INSTALLATION AND MAINTENANCE INSTRUCTIONS

IM-5-201-US October 2004

PTC and PTF Pivotrol Pump® patent pending

Featuring Reliable PowerPivot® Technology
Pivotrol PTC/PTF cover PPC/PPF cover
bolts rated to 200 psig bolts rated to
125 psig

CAUTION
If upgrading pump from
125 psig to 200 psig
you must upgrade bolts
to grade B7, Stock
#73181 as shown

Safety Information
Safe operation of these products can be guaranteed only if they are properly installed, commissioned, used and main-
tained by qualified personnel (see point 11 on this document) in compliance with the operating instructions. General
installation and safety instructions for pipeline and plant construction, as well as the proper use of tools and safety
equipment, must also be complied with.

1. Intended use IV) Spirax Sarco products are not intended to withstand
Referring to the Installation and Maintenance Instructions, external stresses that may be induced by any system to
Nameplate and Technical Information Sheet, check that the product which they are fitted. It is the responsibility of the installer
is suitable for the intended use/application. The products listed to consider these stresses and take adequate precautions
below comply with the requirements of the European Pressure to minimise them.
Equipment Directive 97/23/EC and carry the CE mark when so
required. The products fall within the following Pressure Equipment V) Remove protective covers from all connections before
Directive categories: installation.
2. Access
Group 2 Gases Ensure safe access and if necessary a safe working platform (suitably
Product guarded) before attempting to work on the product. Arrange suitable
Iron Steel
lifting gear if required
PTC 2 N/A 3. Lighting
Ensure adequate lighting, particularly where detailed or intricate
PTF N/A 2 work is required.

I) The products have been specifically designed for use on 4. Hazardous liquids or gases in the pipeline
steam, air and inert industrial gases which are in Group 2 Consider what is in the pipeline or what may have been in the
of the above mentioned Pressure Equipment Directive. pipeline at some previous time. Consider; flammable materials, sub -
The product’s use on other fluids may be possible but, if stances hazardous to health, extremes of temperature.
this is contemplated, Spirax Sarco should be contacted to 5. Hazardous environment around the product
confirm the suitability of the product for the Consider; explosion risk areas, lack of oxygen (e.g. tanks, pits),
application being considered. dangerous gases, extremes of temperature, hot surfaces, fire haz-
II) Check material suitability, pressure and temperature and ard (e.g. during welding), excessive noise, moving machinery.
their maximum and minimum values. If the maximum oper- 6. The system
ating limits of the product are lower than those of the system Consider the effect on the complete system of the work proposed.
in which it is being fitted, or if malfunction of the product Will any proposed action (e.g. closing isolation valves, electrical iso-
could result in a dangerous overpressure or overtempera- lation) put any other part of the system or any personnel at risk?
ture occurrence, ensure a safety device is included in the Dangers might include isolation of vents or protective devices or the
system to prevent such over-limit situations. rendering ineffective of controls or alarms. Ensure isolation valves
III) Determine the correct installation situation and direction are turned on and off in a gradual way to avoid system shocks.
of fluid flow.
 7. Pressure systems 12. Handling
Ensure that any pressure is isolated and safely vented to atmospheric Manual handling of large and/or heavy products may present a risk of
pressure. Consider double isolation (double block and bleed) and the injury. Lifting, pushing, pulling, carrying or supporting a load by bodily
locking or labelling of closed valves. Do not assume that the system force can cause injury particularly to the back. You are advised to
has depressurised even when the pressure gauge indicates zero. assess the risks taking into account the task, the individual, the load
and the working environment and use the appropriate handling method
8. Temperature
depending on the circumstances of the work being done.
Allow time for temperature to normalise after isolation to avoid dan-
ger of burns. 13. Residual hazards
In normal use the external surface of the product may be very hot. If
9. Tools and consumables
used at the maximum permitted operating conditions the surface
Before starting work ensure that you have suitable tools and/or con-
temperature of some products may reach temperatures in excess of
sumables available. Use only genuine Spirax Sarco replacement parts.
450°F. Many products are not self-draining. Take due care when
10. Protective clothing dismantling or removing the product from an installation (refer to “
Consider whether you and/or others in the vicinity require any pro- Maintenance Instructions”).
tective clothing to protect against the hazards of, for example,
14. Freezing
chemicals, high/low temperature, radiation, noise, falling objects,
Provision must be made to protect products which are not self drain-
and dangers to eyes and face.
ing against frost damage in environments where they may be
11. Permits to work exposed to temperatures below the freezing point.
All work must be carried out or be supervised by a suitably compe-
15. Disposal
tent person.
Unless otherwise stated in the Installation and Maintenance
Installation and operating personnel should be trained in the correct
Instructions, this product is recyclable and no ecological hazard is
use of the product according to the Installation and Maintenance
anticipated with its disposal providing due care is taken.
Instructions.
Where a formal ‘permit to work’ system is in force it must be com- 16. Returning Products
plied with. Where there is no such system, it is recommended that a Customers and stockists are advised that under EC Health, Safety
responsible person should know what work is going on and, where and Environment Law, when returning products to Spirax Sarco they
necessary, arrange to have an assistant whose primary responsibili- must provide information on any hazards and the precautions to be
ty is safety. taken due to contamination residues or mechanical damage which
Post ‘warning notices’ if necessary. may present a health, safety or environmental risk. This information
must be provided in writing including Health and Safety data sheets
relating to any substances identified as hazardous or potentially
hazardous.

Operating Pressure Range 5 to 200 psig (.34 to 13.8 barg)

1/2" NPT
Exhaust 1/2" NPT
Outlet Motive
Pressure Exhaust Motive
Inlet Outlet Pressure
22 Inlet
7

5
6
2
3
1
19 9
4
10
11 9
12
8
13
14 16
15 17
18

Stainless
Steel
Liquid Check
Outlet Valve
(21) Figure 1

Liquid
20 Inlet
1/2" Drain
Connection
 How The Pivotrol Pump® Operates
1. In the normal position before start up the float (18) is at its lowest position with the steam inlet valve (4) is closed, the exhaust valve (6) is
open.
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).
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 (21). 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 float’s (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.

Installation — Vented Systems (Fig. 2)

Vent to atmosphere Operating Steam
or Gas Supply

Pump
Exhaust Condensate
Return
Line

Vented
Receiver

Filling H
Head Height

Inlet
At least
Strainer 12"
12" Seal
on overflow Preferred
6" Min. Pivotrol® TD 42L or 52L Trap
(if fitted)
Filling Pump When steam supply
Height is used

Figure 2

Recommended installation of Pivotrol ® Pump when fitted with a reservoir or vented receiver. In an “open” system flash steam must be vented or
condensed ahead of pump inlet. Application details will dictate which of the following options will be necessary to accomplish this.

Caution: Before installation or any maintenance is performed, ensure that all condensate, steam, air or gas lines are closed to prevent personal injury.
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 Fig. 2. For other filling
head variations, see the capacity table on TI-5-030-US.

Recommended Maximum Filling Head: 48" Standard Filling Head: 12" Minimum Filling Head:
2" x 2" & 3" x 2" PTC/PTF 2" x 2" & 3" x 2" PTC/PTF 3" x 2" = -1" PTC/PTF
2" x 2" = -3" PTC/PTF

Limiting Operating Conditions

Filling Head Filling Height
Filling Head Requirements
Above Pump Cover From base of Pump
Standard recommended PTC 12" (305mm) 36.9" (951mm)
PTF 12" (305mm) 44.1" (1120mm)
Max filling head PTC 48" (1219mm) 72.9" (1852mm)
PTF 48" (1219mm) 80.1" (2035mm)
Min filling head PTC 2 x 2 -3" (-76mm) 21.9" (556mm)
PTC 3 x 2 -1" (-25mm) 23.9" (607mm)
PTF 2 x 2 -3" (-76mm) 29.1" (739mm)
PTF 3 x 2 -1" (-25mm) 31.1" (790mm)
Max Number of Cycles per minute = 6
Specific gravity of pumped liquid options = 0.9 to 1.0 0.8 to 0.89 0.65 to 0.79
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 Figure 2. For proper receiver sizing, refer to table 1. All inlet line fittings must be fully ported.

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. The chart below
shows proper vented receiver sizing (per criteria set forth in the A.S.H.R.A.E. Handbook) based on the amount of flash steam present. By sizing
the receiver as shown below, 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 Fig. 2 and piped to a suitable drain. The piping must form a loop type water seal at
least 12" deep immediately after the receiver.

Pump Size—up to 3" x 2"

Flash Steam Receiver Vent Line
Up to Diameter Length Diameter
75 pph 3" 30" 1-1/2"
150 pph 4" 30" 2"
300 pph 6" 36" 2-1/2"
600 pph 8" 36" 3"
900 pph 10" 36" 4'
1200 pph 12" 36" 5"
Table 1 2000 pph 16" 36" 6"

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 waterhammer in the condensate return line.

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 fig 9.

4. Connect the operating medium (steam, air or gas) supply 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 trap / drain discharge should be piped into the
receiver ahead of the pump for steam systems. For increased service life operate the pump with motive pressures of 15 to 20 psig
above the pump back pressure, while ensuring the maximum required pump capacity is still achieved.

Note:When available motive pressure exceeds 200 psig, a Spirax Sarco pressure reducing valve 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
pump cover or 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 Figure 2.

Installation — Closed Loop Systems (Figs. 3 & 4)

A closed-loop installation is one in which the exhaust line of the pump is piped back (pressure equalized) to the reservoir being drained.

Caution:Before installation or any maintenance is performed, ensure that all steam, condensate, air or gas lines are closed to prevent personnel
injury.

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 Fig. 3. For other
filling head variations, see Capacity Table on TIS 5.202.

Recommended Maximum Filling Head: 48" Standard Filling Head: 12" Minimum Filling Head:
2" x 2" & 3" x 2" PTC/PTF 2" x 2" & 3" x 2" PTC/PTF 3" x 2" = -1" PTC/PTF
2" x 2" = -3" PTC/PTF
Limiting Operating Conditions
Filling Head Requirements Filling Head Filling Height
Above Pump Cover From base of Pump
Standard recommended PTC 12" (305mm) 36.9" (951mm)
PTF 12" (305mm) 44.1" (1120mm)
Max filling head PTC 48" (1219mm) 72.9" (1852mm)
PTF 48" (1219mm) 80.1" (2035mm)
Min filling head PTC 2x2 -3" (-76mm) 21.9" (556mm)
PTC 3x2 -1" (-25mm) 23.9" (607mm)
PTF 2x2 -3" (-76mm) 29.1" (739mm)
PTF 3x2 -1" (-25mm) 31.1" (790mm)
Max Number of Cycles per minute = 6
Specific gravity of pumped liquid options = 0.9 to 1.0 0.8 to 0.89 0.65 to 0.79

2. To prevent equipment flooding during the pump discharge stroke, a reservoir pipe should be installed in a horizontal plane ahead of the pump
as shown in Fig. 3. For proper reservoir sizing, refer to “Inlet Reservoir Piping” table 2 shown on this page. All inlet line fittings must be fully
ported. If desired, overflow piping can be installed using a properly sized float and thermostatic trap. The trap inlet should be located at the
maximum allowable water level, at or near the top of the reservoir, and it should discharge to a suitable drain.

3. For best performance, horizontal piping 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 waterhammer in the condensate return line.

Note: To achieve rated capacity, and maintain the pumps warranty, pump must be installed with check valves as supplied by Spirax Sarco, Inc.

4. Connect the operating medium (steam only) supply to the motive supply inlet in the cover. Supply main should have a strainer and steam trap
installed upstream of the supply inlet. The steam trap discharge should be piped to the downstream piping (Non-flooded).

Note:When available motive pressure exceeds 200 psig, a Spirax Sarco pressure reducing valve 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 backpressure and achieve desired capacity. A safety relief valve should be installed at the
connection provided in the pump cover or in the motive steam supply piping.

5. Exhaust line must be piped, unrestricted, to the top of the reservoir in order to equalize all pressures and ensure condensate drains by gravity.
On vacuum systems the exhaust line may be connected to the steam space being drained. A thermostatic air vent should be installed at the
highest point of the exhaust line to vent all non-condensibles during start-up. Any horizontal runs in the exhaust line should be pitched so that
the line is self-draining.

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 4.

Inlet Reservoir Piping

To drain condensate from a single piece of equipment in a “closed system”, a reservoir should be installed in a horizontal plane ahead of the pump.
Sufficient reservoir volume is needed above the filling head level to accept condensate reaching the pump during the discharge stroke. The chart below
shows minimum reservoir sizing, based on condensate load, needed to prevent equipment flooding during the pump discharge stroke. The reservoir can
be a length of large diameter pipe or a tankshown in Table 2.

Pump Size—up to 3" x 2"

Liquid Pipe Size

Lb. per Hr. 1-1/2" 2" 3" 4" 6"
500 or less 2'
1000 3' 2'
1500 5' 3'
2000 6' 4' 2'
3000 6' 3'
4000 8' 3.5' 2'
5000 10' 4.5' 2.5'
6000 5.5' 3'
7000 6' 3.5'
8000 7' 4'
9000 8' 4.5' 2'
10,000 9' 5' 2.2'
11,000 10' 5.5' 2.4'
Table 2
 P1

Return Line
Balanced
Pressure
Thermostatic
Air Vent
Pilot Operated
Temperature 1/2" HP Steam
Control Valve Supply

Heat Exchanger

Reservoir

Draining L.P. Heat Exchanger to Filling

Overhead Return. Pressure at PP Head Spira-tec
Pump outlet P2 exceeds pressure Steam Trap
of supply to Heat Exchanger P1. Loss Detector

Figure 3 P2 Thermo-Dynamic®
Trap

P1

Steam Balanced
Wye Strainer Supply Pressure
Thermostatic
Air Vent
Pilot Operated
Temperature Control Valve

Flow
Temperature Heater
Control Sensor
Return
Centrifugal
Pump
Reservoir Pipe

Draining L.P. Heat Exchanger to Steam

Overhead Return. Pressure at PP Pump Supply
outlet P2 does not exceed pressure of
supply to Heat Exchanger P1.
P2

Figure 4
Float & Thermostatic
Steam Trap

Installation—Multiple Pressure Powered Pumps™

To ensure even wear and extended service life of each of the pumps in a multiple pump set the pumps should not be staged so that a primary
pump operates continuously and the secondary pump seldom operates. Each pump should be piped to ensure even operation of each pump.
When piping multiple pumps into a single return line an additional check valve should be fitted in the single return line to reduce the likelihood of
waterhammer in the return line due to high flowrates and velocities induced during multiple pump discharge cycles.

Startup Procedure (All Hookups)

1. Slowly open supply (steam, air or gas) to provide pressure at the PP Pump inlet valve. Check that trap/drainer on motive line is operational.
2. Open gate valves in the PP Pump inlet and discharge lines.
3. Open valve(s) ahead of unit allowing condensate to enter the receiver/reservoir and fill the PP Pump body. Pump will discharge when full.
4. Observe operation for any abnormalities. PP Pump(s) should cycle periodically with an audible exhaust at the end of the pumping cycle. If any
irregularities are observed, recheck installation instructions for proper hookup. Consult factory if necessary.
5. If overflow piping has been provided, check that a water seal has been established to prevent any steam from being vented during normal
operation. Prime overflow piping if necessary.

6
Maintenance: Inspection & Replacement.
CAUTION:
Before removing the cover and mechanism assembly, be sure the pump is completely isolated and relieved of any internal pressure to prevent
personal injury. Motive supply, exhaust / tie-back, condensate inlet and discharge lines should all be closed prior to performing any work on the
pump. Also ensure any hot parts have cooled to prevent risk of injury from burns. Use caution when removing cover and gasket. Gasket contains
thin stainless steel reinforcement that may cause cuts to the skin. Care should be taken to prevent personal injury from the strong snapping action.
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.
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.
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 diagram A.
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 diagram B. 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 positon.
The cover must be orientated so the “V” cast in to the pump cover lines up with the body casting “part line” as indicated in diagrams C & D.
4. Assemble cover bolts and torque to 46-50 ft/lbs in a cross pattern as shown in diagram E.

A B C

Figure 5B

Casting
Part
Line

Cover 'v' Flange

D Studs Nuts
Gaskets

8
1
Table A
4 5
Check Valve Assembly Instuctions
6 Torque Requirements
3
PTC w/ Stainless Steel Checks 105-115 ft-lbs.
2 7
E (142-156 Nm)
Pressure Powered Pump™ Troubleshooting Checklist
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:
Installation and troubleshooting should be performed by qualified service personnel. Before breaking any connections of the pump or piping system
every effort should be made to assure that internal pressure has been relieved and that the motive supply line is shut off to prevent inadvertent
discharge of the pump. When breaking any connection, piping/bolts should be removed slowly so that if the line is under pressure, this fact will be
apparent before completely removing the pipe or component. Always relieve pressure before breaking any joint.

Symptom Cause Check and Cure

1. Pump fails to operate on startup. 1. a) Motive supply closed. 1. a) Open valve(s) to supply motive
pressure to pump.
b) Condensate inlet line closed. b) Open all valves to allow condensate to reach pump.
c) Condensate discharge line closed. c) Open all valves to allow free discharge from pump
to destination.
d) Motive pressure insufficient to d) Check motive pressure and static backpressure.
overcome backpressure. Adjust motive pressure to 10-15 psi higher than stat-
ic backpressure.
e) Check valves(s) installed in wrong e) Verify proper flow direction and correct, if required.
direction.
f) Pump air-locked. f) On vented system, assure that vent line is unre-
stricted to atmosphere and self-draining to the pump
or receiver. On a closed system, isolate the pump
from the pressurized space being drained. (Exhaust
tie-back line closed.) Break exhaust connection at
pump cover. Keep personnel clear of exhaust con-
nection. If pump begins to cycle, air locking has
occurred. Recheck that exhaust tie-back is in accor-
dance 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. Supply line/equipment flooded, but 2. a) Pump undersized. 2. a) Verify rate capacity per TIS 5.030 capacity table.
pump appears to cycle normally Increase check valve size or install additional pump
(periodic audible exhaust observed). as required.
b) Insufficient filling head. b) Verify required filling head per TIS 5.030. Lower
pump to achieve required filling head.
Remove check valve & visually c) Insufficient motive pressure to c) Check motive pressure setting and maximum back-
inspect, body and plate faces, hinge achieve rated capacity. pressure during operation. Compare to capacity
and spring. table of TIS 5.030. Increase motive pressure as
required to meet load conditions.
d) Restriction in condensate inlet line. d) Verify that fully ported fittings are used. Blowdown the
strainer, if fitted. Check that all valves are fully open.
e) Inlet check valve stuck open e) Isolate inlet check valve and relieve line pressure.
(debris). Clean seating surfaces and reinstall or replace, if
necessary.

3. a) Check motive pressure and static back-pressure (at

3. a) Discharge line closed or blocked. pump discharge). If equal, a closed or blocked dis-
charge line is suspected. Check all valves down-
stream of pump to assure an unobstructed discharge.
b) After checking per 3(a), isolate discharge check
b) Discharge check valve stuck valve and relieve line pressure. Remove check
3. Supply line/equipment flooded, and closed. valve & visually inspect body and plate faces, hinge
pump has stopped cycling (audible and spring. Clean seating surfaces and reinstall or
periodic exhaust not observed). replace, if necessary.
c) Insufficient motive pressure. c) If motive pressure is below static backpressure,
increase motive pressure setting to 10-15 psig
above static backpressure. Do not exceed rated
pressure limits of equipment.
For steps 3(d) through 3(g) on page 7—With
exhaust/tie-back line isolated from the equipment
being drained (close-loop systems), break the
exhaust/tie-back connection at the pump cover
and—
 Symptom Cause Check and Cure
Important Safety Note: d) Motive inlet valve leaking and/or d) Slowly open motive supply line, leaving the conden-
For steps (d) through (g) it is necessary worn. sate inlet and discharge lines closed. Observe the
to break the exhaust/tie-back line at the exhaust connection for steam or air leakage. If leak-
pump exhaust connection. On closed age is observed, an inlet valve problem is indicated.
loop systems, care should be exercised Isolate pump, remove cover and mechanism
to assure that the pump is isolated assembly and visually inspect. Replace inlet valve
(motive supply, condensate inlet and and seat assembly.
discharge, and exhaust/tie-back line all e) Mechanism Faults e) With motive line open, slowly open condensate inlet
closed) and that case pressure is i) Broken spring line to the pump, allowing pump to fill and observe
relieved prior to breaking this connec- ii) Ruptured float exhaust connection. Keep personnel clear of
tion to avoid injury to personnel. Also, exhaust! If condensate runs out exhaust connec-
under fault conditions, it is possible that tion, a mechanism fault is clearly indicated. Isolate
hot condensate may run out of the pump by shutting off motive supply and condensate
exhaust connection when broken for inlet, remove cover and mechanism assembly, and
both closed loop and vented systems. visually inspect. Examine springs and float for obvi-
This possibility should be taken into ous defects. Stroke mechanism and check for any
consideration when performing these source of binding or increased friction. Repair
steps to avoid scalding of personnel or and/or replace all defects observed.
water damage to nearby equipment. f) Exhaust/tie-back causing vapor f) If mechanism is heard to trip and no fluid is observed
lock (vented or closed loop). running out the exhaust connection, slowly open the
discharge line from the pump and observe operation.
Keep personnel clear of exhaust connection! If
pump cycles normally, a fault in the exhaust/tie-back
line is suspected. Recheck the exhaust/tie-back pip-
ing layout for compliance with the installation instruc-
tions. Exhaust/tie-back line must be self-draining to
prevent vapor locking the pump.
g) Inlet check valve stuck closed. g) If mechanism is not heard to trip and fluid is not
observed running from the exhaust connection, it is
suspected that the fault lies in the condensate inlet
piping. Assure that all valves leading to the pump
have been opened. If so, this indicates that the inlet
valve is stuck closed. Isolate the pump and check
valve and relieve line pressure. Visually inspect the
head, seat and stem. Clean seating surfaces and
reinstall or replace, if necessary. Reinstall
exhaust/tie-back connection and open line.

4. Chattering or banging in return main 4. a) Vacuum created at pump outlet 4. a) Install a vacuum breaker at the top of the lift (at high
after pump discharges. after discharge because of acceler- point in return line). For pressurized return systems
ation/deceleration of large water and air eliminator may be required downstream of
slug in return main (usually results the vacuum breaker. (See Fig. 8).
from long horizontal run with multi-
ple rises and drops).
b) Pump “blow-by”. b) Check condensate inlet pressure and static back-
pressure 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 conden-
sate inlet line which would increase inlet line pres-
sure. Replace any faulty traps. On closed loop sys-
tems, if condensate inlet pressure can exceed static
backpressure under normal operation (i.e. boost in
equipment operating pressure via a modulating con-
trol 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 nor-
mally when condensate is present (See Fig. 4)

5. Vent line discharging excessive flash 5. a) Faulty steam traps discharging live 5. a) Check for leaking traps discharging into condensate
steam (vented applications only). steam into condensate inlet line return. Repair or replace faulty traps. (See also 4(b),
(See also 4(b), Pump “Blow-By”). Pump “Blow-By”).
b) Excessive (over 50 lb/hr) flash b) Vent receiver ahead of pump.
steam being vented through pump.
c) Exhaust valve stuck or worn. c) Isolate pump and remove cover and mechanism
assembly. Remove exhaust head and seat assem-
bly. Visually inspect seating surface. Clean and rein-
stall or replace, if worn.
 Other Typical Hook-up Sketches
Float-
Operated
Air Vent The hook-up sketches shown do not necessarily represent recom-
mended arrangements for specific service conditions; but rather
serve only to illustrate the variety of applications where the pres-
sure-powered pump can be utilized. Design requirements for each
application should be evaluated for the best condensate recovery
arrangement tailored to your specific needs.
Reservoir
For use of the pressure powered pump in hook-ups other than
Figure 8 those described previously, and for any additional information you
Pressure Powered Pump may require, contact Spirax Sarco Applications Engineering
Discharging to Long Delivery Line Department, toll free:
(Air Eliminator needed with seal in piping)
1-800-833-3246
Non-Electric
Pressure Powered Pump

†H - Total lift or back pressure is the height (H) in feet x

0.433 plus PSIG in return line, plus downstream piping LP
friction presure drop in PSI calculated at a flow rate of Flash
Steam
the lesser of the 6 times the actual condensate flowrate.
Exhaust Steam
Vented to
LP System

Total Lift
†H
Flash Recovery
Vessel
HP Condensate
& Flash Steam

Thermo-Dynamic Back
Steam Trap Wye Condensate Pressure
Wye
Strainer Strainer Great
Than LP
Flash
Pressure
Non-Electric
Figure 10 Non-Electric
Figure 9 Pressure
Pressure
Powered Pump
Thermo-Dynamic
Powered Pump Steam Trap
Flash Steam Recovery
Pressure Powered Wye at Pressure Above or
Strainer
Pump Draining Water Below Atmospheric
from Sump Pit
15" Swing Check

Steam Wye Vacuum

1" Equalizer Line Strainer Breaker
Supply
Return
Main Air Vent
Self Acting
Temperature
Vacuum Control Arrangement of Small
Space Flow Steam/Liquid Heat Exchanger
Temperature where steam space pressure
Control may fall below back presure.
Sensor
Steam
Supply Heater
Total Lift
H Alternate
P Discharge Return Wye
Filling Head Connection Strainer Float & Thermostatic
Centrifugal Pump Steam Trap
Multiple Loads
Wye Connected to
Strainer Vented Receiver
Spira-tec Steam Trap
Loss Detector
Thermo- Vent
Dynamic Head “H” must be enough to give trap
Steam Trap capacity needed when steam space
Non-Electric pressure falls to zero.
Pressure
Pipe to Drain Powered Pump
Pipe to
Drain
Figure 12
Non-Electric
Pressure
Draining Small Heat Powered Pump
Exchanger and Other Loads
Figure 11 - Draining Condensate from Vacuum Space to Return Main to Pressure Powered Pump

Spirax Sarco Technical Support Department

Toll Free at: 1-800-833-3246

SPIRAX SARCO, INC. • 1150 NORTHPOINT BLVD. • BLYTHEWOOD, SC 29016

PHONE 803-714-2000 • Fax 803-714-2222
www.spiraxsarco.com/us