IB-108-C PT-104 Pumping Trap Installation and Maintenance This bulletin should be used by experienced personnel as a guide to the installation and maintenance of the Pumping Trap or Pumping Trap Package. Selection or installation of equipment should always be accompanied by competent technical assistance. We encourage you to contact Armstrong or your local Representative if further information is required. The maximum operating pressure for Armstrong Model PT-100 Series pumping traps is 100 psig (7 bar). The maximum design pressure for PT-100 models is 150 psig at 450°F (10 bar @ 232°C). The PT-100 Series pumping traps weigh 140 lb (64 kg). Figure 1 PT-100 Series Pump Trap Note: Although the maximum operating pressure is 100 psi (7 bar), it is highly recommended that the motive be set only 15 - 20 psi (1.0 - 1.4 bar) above the discharge pressure. Applications with greater than 18" of filling head or condensate temperature less than 185°F, it is recommended that the motive pressure be set 25-35 psi above the backpressure. Air is the preferred motive for condensate temperatures less than 180°F (82°C). This will provide optimum performance and reduce venting time between cycles. Pumping Trap Operation 1. At start-up, the float lies at its lowest position in the bottom of the body. The motive inlet valve is closed and the vent valve is open. 2. Liquid enters the pump body by gravity through the inlet swing check valve. Back pressure (typically) holds the discharge stainless steel check valve closed. The float becomes buoyant and begins rising. 3. Continued rising of the float, through linkage, increases spring tension until the float reaches its upper tripping point. Energy is then released instantly from the springs, causing the linkage to snap upwards over center. This upward motion opens the motive inlet valve and closes the vent valve simultaneously. See Figure 2 on Page 2. 4. Steam, air, or inert gas enters the inlet valve and builds pressure inside the Pumping Trap. This pressure will close the inlet check valve and force liquid out through the discharge check valve. 5. The discharge cycle will lower the float level and, through linkage, increase spring tension until the float reaches its lower tripping point. Energy is then released instantly from the springs, causing the linkage to snap over center downward. This downward motion closes the motive inlet valve and opens the vent valve. 6. Venting of pressure from the body opens the inlet check valve and closes the discharge check valve. Liquid now flows by gravity through the inlet check valve into the pumping trap body as a new cycle begins. Figure 2 Suggested Installation of Accessories The bronze gauge glass assembly will have male NPT connections. Two (2) 1" x 1/2" Bushings will be needed for installation. Cycle Counter: There are two (2) 1" connections on the cap of the pumping trap where the cycle counter may be mounted. Various fittings will be required to reduce from 1" female NPT to 1/4" NPT. It is very important that a steel siphon or "pig tail" be used prior to the cycle counter to avoid any damage to the cycle counter. See Figure 3 below. Cycle Counter Installation Note: On pre-piped packaged units, inspect and tighten all threaded fittings (such as unions, etc.) that may have loosened during shipment. Figure 3 Filling Head: Install the pumping trap below the equipment being drained. A recommended filling head of 6" (152 mm) is recommended for the Model PT-104. Filling head is the distance between the bottom of a vented receiver or reservoir pipe and the top of the pumping trap cap. See typical hook-up on Page 7 for an example. All inlet fittings must be fully ported and match the pump's liquid inlet connection size. Greater fill heads increase the capacity of the pump trap, however, it is not recommended to have a filling head greater than 24 inches. Reference capacity chart for multiplying factors for other filling heads in Cat. 326. 2 Liquid Reservoir: Liquid flowing from the equipment being drained must be stored during the pump’s discharge cycle. A liquid reservoir (pipe reservoir) or vented receiver should be installed in a horizontal plane to prevent flooding of equipment. Please contact your local Armstrong representative for questions regarding reservoir pipe sizing or reference reservoir sizing data in catalog 326. Also see typical hook-ups on Page 7. Check Valves: NOTE: The pumping trap will not function without inlet and discharge check valves. Connect the Armstrong supplied check valves to the pump. The swing check is the inlet check valve and the spring assisted valve is used at the pump discharge. The use of Armstrong supplied check valves is necessary to ensure the pump will attain published capacities. Stainless steel in-line spring type check valves are recommended for applications where the differential pressure between the motive pressure and back pressure is greater than 25 psi. For air or 40 psi steam, stainless steel check valves are also a good choice for critical applications where the extended life of the stainless steel check valve would be of great value. The following guidelines apply if the Pumping Trap is installed without Armstrong supplied check valves. -- Inlet check valves should be bronze swing type with teflon disc, Class 150 (minimum). Pipe size of the check valve must match the size of the pump's liquid inlet connection. -- Discharge check valve should be in-line spring assist type, Class 150 (minimum) and match the size of the pump's liquid discharge connection. Motive Inlet Piping: Connect the motive force piping (steam, air or inert gas) to the inlet connection on the pump cap. Proper piping and trapping of the motive supply line must include a strainer, check valve, properly sized drip leg with mud pocket, and drip trap (for steam motive). The drip trap discharge line should be connected to the reservoir piping or vented receiver when practical. See Figure 5 and 6 on Page 7. It is recommended to install a union near the motive inlet. Note: To visually determine the location of the motive connection for Series PT-104, see Figure 4 below. Figure 4 1” NPT 6 Places 18.5 1/2” NPT Vent Connection 1/2” - 13 Lifting Lug Connection 2 Places Optional Inlet 6” Withdrawl Height Optional Inlet/Outlet Connection Cycle Counter Connection 12.03 .36 13.5 10.07 12.50 1.25 1/2” NPT Motive Connection 1.30 5.5 Outlet 3 Optional Outlet 10.73 Maximum operating pressures for the pump trap 100 psi (7 bar). A pressure reducing valve must be used when the motive pressure exceeds 100 psi (7 bar). It is also recommended that motive pressure be set between 15-20 psi (1.0 - 1.4 bar) above the total discharge pressure (total discharge pressure = vertical lift in psi plus return line pressure). This pressure setting keeps venting time to a minimum and, when using steam, reduces the temperature differential. The PRV should be installed as far from the pump trap as possible. A good rule is to use a minimum of 10' of 1" pipe between PRV and pump inlet. Installation of a safety relief valve and pressure gauge is recommended in the motive force supply line. The relief valve should be set for 125 psig (9 bar). Vent Connection ("Open System" - vented to atmosphere): Piping from the pump's cap connection labeled "Vent" should be installed vertically upward when possible and unrestricted. If piping travels greater than three feet, the piping should be expanded to one inch or greater. If a horizontal run is required, this line should be pitched toward the pump trap in order to be self draining. It is recommended to install a union near the vent connection. Note: To visually determine the location of the vent connection for Series PT-104, see Figure 4 on page 3. Vent Connection (Closed loop system): From the pump cap connection labeled "Vent", the equalizing line should be routed to the top of the reservoir piping or the outlet piping immediately after the heat exchange equipment. An Armstrong thermostatic air vent is recommended (for steam) at the high point of the exhaust line. (See Figure 8 on Page 7.) Piping of the equalizing line should be a minimum 3/4" (20 mm) diameter and must be pitched in order to be self draining. If pressure from the equipment being drained could ever exceed back pressure, a properly sized inverted bucket steam trap with a large vent or a float and thermostatic trap must be installed between the pump and discharge check valve. See Figure 8 on Page 7. Packaged Receiver Vent Connections: The receiver vent must be unrestricted and atmospherically vented unless an ASME coded tank in a closed loop arrangement is specified. Packaged Pump Trap Vent Connections: Piping from the pump's cap connection labeled "vent" should be installed upward to connect with the receiver vent line, and be a minimum of one 3/4" (20 mm) diameter. NOTE: Replace any temporary plastic plugs in these connections with permanent steel plugs or appropriate fittings before start-up. 4 START-UP 1. Slowly open motive force (steam, air or inert gas) supply to Pumping Trap providing pressure to the inlet valve. Check for proper operation of drip trap on the motive line if using steam. 2. Open isolation valves leading to pump liquid inlet and discharge lines. 3. Open any additional valves upstream allowing liquid to enter Pumping Trap from the equipment being drained. Pump will begin discharging when body is nearly full. 4. Proper operation includes an audible exhaust after each pump cycle. If operation doesn't seem proper, recheck the installation and start-up procedure. Contact Armstrong or your local Armstrong Representative if necessary. 5. Armstrong strongly recommends the use of overflow piping on receiver tanks in open condensate return systems, on ALL pump trap skids. Properly installed overflow piping increases the efficiency of the system, while addressing potential safety issues involved with the unintentional escape of hot condesate. One suggestion would be the use of a "P"-trap to form a sufficient water seal. Be sure to check that a water seal has formed to prevent venting of steam through the overflow connection during operation. Maintenance - Replacing the Valve Actuator Assembly 1. Close the valves in the motive supply, vent, condensate supply and discharge lines. Also close the shut-off valve to the receiver for packaged units. Make sure that the pumping trap is completely relieved of pressure before breaking any connections. 2. Break motive inlet and vent (all cap) connections. Remove bolts and lift the cap. A 6 inch (152 mm) withdrawal distance is required in order to remove the mechanism assembly with float for the Armstrong PT-100 Pumping Trap. 3. Remove the cap from the body and place on a sturdy workbench. 4. Remove the entire mechanism from the cap by loosening the two bolts on each side of the mounting bracket (see Page 2, Figure 2). 5. Remove the cotter pins from the front clevis pins that hold the springs in place. Front clevis pins are the ones closest to the float. The springs will then drop down. 6. Remove the (1) cotter pin holding the valve actuator clevis pin in place and pull the clevis pin out. 7. Remove the valve actuator assembly (see Page 2, Figure 2). 8. Place new valve actuator assembly in position. Note: When bolting the mechanism back on the cap it is critical to follow the proper steps below. Operational problems can occur with improper valve settings. 1. Place the complete mechanism back on the cap; however, only hand tighten the main mechanism bolts. (See Page 2, Figure 2 for drawing of the complete mechanism assembly.) 5 2. Holding the vent valve tightly to the seat pull down (toward the cap) on the rear spring arm. See Page 2 Figure 2 for rear spring arm. This will push the vent valve tightly into the seat. 3. Holding the valve and springs in the above position tighten the main mechanism bolts all the way down until they are snug. 4. Actuate the mechanism a few times by hand to make sure the operation is smooth and both the motive and vent valves are seating properly. 5. Replace the cap on the body with a new body gasket. TYPICAL HOOK-UPS NOTE: Hook-up sketches depict the Pumping Trap for clarity. However, the cap inlet and vent connections are actually located closer to each other than shown. Vented System FIGURE 5: Pumping of condensate from vented receiver handling single or multiple steam trap discharges. Motive force of steam is depicted. 6 Closed Loop Systems A closed loop system must be installed with caution and if any questions arise, contact Armstrong Fluid Handling's Application Engineering Department. FIGURE 7: Draining liquid from equipment under vacuum. The Pumping Trap provides drainage assistance whether liquid discharge is to gravity or overhead. FIGURE 8: Drainage from a heat exchanger in a closed-loop system where the supply pressure may be higher or lower than the back pressure. If the heat exchanger pressure exceeds the back pressure the pumping trap will be idle and the steam trap will prevent the steam from "blowing through" into the return line. Motive force of steam is depicted. NOTE: It is suggested that Armstrong Fluid Handling's Application Engineering Department be contacted prior to installation. 7 TROUBLESHOOTING FLOW CHARTS For Safety of Personnel - Motive line piping should be isolated from equipment and pump pressure should be relieved prior to breaking connections. WARNING: WATER MAY RUN OUT OF THE VENT CONNECTION WHEN PIPING IS BROKEN. CARE SHOULD BE TAKEN TO AVOID DANGER TO PERSONNEL OR DAMAGE TO NEARBY EQUIPMENT. 1. Pump Does Not Cycle During Start-Up Is motive inlet supply closed? Yes No No Is the pumping trap filling with condensate? Yes Is condensate discharge line valved off? Open necessary valve(s). Yes No Yes Is motive pressure too low to overcome back pressure? No Increase motive pressure to 15 psi (1.0 bar) greater than back pressure. Yes Is pump vented to Yes Make certain vent line atmosphere. is unrestricted and self draining. Is pump airbound? No No Is filling head greater than 24 inches? (See Fig. 5 for filling head) No Consult Factory Representative. Yes For closed loop: Isolate pump vent line from pressurized equipment and with personnel clear, break vent connection piping. If pump cycles, make sure line is self- draining and consider a thermostatic air vent at high point in vent line (if steam is used). Is there steam motive? Yes Pump may be filling too quickly causing a temporary flooded state. Change motive to air, if possible. If not, install horizontal reservoir piping no more than 12 inches above the PT-104 cap. See Page 7, Figure 5 for piping reservoir/vented receiver. 8 TROUBLESHOOTING FLOW CHARTS--Continued... For Safety of Personnel - Motive line piping should be isolated from equipment and pump pressure should be relieved prior to breaking connections. WARNING: WATER MAY RUN OUT OF THE VENT CONNECTION WHEN PIPING IS BROKEN. CARE SHOULD BE TAKEN TO AVOID DANGER TO PERSONNEL OR DAMAGE TO NEARBY EQUIPMENT. 2. Excessive flash steam passed through vent Are defective steam traps discharging into Yes condensate inlet line? Repair or replace traps. No Is reservoir piping or vented receiver used before pump? Yes Vent valve may be leaking. No Add liquid reservior. 3. Pump cycles but equipment or piping is flooded Is pump undersized per Bulletin Catalog 326? No Does piping provide insufficient filling head per Catalog 326? No Is motive pressure insufficient for pump to provide rated capacity per Catalog 326? No Is back pressure greater than anticipated? No Is condensate inlet line restricted? Isolate pump, remove cap, and inspect for dirt. Visually inspect valve and seat. Replace if worn. NOTE: See catalog 326 for sizing. Yes Install additional pump. Yes Lower pump as necessary. Yes Increase motive pressure as required. Yes Verify pump rated capacity per Catalog 326 at actual conditions and increase motive pressure as required. Yes Use full ported fittings, open all valves fully and eliminate any blockages. No Is inlet check valve hanging open? Yes Isolate and inspect check valve and clean or replace as required. Yes 9 TROUBLESHOOTING FLOW CHARTS--Continued... For Safety of Personnel - Motive line piping should be isolated from equipment and pump pressure should be relieved prior to breaking connections. WARNING: WATER MAY RUN OUT OF THE VENT CONNECTION WHEN PIPING IS BROKEN. CARE SHOULD BE TAKEN TO AVOID DANGER TO PERSONNEL OR DAMAGE TO NEARBY EQUIPMENT. 4. Pump stops cycling and equipment is flooded Is motive pressure insufficient? Yes No Are motive pressure and static back pressure at pump equal? No Is discharge check valve stuck closed? Yes Check for a closed downstream valve or line blockage. Yes Isolate and inspect check valve and clean or replace as required. Yes Problem is within the vent line. Make sure piping is not reduced below the vent connection size and piping is pitched back toward the pump. No Isolate vent line from equipment being drained and break piping at pump vent connection. Does the pump cycle? Increase motive pressure to 15 psi (1.0 bar) greater than back pressure. No With condensate inlet and discharge lines closed and motive pressure line slowly opened, does leakage occur at vent connection? Yes Remove cap and inspect for dirt. Visually inspect valve and seat. Replace if worn. (Valve replacement requires removal of pump cap.) No Slowly open condensate inlet line and, with motive pressure line open, observe vent connection (keeping personnel clear). Does liquid run out vent connection? Yes No Yes No If mechanism does not cycle, is an upstream valve closed? No Inlet check valve is stuck closed. Yes Replace Required Parts Contact local Armstrong Representative. No If mechanism cycled, open liquid discharge line. Does pump work normally? Are springs broken? Yes Yes 10 Vent line may be vapor locked. Ensure it's self draining. Open valve. Isolate and inspect check valve and clean or replace as required. TROUBLESHOOTING FLOW CHARTS--Continued... For Safety of Personnel - Vent line piping should be isolated from equipment and pump pressure should be relieved prior to breaking connections. WARNING: WATER MAY RUN OUT OF THE VENT CONNECTION WHEN PIPING IS BROKEN. CARE SHOULD BE TAKEN TO AVOID DANGER TO PERSONNEL OR DAMAGE TO NEARBY EQUIPMENT. 5. Chattering or knocking in return line after discharge Piping design combined with operation of pump creating vacuum at pump outlet? Yes Install vacuum breaker at return line high point. No Does condensate inlet pressure equal or exceed static back pressure? Yes Are failed steam traps increasing condensate inlet pressure? Yes Repair or replace traps. No A steam trap is required after the pump in closed loop modulating systems. See Figure 9 on page 8. 6. Excessive chatter from inlet check valve (For low liquid inlet) Is check valve either supplied by Armstrong or follow Armstrong recommendations? Yes Is check valve worn? No No Install proper check valve. Yes Repair or replace check valve as required. Consider installation of a stainless steel in-line check valve. For additional information on Pumping Traps, contact your Armstrong Representative and request Catalog 326. 11 Armstrong Fluid Handling, Inc. Limited Warranty and Remedy Armstrong Fluid Handling, Inc. (“Armstrong”) warrants to the original user of those products supplied by it and used in the service and in the manner for which they are intended, that such products shall be free from defects in material and workmanship for a period of one (1) year from the date of installation, but not longer than 15 months from the date of shipment from the factory [unless a special warranty period applies as listed below]. This warranty does not extend to any product that has been subject to misuse, neglect or alteration after shipment from the Armstrong factory. Except as may be expressly provided in a written agreement between Armstrong and the user, which is signed by both parties, Armstrong DOES NOT MAKE ANY OTHER REPRESENTATIONS OR WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. The sole and exclusive remedy with respect to the above limited warranty or with respect to any other claim relating to the products or to defects or any condition or use of the products supplied by Armstrong, however caused, and whether such claim is based upon warranty, contract, negligence, strict liability, or any other basis or theory, is limited to Armstrong’s repair or replacement of the part or product, excluding any labor or any other cost to remove or install said part or product, or at Armstrong’s option, to repayment of the purchase price. As a condition of enforcing any rights or remedies relating to Armstrong products, notice of any warranty or other claim relating to the products must be given in writing to Armstrong: (i) within 30 days of last day of the applicable warranty period, or (ii) within 30 days of the date of the manifestation of the condition or occurrence giving rise to the claim, whichever is earlier. IN NO EVENT SHALL ARMSTRONG BE LIABLE FOR SPECIAL, DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING, BUT NOT LIMITED TO, LOSS OF USE OR PROFITS OR INTERRUPTION OF BUSINESS. The Limited Warranty and Remedy terms herein apply notwithstanding any contrary terms in any purchase order or form submitted or issued by any user, purchaser, or third party and all such contrary terms shall be deemed rejected by Armstrong. Special Warranty Periods are as follows: Three (3) years after installation, but in no event longer than 39 months after shipment from Armstrong's factory. PT100, 200, 300, 3500 and 400 Series Standard Pumping Traps. PT100, 200, 300, 3500 and 400 Series Replacement Cap Assemblies and Rescue Cap ®. ©2009 Armstrong International, Inc. Designs and Materials are subject to change without notice. Armstrong Condensate Management Group, 221 Armstrong Blvd., Three Rivers, MI 49093 -USA Ph: (269) 278-6500 Fax: (269) 279-3150 IB-108-B armstronginternational.com 9/09 Printed In U.S.A.
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