TLV PowerTrap GP10L User manual
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 March 2004
GP10L/GT10L
Copyright © 2004 by TLV CO., LTD.
All rights reserved
ISO 9001/ ISO 14001
Manufacturer
Kakogawa, Japan
is approved by LRQA LTD. to ISO 9001/14001
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
1
Contents
Introduction......................................................................... 2
Safety Considerations ........................................................ 3
General Description............................................................ 5
Application ............................................................................................................... 5
Operation............................................................................ 6
Specifications ..................................................................... 7
Configuration ...................................................................... 7
Installation .......................................................................... 8
Open System Piping ................................................................................................ 8
Closed System Piping.............................................................................................. 9
Installation Procedure .............................................................................................. 9
Size of the Condensate Receiver / Reservoir Pipe................................................. 14
Installing Several PowerTrap Units in Parallel ..................................................... 16
Installation and Maintenance Space ................................ 17
Anchoring the Body................................................................................................ 17
Maintenance Space ............................................................................................... 17
Operation and Periodic Inspection ................................... 18
Operation............................................................................................................... 18
Periodic Inspection and Diagnosis ......................................................................... 19
Disassembly / Reassembly .............................................. 21
Replacement Parts ................................................................................................ 22
Recommended Tools List for Disassembly / Reassembly...................................... 23
1. Removing / Reattaching the Body from / to the Cover ....................................... 24
2. Removing / Reattaching the Float...................................................................... 25
3. Separating / Rejoining the Trap Rod and Trap Unit (GT10L only)...................... 26
4. Removing / Reattaching the Trap Unit (GT10L only) ......................................... 26
5. Removing / Reattaching the Snap-action Unit.................................................... 27
6. Removing / Reinstalling the Motive Medium Intake and Exhaust Valves............ 27
7. Removing / Reinstalling the Motive Medium Intake and Exhaust Valve Seats ... 28
Troubleshooting................................................................ 29
Determining the Problem from the Symptoms ....................................................... 29
Types of Failure and their Causes ......................................................................... 30
Causes and Corrective Measures.......................................................................... 31
Product Warranty.............................................................. 34
Service.............................................................................. 35
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
2
Introduction
Thank you for purchasing the 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 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.
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
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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.
DANGE
R
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 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.
Safety considerations are continued on the next page.
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
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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.
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
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General Description
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
The PowerTrap is used to discharge liquid from vacuum-pressure or low-pressure
areas to high-pressure areas, or from lower to higher elevations.
The GT model is the same as the GP, but with an additional steam trap function, making
it suitable for use in instances in which the inlet pressure may alternately be lower than
or higher than the outlet pressure.
There are two types of delivery systems (piping methods): the closed system and the
open system. Use of the GT model or the GP model is determined by the type of
system.
Check to make sure that the PowerTrap model that has been purchased is suitable for
use on the type of system that is being planned for installation.
Type of
System Closed System Open System
System
Overview
Benefits !"
No need for external steam trap
(GT model features built-in trap)
!"
No flash steam discharge
!"
Small reservoir
!"
Use with vacuum equipment
possible
!"
No need for large venting pipe
!" Collection of condensate from multiple
equipment possible
!" Can be used where trap is lower than
receiver, such as equipment situated
near grade (providing there is sufficient
differential pressure)
Notes !"
Only one piece of equipment
possible per system
!"
Equipment has minimum height
requirement to ensure that
condensate flows naturally, by
gravity (approx. 0.5 m (20 in))
!"
Separate steam trap required for each
piece of equipment
!"
Requires venting pipe to discharge flash
steam to atmosphere
Mechanical pump with built-in trap
GT10L
Model
Where there is ALWAYS a
negative pressure differential
(e.g. vacuum equipment), GP10L
can be used
Mechanical pump
GP10L
Equip-
ment
Reservoir Condensate
Recovery
Line
Exhaust
Pi
p
e
Steam
Trap
Steam
Trap Receiver
Pit
Condensate
Recovery
Line
Exhaust
Pi
p
e
Discharge to
Atmosphere
Power
Trap
Equip-
ment
Equip-
ment Power
Trap
Venting
Pi
p
e
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
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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 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 (1) below.
• In the case of the GT, the main valve on the trap unit opens as the float rises.
When P1> Pb(when the inlet pressure (P1) 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).
• When P1≤Pbfor both the GP and GT models, 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 (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 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
(1) below.
(1) and (3) Pumped Medium Flow or Discharge
(exhaust step)
(2) Pumped Medium Supply
(intake step)
Check
Valve
Check Valve Check Valve
Check Valve
Body
Float Steam
Trap
Cover
Exhaust Valve
(open)
Intake Valve
(motive medium)
(closed)
Pumped
Medium
Inlet Pipe
Pumped
Medium
Outlet Pipe
Exhaust Valve
(closed)
Intake Valve
(motive medium)
(open)
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
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Specifications
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.
* 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.
Configuration
No. Part Name No. Part Name No. Part Name
1 Body 5 Nameplate 9 Exhaust Valve Unit
2 Cover 6 Float 10 Plug
3 Cover Gasket 7 Snap-action Unit 11 Trap Unit (GT10L only)
4 Cover Bolt 8 Intake Valve Unit
Model
Maximum Allowable Pressure*
Nominal Diameter
Maximum Operating Temperature
Maximum Operating Pressure
Valve No.**
Serial Number
Maximum Allowable Temperature*
Condensate Inlet
Condensate Outlet
Motive Medium Inlet
Exhaust Outlet
Detail of Intake / Exhaust Valve
and Valve Seat
These screw holes are
for the flange connection.
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
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Installation
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
Open System Piping
[Ci]
[Vo]
Condensate
Recovery
Line
Primary
Pressure for
Motive
Medium
Motive
Medium
Supply
Pressure
[Pm]
Pump
Exhaust
[Co]
Steam Using
Equipment
Condensate
Receiver
[Ve]
[Vi]
Back
Pressure
[Pb]
Steam Trap
Flash Steam
Temperature
Controller
Steam
Trap
Overflow
Other Steam Using
Equipment
Filling Head [A]
[D]
Sm
Sv
Se
Si So
Sr
Maximum
Equipment
Pressure
[P1]
Steam
for
Heating
Condensate
Supply
[Q]
Pipe the discharge to a safe area such as a pit.
[Ki]
[Rm]
[St]
TLV
GP
Steam Trap
Backflow Water Hammer
Prevention Check Valve
[Km]
[Vm]
Maximum Height: 3m (10 ft)
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.
Pipe the discharge to a safe place such as a pit.
Note: This sketch is for explanation purposes only
and is not intended as an installation design.
Q Condensate Supply Se Exhaust Pipe Rm Motive Medium Pressure
A Filling Head Sv Vent Pipe Reducing Valve
Pm Motive Medium Supply Pressure Dh Condensate Receiver St Steam Trap on Drip leg
Pb Back Pressure GP PowerTrap Vi Valve on Condensate Inlet Pipe
Si Condensate Inlet Pipe Ci Condensate Inlet Check Valve Vo Valve on Condensate Outlet Pipe
So Condensate Outlet Pipe Co Condensate Outlet Check Valve Vm Valve on Motive Medium Supply
Sr Condensate Recovery Line Ki Condensate Inlet Strainer Pipe
Sm Motive Medium Supply Pipe Km Motive Medium Strainer Ve Valve on Exhaust Pipe
Back
Pressure
[Pb]
[Dh]
TLV
GP
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
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Closed System Piping
[Ci]
[Vo]
Condensate
Return
Line
Motive
Medium
Supply
Pressure
[Pm]
Pump Exhaust
[Co]
Steam
Using
Equipment
Condensate
Reservoir [Dh]
[Ve]
[Vi]
Back
Pressure
[Pb]
Temperature
Controller
Air and Non-condensible Gas Discharge
Filling Head [ A]
Sm
Sv
Se
Si So
Sr
Maximum
Equipment
Pressure
[P1]
Steam
for
Heating
Condensate
Supply
[Q]
Pipe the discharge to a safe area such as a pit.
[Ki]
[Rm]
[St]
TLV GT
Backflow Water Hammer
Prevention Check Valve
[Av]
[Vb]
Condensate Outlet Distance from Floor [B]
Primary
Pressure for
Motive
Medium
[Km]
[Vm]
NOTE: 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 motive medium, please
consult TLV for assistance.
Q Condensate Supply Se Exhaust Pipe Rm Motive Medium Reducing Valve
A Filling Head Sv Vent Pipe St Steam Trap on Drip Leg
Dh Condensate Reservoir Vi Valve on Condensate Inlet PipePm Motive Medium Supply
Pressure GT PowerTrap Vo Valve on Condensate Outlet Pipe
Pb Back Pressure Ci Condensate Inlet Check Valve Vm Valve on Motive Medium Supply
Si Condensate Inlet Pipe Co Condensate Outlet Check Pipe
So Condensate Outlet Pipe Valve Ve Valve on Exhaust Pipe
Sr Condensate Recovery Line Ki Condensate Inlet Strainer Va Air Vent or Valve
Sm Motive Medium Supply Pipe Km Motive Medium Strainer Vb Bypass Valve
Installation Procedure
Refer to the systems outlined in the “General Description” section on page 5 to select
the correct system and PowerTrap model (GT or GP) for the application. Installation,
inspection, maintenance, repairs, disassembly and adjustment should be done only by
trained maintenance personnel.
(1) Pumped Medium:
!"Fluids that can be discharged through the PowerTrap are limited to steam
condensate, water and non-flammable, non-toxic fluids with specific gravities
0.85 – 1.0. PowerTraps that have been specially constructed for other specific
fluids are not limited by this restriction.
Pipe the discharge to a safe area such as a pit 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.
NOTE: This sketch is for explanation purposes only
and is not intended as an installation design.
Back
Pressure
[Pb]
Air and Non-condensable Gas Dischar
g
e
[Va]
TLV
GP/GT
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
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(2) Motive Medium Supply Piping:
!"The motive medium supply pipe diameter should be at least 15 mm (½”).
!"Install a 40-mesh or finer strainer on the PowerTrap motive medium supply
pipe, as close to the PowerTrap as possible, while allowing sufficient space for
maintenance of the strainer. Strainers should be angled in the 3 or 9 o’clock
positions for horizontal installations.
!"The maximum motive medium inlet pressure is 1.05 MPaG (150 psig, 10.5 barg).
!"For Open Systems: Steam, compressed air, nitrogen or other non-flammable,
non-toxic fluids may be used as the motive medium.
!"For Closed Systems: Use steam or some other such condensable gas as the
motive medium. Except in special cases, do no use non-condensable gases 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/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 motive medium is compressed air or
nitrogen.
(3) Pressure Reducing Valve on the Motive Medium Supply Piping:
!"When the motive medium pressure is greater than 1.05 MPaG (150 psig, 10.5
barg), install a TLV COSPECT Series pressure reducing valve in order to reduce
the motive medium pressure to the PowerTrap. Use good piping practices when
selecting the installation location for COSPECT.
Be sure to install a safety valve between the pressure reducing valve and the
PowerTrap.
!"When the motive medium pressure is less than 1.05 MPaG (150 psig, 10.5 barg),
if a reducing valve is to be installed to slow the speed of the flow, the installation
of a safety valve is not required.
!"Install the pressure reducing valve as far away from the PowerTrap as possible.
When the motive medium pressure is less than 0.5 MPaG (72.5 psig, 5 barg): at
least 3 m (10 ft)
When the motive medium pressure is 0.5 MPaG or greater (72.5 psig or greater,
5 barg or greater): at least 3 m + 1 m / 0.1 MPaG (1 barg) over 0.5 MPaG
(5 barg) (10 ft + 1 ft / 4.5 psig over 72.5 psig)
!"The pressure setting on the pressure reducing valve should be between 0.05 and
0.15 MPa (7 – 20 psi, 0.5 – 1.5 bar) higher than the back pressure.
When the discharge capacity of the PowerTrap is insufficient for the set motive
pressure, increase this set pressure even further.
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
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(4) Exhaust Piping:
!"The exhaust pipe diameter should be at least 15 mm (½”).
!"The exhaust pipe should be connected to the top of the condensate receiver/
reservoir.
!"For Open Systems: If the GP exhaust line has to discharge to atmosphere, a
sound level of approximately 90 dB may be emitted from the exhaust pipe
discharge outlet for intervals of two or three seconds. If soundproofing measures
are necessary, install a silencer. (If the exhaust line is connected to the
condensate receiver, the sound level will be below 60dB.)
!"Make sure that the distance from the ground to the highest point on the exhaust
pipe (where it enters the receiver/reservoir pipe) does not exceed 3 m (10 ft).
If it exceeds 3 m (10 ft), condensate must be drained from the exhaust pipe in
order not to obstruct the exhaust. Implement one of the following
countermeasures: (See the figures below.)
(a) For Open Systems only: Add a float-type steam trap to the exhaust 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 condensate inlet pipe between the reservoir pipe and the strainer, being
sure to install a check valve on the piping to prevent backflow of condensate
from the condensate inlet pipe to the exhaust pipe. (Figure 2)
(5) Inlet and Outlet Piping
!"Install a 60-mesh strainer on the PowerTrap condensate inlet pipe.
The installation should be in a location that allows sufficient space for
maintenance of the strainer.
!"Ensure the inlet and outlet check valves are installed in the correct direction. The
check valve on the inlet pipe in particular should be installed right next to the
PowerTrap.
!"The check valves should be ones provided by TLV, as other check valves may
not give the proper discharge capacity.
Equipment
Power
Trap
Power
Trap
Vent Line Vent Line (open system only)
Exhaust Piping Exhaust Piping
Pit Pit
Figure 1: Open Systems Figure 2: Open & Closed Systems
Inlet
Pipe
Outlet
Pipe
Max. 3 m
(10 ft) Max. 3 m
(
10 ft
)
Condensate
Receiver
Inlet
Pipe
Outlet
Pipe
Equipment
Condensate
Receiver
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
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(6) Valves on the Various Pipes
!"In order to ensure the proper discharge capacity for the valves on the condensate
inlet and outlet pipes and the valves on the motive medium supply and exhaust
pipes, use full bore ball valves or gate valves.
If it is necessary to reduce the velocity of the motive medium supply, a needle
valve can be used. However, be aware that the discharge capacity will be
reduced. (Refer to “Operation” 1.e on pages 18 and 19.)
!"Install union or flanged joints between the valves and the PowerTrap to allow for
easy maintenance.
!"Be sure to provide the necessary maintenance space for PowerTrap
disassembly and repair (see “Installation and Maintenance Space”).
(7) Condensate Receiver/Reservoir Pipe and Filling Head
!"When choosing the size of the condensate receiver/reservoir pipe, please refer to
“Size of the Condensate Receiver/Reservoir Pipe” on pages 14 and 15.
The size and vent pipe aperture are determined by (a) the amount of flash steam
in the in-flowing condensate and (b) the amount of condensate held back while
the PowerTrap is discharging condensate.
If the condensate receiver is small, the flow of flash steam will cause the
condensate to flow out the vent pipe.
If the vent pipe size is small, the pressure in the condensate receiver will rise,
restricting condensate inflow.
Be sure to select a condensate receiver/reservoir pipe of the correct size.
!"The filling head represents the distance from the bottom of the PowerTrap (from
grade) to the bottom of the condensate receiver or reservoir pipe.
The standard filling head is 630 mm (25").
When an installation calls for a lower filling head, a filling head of less than
630 mm (25") is allowable. However, filling heads lower than the minimum filling
heads listed below must not be used:
Inlet Check Valve Model: Minimum Filling Head:
TLV CK3MG 450 mm (18")
TLV CKF3M 550 mm (22")
Swing Check Valve 350 mm (14"); motive medium pressure
≤0.5 MPaG (72.5 psig, 5 barg)
!"For Open Systems: If venting flash steam to a high area, an overflow pipe must
be installed to discharge condensate to a safe area.
• When discharging flash steam from the receiver upward through the
pipe to outside atmosphere, be sure to install an overflow pipe and
discharge to a safe area such as a pit. Failure to install an overflow pipe
is dangerous, as condensate may spurt from the vent pipe and could
result in burns and other injuries.
• To minimize the discharge of flash steam from the overflow pipe, use an
overflow pipe with a U-shaped section about 300 mm (12”) in length.
WARNING
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
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Examples of Overflow Piping for Open Systems
Condensate
Receiver
Vent Pipe
Overflow Pipe
Flash Steam
To
PowerTrap
Condensate
Condensate Receiver
300 mm
(12 ")
Vent Pipe
Overflow
Pipe discharge to a safe area such as a pit.
Flash
Steam
a.
b.
Use either
piping route
a. or b.
!"For Closed Systems: An air vent for steam or a manual valve is required to
discharge the initial air in the steam-using equipment and the condensate
reservoir pipe or any gas generated in the system. For positioning of the air vent
or valve, see [Va] in the closed system drawing on page 9. When releasing the
initial air using a manual valve, leave the valve [Va] slightly open until the
PowerTrap has cycled 2 – 3 times.
(8) Velocity at Outlet Piping
The PowerTrap uses the motive medium supply pressure to push out the
condensate in the trap.
!"The GP10L/GT10L can discharge approximately 6 liters (1.6 U.S. gal) of
condensate 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 condensate outlet pipe
during the discharge operation is between 0.7 and 7.2 metric tonnes (190 and
1900 U.S. gal) per hour.
!"When a condensate flowmeter is to be installed in the condensate outlet piping, it
should be selected to reflect the intermittent operation and should be sized to
accommodate the maximum and minimum instantaneous flow.
For details, contact TLV.
Note: This sketch is for
explanation
purposes only and
is not intended as
an installation
design.
To
PowerTrap
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
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Size of the Condensate Receiver / Reservoir Pipe
When selecting the receiver/reservoir pipe for the
PowerTrap, select from among the following 3 conditions:
#When large quantities of flash steam are involved
(For open systems using steam)
a) Determining the amount of flash steam:
Amount of flash steam Fs = Qd ×(hd’ −hh’) / r
Fs : amount of flash steam (kg/h) (lb/h)
Qd : amount of condensate (kg/h) (lb/h)
hd’ : specific enthalpy (J/kg) (Btu/lb) of saturated condensate at
condensate inlet set pressure (P1)
hh’ : specific enthalpy (J/kg) (Btu/lb) of saturated condensate at
condensate receiver set pressure (P2)
r : specific enthalpy (J/kg) (Btu/lb) vaporization (latent heat of
steam) at condensate receiver set pressure (P2)
b) Determining the condensate receiver diameter and vent pipe diameter according
to the amount of flash steam:
In the following table, the receiver length is 1 m (3.5 ft).
Vented Receiver Table
(For atmospheric, open system installations)
Flash Steam
up to ~
kg/hour
Receiver
Diameter
mm (in)
Vent Line
Diameter
mm (in)
Flash Steam
up to ~
lb/hour
Receiver
Diameter
(in)
Vent Line
Diameter
(in)
25 80 (3) 25 (1) 50 3 1
50 100 (4) 50 (2) 75 4 1½
75 125 (5) 50 (2) 100 4 2
100 150 (6) 80 (3) 200 6 2½
150 200 (6) 80 (3) 300 8 3
200 200 (8) 100 (4) 400 8 4
300 250 (10) 125 (5) 600 10 4
400 300 (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
Condensate
Receiver
P1
P2
Flash Steam
Condensate
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
15
$When flash steam is not involved
(For closed systems)
Determining the reservoir pipe diameter and
length based on the amount of condensate:
Condensate Reservoir Pipe Table
(For equalized, closed system installations)
Amount of
Condensate Reservoir Diameter (mm) & Length (m) Amount of
Condensate Reservoir Diameter (in) & Length (ft)
(kg/h) 40 50 80 100 150 200 250 (lb/h) 1½ 2 3 4 6 8 10
300 1.2m 0.7 500 3.0 ft 2.0
400 1.5 1.0 700 4.0 2.5 1.0
500 2.0 1.2 0.5 1000 5.5 3.5 1.5
600 1.5 0.6 1200 4.5 2.0 1.0
800 2.0 0.8 0.5 1500 2.5 1.5
1000 1.0 0.7 2000 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 reduced by 50% when the motive pressure (Pm) divided by the
back pressure (Pb) is "2" or greater. (When Pm ÷ Pb≥2)
%When there are small quantities of flash steam and a large amount of condensate
(E.g., open systems pumping large amounts of super-cooled condensate)
Consult the sizing tables in sections #and $above.
Select the condensate receiver size based on the larger of #and $.
Select the vent pipe diameter from #.
Condensate
Receiver /
Reservoir
P1
P1
Condensate
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
16
Installing Several PowerTrap Units in Parallel
Refer to the figure below for the piping when several PowerTrap units are to be
installed after the same condensate inflow pipe.
The size of the condensate inflow pipe and condensate recovery line is determined by
the number of PowerTrap units installed.
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ì‹C‘Ì ‘
ì‹C‘Ì
—¬“ü
…“ªA
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TLV
ƒpƒ
[
ƒgƒ‰ƒbƒv
TLV
ƒpƒ
[
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NOTE: This sketch is for explanation purposes only and is not intended as an installation design.
Number of PowerTrap
Units Installed
Condensate Inlet
Pipe Size
Pumped Condensate
Return Line Size
2 40 mm (1½”) 32 mm (1¼”)
3 50 mm (2") 32 mm (1¼”)
4 65 mm (2½”) 32 mm (1¼”)
5 65 mm (2½”) 40 mm (1½”)
6 80 mm (3") 40 mm (1½”)
Condensate
Vent Pipe Manifold
Motive
Medium
Supply
Motive
Medium
Supply
Exhaust Pipe
Pumped Condensate Return Line
Condensate Inlet Pipe
Condensate
Recovery
Line
Filling Head
Receiver/
Reservoir
TLV
GP/GT
TLV
GP/GT TLV
GP/GT
Exhaust Pipe
Exhaust Pipe
Motive Medium
Supply
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
17
Installation and Maintenance Space
Anchoring the Body
Unit:mm(in)
Flange Connection
Nominal Size & Pressure Rating Stud Bolt
1" ASME Class 125 & 150 ½"-13 UNC x 3½"
25 mm PN 10,16, 25* M12 x 85 mm
TLV
CKF3M
Wafer
Check
Valve
Flange Connection
Pipe
Flange
* PN 25 is cast steel only
Maintenance Space
The maintenance space shown in the figure below should be provided to enable inspection
and disassembly/repair of the PowerTrap.
Unit: mm (in)
Anchor Fixture Set is sold as an option
(Consisting of two anchor brackets and two hex bolts)
(Suitable Anchor Bolt Size: M12)
(Bolt Holes in Product Body: ø15)
3 (1/8”)
15 mm (1/2”)
13(1/2”)
17(21/32”)
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
18
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
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.
• When beginning operation, make sure that the operator stays well clear
of the release area of the vent line and overflow piping.
At the start-up of operation, large quantities of condensate may flow,
causing the PowerTrap to momentarily overload. If this occurs in open
systems, hot condensate may spurt from the vent piping or overflow
piping and could result in burns, other injuries or damage to equipment.
WARNING
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
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
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 or burns
or other injury due to malfunction or the discharge of fluids.
CAUTION
Installation, inspection, maintenance, repairs, disassembly, and adjustment should be
done only by trained maintenance personnel.
Operation
(1) Valve Operation
Refer to the drawings in “Installation” on pages 8 and 9 to become familiar with the
symbols used for the various valves.
If water hammer has occurred, immediately cease operation and close any valves
that are operating.
a) Slowly open the valve [Ve] on the exhaust pipe.
b) Slowly open the valve [Vm] on the motive medium supply pipe.
Make sure that there is no sound of flow from the exhaust pipe [Se] or the
condensate inlet pipe [Si].
c) Slowly open the valve [Vo] on the condensate outlet pipe.
d) Slowly open the valve [Vi] on the condensate inlet pipe.
When using a manual valve [Va] for venting air on a closed system, leave the
valve [Va] slightly open until the PowerTrap has cycled 2 or 3 times in order to
release any air inside the system, then close the valve [Va].
e) The
PowerTrap is normal if it operates intermittently; first exhausting the motive
medium to fill with condensate, then taking in motive medium to force the
condensate out.
!The interval of operation will vary greatly depending on the amount of
condensate inflow, the temperature, the motive medium (steam or gas) and the
172-65043MA-02 (GP10L/GT10L PowerTrap) 9 Mar 2004
19
motive pressure. (The interval of operation is considered to be the length of time
between the start of one discharge cycle and the start of the next discharge
cycle.)
The interval of operation Tc (s) can be roughly determined using the following
formula:
Tc = 21,600/Q or Tc = 47,600/Qp
Q: amount of inflowing condensate (kg/h)
Qp: amount of inflowing condensate (lb/h)
!The GP10L/GT10L can discharge approximately 6 liters (1.6 U.S. gal) of
condensate 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.
(2) If an error such as a leak or water hammer occurs after beginning PowerTrap
operation, shut off the valves immediately in the following order:
valve [Vm] on motive medium supply pipe →condensate inlet valve [Vi] →
condensate 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 page 29.
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 3
months.
!"Check the following items:
a) There should be no leakage from the PowerTrap or from any of the
connections.
b) The
PowerTrap unit should be operating cyclically (one indication being the
sharp, mechanical sound of the snap-unit operating at the transition between
the filling and the discharge parts of the cycle). Immediately after the end of
the discharge part of the cycle and during the filling part of the cycle, the
sound of flow in the exhaust pipe should be heard. During the pumping
(discharge) part of the cycle, flow in the motive medium supply pipe should be
heard.
c) Condensate should not accumulate in the steam-using equipment, and the
temperature of the equipment should not be abnormally low.
d) For open systems, verify that an overflow pipe from the condensate receiver is
installed.
e) For open systems, no steam should be seen flowing out through the vent
pipe.
f) There should not be any abnormal noise from the condensate outlet pipe or
the condensate recovery line when the PowerTrap operates.
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