ADCA FLT Bedienungsanleitung
VA L STEAM
ADCA
IMI FLT27.040 E 00.22
FLT
INSTALLATION AND MAINTENANCE INSTRUCTIONS
ADCA
We reserve the right to change the design and material of this product without notice.
FLT27 / FLT29
FLT37 / FLT39
FLT47 / FLT49
FLOAT AND THERMOSTATIC
STEAM TRAPS
VA L STEAM
ADCA
IMI FLT27.040 E 00.22
ADCA
GENERAL INFORMATION
• These instructions must be carefully read before performing any work involving
VALSTEAM ADCA products. Failure to observe these instructions may result in
hazardous situations.
• These instructions describe the entire life cycle of the product. Keep them in a
location that is accessible to every user and make these instructions available to
every new owner of the product.
• Current regional and plant safety regulations must be considered and followed
during installation, operation, and maintenance work.
• The images shown in these instructions are for illustration purposes only.
• For the problems that cannot be solved with the help of these instructions, please
contact VALSTEAM ADCA or its representative.
VALSTEAM ADCA ENGINEERING S.A
Zona Ind.da Guia
Pav.14 - Brejo
3105-467 Guia, Pombal
PORTUGAL
We reserve the right to change the design and material of this product without notice.
VA L STEAM
ADCA
IMI FLT27.040 E 00.22
ADCA
CONTENT
1. SAFETY INFORMATION 5
1.1. Explanation of symbols 5
1.2. Intended use 5
1.3. Qualication of personnel 6
1.4. Personal protective equipment 6
1.5. The system 6
1.6. ATEX 7
1.7. General safety notes 7
2. PRODUCT INFORMATION 9
2.1. Principle of operation 9
2.2. Certication 10
2.3. Product identication 11
2.4. Technical data 12
3. TRANSPORT, STORAGE AND PACKAGING 12
4. INSTALLATION 13
4.1. Preparation for installation 14
4.2. Changing ow direction 15
4.3. Installation procedure 16
5. START-UP 17
5.1. Preparation for start-up 17
5.2. Start-up procedure 17
6. OPERATION 18
6.1. Operating the BDV and HVV units 18
6.2. Operating the FLL 18
7. SHUTDOWN 19
7.1. Shutdown procedure 19
8. PARTS LIST 20
9. MAINTENANCE 22
9.1. Maintenance procedure 22
9.2. Cleaning/replacing the mechanism assembly 22
9.3. Replacing the oat 23
9.4. Fitting the retrot BDV, HVV, AFZ and VB21M units 24
9.5. Replacing the FLL oat lifting lever 24
9.6. Tightening torques 25
VA L STEAM
ADCA
IMI FLT27.040 E 00.22
ADCA
5
1. SAFETY INFORMATION
1.1. Explanation of symbols
Hazardous situation which, if not avoided by applying the correct preventive
measures, will result in fatal or serious injury and/or considerable damage to
property.
DANGER
Hazardous situation which, if not avoided by applying the correct preventive
measures, could result in fatal or serious injury and/or considerable damage
to property.
WARNING
Hazardous situation which, if not avoided by applying the correct preventive
measures, could result in moderately severe or minor injury.
CAUTION
Situation which, if not avoided, can result in property damage or product
malfunction.
NOTICE
Indicates additional information, tips and recommendations.
NOTE
1.2. Intended use
Refer to the markings on the device, such as nameplate and laser markings, Information
Sheet (IS) and these Installation and Maintenance Instructions (IMI) to check that the
product was designed for the intended use and meets the specications used for sizing
and selection. This includes checking application, material suitability, process medium,
pressure and temperature as well as their respective limiting values.
VALSTEAM ADCA does not assume any responsibility for damage resulting from
inappropriate use of the product, damage caused by external stresses or any other
external factors. Correct installation of the product is the full responsibility of the contractor.
VA L STEAM
ADCA
IMI FLT27.040 E 00.22
ADCA
6
Inappropriate use of the product is any use other than the one described in this chapter.
Inappropriate use also includes:
• Use of spare parts which are not genuine;
• Performance of maintenance work not described in these instructions;
• Use outside the limits dened by the accessories connected to the product.
• Unauthorized modications to the product.
If the product is to be used for an application or with a uid other than the one it was
designed for, contact VALSTEAM ADCA.
1.3. Qualication of personnel
Handling, installation, operation and maintenance work must be carried out by fully
trained and qualied personnel, capable of judging the work which they are assigned
to perform and recognizing potentially hazardous situations. They should be trained to
properly use this product according to these Installation and Maintenance Instructions.
Where a formal “Permits to Work” system is implemented in the plant it must be complied
with.
1.4. Personal protective equipment
Personal protective equipment should always be worn during work in order to protect
against hazards posed by e.g. the process medium, dangerous temperatures, noise,
falling or projected objects, working at height. These equipment includes a helmet, safety
glasses, safety harness, protective clothes, safety shoes, hearing protection, etc.
Always assess whether you or others in your vicinity require any protective
equipment. When in doubt check with the plant’s health & safety responsible
personnel for details on required protective equipment.
NOTE
1.5. The system
The complete system should be assessed as well as every action (e.g. closing of shut-
o valves, disconnection of the power supply) to ensure this will not bring additional risk
to personnel or property.
Dangerous actions that can result in a hazardous situation include isolation of protective
devices such as safety valve, vents, vacuum relief valves, disconnection of electric safety
devices, sensors and alarms.
VA L STEAM
ADCA
IMI FLT27.040 E 00.22
ADCA
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1.6. ATEX
If the product is in the scope of the ATEX 2014/34/EU directive and as such bears the Ex
marking, consult its specic Additional Instructions for use in Potentially Explosive Areas
(IMI EX). In such cases, handling, installation, operation and maintenance work must
only be performed by personnel qualied and authorized to work in potentially explosive
areas.
1.7. General safety notes
RISK OF BURSTING IN PRESSURE EQUIPMENT
Valves, ancillaries and pipelines are pressure equipment. Working above
their operating limits or improper opening can lead to component bursting.
• Observe the maximum operating limits of the product and check if they are
lower than those of the system in which it is being installed. Check the product
Information Sheet (IS).
• Install a safety device.
• Before starting any work on the product, depressurize it and cool or heat it up
to ambient temperature. This also applies to the line in which it is tted.
• Drain the process medium from the product and all the relevant plant sections.
DANGER
RISK OF BURNS
Depending on the operating conditions, products and pipelines may get very
hot or cold and cause burn injuries.
• Do not touch the product while it is hot or cold, allowing it rstly to cool down
or heat up.
• Wear protective clothing and safety gloves during working operation.
• Thermally insulate tubes and product’s as a preventive measure.
RISK OF INJURY CAUSED BY FLUID ATTACK ON PRODUCTS
MATERIALS
The product must only be used with mediums that do not attack the materials
of the product (body, gaskets, seals). Otherwise, leaks may occur, and hot
and/or hazardous uid can escape.
• Do not use the product with mediums other than the ones it was designed for.
Check section 1.2 - Intended Use.
• Prevent medium contamination.
WARNING
VA L STEAM
ADCA
IMI FLT27.040 E 00.22
ADCA
8
RISK OF INJURY CAUSED BY UNDER TIGHTENED PRODUCT OR
ITS COMPONENTS
Excessively low tightening torques may cause medium to escape or and/or
components to be projected at high speed which may result in a hazardous
situation depending on the medium, chemical properties and/or its operating
conditions.
• Do not loosen any screw while the equipment is pressurized.
• Observe the specied tightening torques on these Installation and Maintenance
Instructions. If the relevant torque value is not mentioned contact VALSTEAM
ADCA.
RISK OF HEARING LOSS
Depending on the operating conditions, the product may generate loud
noises.
• Wear hearing protection when in the vicinity of the product.
RISK OF INJURY AS A RESULT OF ILLEGIBLE INFORMATION
Important information written in the product nameplate, markings and warning
signs may wear overtime or get illegible due to e.g. dirt accumulation, resulting
in hazardous situations and personal injury or property damage.
• Keep nameplates, markings and warning signs in a legible state, replacing
when illegible, missing or damaged.
WARNING
RISK OF INJURY DUE TO RESIDUAL PROCESS MEDIUM
Direct contact with dangerous process medium may lead to personal injury,
e.g. smoke inhalation and chemical burns.
• Drain the process medium from the product and all the relevant plant sections.
• Wear protective clothing, safety gloves, mask, and eye protection.
RISK OF INJURY DUE TO IMPROPER HANDLING
Manual handling (e.g. lifting, carrying, pushing, pulling) of large and/or heavy
products may result in personal injury.
• Assess the risk associated with the handling task.
• Use adequate handling methods and appropriate auxiliary handling equipment.
CAUTION
VA L STEAM
ADCA
IMI FLT27.040 E 00.22
ADCA
9
RISK OF PRODUCT DAMAGE DUE TO EXCESSIVELY HIGH
TIGHTENING TORQUES
High tightening torques may lead to premature wearing of product components.
• Observe the specied tightening torques on these Installation and Maintenance
Instructions. If the relevant torque value is not mentioned contact VALSTEAM
ADCA.
NOTICE
2. PRODUCT INFORMATION
The ADCA FLT27 and FLT29 (SG iron), FLT37 and FLT39 (carbon steel) and FLT47
and FLT49 (stainless steel) are oat and thermostatic steam traps with integral air vent
designed for modulating discharge of condensate and air venting, ensuring maximum
system heat transfer.
Typical applications include unit heaters, heat exchangers, dryers, jacketed vessels and
other applications where continuous discharge is essential.
These steam traps can be installed in horizontal or vertical pipelines
2.1. Principle of operation
A oat (8) opens or closes the valve
seat (4), by moving the plug (6) via a
simple lever mechanism according with
the condensate level inside the steam
trap, changing its position in relation to
the seat. Condensate discharge and
opening of the equipment is proportional
to the movement of the oat. As the oat
rises, so does the discharge capacity.
Discharge is modulating and does not
interfere with automatic controls, if tted.
Air venting is ensured by a thermostatic
air vent (9) located in the steam space
above the condensate level. After releasing the initial air, it remains closed until air and
other non-condensable gases accumulate during normal operation and cause it to open
by reducing the temperature of the air/steam mixture. The thermostatic air vent oers the
added benet of increasing condensate capacity on cold start-up.
The steam trap can be supplied without air vent.
Thermostatic capsule air vents are available on request in alternative to the standard
9
6
Fig. 1
4
8
VA L STEAM
ADCA
IMI FLT27.040 E 00.22
ADCA
10
bimetallic air vent.
The steam trap can be supplied with a variety of options, most of which can also be
retrotted in case the steam trap has been supplied with the optional top and bottom
cover connections.
The steam lock release (SLR) consists in a needle valve integrated in the steam trap
body. Its aperture is tunned manually, with a screwdriver, to allow constant bleeding of
steam, just enough to prevent steam locking. This option is not retrottable.
The oat lifting lever (FLL) is used to manually open the steam trap main valve, to drain
its content or to check the current oat position. This option is not retrottable.
The hand vent valve (HVV) is a retrottable option which can be installed on the top
cover connection. It is used for manual venting and/or depressurization.
The blowdown valve (BDV) is a retrottable option which can be installed on the bottom
cover connection. It is used as a manual drain and/or depressurization.
The anti-freeze device (AFZ) is a retrottable option which can be installed on the
bottom cover connection. It is used for automatic discharge of condensate after system
shutdown to prevent it from freezing inside the steam trap. The valve consists in a simple
mechanism with a spring and a stainless steel ball. The spring force keeps the valve
open as long as the medium pressure is below approximately 0,3 bar, at which point the
medium pressure pushes the ball against the seat and closes the valve.
The vacuum breaker (VB21M) is a retrottable option which can be installed on the
top cover connection. It is used to protect plant and process equipment, such as heat
exchangers, against vacuum condition. A stainless steel ball remains on the seat of the
vacuum breaker when the system is under positive pressure. The ball lifts o the seat in
case of vacuum formation, and air is drawn into the equipment “breaking” the vacuum.
2.2. Certication
This product has been specically designed for use with liquids and gases which are
in Group 2 of the European PED – 2014/68/EU Pressure Equipment Directive and it
complies with its requirements.
FLT27 – CE MARKING – GROUP 2 (PED – European Directive)
PN 16 Category
All sizes SEP
FLT37 and FLT47 – CE MARKING – GROUP 2 (PED – European Directive)
CLASS 150 PN 40 Category
All sizes – SEP
– All sizes 1 (CE marked)
Andere Handbücher für FLT
1
Dieses Handbuch passt für folgende Modelle
6
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