TLV PowerTrap GP14-B User manual

MODEL GP14-B
TYP GP14-B
MODÈLE GP14-B
GP14-B
INSTRUCTION MANUAL
Keep this manual in a safe place for future reference
EINBAU- UND BETRIEBSANLEITUNG
Gebrauchsanleitung leicht zugänglich aufbewahren
MANUEL D UTILISATION
Conserver ce manuel dans un endroit facile d'accès
Copyright (C) 2021 by TLV CO., LTD. All rights reserved.
PowerTrap
PowerTrap
PowerTrap
Deutsch
Français
English

Introduction
Thank you for purchasing the TLV PowerTrap. This product has been thoroughly
inspected before being shipped from the factory. When the product is delivered,
before doing anything else, check the specifications and external appearance to make sure
nothing is out of the ordinary. Also be sure to read this manual carefully before use and
follow the instructions to be sure of using the product properly.
If detailed instructions for special order specifications or options not contained in this
manual are required, please contact TLV for full details.
This instruction manual is intended for use with the model(s) listed on the front cover. It is
necessary not only for installation, but for subsequent maintenance, disassembly/reassembly
and troubleshooting. Please keep it in a safe place for future reference.
The English language instructions can be found on pages 2 – 35.
The contents of this manual are subject to change without notice.
Vorwort
Wir danken Ihnen für den Kauf von TLV PowerTrap. Dieses Produkt wurde nach
Fertigstellung sorgfältig geprüft und verließ unsere Fabrik vollständig und fehlerfrei. Wir
empfehlen Ihnen jedoch, gleich nach Erhalt den einwandfreien Zustand visuell zu
überprüfen und die Spezifikation mit Ihren Bestellunterlagen zu vergleichen. Sollten Sie
dabei Abweichungen von der Spezifikation oder sonstige Fehler feststellen, bitten wir Sie,
uns umgehend zu benachrichtigen.
Wenden Sie sich bitte an TLV für Optionen oder Sonderausführungen, die nicht in dieser
Einbau- und Betriebsanleitung enthalten sind.
Diese Anleitung kann nur für Installation, Betrieb, Wartung, sowie Ausbau und Zusam-
menbau der auf der Vorderseite angegebenen Typen benutzt werden. Wir empfehlen,
vor Einbau und Inbetriebnahme die Anleitung sorgfältig durchzulesen und an einem
leicht zugänglichen Platz aufzubewahren, damit sie im Bedarfsfall zu Rate gezogen
werden kann.
Die Einbau- und Betriebsanweisung auf Deutsch befindet sich auf den Seiten 36 – 69.
Wir behalten uns vor, den Inhalt dieser Betriebsanleitung ohne Ankündigung zu ändern.
Introduction
Nous vous remercions d’avoir choisi le TLV PowerTrap. Ce produit a été contrôlé
minutieusement avant de quitter l’usine. Toutefois, lors de sa livraison et avant toute chose,
nous vous conseillons de vérifier les spécifications et l’apparence externe du produit afin
de confirmer l’absence d’anomalie. Veuillez également lire ce manuel attentivement avant
d'utiliser le produit, et suivre les instructions afin de l'utiliser correctement.
Si vous avez besoin d’instructions détaillées pour des options non contenues dans ce
manuel ou pour des spécifications relatives à des commandes particulières, veuillez
contacter TLV pour plus de détails.
Ce manuel est destiné aux modèles énumérés sur la page de couverture. Il est non
seulement nécessaire pour l'installation, mais également pour tout entretien,
démontage/remontage et détection de problèmes ultérieurs. Nous vous recommandons
de le garder dans un endroit sûr pour de futures consultations.
Le manuel d’utilisation en français se trouve aux pages 70 – 103.
Le contenu de ce manuel est sujet à modifications sans préavis.
— 1 —
English

Contents
Safety Considerations………………………………………………....……....……....…….... 3
General Description…………………………….....……………............................................. 5
Operation……………………………………………………………………………….……............... 6
Specifications……………………………………………………………………………….……..... 7
Configuration……………………………………………………………………………….……....... 7
Installation……………………………………………………………………………….…….............
8
Open System Piping (Steam System Example) …………………………………………..........….... 8
Closed System Piping (Steam System Example)………………………………………..…….......... 9
Installation Procedure……………………………………………………………………………......... 10
Sizing the Condensate Receiver/Reservoir……………………………………………….…......... 14
Installing Several PowerTrap Units in Parallel …………………………………………………..... 17
Installation and Maintenance Space…………………………………………………..
18
Anchoring the Body ………………………………………………………………………………........
18
Maintenance Space ………………………………………………………………………………..…..
18
Operation and Periodic Inspection…………………..……........……..........…...........
19
Operation………………………………………………………….….….….….….….….……..….......
19
Periodic Inspection and Diagnosis………………………………………………………...….......….
20
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. Removing/Reattaching the Baffle………………………………………………………….......... 25
4. Removing/Reattaching the Snap-action and Lever Units…………………………….......…... 26
5. Removing/Reinstalling the Exhaust Valve and Exhaust Valve Seat …………………............ 27
5a. Checking/Adjusting the Gap between the Push Plate and Intake Valve
(Motive Medium)………………………………………………………………………………....... 28
6. Removing/Reinstalling the Intake Valve and Intake Valve Seat (Motive Medium)……......... 29
Troubleshooting………………………………..………...………...........……………..…….......30
Determining the Problem from the Symptoms ………………………………………………..........
30
Types of Failure and their Causes……………………………………………………………........… 31
Causes and Corrective Measures …………………………………………………………...............
32
Product Warranty……………..……..........…...........……………..……..........…................... 35
Service……………..……..........…...........……………..……..........…...........…………...............104
— 2 —
English

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.
WARNING
Indicates an urgent situation which poses a threat of death or
serious injury
DANGER
CAUTION
Indicates that there is a possibility of injury or equipment / product
damage
Symbols
Indicates a DANGER, WARNING or CAUTION item.
CAUTION
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.
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.
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.
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.
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.
Indicates that there is a potential threat of death or serious injury
— 3 —
English

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.
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.
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.
— 4 —
English

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
･No flash steam discharge
･Small reservoir
･Use with vacuum equipment
possible
･Only one piece of equipment
possible per system
･Equipment has minimum height
requirement to ensure that
condensate flows naturally by
gravity (approx. 1 m (40 in))
･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)
･Separate steam trap required for
each piece of equipment
･Requires venting pipe to discharge
flash steam to atmosphere
System
Overview
Benefits
Notes
Type of System
General Description
Closed System Open System
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 PowerTrap GP14-B 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’).
There are two types of delivery systems (piping methods): the closed system and the open
system. The PowerTrap GP14-B you have purchased is a suitable model for both (for closed
system, please install a steam trap at the PowerTrap outlet).
Equip-
ment
Steam
Trap
Steam
Trap
Power
Trap
Equip-
ment
Receiver
Discharge to
Atmosphere
Condensate
Recovery
line
Condensate
Recovery
line
Venting
Pipe
Exhaust
Pipe
Overflow Pipe
Reservoir
Power
Trap
Condensate
Recovery
Line
Exhaust
Pipe
Equipment
Steam
Trap
— 5 —
English

Operation
(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.
(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.
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.
(1) Condensate Inflow (2) Condensate Discharge
Body
Exhaust Valve
［Open］
Exhaust Valve
［Close］
Intake Valve
(Motive Medium)
［Close］
Intake Valve
(Motive Medium)
［Open］
Inlet Check Valve
Inlet Check Valve
Float
Outlet Check Valve Outlet Check Valve
Cover
Condensate
Inlet Pipe
Condensate
Outlet Pipe
Push Rod
— 6 —
English

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.
Motive Medium
Pressure Range
GP14-B (other than below)
GP14-B (Cast Iron in Europe)
0.03 - 1.4 MPaG
0.03 - 1.3 MPaG
0.3 - 14 barg
0.3 - 13 barg
5 - 200 psig
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 psig)
Configuration
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 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.
Exhaust Outlet Exhaust Outlet
Motive Medium Inlet Motive Medium Inlet
Pumped Medium
Inlet Pumped Medium
Inlet
Snap-action Unit
Cover
Pumped Medium
Outlet
Pumped Medium
Outlet
Lever Unit
Cover Gasket
Cover Bolt
Body Float
Nameplate
Refer to the product nameplate for detailed specifications.
Nominal Diameter
Maximum Allowable Pressure*
Maximum Operating Pressure
Valve No.**
Model
Serial Number
Maximum Allowable Temperature* TMA
Maximum Operating Temperature TMO
Motive
Medium Inlet
Exhaust Outlet
Plug
Intake
Valve Unit
Exhaust Valve Unit
— 7 —
English

PowerTrap
Sv
Sm
Pm
Rm
Se
Sf
Ve
Vm
Km
Ci Ki Vi Vb Pb
Pi Sr
Q
Si So
St
Co Vo
Power
Trap
A
Installation
Open System Piping (Steam System Example)
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 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.
Necessity of installing a condensate receiver
It is necessary for storing condensate during pumping.
Condensate cannot enter the PowerTrap while condensate is being pumped.
NOTE: This sketch is for explanation purposes only and is not intended as an installation design.
— 8 —
English

Closed System Piping (Steam System Example)
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 motive
medium, please consult TLV for assistance.
Q
A
Pm
Pb
Si
So
Sr
Sm
Se
SP
Condensate Amount
Filling Head
Motive Medium Supply Pressure
Back Pressure
Condensate Inlet Pipe
Condensate Outlet Pipe
Condensate Recovery Line
Motive Medium Supply Pipe
Exhaust Pipe
Steam Trap on the Power Trap outlet
Sv
Dh
Ci
Co
Ca
La
Ki
Km
Pi
Vent Pipe
Condensate Reservoir
Condensate Inlet Check Valve
Condensate Outlet Check Valve
Check Valve for Air Vent
Air Vent (for Steam)
Condensate Inlet Strainer
Motive Medium Strainer
Equipment Pressure
Rm
St
Vi
Vo
Vm
Ve
Va
Vb
Motive Medium Pressure
Reducing Valve
Steam Trap on Drip Leg
Valve on Condensate Inlet Pipe
Valve on Condensate Outlet Pipe
Valve on Motive Medium Supply Pipe
Valve on Exhaust Pipe
Valve for Air/Gas Discharge
Blowdown Valve
Q
A
Pm
Pb
Si
So
Sr
Sm
Se
Sv
Sf
Dh
Ci
Co
Ki
Km
Rm
Pi
St
Vi
Vo
Vm
Ve
Vb
Condensate Amount
Filling Head
Motive Medium Supply Pressure
Back Pressure
Condensate Inlet Pipe
Condensate Outlet Pipe
Condensate Recovery Line
Motive Medium Supply Pipe
Exhaust Pipe
Vent Pipe
Overflow Pipe
Condensate Receiver
Condensate Inlet Check Valve
Condensate Outlet Check Valve
Condensate Inlet Strainer
Motive Medium Strainer
Motive Medium Pressure
Reducing Valve
Equipment Pressure
Steam Trap on Drip leg
Valve on Condensate Inlet Pipe
Valve on Condensate Outlet Pipe
Valve on Motive Medium Supply Pipe
Valve on Exhaust Pipe
Blowdown Valve
**If the pressure at the PowerTrap inlet exceeds the pressure at the PowerTrap outlet, make sure to install
a steam trap at the PowerTrap outlet. (Steam will blow if no steam trap is installed.)
Make sure the pipe between the PowerTrap and the steam trap is as short and thick as possible.
There should be no rise in piping between the PowerTrap and the steam trap.
Select the steam trap based on the pump discharge capacity of the PowerTrap. Consult TLV for details.
*
Ci
Vo
Km
Co
Steam-using
Equipment
Vm
Ve
Vi
Pb
Sm
Sv
Se
Si
So
Ki
Rm
St
Vb
Sr
Power
Trap
Va
Ca
La
Sp**
Condensate
Recovery
Line
Motive
Medium Motive Medium Supply Pressure Pm
Pump
Exhaust
Back
Pressure
Temperature Controller
Air and Non-condensate
Gas Discharge
Filling
Head A
Equipment
Pressure
Steam for
Heating
Backflow
Water
Hammer
Prevention
Check Valve
Condensate
Reservoir Dh
When the rise in piping is 30 m (100 ft) or farther from the
PowerTrap, installation of check valve is recommended
for the prevention of return water hammer.
NOTE: Pipe the discharge to a
safe area such as a pit.
Condensate
Amount Q
Pi
— 9 —
English

Installation Procedure
Installation, inspection, maintenance, repairs, disassembly, adjustment and valve opening/closing
should be carried out 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. PowerTrap
that have been constructed for other specific fluids are not limited by this restriction.
(2) Motive Medium Supply Piping:
• The motive medium supply pipe diameter should be at least 20 mm ( ").
• 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.
• See "Specifications" on page 7 for the maximum motive medium inlet pressure.
• 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 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 supply pressure of the motive medium is greater than the maximum operating
pressure of the PowerTrap, install a TLV COSPECT series pressure reducing valve. Make sure
that the motive medium pressure is lower than the maximum operating pressure of the
PowerTrap. Use good piping practices when selecting the installation location for COSPECT.
In this case, be sure to install a safety valve between the pressure reducing valve and the
PowerTrap.
• When the supply pressure of the motive medium is less than the maximum operating pressure
of the PowerTrap, if a pressure 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 for every 0.1 MPaG (1 barg) over 0.5 MPaG (5 barg)
10 ft + 1 ft for every 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.
/
34
— 10 —
English

Figure 1: Open Systems Figure 2: Open & Closed Systems
* For Open Systems only
** For Closed Systems only
Vent Line
Equipment
When the
exhaust
piping is
3 m (10 ft.)
or more
Outlet
Pipe
Inlet
Pipe
Power
Trap
Pit Pit
Close to
Power
Trap
Pit
Exhaust
Piping Receiver
Overflow
Pipe
Steam
Trap
When the exhaust piping height exceeds 3 m (10 ft.)
Equipment
Receiver/
Reservoir
Power
Trap
Vent Line*
Overflow
Pipe*
Pit
Exhaust
Piping
Check
Valve
Pit
Inlet
Pipe
Outlet
Pipe
Steam trap**
When the
exhaust
piping is
3 m (10 ft.)
or more
Close to
Power
Trap
(5) Inlet and Outlet Piping
• Install a 40-mesh or finer strainer on the PowerTrap pumped medium inlet pipe.
The installation should be in a location that allows sufficient space for maintenance
of the strainer.
• Ensure that 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.
• Only TLV check valves (CK3MG, CKF3MG) should be used; proper discharge capacity cannot
be guaranteed with other check valves.
(6) Valves on the Various Pipes
• In order to ensure the proper discharge capacity, use full bore ball valves or gate valves on
the pumped medium inlet and outlet lines as well as on the motive medium supply
and exhaust lines.
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 19 and 20).
• 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" on page 18).
(4) Exhaust Piping:
• The exhaust pipe diameter should be at least 25 mm (1").
• The exhaust pipe should be connected to the top of the receiver/reservoir.
• For Open Systems: If the GP exhaust line has to discharge to atmosphere, a sound level of
approximately 90 – 110dB may be emitted from the exhaust pipe discharge outlet for two
to 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) does not exceed 3 m (10 ft).
If it exceeds 3 m (10 ft) and steam is used as the motive medium, 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
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 exhaust pipe must be connected to the top of the reservoir.
— 11 —
English

To PowerTrap
To PowerTrap
Overflow Pipe
Condensate
Condensate
Loop Seal
There is a possibility of condensed hot water dripping from vent pipe outlet.
Make sure to extend to where people do not pass.
300 mm
(12 in)
Condensate
Receiver
1) 2)
Flash Steam
Flash Steam
Condensate
Receiver
Flash Steam
Vent Pipe Vent Pipe
Overflow Pipe
Pipe the discharge to a safe place such as a pit.
High temperature steam or hot water may splash.
NOTE: This sketch is for
explanation purposes only
and is not intended as an
installation design.
Examples of Overflow Piping for Open Systems
(7) Receiver/Reservoir Pipe and Filling Head.
• Please refer to “Sizing the Condensate Receiver/Reservoir” on pages 14 and 15.
The size and vent pipe aperture are determined by (a) the amount of any flash steam in the in-
flowing condensate (pumped medium) and (b) the amount of pumped medium held back while
the PowerTrap is discharging.
If the receiver is small, the flow of flash steam may cause condensate to flow out the vent pipe.
If the vent pipe size is small, the pressure in the receiver will rise, restricting the pumped
medium inflow.
Be sure to select a 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 receiver/reservoir.
The standard filling head is 860 mm (36").
When an installation calls for a lower filling head, a filling head of less than 860 mm (36") is
allowable. However, the minimum filling head is 710 mm (30").
• 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.
WARNING
･Be sure to install a vent pipe and an overflow pipe. Failure to install an
overflow pipe is dangerous, as condensate may spurt from the vent
pipe and could result in burns and other injuries.
･Pipe the vent pipe and the overflow pipe to a safe place such as a pit.
･Piping size of the overflow pipe should be the same or larger than
condensate inlet pipe.
— 12 —
English

(8) Velocity at Outlet Piping
The PowerTrap uses the motive medium supply pressure to push the pumped medium out
of the trap.
• The GP14-B can discharge approximately 30 liters (8 U.S. gal) of pumped
medium for each discharge operation.
• The amount of time required for each discharge operation will be between 3 and 30
seconds, depending on the back pressure and the motive medium pressure.
This means that the instantaneous flow through the pumped medium outlet pipe during the
discharge 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 and should be sized to accommodate the
maximum and minimum instantaneous flow.
Contact TLV for details.
(9) For Closed Systems:
• An air vent (for steam) [La] or valve for air discharge [Va] is required to discharge the initial air
in the equipment and the reservoir pipe or any gas generated in the system. In this case,
installing the check valve for air vent [Ca] will prevent air from being sucked in from the outlet
of the vent pipe [Sv]. This check valve must be installed when the pressure inside the piping
becomes negative. A valve for air discharge [Va] can be installed instead of the air vent (for
steam) [La] and check valve for air vent [Ca].
When releasing the initial air using a valve for air discharge, leave the valve for air discharge
[Va] slightly open until the PowerTrap has cycled 2 – 3 times. Close the valve for normal
operation.
• Refer to “(2) When flash steam is not involved” in “Sizing the Condensate Receiver/
Reservoir” for information on condensate reservoir sizing.
For more details, contact TLV.
Explanations for overflow piping for open Systems
1) If flash steam can be discharged from overflow pipe
Install overflow pipe and vent pipe separately.
2) If flash steam should not be released from overflow pipe (prevent flash steam release)
Install overflow pipe and vent pipe separately. For overflow pipe, install loop seal (approx.
300 mm (12 in)). Flash steam release from overflow pipe can be prevented since water
always accumulates at loop seal. Piping size should be the same or larger than condensate
supply pipe.
NOTE: • There is a possibility of rust becoming clogged and/or corrosion since water is
always present in the loop seal. The possibility is greater if the piping diameter is
too small (generally 25 mm (1 in) or smaller).
• If the loop seal becomes clogged, hot overflow water will blow from vent pipe.
Make sure to install vent pipe to lead to a safe place
• Do not install loop seal on the vent pipe
Contact TLV if neither 1) nor 2) above can be installed.
• For Closed Systems: An air vent for steam or a manual valve is required to discharge
the initial air in the equipment and the 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.
— 13 —
English

Sizing the Condensate Receiver/Reservoir
When selecting the receiver/reservoir for the
PowerTrap, select from among the following 3 conditions:
①When large quantities of flash steam are involved
(For open systems using steam)
a) Determining the amount of flash steam:
Amount of flash steam Fs = Q x(hd’ - hh’) / r
Fs : amount of flash steam (kg/h) (lb/h)
Q : amount of condensate (kg/h) (lb/h)
hd’: specific enthalpy (kJ/kg) (Btu/lb) of saturated condensate at
condensate inlet set pressure (Pi)
hh’: specific enthalpy (kJ/kg) (Btu/lb) of saturated condensate at
condensate receiver set pressure (Ph)
r : specific enthalpy (kJ/kg) (Btu/lb) vaporization (latent heat of
steam) at condensate receiver set pressure (Ph)
b) Determine the vent pipe diameter according to the amount of flash steam in Vented
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 condensate receiver
length of 1 m (3.3 ft).
( i ) is the overflow pipe diameter multiplied by 3 or more.
(ii) is the minimum receiver diameter according to the amount of flash steam in Vented
Receiver Table - 1 shown on the next page.
(iii) is the minimum receiver diameter according to the amount of condensate in Vented
Receiver Table - 2 shown on the next page.
NOTE: Receiver 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)
Pi Qi
Ph
Flash Steam
Condensate
Receiver
×
— 14 —
English

25
50
75
100
150
200
300
400
500
700
800
1000
1100
1400
1500
Receiver
Diameter
mm (in)
(Length: 1 m)
Flash Steam
up to ~
kg/h
Flash Steam
up to ~
lb/h
Receiver
Diameter
in
(Length: 3.5 ft)
Vent Line
Diameter
in
Vent Line
Diameter
mm (in)
50
75
100
200
300
400
600
800
1000
1400
1600
2000
2200
2800
3000
3
4
4
6
8
8
10
12
14
16
18
20
20
22
24
1
1
2
2
3
4
4
6
6
8
8
8
10
10
10
(3)
(4)
(5)
(6)
(8)
(8)
(10)
(12)
(14)
(16)
(18)
(20)
(20)
(22)
(24)
80
100
125
150
200
200
250
300
350
400
450
500
500
550
600
(1)
(2)
(2)
(3)
(3)
(4)
(5)
(5)
(6)
(8)
(8)
(8)
(10)
(10)
(10)
25
50
50
80
80
100
125
125
150
200
200
200
250
250
250
Vented Receiver Table - 1
(For atmospheric, open system installations)
/
12
/
12
Amount of
Condensate
kg/h
Receiver
Diameter
mm (in)
(Length: 1 m)
(3)
(4)
(5)
(6)
(8)
(10)
80
100
125
150
200
250
Vented Receiver Table - 2
(For atmospheric, open system installations)
1000 or less
1500
2000
3000
6000
10000
Amount of
Condensate
lb/h
Receiver
Diameter
in
(Length: 3.5 ft)
3
4
5
6
8
10
2200 or less
3300
4400
6600
13000
22000
NOTE: When amount of flash steam and condensate are between two values in the table, select
the larger value (one line below).
— 15 —
English

Condensate
Reservoir
Pi
PowerTrap
②When flash steam is not involved
(For closed systems)
Determining the reservoir diameter and
length based on the amount of Condensate:
300 or less
400
500
600
800
1000
1500
2000
3000
4000
5000
6000
7000
8000
9000
10000
Amount of
Condensate
(kg/h)
Reservoir Diameter (mm) & Length (m) Reservoir Diameter (in) & Length (ft)
500 or less
700
1000
1200
1500
2000
3000
4000
5000
6000
7000
8000
9000
10000
12000
14000
16000
18000
20000
Amount of
Condensate
(lb/h)
40
1.2m
1.5
2.0
50
0.7
1.0
1.2
1.5
2.0
80
0.5
0.6
0.8
1.0
1.5
2.0
100
0.5
0.7
1.0
1.3
2.0
150
0.6
0.9
1.2
1.4
1.7
2.0
200
0.5
0.7
0.8
1.0
1.2
1.3
1.5
1.7
250
0.5
0.6
0.7
0.8
0.9
1.0
1
3.0 ft
4.0
5.5
2
2.0
2.5
3.5
4.5
3
1.0
1.5
2.0
2.5
3.5
4.5
6.5
4
1.0
1.5
2.0
3.0
4.0
5.0
5.5
6.5
6
1.5
2.5
2.5
3.0
3.5
4.0
4.5
5.0
6.0
6.5
8
1.5
1.5
2.0
2.5
2.5
3.0
3.5
4.0
4.5
1.5
10
1.5
1.5
2.0
2.5
2.5
3.0
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)
③When 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 ①and ②above.
Select the condensate receiver size based on the larger of ①and ②.
Select the vent pipe diameter and overflow pipe diameter from ①.
Reservoir Table
(For equalized, closed system installations)
/
12
— 16 —
English

Pumped Medium Return Line
Pumped Medium Inlet Pipe
Pumped Medium
Exhaust Pipe
Filling Head A
Motive
Medium
Supply
Motive
Medium
Supply
Motive
Medium
Supply
Overflow Pipe
Medium Return
(Main Line)
Vent Pipe
Exhaust Pipe Manifold
Exhaust Pipe
Exhaust Pipe
TLV
Power
Trap
TLV
Power
Trap
TLV
Power
Trap
Receiver
Installing Several PowerTrap Units in Parallel
Refer to the figure below as a general guide for the piping when several PowerTrap units are to be
installed after the same pumped medium inlet pipe.
The size of the pumped medium inlet pipe, return line and exhaust pipe manifold is determined by
the number of PowerTrap units installed.
When specifications exist separately from the instruction manual, follow the specifications.
NOTE: This sketch is for explanation purposes only and is not intended as an installation design.
40 mm (1 in)
50 mm (2 in)
65 mm (2 in)
65 mm (2 in)
80 mm (3 in)
80 mm (3 in)
100 mm (4 in)
100 mm (4 in)
125 mm (5 in)
125 mm (5 in)
125 mm (5 in)
150 mm (6 in)
200 mm (8 in)
200 mm (8 in)
200 mm (8 in)
Number of
PowerTrap
Units Installed
Pumped Medium
Inlet Pipe Size Pumped Medium Return Line Size
Exhaust Pipe
Manifold Size
Overflow
Pipe Size Vent Pipe Size
/
12
/
12
/
12
2
3
4
5
6
See the Vent
Line Diameter
column in
Table-1 on
page 15
Determine
overflow pipe size
according to
“Sizing the
Condensate
Receiver/Reservoir”
on page 14
— 17 —
English

( )
/
34
( )
/
316 ( )
/
3 16
(1 )
/
14
/
18
(1 ) /
18
(1 )
(3 )
/
5 16
100
29 29315.5 5.5
19
(1 )
/
916
( )
/
18
20
( )
/
13 16
20
( )
/
13 16
3.2
40
( )
/
13 16 ( )
/
13 16
(2 )
/
38
20 2060
C10C10
C10C10
( )
/
34
19
( )
/
34
19
(2 )
/
916
( )
/
916
(1 )
/
916
/
38
( ) 65
1510 40
PowerTrap
(1 )
/
916
/
15 16
(10 )
/
34
(5 )
/
716
(11 )
/
716
/
58
(9 )
/
716
(14 )
/
316
(31 )
/
12
(31 )
/
12
(~78 )
/
34
(~78 )
/
34
~268
Installation and Maintenance Space
Anchoring the Body
Maintenance Space
The maintenance space shown in the figure below should be provided to enable disassembly,
inspection and replacement of the PowerTrap.
40
( )
/
13 16
21
( )
/
13 16
20
(10 )
/
916
173
138
290
800
800
~2000
~2000
240
360
Anchor Bolt with nut
M16, 2 pcs.
(Customer
Supplied)
Hex Bolt with Nut
M16 x 50 mm, 2 pcs.
( "-11UNC x 1 ")
included with
Anchor Fixture Set)
Unit: mm (in)
Unit: mm (in)
Anchor Fixture Set included in the package.
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 fixture set:
Anchor fixture ×2
Hex bolt (M16) ×2
Hex nut (M16) ×2
Washer (Diameter: 16)×2
— 18 —
English