exhaust Pipe 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 Stea...

Страница 7: ...2 When the float rises to its high level the push rod on the snap action unit rises quickly simultaneously closing the exhaust valve and opening the intake motive medium valve The pressure supplied 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 condens...

Страница 8: ...ions This item is omitted from the nameplate when there are no options Motive Medium Pressure Range GP10 GT10 0 03 1 05 MPaG 0 3 10 5 barg 5 150 psig GP14 GT14 0 03 1 4 MPaG 0 3 14 barg 5 200 psig GP14 GT14 Cast Iron in Europe 0 03 1 3 MPaG 0 3 13 barg 5 185 psig Maximum Allowable Back Pressure 0 05 MPa 0 5 bar 7 psi less than motive medium pressure used but not to exceed 1 05 MPaG 10 5 barg 150 p...

Страница 9: ...ther Steam using Equipment Max Height 3 m 10 ft Sm Se Si So Sr Equipment Pressure Steam for Heating Condensate Amount Q Ki Rm St Sv TLV Power Trap Steam Trap Backflow Water Hammer Prevention Check Valve Vb Backflow Water Hammer Prevention Check Valve Sf Overflow Condensate If water hammer due to steam backflow in the condensate recovery line is expected installation of a check valve vertically and...

Страница 10: ...ing Head A Products shown in the are the valves Those can be used independently Steam using Equipment Air and Non condensate Gas Discharge NOTE This sketch is for explanation purposes only and is not intended as an installation design In closed system applications the motive medium must be compatible with the liquid being pumped If a non condensable gas such as air or nitrogen is used as the motiv...

Страница 11: ...or periods of 2 months or longer install piping connecting the motive medium supply line to the receiver reservoir pipe 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 PowerTrap and where it enters the receiver reservoir pipe See item St in the drawings on pages 8 and 9 This measure is not necessary when the ...

Страница 12: ...pipe 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 For Closed Systems only The exhaus...

Страница 13: ...ling head of less than 860 mm 36 in is allowable However the minimum filling head is 710 mm 30 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 Overflow pipe should be installed at the side of the receiver Be sure to install a vent pipe and an overflow pipe Failure to install an overflow pipe is dangerous as condens...

Страница 14: ... 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 operation is between 4 and 40 metric tonnes 1 060 and 10 600 U S gal per hour When a flowmeter is to be installed in the pumped medium outlet piping it should be selected to reflect the intermittent operation an...

Страница 15: ...nted Receiver Table 1 shown on the next page c Determine the overflow pipe diameter Dop refer to the figure below NOTE The overflow pipe diameter should be at least as large as the condensate inlet pipe diameter Dcip refer to the figure below d Determine 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 co...

Страница 16: ...0 300 12 125 5 800 12 6 500 350 14 150 6 1000 14 6 700 400 16 200 8 1400 16 8 800 450 18 200 8 1600 18 8 1000 500 20 200 8 2000 20 8 1100 500 20 250 10 2200 20 10 1400 550 22 250 10 2800 22 10 1500 600 24 250 10 3000 24 10 Vented Receiver Table 2 For atmospheric open system installations applicable trap GP10 GP14 Amount of Condensate kg h Receiver Diameter mm in Length 1 m Amount of Condensate lb ...

Страница 17: ...000 3 5 2 0 1500 1 5 1 0 3000 4 5 3 0 2000 2 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 r...

Страница 18: ...ly Overflow Pipe Receiver Medium Return Main Line Vent Pipe Exhaust Pipe Manifold TLV Power Trap Exhaust Pipe Exhaust Pipe Motive Medium Supply Motive Medium Supply TLV Power Trap TLV Power Trap NOTE This sketch is for explanation purposes only and is not intended as an installation design Number of PowerTrap Units Installed Pumped Medium Inlet Pipe Size Pumped Medium Return Line Size Exhaust Pipe...

Страница 19: ...ckage Fixture is designed so that the body can be moved backwards opposite direction to the cover Failure to use fixtures or use of other than those provided may prevent mobility of the body and inhibit maintenance Consisting of two anchor brackets and two hex bolts with nuts Suitable Anchor Bolt Size M16 Bolt Holes in Product Body ø19 Anchor Bolt with nut M16 2 pcs Customer Supplied Hex Bolt with...

Страница 20: ...essure 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 in damag...

Страница 21: ...mped medium inlet valve Vi pumped medium outlet valve Vo valve Ve on exhaust pipe 3 Whenever any type of malfunction is suspected in the PowerTrap refer to the Troubleshooting section on pages 34 38 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 perform...

Страница 22: ... shafts in the intake motive medium and exhaust 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 specified range The exhaust valve will have some movement when open but should be stable when closed d Make sure the float is not damaged and has not filled with water e Make sure all nuts and bolts are properly insta...

Страница 23: ...ocedures 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 page 18 Installation and Maintenance Space maintenance can be carried out w...

Страница 24: ...take 5B Motive Medium Intake 6A Cover Gasket 6B Cover Gasket Continued next page Plug Screen Plug Screen Spring Washer Hex Bolt Spring Washer Hex Bolt Split Pin Spring Washer Float Split Pin Gasket Exhaust Valve Seat Exhaust Valve Connecting Pin Flat Washer Motive Medium Intake Valve Motive Medium Intake Valve Seat Valve Seat Gasket Valve Unit GP10 GT10 Valve Unit GP14 GT14 GP10 GT10 Graphite Comp...

Страница 25: ...ast Iron 8D Cover Unit for GT14 Cast Iron 9A Cover Unit for GP10 Cast Steel 9B Cover Unit for GT10 Cast Steel 9C Cover Unit for GP14 Cast Steel 9D Cover Unit for GT14 Cast Steel When ordering cover units be sure to indicate PowerTrap model connection type and size Connecting Pin Spring Washer Split Pin Spring Washer Hex Bolt Connecting Pin Spring Washer Split Pin Spring Washer Hex Bolt ...

Страница 26: ...1 6 S 3 Extension Bar L 150 mm 5 7 8 in 6 6 8 4 Open end Torque Wrench 30 60 N m 22 44 lbf ft 14 mm 9 16 in 17 mm 21 32 in 19 mm in 22 mm 7 8 in 1 2 5a 1 8a 2 5a 5 Offset Wrench 13 mm in 19 mm in 27 mm 1 1 16 in 30 mm 1 3 16 in 38 mm 1 in 3 4 5 1 6 3 4 5 1 6 8 6 Adjustable Wrench L 300 mm 12 in 1 2 1 2 7 Needle Nose Pliers 5 6 5 6 7 8 Open end Wrench 22 mm 7 8 in 17 mm 21 32 in 5a 5a 8a 1 N m 10 k...

Страница 27: ... that hold the anchor brackets to the body and rotate the anchor brackets on their base bolts so that they will not interfere with removal of the body from the cover Reverse steps in disassembly Body Cover Make sure to secure sufficient space around the body to allow it to be pulled straight off As the body weighs approximately 90 kg 200 lb use a block and tackle hoist to assist in its removal Whe...

Страница 28: ... float without twisting the lever arm Loosen the float only one turn with the two wrenches Complete the removal of the float with both hands being careful not to drop the float or lose the spring washer Be sure to reassemble with the spring washer Using two wrenches as described in disassembly tighten to a torque of 60 N m 44 lbf ft 3 Removing Reattaching the Baffle Part Disassembly Reassembly Bol...

Страница 29: ...ver unit bolt holes to the bolt holes in the cover GT10 GT14 To remove only the snap action unit leaving the lever unit still attached to the trap unit a Support the snap action unit and lever units in one hand while removing the four bolts b Remove the snap action unit then carefully tip the lever unit forward until it rests on the trap unit Align the snap action unit to the lever unit then posit...

Страница 30: ... pin to secure it in place Adjustment of the gap between the push plate and intake valve motive medium When a snap action unit that has been removed from the cover is reinstalled without being overhauled it is not necessary to adjust the gap between the push plate and the intake valve motive medium It is necessary to inspect and adjust the gap 3 0 3 mm 0 118 0 012 in only when installing a new sna...

Страница 31: ...3 0 3 mm 0 118 0 012 in the gauge will stop when the valve contacts the no go lip Go No Go Feeler Gauge 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 Adjusting the gap between the push plate and intake valve motive medium No action required When a snap action unit that has been removed from t...

Страница 32: ... valve with new and assemble in reverse order of disassembly Intake Valve Seat motive medium Valve Seat Gasket 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 a needle tool dislocate the valve gasket then catch and lift it out with either the needle or needle nose pliers Make sure you have removed the o...

Страница 33: ... in place 8 Removing Reattaching the Trap Unit GT10 GT14 only It is possible to remove the snap action and lever units without removing the trap unit see step 4 Remove the connecting pin step 7 before proceeding Part Disassembly Reassembly Bolts Spring Washers Using a 19 mm in socket wrench with an extension bar loosen the bolts holding the trap unit to the cover Coat the bolt threads trap unit bo...

Страница 34: ... touching the float Go No Go Lever Unit Arm Float Lever Unit Lock Nut Feeler Gauge Pivot Pin Adjusting the gap between the lever unit arm and pivot pin No action required When a trap unit that has been removed from the cover is reinstalled without being overhauled do not loosen the lock nuts If the previous inspection reveals that the gap is out of the accepted range proceed with gap adjustment Us...

Страница 35: ...lation 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 ...

Страница 36: ...ere a continuous flowing sound from the exhaust pipe NO YES NO NO YES NO NO YES NO NO YES Has the 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...

Страница 37: ...ive medium pressure must be about 0 1 MPa 15 psi 1 bar higher than the back pressure see pages 10 and 11 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 When using the GP10 GP14 the pumped medium inlet pressure exceeds the back pressure See G 1 on page 38 When the pumped medium inlet pressure exceeds the...

Страница 38: ...t pipe at a point just above where the exhaust pipe exits the body of the unit For the GT10 GT14 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 pumped medium from the pumped medium inlet pipe to the exhaust pipe 2 The filling head is insufficient 3 The pumped medi...

Страница 39: ... scale caught or any other abnormality 3 Check other possible factors that might hinder operation After performing the above inspection repair any defects discovered or replace the PowerTrap F Faulty check valve 1 Dirt or scale is caught in the pumped medium inlet check valve or the valve is worn or getting hung up The operating medium that has been supplied is leaking from the inlet check valve p...

Страница 40: ...been damaged 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 Malfunction...

Страница 41: ... México 52763 Mexico Tel 52 55 5359 7949 Fax 52 55 5359 7585 In Argentina Ciudad Autónoma de Buenos Aires Argentina Tel 54 0 11 4781 9583 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 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...

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