Velan Valves Ltd

Leicester, England

THERMOSTATIC TRAP

MODELS N150/300/675/900/1500/2500/2600

INSTALLATION, SERVICING AND MAINTENANCE

INSTRUCTIONS

CONTENTS PAGE

1. FEATURES 2
a. Fast Warm Up 4
b. Positive Steam Trapping 4
c. Condensate Discharge 5
d. Check Valve 5

2. INSTALLATION AND OPERATION 6

3. ADJUSTMENT
a. Bi-metal/valve clearance 9
b. High Back Pressure 11

4. MAINTENANCE
a. Testing of Valve Seat and Gasket 12
b. Removal of Bimetal 12
c. Repair of Valve and Valve Seat 14
d. Re-assembly 16

5. TOOL PART NUMBERS 21

6. BOLTING TORQUES 21

1
Rev 1 - 17/07/08
MODELS N150/300/675/900/1500/2500/2600

INSTALLATION, SERVICING AND MAINTENANCE

INSTRUCTIONS

1. FEATURES
The Type ‘N’ Trap range is particularly suitable for high pressure/high temperature
trapping applications in power plants, marine applications, superheated mains and
other equipment. The forged steel design and stainless steel parts, stellite faced
where necessary, assure long life under severest service.

N150/300

Cover : Forged Steel

Strainer : Stainless Steel Rocker : Stainless Steel

Cover Gasket Screwed Seat

S/S Spiral wound Stainless Steel/Stellited
Non-Asbestos filler

Body : Forged Steel Valve Assembly :

Stainless Steel

Bottom Plug Gasket

S/S Spiral wound
Non-Asbestos filler

Strainer Plug : Steel Test Plug : Steel

2
N675/900/1500
Cover : Forged Steel
Strainer : Stainless Steel Rocker : Stainless Steel

Cover Gasket Welded Seat

S/S Spiral wound Stainless Steel/Stellited
Non-Asbestos filler

Bimetal Element : Valve Assembly :

Ruflex GB14 Stainless Steel

Bottom Plug Gasket Body : Forged Steel

S/S Spiral wound
Non-Asbestos filler

Strainer Plug : Steel Test Plug : Steel

N2500/2600
Cover : Forged Alloy
Strainer : Stainless Steel Steel Rocker : Stainless Steel

Cover Gasket Welded Seat

S/S Spiral wound Stainless Steel/Stellited
Non-Asbestos filler

Bimetal Element : Valve Assembly :

Ruflex GB14 Stainless Steel

Bottom Plugs : Alloy Body : Forged Alloy

Steel Steel
3
a. Fast warm up with automatic air venting
When cold the bi-metal relaxes and the discharge valve is wide open allowing air,
gasses and cold water to clear quickly, ensuring no air binding or water logging occurs
to delay equipment warm up. Steam wasting by-passes, or other secondary air venting
systems are unnecessary.

b. Positive Steam Trapping

i : Saturated Steam
Incoming steam contacting the bimetal element causes the bimetal to deflect and
develops thermal power to act on the valve stem, overcoming the line pressure and
closing the valve tight. The power of the bimetal element increases or decreases as a
function of the relative temperature of saturated steam. The same element operates
efficiently at any given pressure within its range.

ii : Superheated steam
As for saturated steam, but the higher steam temperature develops more bimetal pull
and shuts the valve even tighter.

4
c. Condensate Discharge

Cooler condensate gradually reduces the bimetal force until the unbalanced pressure
on the valve cracks the orifice and releases the flow. This is the first stage of the
smooth opening. The second stage occurs as the flow is released , the unbalanced
pressure acts on the full valve area, increasing its force, fully opening the orifice for
maximum capacity flow.

d. Check Valve

For traps installed in a condensate return system, or a multiple collection header,

excess back pressure, traps discharging on different cycles, a drop in line pressure
or discharge to overhead return lines, can cause a reverse flow of condensate
through the trap. Separate check valves are required down-stream of the trap to
prevent this occurring.
However the free floating self heating valve inside the Plenty trap will close
immediately reverse flow is present and no additional valve is necessary.

5
2. INSTALLATION AND OPERATION

a. The trap can be installed in any convenient position see fig 5. In the vertical
position with the inlet on top, the trap is self-draining and therefore freezeproof,
provided the condensate can drain away see fig 6. Direction of flow is indicated
by arrows- integrally forged under the body and on the cover.

Horizontal Vertical Angle

Fig.5 All position installation

Fig.6 Self draining

b. Install the trap 5' - 8' (1.5m - 2.5m) from the equipment drain point when possible.
The minimum distance is 18inches (0.5m). This cooling leg acts as a storage
chamber improving the trap operation.

Figures 7 and 8 indicate correct methods for collecting condensate from

steam mains, ensuring that most of the condensate flowing along the main can be
collected.

Dirt Pocket
Flow
5-8 FT
Fig.7 Dirt Pocket

5-8 FT

Fig.8

c. Secondary air vents, check valves and strainers are not necessary, these are
incorporated in the trap.
6
d. Where a bypass is required the equivalent piping king should be used. This
provides considerable savings in space and construction costs compared to the
standard bypass, see fig 9. The piping king unit allows “in line” maintenance.

Plenty Piping King Unit

Standard Bypass Configuration

Fig. 9

e. Blow out the line or unit with air, or steam if possible, before installing the trap, to
remove dirt and scale.

f. The trap and at least the last 2 - 3 feet (0.6m - 1.0m) of the cooling leg should not
be insulated, otherwise the trap performance will be affected.

g. It is not necessary to disassemble the trap when welding into position. However
correct welding procedures must be used without excessive heat input.

h. When operating, the trap will adjust to the quantity and flow condition of the
condensate. If intermittent, the trap will discharge intermittently. However if
condensate flow is continuous the trap will also discharge continuously.

7
i. For checking operation of the trap when installed in a closed return system a test
valve can be fitted as shown as in fig 10. Alternatively the trap can be supplied
with a thermometer fitted to the outlet connection, or a contact temperature
recorder used to measure the temperature differential across the trap. Ultrasonic
meters must be used with care if the trap is operating in a continuous discharge
mode as the results indicated can be misleading.

j. Pressure waves in excess of normal operating pressures (water hammer) will

overcome the bimetal closing force, opening the valve and dissipating the excess
pressure downstream, preventing damage to the internals.

k. Clean strainers periodically otherwise they may plug up and prevent the free flow
of condensate. For efficient, fast and economical cleaning, install a small valve to
the strainer blowdown connection (optional) as in Fig 11.

Shut - off Valve

Strainer Test Valve

Blowdown Valve

Complete
Recommended
assembly

Fig. 10

8
3. ADJUSTMENT
NOTE: Before undertaking any adjustment or repair work, always ensure that the
steam trap is fully isolated from the system. Before removing any covers or plugs,
loosen bolting and break gasket seal to release any pressurised steam trapped in
the body.

a. Bimetal/Valve Clearance
The discharge temperature of condensate is dependent upon the clearance
setting ‘ X ‘ fig.11. Increasing the clearance reduces the force exerted on the
valve by the bimetal, allowing a closer to saturation discharge temperature. It will
also increase capacity, conversely, reducing this clearance increases the bimetal
force requiring an increased amount of sub-cooling before discharge can take
place. This will hold back condensate utilising its heat before discharge giving
efficient energy utilisation. It will also reduce discharge capacity.

Fig. 11

The clearance is measured at point ‘ X ‘ fig.11 between the top of the rocker plate
and the underside of the adjusting nut. The standard factory setting is made at an
ambient temperature of 65 Deg F ( 18 Deg C ) and will allow the valve to
commence opening at 15 Deg F ( 8 Deg C ) approx. Below saturation, with full
discharge, as shown in the individual capacity diagrams for each model, around
40 Deg F (22 Deg C).

The standard factory setting is made with the bimetal at an ambient temperature
of 65 Deg F (18 Deg C). If it is not possible to make the setting at this temperature
an alternative setting as shown in the table below should be used, for the
appropriate ambient (bimetal) temperature.

9
BIMETAL PLATES – RUFLEX GB-14

NOTE
A) COLD CLEARANCE GAUGE SHOULD BE A SLIDING FIT BETWEEN THE LOCKNUT
AND ROCKER.
B) WHEN CHECKING THE CLEARANCE 'A' WITH THE GAUGE DO NOT REDUCE THE
CLEARANCE 'B' BETWEEN THE BIMETAL SEGMENTS, THIS MUST ALWAYS BE
EQUAL TO THE SPACER IN THE ELEMENT.
'A'

'B'

SETTINGS IN INCHES

10
A standard setting gauge is available – See tool part numbers, or feeler
Gauges of the correct amount can be used.

The gauge should be a sliding fit between the locknut and rocker plate, and it is
important that the clearance ‘Y’ between the bimetal segments is not reduced.
This should always be equal to the spacer in the element fig.11

To alter the clearance release the locknut from the adjusting nut, fit a stem key (see
tool part numbers) to the flat on the stem below the bimetal fig.12. Turn the adjusting
nut anti-clockwise to increase the clearance, or clockwise to reduce.

Do not increase clearance beyond point where the trap passes steam.

On completing setting operation, relock the adjusting nut with the locknut.

Locknut
Stem Key
Adjusting
Nut

Fig. 12

b. High Back Pressure

The trap will operate against high back pressures, but the discharge temperature
and discharge capacity will be correspondingly affected. For effective operation
against back pressures in excess of 30%, the clearance should be increased
gradually, up to a maximum of one full turn of the locknut approximately, ensuring
that the trap continues to close tight on [Link] not confuse with the discharge of
flash steam released by the hot condensate.

The trap can operate against back pressure of 80%

11
4. MAINTENANCE
After completely isolating from live steam alterations can be performed with the trap in
line by removing the cover.
The traps are designed for easy servicing and dis-assembly of parts without
removing the trap body from the line.

a. Testing of valve seat and gasket.

If the trap leaks steam after trying re-adjustment inspect valve and valve seat. If
no visible sign of damage, apply air or water pressure through outlet connection
and observe for signs leakage above the valve. See fig.13.

Check for possible leakage

Steam air or water pressure

Steam , Air or
Water Pressure

Fig. 13

b. Removal of Bimetal

The bimetal element can be removed without disassembly of the seat or valve.
Unscrew the screws securing the holder to the body, lift the element from the
rear, until the valve stem slips through the slot in the rocker, and then lift out the
element fig.14

Inspect the element for dirt lodging between the segments and clean if necessary.

12
Unscrew securing screw

Fig. 14

To replace the element reverse the above procedure relocating the valve stem
and adjusting nut into the rocker plate and locating the holder into the body.
Before final tightening of the holding screws the bimetal must be located centrally
in line with the centre of the valve orifice. This is to ensure that the bimetal force
is directed along the axis of the valve stem. To assist with this an alignment bar,
locating the orifice, bimetal slot and rocker plate is available. See tool part
numbers. To use the line bar, for model N-2500/2600 remove the test plug under
the valve, locknut and adjusting nut from the valve stem, and remove the valve
through the test plug. Insert the liner bar from below body through the valve seat
and rocker plate fig.15, until the appropriate diameter locates in the seat orifice.
This will ensure that the bimetal is correctly aligned. Tighten bimetal holder
screws and remove the liner bar.

Liner Bar Fig. 15

For models N-600/675/900/1500 a multi diameter liner bar is available. This is

used from above the trap. Lift out of the rocker plate from its support bridge. Pass
the liner bar down the bimetal slot until appropriate diameter is fully inserted into
the orifice. Tighten the holding screws, remove the liner bar and replace the
rocker plate.

NOTE:
The bimetal is supplied fully assembled on its mounting block and should not be
removed, or the bimetal clamping screws loosened. Each plate must be
concentric and in line with each other. Any plates out of the square may interfere
with the free movement of the valve. Bimetal plates must be also fitted the
correct way up, otherwise they will exert a negative force. Markings on the under
side, and on the rear edge indicate whether plates are assembled correctly.

13
c. Repair of valve and valve seat

(i). Valve

Slight damage to the valve (which has a hardness of 53Rc, 500 BHN) can be
repaired by lapping (grinding) with the valve seat using an appropriate
compound.

If the valve is badly ‘wiredrawn’ or eroded, it should be replaced with a new

valve assembly.

(ii). Valve Seat (Welded)

The heavy stellite deposit ensures a long trouble free operating life under nor-
mal operating conditions. The sea weld construction prevents leakage between
the body and set by “backflow erosion” or “flash” forming beneath the valve.
Minor damage can be repaired by relapping using an appropriate re-grinding
compound. The seat can be relapped as shown in fig.16 using a hand drill, or if
in the workshop a hand held air tool. Final lapping should be completed by
hand with the valve in its correct operating position. If necessary the seat can
be replaced as follows:

Fig. 16

14
Remove the damaged seat using a 5/8” drill to remove the seal weld fig.17.

5/8 Drill

Fig.17
Locate the new seat squarely in the body recess. The locating tool fig.18 will
keep the seat correctly positioned during welding. Seal weld using a stainless
309 or similar electrode 3/32” (2.5mm) Dia in accordance with an appropriate
weld procedure.
Electrode

Brass Tip

Stainless Steel

Fig.18
iii) Valve Seat (Screwed)
low-pressure N traps 150/300 (now replaced by equivalent SF cage unit
models) contain a screwed valve seat. Check for leakage (see above) also at
points ‘A’ & ‘B’ fig.19. If trap leaks at ‘A’ between seat and body.

A B

Steam , Air or
Water Pressure

Fig.19

15
Check valve seat is correctly screwed in. If valve seat is damaged on its body
seating area, replace with new seat. When seating ‘land’ in the body is damaged,
remachine seat bevel using 60° countersink fig.20.

If the thread in the body is eroded, the body should be replaced.

60°

Fig.20

NOTE:
After seat replacement, finally lap valve and seat by hand and check for leakage
at body/valve seat joint, and valve and valve seat. If the trap leaks through the
seat after reassembly and a new valve assembly has been fitted, check that the
valve assembly has been fitted, check that the valve assembly is not contacting
the inside of the cover preventing seating. If so either incorrect valve assembly is
used, or the cover incorrectly assembled - see below.

d. Re-assembly

i) Strainer
Ensure strainer is clean. If damaged or partially blocked. Fit new screen. Replace
strainer with flat section adjacent to bimetal pack and located in strainer recess
above strainer plug.

ii) Cover Gasket

Fit a new spiral wound gasket into the body recess, ensuring that the inner ring is
fully supported for 100% of its periphery. This is important. If any part of this first
ring is not supported by the body and cover gasket faces, leakage may occur.

iii) Cover
The cover must be fitted with the direction of flow arrow towards the outlet
connection. The forged recess must be above the valve stem, and the top of the
strainer located in the recess in the cover. To ensure correct positioning, for
models N-675/900/1500, one stud is fitted with a collar, which locates in the
appropriate enlarged bolt hole on one side of the cover.

16
To ensure no leakage spiral wound gaskets must be compressed correctly.
Plenty Velan ensures this by machining the recess and spigot so that the correct
compression is applied when the cover is in complete contact with the body
flange.

The gasket must be compresses evenly. This is achieved by tightening the nuts
by small equal amounts moving diagonally opposite across the cover.

Correct compression is applied when the cover is in full metal contact with the
body.

iv) Bottom Plugs

Ensure both test plugs are fully tightened fitting new gaskets if necessary. For
current production a shoulder is machined on the plug to ensure correct
compression of the gasket. Ensure that the plug is tightened until this shoulder is
in contact with the trap body.

Some older models may be fitted with ½” NPT taper plugs.

17
N150/300

18
N675/900/1500

19
N2500 / N2600

20
5. TOOL PART NUMBERS

SETTING SEAT LOCATING

MODEL STEM KEY LINER BAR
GAUGE TOOL
N150/300 L99002 L99005/B1 L99014 NOT REQUIRED

N675 L99002 L99005/B1 L99027 L99046

N900/1500 L99002 L99005/B1 L99002 L99045

N2500 L99002 L99005/B2 L99011 L99046

6. BOLTING TORQUE

C0VER
MODEL
[Link] Nm
N150/300
60 81
N675/900/1500

N2500 / N2600 180 244

21