ADCA FLT80 User manual

VA L STEAM
ADCA
IMI FLT80.080 E 00.23
ADCA
We reserve the right to change the design and material of this product without notice.
FLOAT AND THERMOSTATIC
STEAM TRAPS
FLT80
INSTALLATION AND MAINTENANCE INSTRUCTIONS

VA L STEAM
ADCA
IMI FLT80.080 E 00.23
ADCA
GENERAL INFORMATION
• These instructions must be carefully read before performing any work involving
VALSTEAM ADCA products. Failure to observe these instructions may result in
hazardous situations.
• These instructions describe the entire life cycle of the product. Keep them in a
location that is accessible to every user and make these instructions available to
every new owner of the product.
• Current regional and plant safety regulations must be considered and followed
during installation, operation, and maintenance work.
• The images shown in these instructions are for illustration purposes only.
• For problems that cannot be solved with the help of these instructions, please
contact VALSTEAM ADCA or its representative.
VALSTEAM ADCA ENGINEERING S.A
Zona Ind.da Guia
Pav.14 - Brejo
3105-467 Guia, Pombal
PORTUGAL
[email protected]
We reserve the right to change the design and material of this product without notice.

VA L STEAM
ADCA
IMI FLT80.080 E 00.23
ADCA
CONTENT
1. SAFETY INFORMATION 4
1.1. Explanation of symbols 4
1.2. Intended use 4
1.3. Qualication of personnel 5
1.4. Personal protective equipment 5
1.5. The system 5
1.6. ATEX 6
1.7. General safety notes 6
2. PRODUCT INFORMATION 8
2.1. Principle of operation 8
2.2. Certication 9
2.3. Product identication 9
2.4. Technical data 10
3. TRANSPORT, STORAGE AND PACKAGING 10
4. INSTALLATION 12
4.1. Preparation for installation 12
4.2. Installation procedure 13
5. START-UP 14
5.1. Preparation for start-up 14
5.2. Start-up procedure 14
6. OPERATION 15
6.1. Operating the BDV unit 15
7. SHUTDOWN 16
7.1. Shutdown procedure 16
8. PARTS LIST 17
9. MAINTENANCE 18
9.1. Maintenance procedure 18
9.2. Cleaning/replacing the mechanism assembly 18
9.3. Replacing the oat 19
9.4. Fitting the retrot BDV and AFZ units 20
9.5. Tightening torques 21
10. TROUBLESHOOTING 21
11. DISPOSAL 22
12. RETURNING PRODUCTS 22

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1. SAFETY INFORMATION
1.1. Explanation of symbols
Hazardous situation which, if not avoided by applying the correct preventive
measures, will result in fatal or serious injury and/or considerable damage to
property.
DANGER
Hazardous situation which, if not avoided by applying the correct preventive
measures, could result in fatal or serious injury and/or considerable damage
to property.
WARNING
Hazardous situation which, if not avoided by applying the correct preventive
measures, could result in moderately severe or minor injury.
CAUTION
Situation which, if not avoided, can result in property damage or product
malfunction.
NOTICE
Indicates additional information, tips and recommendations.
NOTE
1.2. Intended use
Refer to the markings on the device, such as nameplate and laser markings, Information
Sheet (IS) and these Installation and Maintenance Instructions (IMI) to check that the
product was designed for the intended use and meets the specications used for sizing
and selection. This includes checking application, material suitability, process medium,
pressure and temperature as well as their respective limiting values.
VALSTEAM ADCA does not assume any responsibility for damage resulting from
inappropriate use of the product, damage caused by external stresses or any other
external factors. Correct installation of the product is the full responsibility of the contractor.

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Inappropriate use of the product is any use other than the one described in this chapter.
Inappropriate use also includes:
• Use of spare parts which are not genuine;
• Performance of maintenance work not described in these instructions;
• Use outside the limits dened by the accessories connected to the product.
• Unauthorized modications to the product.
If the product is to be used for an application or with a uid other than the one it was
designed for, contact VALSTEAM ADCA.
1.3. Qualication of personnel
Handling, installation, operation and maintenance work must be carried out by fully
trained and qualied personnel, capable of judging the work which they are assigned
to perform and recognizing potentially hazardous situations. They should be trained to
properly use this product according to these Installation and Maintenance Instructions.
Where a formal “Permits to Work” system is implemented in the plant it must be complied
with.
1.4. Personal protective equipment
Personal protective equipment should always be worn during work in order to protect
against hazards posed by e.g. the process medium, dangerous temperatures, noise,
falling or projected objects and working at height. These equipment includes a helmet,
safety glasses, safety harness, protective clothes, safety shoes, hearing protection, etc.
Always assess whether you or others in your vicinity require any protective
equipment. When in doubt check with the plant’s health & safety responsible
personnel for details on required protective equipment.
NOTE
1.5. The system
The complete system should be assessed as well as every action (e.g. closing of shut-
o󰀨 valves, disconnection of the power supply) to ensure this will not bring additional risk
to personnel or property.
Dangerous actions that can result in a hazardous situation include isolation of protective
devices such as safety valves, vents, vacuum relief valves, disconnection of electric
safety devices, sensors and alarms.

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1.6. ATEX
If the product is in the scope of the ATEX 2014/34/EU directive and as such bears the Ex
marking, consult its specic Additional Instructions for use in Potentially Explosive Areas
(IMI EX). In such cases, handling, installation, operation and maintenance work must
only be performed by personnel qualied and authorized to work in potentially explosive
areas.
1.7. General safety notes
RISK OF BURSTING IN PRESSURE EQUIPMENT
Valves, ancillaries and pipelines are pressure equipment. Working above
their operating limits or improper opening can lead to component bursting.
• Observe the maximum operating limits of the product and check if they are
lower than those of the system in which it is being installed. Check the product
Information Sheet (IS).
• Install a safety device.
• Before starting any work on the product, depressurize it and cool or heat it up
to ambient temperature. This also applies to the line in which it is tted.
• Drain the process medium from the product and all the relevant plant sections.
DANGER
RISK OF BURNS
Depending on the operating conditions, products and pipelines may get very
hot or cold and cause burn injuries.
• Do not touch the product while it is hot or cold, allowing it rstly to cool down
or heat up.
• Wear protective clothing and safety gloves during working operation.
• Thermally insulate tubes and product’s as a preventive measure.
RISK OF INJURY CAUSED BY FLUID ATTACK ON PRODUCTS
MATERIALS
The product must only be used with mediums that do not attack the materials
of the product (body, gaskets, seals). Otherwise, leaks may occur, and hot
and/or hazardous uid can escape.
• Do not use the product with mediums other than the ones it was designed for.
Check section 1.2 - Intended Use.
• Prevent medium contamination.
WARNING

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RISK OF INJURY CAUSED BY UNDER TIGHTENED PRODUCT OR
ITS COMPONENTS
Excessively low tightening torques may cause medium to escape and/or
components to be projected at high speed which may result in a hazardous
situation depending on the medium, chemical properties and/or its operating
conditions.
• Do not loosen any screws while the equipment is pressurized.
• Observe the specied tightening torques on these Installation and Maintenance
Instructions. If the relevant torque value is not mentioned contact VALSTEAM
ADCA.
RISK OF HEARING LOSS
Depending on the operating conditions, the product may generate loud
noises.
• Wear hearing protection when in the vicinity of the product.
RISK OF INJURY AS A RESULT OF ILLEGIBLE INFORMATION
Important information written in the product nameplate, markings and warning
signs may wear overtime or get illegible due to e.g. dirt accumulation, resulting
in hazardous situations and personal injury or property damage.
• Keep nameplates, markings and warning signs in a legible state, replacing
when illegible, missing or damaged.
WARNING
RISK OF INJURY DUE TO RESIDUAL PROCESS MEDIUM
Direct contact with dangerous process medium may lead to personal injury,
e.g. smoke inhalation and chemical burns.
• Drain the process medium from the product and all the relevant plant sections.
• Wear protective clothing, safety gloves, mask, and eye protection.
RISK OF INJURY DUE TO IMPROPER HANDLING
Manual handling (e.g. lifting, carrying, pushing, pulling) of large and/or heavy
products may result in personal injury.
• Assess the risk associated with the handling task.
• Use adequate handling methods and appropriate auxiliary handling equipment.
CAUTION

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RISK OF PRODUCT DAMAGE DUE TO EXCESSIVELY HIGH
TIGHTENING TORQUES
High tightening torques may lead to premature wearing of product components.
• Observe the specied tightening torques on these Installation and Maintenance
Instructions. If the relevant torque value is not mentioned contact VALSTEAM
ADCA.
NOTICE
2. PRODUCT INFORMATION
The ADCA FLT80 is a series of high capacity oat and thermostatic steam traps with
integral air vent designed for modulating discharge of condensate and air venting,
ensuring maximum system heat transfer.
Typical applications include unit heaters, heat exchangers, dryers, jacketed vessels and
other applications where continuous discharge is essential and high loads are involved.
2.1. Principle of operation
A oat (8) opens or closes the valve seat
(4), by moving the valve (6) via a simple
lever mechanism according with the
condensate level inside the steam trap,
changing its position in relation to the
seat. Condensate discharge and opening
of the equipment is proportional to the
movement of the oat. As the oat rises,
so does the discharge capacity. Discharge
is modulating and does not interfere with
automatic controls, if tted.
Air venting is ensured by a thermostatic
air vent (9) located in the steam space above the condensate level. After releasing the
initial air, it remains closed until air and other non-condensable gases accumulate during
normal operation and cause it to open by reducing the temperature of the air/steam
mixture. The thermostatic air vent o󰀨ers the added benet of increasing condensate
capacity on cold start-up.
The steam trap can be supplied without air vent.
The steam trap can be supplied with a variety of options, most of which can also be
retrotted in case the steam trap has been supplied with the optional bottom cover
connections.
1
5
3
4
2
6
7
8
9
10A 10
Fig. 1

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The blowdown valve (BDV) is a retrottable option which can be installed on the bottom
cover connection. It is used as a manual drain and/or depressurization.
The anti-freeze device (AFZ) is a retrottable option which can be installed on the
bottom cover connection. It is used for automatic discharge of condensate after system
shutdown to prevent it from freezing inside the steam trap. The valve consists in a simple
mechanism with a spring and a stainless steel ball. The spring force keeps the valve
open as long as the medium pressure is below approximately 0,3 bar, at which point the
medium pressure pushes the ball against the seat and closes the valve.
2.2. Certication
This product has been specically designed for use with liquids and gases which are
in Group 2 of the European PED – 2014/68/EU Pressure Equipment Directive and it
complies with its requirements.
CE MARKING – GROUP 2 (PED – European Directive)
PN 16 Category
3" and 4" – DN 80 and 100 2 (CE marked)
If the product falls within category SEP it must not be CE marked, unless
other directives are applicable.
NOTE
This product is not in the scope of the ATEX 2014/34/EU directive as it does not have its
own potential ignition source. Personnel responsible for the plant installation must assess
the risks caused by static electricity and take the necessary precautionary measures to
prevent static charge. These measures include e.g. connection of the product to the
equipotential bonding system.
2.3. Product identication
The following items are indicated on the product nameplate or directly on its body:
• Manufacturer
• Product model (e.g. FLT80)
• Pressure rating (e.g. PN 16 )
• Nominal size (e.g. DN80)
• Max. di󰀨erential pressure (e.g. DP: 12 bar)
• Max. operating temperature (e.g. TMO: 250 ºC)
• Max. operating pressure (e.g. PMO: 12 bar)
• Min. admissible temperature (e.g. -10 ºC)

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• Max. admissible temperature (e.g. TMA: 300 ºC @ 11 bar)
• Max. admissible pressure (e.g. PMA: 14,8 bar @ 100 ºC)
• Flow direction (indicated by an arrow)
• Serial number and year of manufacturing (e.g. Reg.:17483/19)
• CE Marking (when applicable – see section 2.2 – Certication)
• EX Marking (when applicable e.g. EX h IIB T6…T3 Gb – see section 2.2 –
Certication)
2.4. Technical data
For technical data including dimensions, materials, limiting conditions and versions refer
to the product's respective Information Sheet (IS).
3. TRANSPORT, STORAGE AND PACKAGING
RISK DUE TO FALLING LOADS
Loads may tip or fall over resulting in demage to property, serious injury or
death.
• Use suitable equipment when moving or lifting suspended loads.
• Make sure no one is standing below the suspended load.
WARNING
RISK OF INJURY DUE TO IMPROPER HANDLING
Manual handling (e.g. lifting, carrying, pushing, pulling) of large and/or heavy
products may result in personal injury such as back injury.
• Assess the risk associated with the handling task.
• Use adequate handling methods and appropriate auxiliary handling equipment.
CAUTION

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RISK OF PRODUCT DAMAGE DUE TO IMPROPER STORAGE
• Do not remove any packaging or protective covers until immediately before
installation at the site.
• Store the product in a solid base in a dry, cool and dust-free environment.
• Until its installation, protect it from the weather, dirt, corrosive atmospheres and
other harmful inuences.
RISK OF PRODUCT DAMAGE DUE TO LONG TERM STORAGE
Some product components may deteriorate with time (e.g. valve packings,
seals).
• Do not store the product for more than 12 months.
• If for any reason the product must be stored for longer periods of time contact
VALSTEAM ADCA.
NOTICE
Products are individually wrapped in plastic lm, thermo shrinkable plastic and/or stored
in a cardboard box as they leave VALSTEAM ADCA. Avoid removing packaging and any
protective cover until immediately before installing the product at the site.
If the transport packaging has any shipping damage contact VALSTEAM
ADCA or its representative.
NOTE
Before storing and transporting the product protect it from impacts and mechanical
damage, paying special care with sealing surfaces and other fragile parts.
If the corrosion protection (paint and other surface coatings) of the product is
damaged during transport or other handling procedures repair it immediately.
NOTE

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4. INSTALLATION
Before performing any installation work, refer to section 1 – Safety information.
RISK OF INJURY DUE TO INSUFFICIENT SUPPORT
DURING INSTALLATION
Insu󰀩cient support of the product during installation may cause it to fall and
cause personal injury.
• Ensure the product is safely held in place during installation.
• Wear protective safety shoes.
WARNING
RISK OF PRODUCT DAMAGE DUE TO STRESS
The product is not intended to withstand external stresses that may be
inducted by the system to which it is being connected to.
• Make sure that the connected pipe does not subject the body to any stress
(forces or torques) during installation and operation.
• Do not use the product as an elevation point.
NOTICE
4.1. Preparation for installation
Before installation, make sure the following conditions are met:
• The installation area has easy access and the product is to be installed in a position
where operation and maintenance work can be performed safely.
• The product will be installed with proper support and free of any stresses that can
be induced by the system due to e.g. pipe expansions. The necessary precautions
are recommended during system design.
• The pipeline where the product will be installed is designed in such a way that it
takes into account the weight of the product. The pipeline may require support on
both sides next to the product, particularly if its size and weight are considerable
and especially if vibrations are to be expected in the system.
• The product is not damaged.
• Make sure all the necessary materials and tools are readily available during
installation work.
• Referring to this Installation and Maintenance Instructions (IMI), Information Sheet
(IS) and nameplate, check that the product is suitable for the intended installation:
temperature, medium, pressure, temperature, etc. – see section 1.2 – Intended
use.

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• Check that there are no foreign bodies inside the pipelines and ancillaries, ushing
may be necessary. These should be thoroughly cleaned.
• Check any mounted pressure gauges and make sure these function properly.
• An additional ADCA pipeline strainer or lter may be necessary to install upstream
of the steam trap in some applications, preventing solid particles in the process
medium from damaging it.
• The pipelines are layed out with a gradient so that condensate is free to fall towards
the steam trap.
Assembly Drawings (AD) with assembly details and parts lists are available
on request.
NOTE
4.2. Installation procedure
1. Remove plastic lm and other packaging, as well as the protective covers which
are placed on anges or connection ends. Make sure the steam trap is free from
foreign matter.
2. The steam trap must be installed with vertical inlet pipeline and horizontal outlet.
3. The steam trap has an arrow or inlet/outlet designations, be sure that it is installed
in the appropriate direction according to uid ow.
4. The steam trap is supplied with a supporting bracket which should be secured onto
a frame or directly on the oor. Use appropriate bolts on the pre-drilled holes. If the
steam trap is to be suspended, ensure there is appropriate support on the pipeline
taking into account the weight and size of the product as well as vibrations and
other stresses.
5. Take care with jointing materials and sealing compounds to ensure that none may
be permitted to block or enter the steam trap causing malfunction. In case of anged
connections use appropriate ange gaskets.

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5. START-UP
Before performing the start-up procedure, refer to section 1 – Safety Information.
The start-up procedure must be followed every time the product is put back into service.
5.1. Preparation for start-up
Before starting up, make sure the following conditions are met:
• All works on the system have been completed.
• All the necessary safety devices have been installed.
• When required, warning notices are used to alert others that the system is starting
up.
• The product is correctly installed – see section 4 – Installation.
• Referring to these Installation and Maintenance Instructions (IMI), Information Sheet
(IS) and nameplate, check that the product is suitable for the intended installation:
temperature, medium, pressure, temperature, etc. – see section 1.2 – Intended
use.
• A safety check was performed by qualied personnel. Checking for leaks, structural
damage and integrity of system components.
RISK OF PRODUCT DAMAGE DUE TO CONTAMINATION
The plant operator is responsible for cleaning the pipelines in the plant as
well as keeping the product well maintained. At start-up, the presence of
small particles in the medium (dirt, scale, weld splatters, etc.) may damage
the product or cause malfunction.
• Flush pipelines before start-up.
• Clean protection varnishes from pipes and anges, leftover paint, graphite,
grease, etc.
• Use a pipeline strainer or a lter.
NOTICE
5.2. Start-up procedure
1. Open shut-o󰀨 valves slowly, until normal operating conditions are achieved.
2. Check for any leaks.
3. Check the steam trap to ensure it is operating correctly.

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24 hours after system start-up, it is recommended to check pipe connection
for leaks and retighten when necessary. Clean strainers/lters to avoid
blocking.
NOTE
6. OPERATION
Before operating the product refer to section 1 – Safety Information.
Immediately after completing the start-up procedure, the product is ready for operation.
6.1. Operating the BDV unit
RISK OF BURNS FROM BDV VALVE OPERATION
Operating the BDV valve discharges hot medium to the atmosphere which
may cause burn injuries.
• Wear protective clothing, safety glasses and heat-resistant gloves during
operation.
• When operating the valve stand to the side well clear of its outlet.
RISK OF INJURY DUE TO EXCESSIVELY LOOSENING THE BDV
VALVE SCREW
Excessively loosening the valve screw while operating may cause the retainer
to break or come loose. This may result in the screw blowing o󰀨 leading to
personal injury and product malfunction.
• Loosen the valve screw slowly and do not unscrew it excessively.
WARNING
1. Open the BDV by slowly unscrewing the valve screw. Be careful to avoid contact
with the hot medium which will be discharged through the valve whole as it opens.
2. Close the valve by tightening the valve screw to a torque of 20 to 25 Nm ensuring
that there is no leakage.
3. Periodical valve operation is recommended to ensure correct functioning.

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7. SHUTDOWN
Before performing the shutdown procedure, refer to section 1 – Safety information.
7.1. Shutdown procedure
1. Switch o󰀨 the system and secure it so it cannot be turned on by unauthorized
personnel.
2. Fully close the upstream shut-o󰀨 valve, to stop the process medium from owing
through the steam trap.
3. Make sure the pipeline and the steam trap are not under pressure and are at a safe
temperature.
4. Allow medium to cool down and completely drain it from the pipeline and steam
trap.
5. Fully close the downstream shut-o󰀨 valve.
6. If the steam trap is to be removed from the pipeline – see section 3 - Transport,
storage and packaging.

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8. PARTS LIST
1
5
3
4B
2
810A
10
7
9
4A
46
Fig. 2
Fig. 3 - Optional BDV and AFZ units.
51
BDV - Blowdown valve
(Manual)
61
AFZ - Anti-freeze device
(Automatic)
POS.
Nº DESIGNATION SPARE PARTS
1Body
2Cover
3Gasket X
4Seat X
4A Studs
4B Nuts
5Gasket X
6Valve X
7Lever X
8Float X
9Automatic air vent X
10 Bolts
10A Nuts
11 Plug
12 Gasket X
51 Blowdown valve
61 Anti-freeze device

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9. MAINTENANCE
Before performing a maintenance procedure, refer to section 1 – Safety information.
The product requires maintenance to ensure that it operates correctly and safely
throughout its lifetime. Maintenance work should be performed in a planned manner
at periodic intervals. These intervals must be dened by the operator according to the
service conditions.
9.1. Maintenance procedure
1. Make sure all the necessary materials and tools are readily available during
maintenance work.
2. Perform the shutdown procedure – see section 7 – Shutdown.
3. Perform the maintenance procedure – see the following sections.
4. Put the product back into operation – see section 5 – Start-up.
9.2. Cleaning/replacing the mechanism assembly
1. Undo the bolts (10) gradually in a crisscross pattern
and separate the cover (2) from the body (1).
2. Remove the body gasket (3), unscrew nuts (4B),
remove gasket (5) and mechanism assembly (4, 6,
7, 8).
3. Clean or replace the mechanism assembly (4, 6, 7,
8). When cleaning use fresh water and a cloth.
4. Clean body (1) and cover (2) surfaces thoroughly,
leaving no remaining graphite leftovers.
5. If the automatic air vent (9) needs replacing, remove
the spring (9B) and thermostatic element (9A).
Unscrew the seat (9C). Clean the female thread thoroughly, removing all signs of
leftover silicone. Apply a suitable silicone sealant to the thread of the new seat and
tighten with the recommended torque – see section 9.5 – Tightening torques.
6. Install a new thermostatic element (9A) securing with the spring (9B).
7. Fit a new gasket (5) and install the mechanism assembly (4, 6, 7, 8) with the oat
(8) on the top. Secure it by tightening the nuts (4B) onto the studs (4A) with the
recommended torque – see section 9.5 – Tightening torques.
8. Fit a new body gasket (3) and install the cover (2) with the inlet pointing upwards.
9. Apply a suitable lubricant to the threads of the bolts (10), and tighten gradually in
a crisscross pattern until the recommended torque is achieved – see section 9.5 –
Tightening torques.
9A
9C
9B
Fig. 4 - Replacing the automatic
air vent.

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9.3. Replacing the oat
8
7
4
8A
8B
Fig. 5 - Replacing the oat.
1. Undo the bolts (10) gradually in a crisscross pattern and separate the cover (2)
from the body (1).
2. Remove the body gasket (3) and clean surfaces thoroughly, leaving no remaining
graphite leftovers.
3. Secure the oat (8), unscrew the bolt (8A) and remove the serrated washer (8B).
4. Attach the new oat to the lever (7) by screwing the bolt (8A) with a new serrated
washer (8B) in place.
5. Fit a new body gasket (3) and install the cover (2) with the inlet pointing upwards.
6. Apply a suitable lubricant to the threads of the bolts (10), and tighten gradually in
a crisscross pattern until the recommended torque is acheived – see section 9.5 –
Tightening torques.

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9.4. Fitting the retrot BDV and AFZ units
The BDV and AFZ units can only be installed in steam traps which have been
supplied with the optional bottom cover connection.
NOTICE
12
11
BDV
AFZ
Fig. 6 - Optional BDV and AFZ units.
1. Unscrew the plug (11) and remove the gasket (12) if any.
2. Fit the gasket (12) supplied with the retrot kit (not applicable in NPT versions)
and screw the unit to be installed (BDV or AFZ), tightening with the recommended
torque – see section 9.5 – Tightening torques.
3. In case a BDV has been installed, ensure the valve is closed by tightening the
valve screw to a torque of 20 to 25 Nm.
4. In case a AFZ has been installed make sure to connect a Ø8 mm tube on the
supplied compression tting to direct the discharge to a safe place.