Model: 1100 Float-Controlled Condensate Trap, PN 25

Transcription

1 1 Safety instructions Model: 1100 Float-Controlled Condensate Trap, PN Proper use Any improper use, intervention in the design and deviation from the design data automatically lead to termination of the warranty. The float-controlled condensate trap is designed for the discharge of condensate from steam, compressed air and pressure gas systems. Any other usage is not permitted. The manufacturer is not liable for damage resulting from any other usage. The user or operator bears the risk in this case. This also applies analogously to incorrect assembly, start-up, use and maintenance. 1.2 Warnings and symbols Personal risk due to escaping operating medium because of pressure, temperature and weight. Failure to comply with these warnings results in the risk of accidents. Follow the instructions in this operating manual. The operator must ensure that this operating manual and, if necessary, other relevant documents are available on site. Only trained or instructed personnel may be assigned to handling this equipment. Any mode of operation that may impair safety must be avoided. 2 General description and usage 2.1 Design of the condensate trap Housing flange part 11 Float with fork 2 Housing gasket 12 Maxosglas 3 Housing side part 13 RWG frame 8 19 Additional equipment RWG 4 Control screw 14 2 gaskets for RWG 5 Housing screws 15 RWG Screws 6 Screw plug 16 Gasket 7 Protective sleeve 17 Frame 8 Supporting screw 18 Cutting ring threaded joint 9 Float control assembly 19 Gasket Picture 1: Model Supporting body assembly with rotary valve and cotter pin 20 Gasket 2.2 Operation limits of housing material (Design) max. operating pressure (bar g) max. operating temperature ( C) -10/ Page 1 of 6 01/2017 -Di. Subject to modifications

2 2.3 Function limit of control unit Cross section max. line pressure in bar g IIa 25 III 12 IV 11 V 2,5 VI 20 VIa 25 VII 18 VIIIa 4 VIIIb Discharge capacity (for hot condensate) Picture Function For the cold condensate the discharge capacity is higher because of medium temperature and density. Due to the gravity the condensate flows downwards to the lowest point, which is the condensate trap housing. In the lowest position of the float the outlet cross-section is close. Rising of the liquid level lifts the float and opens the outlet. Condensate will be discharged through the upturned immersion tube. Decreasing condensate level closes the outlet again. 2.6 Compensation line In order to get proper function, the non-condensable gas must be able to leave the housing. Due to the vertical installation, the non-condensable gas is able to leave the housing and flows into the steam/gas chamber capsule above it, which has the same pressure level. If the self-venting through the pipe must be extended, the control screw (4) can be replaced by a cutting ring screw bolt and a compensation line can be installed leading upwards. 2.7 Automatic venting RIFOka-automatic capsule venting valve (venting to interior): For start-up and permament venting with high venting capacity. An special liquid inside the membrane capsule evaporates and condenses only a few degrees below the boiling point of water. See Picture 3. Picture 3 -Di. Subject to modifications 01/ Gastight under-level float control (only for gas applications) Page 2 of 6 For gas applications, a gastight under-level float control is nearly exclusively used. Consult with Rifox, if necessary.

3 3 Assembly 3.1 Flow Direction Vario WR Vario WL Vario SO Vario SU Picture 4 Vario-WR: Flow direction horizontal from right to left Vario-WL: Flow direction horizontal from left to right Vario-SO: Flow direction vertical from top to bottom Vario-SU: Flow direction vertical from bottom to top 3.2 Modification for a different flow direction The RIFOmat Vario 1100 is delivered according to the purchasing specification, as shown in Picture 5. It can be quickly installed on site for a different flow direction, without any problem. Hier s an Example: The RIFOmat Vario 1100 has been delivered as Vario-SU and has to be mounted as Vario-WR. Unscrew the housing hexagon nuts and remove the housing side part (3) sideways. Loosen the supporting screw (8) by unscrewing it for 1-2 full turns. Use a plastic hammer to loosen the float control assembly (9) from its conic housing seat by lightly stroking on the the supporting screw (8). Reposite the housing flange part (1) by turning it 90. Reposite the float control assembly (9), so that the tube (T) pointing vertical downwards. Screw in the support bolt (8) with gasket (19). Tighten it with a standard ring wrench or a open jawed wrench, size 27. Tightening torque according to Section 6.6. Replace the housing gasket (2) if damaged, and mount on the lateral part of housing side part (3). Tighten housing screws (5) evenly crosswise. Tightening torque according to Section Modification for restricted space and horizontal flow In the case of only minimal space for the housing, which projects to the side, the housing side part (3) can be mounted towards to the front or towards the rear by repositioning the housing flange part (1) for the purpose of better maintenance or better visual inspection of a built-on reflective water level gauge, etc. 3.4 Installation The condensate trap Vario 1100 has to be screwed into a pipeline between flanges. Remove transport caps from inlet and outlet. Fitting direction: according to Picture 5. The condensate flow is in the direction of the arrow (note the arrow on housing flange part (1) ). The housing is positioned to the side. The word TOP on the housing side part is at the top and must be legible horizontally. Supporting brackets: The supporting brackets are not necessary for DN15/DN20/DN25 if the pipeline is adequately supported before and after the condensate trap. Condensate traps for DN40/DN50 weight over 34,5 kg, ensure thus proper fixing of the pipeline in front of and behind the condensate trap. To avoid downtimes, it is recommended to install stop valves with bypass to pipeline, both in front of and behind the condensate trap. 4 Start-Up The pressure build-up and heating-up of the housing should not take place abruptly. If leakage is detected after the first inspection, the screws (4 / 5 / 6 / 8 / 15) can be fixed under consideration of the given torque moments, as given in Section 6.6. The screws can only be tightened on when the housing is unpressurized and at room temperature. Page 3 of 6 01/2017 -Di. Subject to modifications

4 5 Observation and check The function s failure can be observed either as condensate blockage or as gas/ steam leakage. Condensate blockage can be determined by a): loosen the control screw (4) for a quarter rotation, while no condensate leakage should occur; and by b): a surface thermometer on the housing for steam applications (if necessary, please consult with Rifox). Gas / steam leakage: can be determined by an ultrasonic measuring device, and for steam applications by a surface thermometer. In case of steam leakage, open the condensate trap according to Section 6.1. Make sure that float (11) can be easily moved. If necessary, disassemble and clean the float control assembly (9). If damages/ wears are detected on parts or on the sealing surface, the complete float control assembly (9) should be replaced. 6 Maintenance / Inspection 6.1 Opening the steam trap and dismantling the float control The steam trap must be depressurized. Shut off the system securely in front of and behind the steam trap. Release any remaining pressure in the housing by loosening the control screw (4) by only a quarter turn. Dismantle the steam trap from the pipeline system. Condensate traps for DN40/DN50 weight over 34,5 kg, apply thus lifting device. Loosen the housing screws (5) evenly crosswise. Remove the housing side part (3). Loosen the supporting screw (8) and screw out 1 to 2 turns. With a few light strokes using plastic hammer on the front side of the supporting screw (8) to loosen the float control assembly (9) from the conic housing seat. Screw out the supporting screw (8) completely. Take out the float control assembly (9). 6.2 Disassembling, cleaning and assembling the float control (Picture 5) After removing the cotter pin (p), the rotary valve (v) can be simply pulled out to the side. Clean the parts using, for example, benzine. Check the rotary valve (v) for wear along the sealing edge. If wear is detected, the support body (b) together with the rotary valve (v) must be replaced. The exactly leakage test must be carried out by RIFOX. During assembly ensure that the notch in the rotary valve (v) points to the punch mark on the support body (b) and the cotter pin (p) is inserted and secured again carefully. It must be possible to move the float up and down easily by hand. 6.3 Installation of the float control assembly and assemble the condensate trap b p v Picture 5 The complete float control assembly (9) is inserted into the conical housing seat with the support body. It must be ensured that the tube is positioned vertically downwards. Screw in the supporting screw (8) with gasket (19) and tighten evenly crosswise using a standard ring wrench. Tightening torque according to Section 6.6. Check the housing gasket (2), replace it it is damaged. Put on the housing flange part (1). Tighten the housing screws (5) evenly crosswise. Tightening torque according to Section Di. Subject to modifications 01/2017 Page 4 of 6

5 6.4 RIFOka automatic venting valve (Picture 6) Capsule Function: Startup and continuous venting takes place inward, i.e. towards the condensate side. Near the temperature of ebullition the capsule closes. When the temperature drops, the capsule opens. Replace the capsule (10.3): Dismantle the complete float control assembly (9) as described in Section 6.1. Loosen the hexagon nut (10.5) with wrench size 19. Screw up the support frame (10.4) for approx. 5 mm by turning it counterclockwise. Picture 6 Dismantle the capsule (10.3). Visual check the seat part of valve gate (10) and of capsule (10.3) for wear (cross scoring). Replace the capsule (10.3). Marking S: down to 8 C condensate supercooling. Screw support frame (10.4) against the capsule (10.3) using minimal manual force and align such that the support frame (10.4) is positioned precisely in the crosswise. Hold support frame (10.4) in this position and lock hexagon nut (10.5) morately. Install the float control assembly (9) as described in Section Care and maintenance In the case of a great risk of dirt accumulation, the housing, when it is depressurized, should be rinsed thoroughly from time to time. If necessary, the float control assembly (9) should also be checked according to Section 6.2. The dirt, which has been accumulated in the housing, can be removed away by screwing off the screw plug (6). For special applications, it is advisable to install a separate upstream strainer. The float control assembly (9) usually does not to be special maintained. The maintenance depends primarily on the wear resistance of the valve gasket. See Section 6.1 and Tightening torque Position Part Name Gasket DN15, DN20, DN25 Tightening Torque (Nm) DN40, DN50 4 Control screw 5 Housing screw Copper Soft iron Copper 70 / Soft iron Screw plug Soft iron Supporting screw Soft iron RWG screw Novaphit SGBC / 20 Page 5 of 6 01/2017 -Di. Subject to modifications

6 6.7 Spare parts Only original spare parts can be used capsule 8 19 Additional equipment RWG Additional equipment Picture 7: Housing flange part: EN-JS Float with fork: SS or Housing gasket: Soft iron / Copper 12 Maxosglas: as per DIN Housing side part: EN-JS RWG frame: S 235 JR 4 Control screw: G¼ (BSP), SS gaskets for RWG: Soft material 5 Housing screws: 8.8 acc. DIN 939/ RWG Screws: A4-70, DIN 938/934 6 Screw plug: G½ (BSP), DIN Gasket: Soft iron 7 Protective sleeve: SS Frame: S 235 JR 8 Supporting screw: SS Cutting ring threaded joint: C-Steel Float control assembly: SS / / / , or complete Complete Float Control with built-on membrane capsule venting device RIFOka: SS / / / / VA-Hastelloy Supporting body assembly with rotary valve and cotter pin: SS / / / , or complete Complete Supporting Structure incl. rotary slide valve, cotter pin and built-on RIFOka-membrane capsule venting device: SS / / / Gasket: Soft iron 20 Gasket: Soft iron 7 Conformity assessment The pressure equipment described is a pressure-keeping component in accordance with the Pressure Vessel Directive 2014/68/EU. DN15, DN20, DN25: according to Art. 4, Subs. 3, no CE-Mark. DN40, DN50: Conformity verified through the identifying mark: CE A detailed declaration of conformity assessment according to PED is available as separate document. Please request if necessary, if not attached. -Di. Subject to modifications 01/2017 Page 6 of 6