TLV GT5C Instruction Manual

172-65473A-05 (GT5C PowerTrap) 15 January 2021

GT5C

Manufacturer

881 Nagasuna, Noguchi, Kakogawa, Hyogo, 675-8511, Japan

Tel: [81]-(0)79-422-1122 Fax: [81]-(0)79-422-0112

Introduction ......................................................................... 2

Safety Considerations ........................................................ 3

General Description ............................................................ 5

Application ................................................................................................................ 5

Operation ............................................................................ 6

Specifications ..................................................................... 7

Configuration ...................................................................... 8

Installation .......................................................................... 9

Steam System Example ........................................................................................... 9

Installation Procedure ............................................................................................. 11

Sizing the Condensate Reservoir Pipe ................................................................... 13

Maintenance Space and Tolerance Angle for Installation 14

Operation and Periodic Inspection ................................... 15

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

TLV EXPRESS LIMITED WARRANTY ............................ 31

172-65473A-05 (GT5C PowerTrap) 15 Jan 2021

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 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.

172-65473A-05 (GT5C PowerTrap) 15 Jan 2021

Indicates a DANGER, WARNING or CAUTION item.

DANGER

Indicates an urgent situation which poses a threat of death or serious injury

WARNING

Indicates that there is a potential threat of death or serious injury

CAUTION

Indicates that there is a possibility of injury or equipment / product damage

WARNING

NEVER apply direct heat to the float.

The float may explode due to increased internal pressure, causing accidents leading to serious injury or damage to property and equipment.

CAUTION

Install properly and DO NOT use this product outside the recommended operating pressure, temperature and other specification ranges.

Improper use may result in such hazards as damage to the product or malfunctions that may lead to serious accidents. Local regulations may restrict the use of this product to below the conditions quoted.

Use hoisting equipment for heavy objects (weighing approximately 20 kg (44 lb) or more).

Failure to do so may result in back strain or other injury if the object should fall.

Take measures to prevent people from coming into direct contact with product outlets.

Failure to do so may result in burns or other injury from the discharge of fluids.

When disassembling or removing the product, wait until the internal pressure equals atmospheric pressure and the surface of the product has cooled to room temperature.

Disassembling or removing the product when it is hot or under pressure may lead to discharge of fluids, causing burns, other injuries or damage.

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

Continued on the next page

172-65473A-05 (GT5C PowerTrap) 15 Jan 2021

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.

・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.

system, make sure that all piping connections are properly and securely tightened and gaskets are properly installed.

condensate may flow into the PowerTrap and temporarily cause it to overflow. Open the inlet valve slowly to allow condensate to flow into the trap slowly.

・Repairs or disassembly of the piping, adjustment and valve

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

・Before connecting piping or disassembling the product, close the

inlet and outlet valves and make every effort to reduce the internal pressure to cool the product to room temperature.

・When disassembling connecting parts, remove pipes and bolts

slowly to prevent condensate from suddenly flowing out in the event of residual pressure inside the product.

Disassembling or removing the product when it is hot or under pressure may lead to discharge of fluids, causing burns, other injuries or damage.

172-65473A-05 (GT5C PowerTrap) 15 Jan 2021

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

General Description

Application

PowerTrap GT5C can be used as a standard steam trap, and also has an integrated pumping function that can eliminate and pump out condensate even if condensate cannot be discharged due to very low supply steam pressure because of reduced load in the steam using equipment (this phenomenon is referred to in this document as ‘stall’).

GT5C can also discharge the accumulated condensate when the steam using equipment stops operation, and prevent water hammer when it re-starts operation.

172-65473A-05 (GT5C PowerTrap) 15 Jan 2021

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

Outlet Check Valve

Intake Valve [Open]

Exhaust Valve [Close]

Condensate Outlet

Body

Exhaust Valve [Open]

Intake Valve [Close]

Operation Shaft

Cover

Trap unit

Float

Snap Action unit

Inlet Check Valve

Condensate Inlet Pipe

(A) Condensate Inflow (B) Condensate Discharge

(Exhaust) (Motive Medium Intake)

Air Vent Unit

Operation

(1) When condensate flows from the condensate inlet pipe through the inlet check valve

into the body of the unit, the float rises and the main valve of the trap unit is open as shown in (A) below.

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

equipment pressure (Pi) is greater than the back pressure (Pb)), the condensate passes through the outlet check valve and is discharged through the condensate outlet pipe (normal trapping function). In this case, the integrated air vent unit exhausts internal air to the outlet.

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

unit.

(2) When the float rises to its high level, the push rod on the snap-action unit rises

quickly, simultaneously closing the exhaust valve and opening the intake (motive medium) valve. The pressure supplied by the motive medium causes the internal pressure in the unit to become greater than the back pressure. The inlet check valve closes and the outlet check valve is pushed open, thus discharging the condensate in the unit through the outlet pipe, as shown in (B) below.

(3) As a result of the condensate in the unit being discharged, the water level in the unit

drops and the float descends. When the float reaches its low level, the push rod on the snap-action unit moves down quickly, simultaneously opening the exhaust valve and closing the intake (motive medium) valve and the status reverts to that shown in (A) below.

172-65473A-05 (GT5C PowerTrap) 15 Jan 2021

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

Specifications

Refer to the product nameplate for detailed specifications. Body Material: Cast Iron

Body Material: Stainless Steel

* Maximum allowable pressure (PMA) and maximum allowable temperature (TMA) are

PRESSURE SHELL DESIGN CONDITIONS, NOT OPERATING CONDITIONS.

172-65473A-05 (GT5C PowerTrap) 15 Jan 2021

Configuration

Exhaust Outlet Plug

Motive Medium Inlet

Condensate Inlet

Condensate Outlet

N0.

Parts

Maintenance

Kit

Repair Kit *¹

Float

Snap Action

Spring

A B C D E

Body

Cover

Gaskets, etc. Gasket

✔

Seal set

✔

Cover Bolt

Nameplate

Float

✔

Snap-Action Unit

✔*²

Snap Action Spring

✔

Intake-Exhaust Valve Unit

✔

Trap Unit

✔

Air Vent Unit

✔

Inlet Check Valve

✔

(Flange)

Plug (for drainage)

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

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

required.

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

172-65473A-05 (GT5C PowerTrap) 15 Jan 2021

Installation

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

Pumped medium

Condensate Receiver/Reservoir

Filling Head

Condensate Inlet Strainer

Motive Medium Supply Pressure

Motive Medium Strainer

Back Pressure

Steam Trap

Condensate Inlet Pipe

Valve on Condensate Inlet Pipe

Condensate Outlet Pipe

Valve on Condensate Outlet Pipe

Condensate Recovery Line

Valve on Motive Medium Supply Pipe

Sm1

Motive Medium Supply Pipe

Blowdown Valve

Sm2

Motive Medium Supply Tube

Equipment Pressure

PowerTrap

Sm1

Sm2

Backflow

Water Hammer

Prevention Check Valve

If water hammer due to steam backflow in the condensate recovery line is expected, installation of a check valve vertically and as close as possible to the recovery line is recommended.

When the rise in piping is 30 m (100 ft) or farther from the PowerTrap, installation of a check valve is recommended for the prevention of return water hammer.

Inner diameter should be

at least 8 mm (5/16in)

Backflow Water Hammer

Prevention

Check Valve

Steam System Example

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

1. Standard Installation Example The example below shows the inlet piping is connected to the inlet of GT5C in the same way as a standard steam trap. The condensate inlet pipe [Si] acts like a condensate reservoir. Refer to “Sizing the Condensate Reservoir Pipe” at the end of this section for the size of condensate inlet pipe [Si] (length of Dh).

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

length of condensate reservoir (Dh) in cases where the exhaust pipe is eliminated and there is vertical piping on the pumped medium inlet due to elevated position of the equipment condensate outlet.

172-65473A-05 (GT5C PowerTrap) 15 Jan 2021

+ 23 hidden pages

TLV GT5C Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Introduction

Safety Considerations

General Description

Application

Operation

Specifications

Configuration

Installation

Steam System Example