TLV PowerTrap GT5C User manual

172-65473MA-03 (GT5C PowerTrap) 17 July 2019

GT5C

172-65473MA-03 (GT5C PowerTrap) 17 Jul 2019

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................................... 15

Operation................................................................................................................15

Periodic Inspection and Diagnosis..........................................................................16

Disassembly/Reassembly................................................ 17

Recommended Tools List for Disassembly/Reassembly ........................................18

1. Before Removing/Reattaching............................................................................19

2. Removing/Reattaching the Body from / to the Cover..........................................20

3. Removing/Reattaching the Snap Action Unit......................................................20

4. Removing/Reattaching Each Unit.......................................................................22

5. Removing/Reattaching of Air Vent Unit...............................................................23

6. Positioning Adjustment of the Trap Valve...........................................................24

Troubleshooting................................................................ 25

Determining the Problem from the Symptoms........................................................25

Types of Failure and their Causes..........................................................................26

Causes and Corrective Measures...........................................................................27

Replacement Parts........................................................... 30

Product Warranty ............................................................. 31

Service ............................................................................. 32

172-65473MA-03 (GT5C PowerTrap) 17 Jul 2019

Introduction

Thank you for purchasing theTLV 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 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.

172-65473MA-03 (GT5C PowerTrap) 17 Jul 2019

Safety Considerations

Read this section carefully before use and be sure to follow the instructions.

Installation, inspection, maintenance, repairs, disassembly, adjustment and valve

opening/closing should be carried out only by trained maintenance personnel.

The precautions listed in this manual are designed to ensure safety and prevent

equipment damage and personal injury. For situations that may occur as a result of

erroneous handling, three different types of cautionary items are used to indicate the

degree of urgency and the scale of potential damage and danger: DANGER,

WARNING and CAUTION.

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.

Symbols

Indicates a DANGER, 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 leading to serious injury or damage to property and

equipment.

CAUTION

Install properly and DO NOT use this product outside the

recommended operating pressure, temperature and other

specification ranges.

Improper use may result in such hazards as damage to the product

or malfunctions that may lead to serious accidents. Local regulations

may restrict the use of this product to below the conditions quoted.

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 injury if the object

should fall.

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 the discharge

of fluids.

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.

Continued on next page

172-65473MA-03 (GT5C PowerTrap) 17 Jul 2019

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.

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 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 to ensure the proper handling, such as recovery

or dilution, of hazardous fluids discharged at product outlets.

Outflow of fluid or fluid leaks may lead to hazards such as flammable

conditions or corrosion, which may result in injury, fires, damage or

other accidents.

172-65473MA-03 (GT5C PowerTrap) 17 Jul 2019

General Description

Install properly and DO NOT use this product outside the recommended

operating pressure, temperature and other specification ranges. 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.

CAUTION

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’).

GT5C can also discharge the accumulated condensate when the steam using

equipment stops operation, and prevent water hammer when it re-starts operation.

172-65473MA-03 (GT5C PowerTrap) 17 Jul 2019

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

the discharge of fluids.

CAUTION

(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.

The main valve on the trap unit opens as the float rises. When Pi> Pb(when the

equipment pressure (Pi) is greater than the back pressure (Pb)), the condensate

passes through the outlet check valve and is discharged through the condensate

outlet pipe (normal trapping function).

In this case, the integrated air vent unit exhausts internal air to the outlet.

When Pi≤Pb, the condensate is not discharged and collects in the body of the

unit.

(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 condensate in

the unit through the outlet pipe, as shown in (B) 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 reaches its low level, the push rod on

the snap-action unit moves down quickly, simultaneously opening the exhaust valve

and closing the intake (motive medium) valve and the status reverts to that shown in

(A) below.

Outlet Check Valve

Intake Valve [Open]

Exhaust Valve [Close]

Condensate Outlet

Pipe

Body

Exhaust Valve [Open]

Intake Valve [Close]

Operation Shaft

Cover

Trap unit

Float

Snap Action unit

Inlet Check Valve

Condensate Inlet Pipe

(A) Condensate Inflow (B) Condensate Discharge

(Exhaust) (Motive Medium Intake)

Air Vent Unit

172-65473MA-03 (GT5C PowerTrap) 17 Jul 2019

Specifications

Install properly and DO NOT use this product outside the recommended

operating pressure, temperature and other specification ranges.

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.

CAUTION

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.

CAUTION

Refer to the product nameplate for detailed specifications.

Valve No.**

Nominal Diameter

Model

Maximum Allowable

Pressure*

Maximum Allowable

Temperature*

Serial No.

Maximum Operating

Temperature

Maximum Differential

Pressure

* 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 nameplate when there are

no options.

172-65473MA-03 (GT5C PowerTrap) 17 Jul 2019

Configuration

Exhaust Outlet Plug

Motive Medium Inlet

Condensate Inlet

Condensate Outlet

N0.

Parts

Maintenance

Kit

Repair Kit *¹

Float

Snap

Action

Spring

Body

Cover

Gaskets, etc.

Gasket

✔

Seal set

✔

Cover Bolt

Nameplate

Float

✔

Snap-Action Unit

✔*²

Snap Action Spring

✔

Intake-Exhaust Valve Unit

✔

Trap Unit

✔

Air Vent Unit

✔

Inlet Check Valve

✔

(Flange)

Plug (for drainage)

Please refer to the replacement parts list for maintenance and repair kits.

*¹ The maintenance kit should be purchased along with a repair kit, as gaskets might be required.

*² A snap action spring is also contained in the snap-action unit.

172-65473MA-03 (GT5C PowerTrap) 17 Jul 2019

Installation

Install properly and DO NOT use this product outside the recommended

operating pressure, temperature and other specification ranges.

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.

CAUTION

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

injury if the object should fall.

CAUTION

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

the discharge of fluids.

CAUTION

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.

CAUTION

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.

CAUTION

Steam System Example

For non-standard options, please refer to the additional instruction manual(s) provided.

1. Standard Installation Example

The example below shows the inlet piping is connected to the inlet of GT5C in the

same way as a standard steam trap. The condensate inlet pipe [Si] acts like a

condensate reservoir. Refer to “Sizing the Condensate Reservoir Pipe”at the end of

this section for the size of condensate inlet pipe [Si] (length of Dh).

Pumped medium

Condensate Receiver/Reservoir

Filling Head

Condensate Inlet Strainer

Motive Medium Supply Pressure

Motive Medium Strainer

Back Pressure

Steam Trap

Condensate Inlet Pipe

Valve on Condensate Inlet Pipe

Condensate Outlet Pipe

Valve on Condensate Outlet Pipe

Condensate Recovery Line

Valve on Motive Medium Supply Pipe

Sm1

Motive Medium Supply Pipe

Blowdown Valve

Sm2

Motive Medium Supply Tube

Equipment Pressure

PowerTrap

Sr So

Sm1

QVb

Sm2

Backflow

Water Hammer

Prevention

Check Valve

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.

When the rise in piping is 30 m (100 ft) or farther from the PowerTrap, installation

of a check valve is recommended for the prevention of return water hammer.

Inner diameter should be

at least 8 mm (5/16 in)

Backflow

Water Hammer

Prevention

Check Valve

*Refer to diagrams shown in “Installation Procedure”and “(4)Inlet and Outlet Piping”in this section for the

length of condensate reservoir (Dh) in cases where the exhaust pipe is eliminated and there is vertical piping

on the pumped medium inlet due to elevated position ofthe equipment condensate outlet.

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