Im 5 201 Us PDF
Im 5 201 Us PDF
Im 5 201 Us PDF
IM-5-201-US
April 2014
PTC
PTF-HP
PTF
PTF4
Table of Contents
1.0 Safety Information.................................................................................................................. 3
2.0 General Product Information.................................................................................................. 4
3.0 Installation.............................................................................................................................. 6
4.0 Start-Up Procedure.............................................................................................................. 12
5.0 Maintenance......................................................................................................................... 12
6.0 Other Hook-Up Sketches..................................................................................................... 14
7.0 Troubleshooting................................................................................................................... 15
8.0 Declarations of Conformity (PED)......................................................................................... 18
PTF Range
CE
PED Category
Ductile Iron
Steel
Stainless Steel
PTC Range
II
n/a
n/a
PTF Range
n/a
III
III
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably
guarded) before attempting to work on the product. Arrange suitable
lifting gear if required.
1.3 Lighting
1.8 Temperature
Allow time for temperature to normalize after isolation to avoid danger
of burns.
1.12 Handling
Manual handling of large and/or heavy products may present a risk of
injury. Lifting, pushing, pulling, carrying or supporting a load by bodily
force can cause injury particularly to the back. You are advised to
assess the risks taking into account the task, the individual, the load
and the working environment and use the appropriate handling method
depending on the circumstances of the work being done.
1.14 Freezing
1.15 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions,
this product is recyclable and no ecological hazard is anticipated with its
disposal providing due care is taken.
Provisions must be made to protect products which are not self draining
2.1 Description
The Pivotrol Pump (patented) is a non electric pump which transfers high
temperature condensate, or other liquids from a low point, low pressure
or vacuum space to an area of higher pressure or elevation. This selfcontained unit including PowerPivot technology (patented) uses steam,
compressed air or any other suitable pressurized gas as the pumping
(motive) force.
2.2 Options
Note: PTF4 and PTF-HP only offered with specific gravity option of
0.881.0
PTC
3x2
2x2
PTC
T-Bone
3x3
PTF
3x2
2x2
PTF
T-Bone
PTF Top
PTF-HTF
PTF-HP
3x3
3x2
3x2
PTF4
4x4
Inlet /
Outlet
Flange
Flange
Rating*
Motive /
Exhaust
3x3
RF
NPT or SW
iii) PTF-HTF pumps are not supplied with check valves but require
two. Spirax Sarco recommends the Velan Model F00-1114C-02AA
ANSI 300 RF Flanged cast steel swing type check valve. Capacities
in TI-5-030-US for the PTF-HTF were achieved using these check
valves.
iv) See Techncial Information sheet for design conditions.
ANSI 150
NPT
ANSI 150 or
ANSI 300
NPT or SW
NPT or SW
ii) For complete sizing and selecting data, including capacities, see
TI-5-030-US
Gauge glass
Reflex type gauge glass
Insulation cover
Product
TMA
2.3 Accessories
Product
PMO
PMA
PTC
PTC T-Bone
PTF
200 psig @ 400F
200 psig
PTF T-Bone
PTF Top
PTF-HTF
200 psig @ 750F
PTF-HP
300 psig
300 psig @ 650F
PTF-HP*
300 psig
300 psig @ 650F
PTF4
200 psig
200 psig @ 400F
* When fitted with Reflex Gauge Glass
ANSI 300
ANSI 150 or
ANSI 300
SW
NPT or SW
Standard Recommended
PTC
PTC T-Bone
PTF
PTF T-Bone
PTF Top
PTF-HTF
PTF-HP
PTF4
PTC
PTC T-Bone
PTF
PTF T-Bone
PTF Top
PTF-HTF
PTF-HP
PTF4
PTC 2x2
PTC 3x2
PTC T-Bone
PTF 2 x2
PTF 3x2
PTF T-Bone
PTF Top
PTF-HTF
PTF-HP
PTF4
Filling Head
Above Pump Cover
12
12
12
12
23
12
12
12
48
48
48
48
48
48
60
60
-3
-1
-1
-3
-1
-1
10
1
0
-3
Filling Height
From Base of Pump
36.9
36.9
44.1
44.1
54.9
44.1
42.8
44.3
72.9
72.9
80.1
80.1
80.1
80.1
90.8
29.3
21.9
23.9
23.9
29.1
31.1
31.1
41.9
31.1
30.8
29.3
4. Steam will now flow through the steam inlet valve (4) and develop a
pressure within the body forcing the liquid out through the discharge
check valve (22). The inlet check valve (21) will be closed during the
discharge cycle.
5. As the liquid level in the pump body lowers so does the floats (18)
position. Before the float (18) reaches its lowest position the float
arm assembly (14) is engaged increasing the compression in the
spring (13). When the float (18) is at its lower tripping position in
the body the energy in the spring (13) is released instantaneously
causing the float arm assembly (14) to snap over center downward
moving the push rod (9) down causing the steam inlet valve (4) to
close and exhaust valve (6) to open simultaneously.
6. Liquid will again flow through the inlet check valve (21) to fill the
pump body and the cycle will be repeated.
1/2" NPT
Motive
Pressure
Inlet
3
1
2. When liquid flows, by gravity, through the inlet check valve (21) in to
the pump body, the float (18) will become buoyant and rise.
3. As the float (18) continues to rise the float arm assembly (14) is
engaged which increases the compression in the spring (13). When
the float (18) has risen to its upper tripping position the energy in the
spring is released instantaneously causing the float arm assembly
(14) to snap upwards over center moving the push rod (9) upwards to
simultaneously open the steam inlet valve (4) and close the exhaust
valve (6).
1" NPT
Exhaust
Outlet
23
10
11
12
13
14
15
Outlet 18
16
17
Check Valve
Inlet
Check Valve
(22)
(21)
Liquid
Outlet
Liquid
Inlet
20
1/2" Drain
Connection
Exhaust
Outlet
Motive
Pressure
Inlet
5
4
9
19
3.0 Installation
CautionBefore installation or any maintenance is performed, ensure that all condensate, steam, air or gas lines are closed to prevent personal
injury. Proper lock-out / tag-out procedures must be followed. Ensure all pressurized lines are dissipated and cooled before starting work.
CAUTION
CAUTION
PPC/PPF cover
bolts rated to
125 psig
point, is more than 6 ft. A general rule of thumb (based on a 6 ft. pipe
run and a head of 2 ft.):
Condensate loads from zero to 11000 lb. /hr. use 1
Condensate loads from 11000 to 22000 lb. /hr. use 2
Condensate loads from 22000 to 39600 lb. /hr. use 3
The over-flow must be fitted with a loop seal arrangement or a suitably
sized float trap (preferred), to prevent steam escaping via the over-flow
connection.
Vented Receivers
To drain condensate from single or multiple sources in an open system,
a vented receiver should be installed in a horizontal plane ahead of the
pump. Sufficient volume is needed above the filling head level to accept
the condensate reaching the receiver during the pump discharge stroke.
More importantly, the receiver must be sized to allow sufficient area for
complete flash steam separation from the condensate. By sizing the
receiver appropriately, there will be sufficient volume for condensate
storage and sufficient area for flash steam separation. The receiver can
be a length of large diameter pipe or a tank. A receiver overflow piping
should be installed as shown in Figures 3 or 4 and piped to a suitable
drain. The piping must form a loop type water seal at least 12 deep
immediately after the receiver.
Note: To achieve rated capacity and maintain the pumps warranty,
each pump must be installed with the check valves as supplied by
Spirax Sarco Inc, except at the inlet on a sump pit application as
shown in Figure 13.
Installation Procedure:
1. Install the pump physically below the receiver to be drained with the
exhaust connection vertically upwards. Pump should be installed
with the recommended filling head (the vertical distance between
the top of the pump and the bottom of the receiver) as shown in
Figures 3 or 4. For other filling head variations, see the capacity table on
TI-5-030- US.
2. To prevent equipment flooding during the pump discharge stroke, a
vented receiver should be installed in a horizontal plane ahead of the
pump as shown in Figures 3 or 4. All inlet line fittings must be fully
ported.
3. Connect the vented receiver to the inlet check valve on the pump.
Connect the discharge to the return main or other installation point.
For best performance, horizontal runs immediately ahead of the inlet
check valve should be kept to a minimum. Connect the discharge to
the return main or other installation point. Where the return line rises to
a high level directly after leaving the pump a second check valve should be fitted at the highest point, either in the horizontal or vertical run, to prevent
water from falling back on the outlet check valve of the pump and reducing its service life. This prevents water-hammer in the condensate return line.
4. Connect the operating medium (motive gas) to the motive inlet in the cover. Supply main should have a strainer and steam trap (steam service) or drain
trap (air or gas service) installed upstream of the supply inlet. The steam discharge should be piped into the receiver. Drain Trap on air service should
be piped to drain. For increased service life, operate the pump with motive pressures between 15 to 20 psig above the pump back pressure, while
ensuring the maximum required pump capacity is still achieved.
Note: When available operating medium pressure exceeds 200 psig, a Spirax Sarco pressure reducing valve (PRV) is required to reduce pressure
to the pump. The PRV should be located as far from the pump as possible. For best operation, motive pressure should be reduced to the minimum
required to overcome pump back pressure and achieve the desired capacity. A safety relief valve should be installed at the connection provided in the
motive supply piping.
5. Any horizontal runs in the exhaust line should be pitched so that the line is self-draining. The exhaust line should be piped, unrestricted, to atmosphere
as shown in Figures 3 or 4.
Check valve to help
reduce likelihood of
backflow and waterhammer.
Operating Steam
or Gas Supply
Condensate
Return
Line
Condensate
Pump
Exhaust
Vented
Receiver
H
Height
Filling
Head
At least
12 Seal
on overflow. Discharge to
be piped to safe location
such that there is no risk
to personnel. A Float &
Thermostatic Trap can be
used in lieu of syphons loop
consults. Factor for trap
size. Trap is preferred.
Inlet
Strainer
Filling
Height
12
Preferred
6 Min.
Pivotrol
Pump
Figure 3
Check Valve
Vent to atmosphere. Vent to be piped to a safe location such
that there is no risk to personnel. Vent head recommeded if
vent not piped to a pit or similar location.
Vent
to
atmosphere
Condensate
Inlet
Pump
Exhaust
Condensate
Return
Line
Height
Vented
Receiver
At least
12"
Seal
on
overflow
At least
12 Seal
on overflow. Discharge to
Filling
be piped to safe location
such that there is no risk to Height
personnel.
Strainer
Filling
Head
Min 12"
above
vent assist
valve
TD
Strainer
PTF4
Figure 4
3.3 Closed (non-vented) systems suitable for ASME and PED compliant pumps only
A closed-loop installation is one in which the exhaust line of the pump is piped back (pressure equalized) to the reservoir or equipment being drained.
Installation Procedure:
1. Install the pump physically below the equipment being drained with
the exhaust connection vertically upwards. Pump should be installed
with the recommended filling head (the vertical distance between
the top of the pump and the bottom of the reservoir) as shown in
Figures 5 or 6. For other filling head variations, see Capacity Table on
TI-5-030-US.
6. If at any time the backpressure against the pump is less than the
pressure in the equipment being drained, a properly sized float and
thermostatic trap must be installed between the pump and discharge
check valve as shown in Figure 6. Consult Spirax Sarco for trap sizing.
4. Connect the operating medium (motive gas) to the motive inlet in the
cover. Supply main should have a strainer and steam trap (steam
Pilot Operated
Temperature
Control Valve
1/2 HP Steam
Supply
Heat Exchanger
Reservoir
Figure 5
Filling
Head
Spira-tec
Steam Trap
Loss Detector
Pivotrol
Pump
P2
Thermo-Dynamic
Trap
P1
Balanced
Pressure
Thermostatic
Air Vent
Steam
Supply
Wye Strainer
Pilot Operated
Temperature Control Valve
Flow
Temperature
Control Sensor
Centrifugal
Pump
Reservoir Pipe
Steam
Supply
Pivotrol
Pump
Return
Heater
P2
Figure 6
When the PTF4 is placed in a Closed System the exhaust line from the
exhaust valve must be piped into the exhaust line from the Vent Assist
Valve. To ensure no back pressure is placed on the Vent Assist Valve the
exhaust line from the exhaust valve must be tied in at least 12 inches
above the Vent Assist Valve. See Figure 7 below.
To size the PTF4 in a closed system:
Establish available motive pressure. Establish static back pressure
on Pump.
Place established pressures in formulae below:
Pump Motive Pressure (psig) min. VAV delta P (psig) > Back
Pressure (psig)
Capacity charts to be read as normal, i.e. at pump motive and back
pressure.
If, Pump Motive Pressure (psig) min. VAV delta P (psig) < Back
Pressure (psig), then isolate or remove VAV and multiply capacity by
0.77 to find reduced capacity without VAV.
VAV = Vent Assist Valve
check valve
Thermostatic
air vent
Alternate vent assist
valve pipe hookup
Condensate
inlet
Exhaust valve
pipe
Vent
assist valve
exhaust pipe
RESERVOIR
12 Min
12 Min
PTF4
Condensate
return
Figure 7
3.4 Closed (non-vented) systems suitable for low specific gravity and volatile fluid application with ASME
compliant pump
The Pivotrol Pump is not ATEX approved and hence is not suitable for use in such applications in the
European Community.
SPECIAL SAFETY NOTE: When using the PTF4 to pump hazardous
fluids and/or in hazardous locations it is essential the Vent
Assist Valves are removed and plugged prior to installation and
commissioning. A PTF4 pump must never be placed in service
in hazardous duty with a Vent Assist Valve attached. Reference
TI-5-030-US for PTF4 capacities without vent assist valve.
inert gases can be used in closed loop systems and purging the system
of all oxygen components must be performed with great emphasis. The
pump must be grounded to the system in which it is installed.
When maintaining or working on Pivotrol pumps in hazardous
environments or pumping hazardous liquids, or using hazardous gases
as pumping motives, it is essential extra precautions must be taken to
ensure safe handling of liquids and gases to prevent burns, asphyxiation
and other personnel injury which may occur in locations in and around
the pump. Be aware of the flash point of gases in the environment
surrounding the pump. Be aware of the flash point of fluids vapor at the
operating pressure set for the pump. All precautions must be taken to
prevent the possibility of spark initiation.
Vapor Supply
NC
To Vent
Condensor
NO
NO
NO
NO
NC
Vent Vacuum
Header
High Point
Accumulators
NC
NO
NO
Exhaust Line
NC
Vent
Vacuum
Header
Figure 8
Vapor
Inlet
Exhaust
Balance
NC
NO
High
Point
Accumulator
NO
NC
Process
Equipment
Process
Equipment
NO
NO
Exhaust Line
Alternate
Location
NO
NO
NO
NO
NC
Figure 9
NO
Process
Equipment
NC
Exhaust
Balance
Alternate
Vapor
Motive
Supply
ReservoirPipe
12
Fill
Head
Strainer
Condensate
Return
10
NO
Condensate
Return
11
5.0 Maintenance
5.1 Inspection
Inspections should be performed on a regular basis to ensure the Pivotrol
Pump mechanism is functioning properly. This is especially important
when installed in a hazardous pumping application to ensure no potential
ignition sources or sparks can occur.
NOTE: Each mechanism assembly is factory set and tested. No
adjustment to the mechanism should be made. If the mechanism
assembly does not function correctly the entire mechanism should
be returned to the factory for replacement under the warranty terms.
Procedure:
1. Break and disconnect all connections to the cover. Remove cover
bolts and lift the cover and mechanism assembly from the body, noting
the cover orientation.
2. Visually inspect the mechanism to verify that it is free of dirt and scale
and that the float and mechanism moves freely.
3. To re-assemble, reverse the above procedure noting the following
points.
a. When installing the cover and mechanism in tight spaces the
mechanism should be held horizontally as shown in Figure 11-A/G.
Ensure gasket surfaces are clean and free of old gasket material
before installing a new gasket.
b. The float should be inserted into the pump body first, carefully
ensuring the cycle counter probe and paddle do not clash with the
body per Figure 11-B/H. Special attention must be made when fitting
the cover and mechanism assembly. Do not knock the mechanism
against the body or similarly hard object as this may dislodge the
pivots and can permanently affect the pumps performance.
c. As the mechanism is inserted into the pump body the mechanism
should be held vertically and gently lowered to its final resting
position as shown in Figure 11-C/J. The cover must be orientated
so the V cast in to the pump cover lines up with the body casting
part line as shown in Figure 11-D/K/L
4. Assemble cover bolts and torque to 46-50 ft-lbs (155-165 ft-lbs for
PTF4 & 300-320 ft-lbs for PTF-HP) in a cross pattern as shown in
Figure 11-E / K / L.
5.2 Replacement
12
Casting
Part
Line
Cover v
Figure 11
A F: PTC & PTF
G K: PTF
L: PTF-HP
Flange
Studs
F
Gaskets
3
2
G
1
8
4
12
K
Cover "v"
Nuts
10
11
8
5
2
13
Receiver
Figure 12
Pressure Powered Pump
Discharging to Long Delivery Line
The hook-up sketches shown do not necessarily represent recommended arrangements for specific service conditions; but rather
serve only to illustrate the variety of applications where the pressure-powered pump can be utilized. Design requirements for each
application should be evaluated for the best condensate recovery
arrangement tailored to your specific needs.
For use of the pressure powered pump in hook-ups other than
those described previously, and for any additional information
you may require, contact Spirax Sarco Applications Engineering
Department, toll free:
1-800-833-3246
LP
Flash
Steam
Exhaust Steam
Vented to
LP System
Total Lift
H
Flash Recovery
Vessel
HP Condensate
& Flash Steam
Thermo-Dynamic
Steam Trap
Condensate
Wye
Strainer
Figure 14
Non-Electric
Pressure
Powered Pump
Figure 13
Pressure Powered
Pump Draining Water
from Sump Pit
Wye
Strainer
Wye
Strainer
Non-Electric
Pressure
Powered Pump
Back
Pressure
Great
Than LP
Flash
Pressure
Thermo-Dynamic
Steam Trap
15 Swing Check
Wye
Strainer
Steam
Supply
1 Equalizer Line
Return
Main
Vacuum
Space
Vacuum
Breaker
Air Vent
Self Acting
Temperature
Control
Flow
Temperature
Control
Sensor
Steam
Supply
Heater
Total Lift
H
P
Filling Head
Alternate
Discharge
Connection
Return
Wye
Strainer
Centrifugal Pump
Wye
Strainer
ThermoDynamic
Steam Trap
Pipe to Drain
Figure 16
Pipe to
Drain
14
Receiver
Non-Electric
Pressure
Powered Pump
7.0 Troubleshooting
If a correctly sized Pressure Powered Pump does not operate properly, an incorrect hookup is suspect in new installations. For existing installations
where the pump operates occasionally or not at all, the cause is often a change in the system supply or back pressure conditions beyond the original
design parameters. With the system conditions and problem symptoms determined, check the following in turn and correct as necessary.
Caution:
Symptom
1. Pump fails to operate on startup.
Cause
1. a) Motive supply closed.
b) Condensate inlet line closed.
c) Condensate discharge line closed.
d) Motive pressure insufficient to
overcome backpressure.
e) Check valves(s) installed in wrong
direction.
f) Pump air-locked.
f) On vented system, assure that vent line is unrestricted to atmosphere and self-draining to the pump or
receiver. On a closed system, isolate the pump from
the pressurized space being drained. (Exhaust tieback line closed.) Break exhaust connection at pump
cover. Keep personnel clear of exhaust connection.
If pump begins to cycle, air locking has occurred.
Recheck that exhaust tie-back is in accordance with
the installation instructions. Install a thermostatic air
vent at a high point in the exhaust line. Assure that
the equalizer line is self-draining.
2. a) Pump undersized.
15
Symptom
Important Safety Note:
For steps (d) through (g) it is necessary
to break the exhaust/tie-back line at the
pump exhaust connection. On closed
loop systems, care should be exercised
to assure that the pump is isolated
(motive supply, condensate inlet and
discharge, and exhaust/tie-back line
all closed) and that case pressure is
relieved prior to breaking this connection to avoid injury to personnel. Also,
under fault conditions, it is possible
that hot condensate may run out of the
exhaust connection when broken for
both closed loop and vented systems.
This possibility should be taken into
consideration when performing these
steps to avoid scalding of personnel or
water damage to nearby equipment.
Cause
d) Motive inlet valve leaking and/or
worn.
e) Mechanism Faults
i) Broken spring
ii) Ruptured float
16
b)
Check condensate inlet pressure and static backpressure at the pump discharge. If the inlet pressure equals
or exceeds the static backpressure, a blow through
problem is suspected. On vented systems, check for
leaking traps discharging into the condensate inlet line
which would increase inlet line pressure. Replace any
faulty traps. On closed loop systems, if condensate
inlet pressure can exceed static backpressure under
normal operation (i.e. boost in equipment operating
pressure via a modulating control valve or significant
decrease in static return main pressure), a pump trap
combination is required. The pump trap combination
will prevent passage of steam into the return main and
allow the pump to cycle normally when condensate is
present (See Fig. 6)
5. a) Faulty steam traps discharging live 5. a) Check for leaking traps discharging into condensate return. Repair or replace faulty traps. (See also
steam into condensate inlet line
4(b), Pump Blow-By).
(See also 4(b), Pump Blow-By).
b) Vent receiver ahead of pump.
b) Excessive (over 50 lb/hr) flash
steam being vented through pump.
c) Isolate pump and remove cover and mechanism
c) Exhaust valve stuck or worn.
assembly. Remove exhaust head and seat assembly. Visually inspect seating surface. Clean and
reinstall or replace, if worn.
Spirax Sarco Inc. warrants only that its personnel will exercise their best
professional knowledge and judgment in performing services and that
work or materials supplied under the purchase order would conform to
contract specifications, be free of defects and workmanship and material
and reflect Spirax Sarcos best technical knowledge and judgment. In
the event that either services provided or product sold are defective,
Spirax Sarco Inc. agrees only to reperform, repair, replace or modify the
defective service or products.
The above warranties are exclusive and are in lieu of all warranties of
merchantability, fitness for purpose or other warranties or guarantees of
any kind or description, expressed or implied.
The above warranties do not cover, and Spirax Sarco Inc. shall have
no responsibility for failure to meet, any warranty caused by any
failure of purchaser or its agents to store, install, operate, inspect or
maintain the product covered by the purchase order in accordance
with the recommendations of Spirax Sarco Inc. or in the absence of
such recommendations, in accordance with the generally accepted
practices in the industry, including but not limited to applicable quality
assurance procedures relating to the installation of products covered by
the purchase order. The remedies of purchaser set forth for the above
warranties are exclusive.
Repair, adjustment, reperformance, modification or replacement of any
equipment or services performed thereunder in the manner and during the
period provided herein shall constitute fulfillment of all liabilities of Spirax
Sarco Inc. to purchaser under the warranty set forth in this document,
whether based on contracts, on negligence of any kind, strict liability or
tort, on the part of Spirax Sarco Inc. or its suppliers or subcontractors of
any tier; or otherwise.
17
18
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