The TLV HR260A is a PowerDyne thermodynamic disc trap designed for supercritical service in high-pressure steam mains and turbines. It features an air-jacketed design that reduces radiant heat loss, minimizing no-load cycling and extending the service life of the trap. The HR260A is capable of handling a maximum operating pressure of 260 barg (26 MPaG) and a maximum operating temperature of 550 °C, making it suitable for demanding power plant applications worldwide.

Features

1. Inline replaceable valve module for ease of maintenance and low cost of repair.
2. Lapped disc provides a steam-tight seal.
3. Air jacket reduces radiant heat loss to reduce no-load cycling and so extend life.
4. Built-in screen with a large surface area for extended trouble-free operation.
5. Hardened working surfaces guarantee long service life.
6. Approved by major power plants worldwide for supercritical steam use.

Safety Considerations

DANGER

Indicates an urgent situation that poses a threat of death or serious injury.

WARNING

Indicates that there is a potential threat of death or serious injury.

• Install properly and DO NOT use this product outside the recommended operating pressure, temperature, and other specification ranges. Improper use may result in such hazards as damage to the product or malfunctions, which may lead to serious accidents.
• Do not subject the trap to condensate loads that exceed its discharge capacity. Failure to observe this precaution may lead to condensate accumulation upstream of the trap, resulting in reduced equipment performance or damage to the equipment.
• Use hoisting equipment for heavy objects (weighing approximately 20 kg or more). Failure to do so may result in back strain or other injury if the object should fall.
• Take measures to prevent people from coming into direct contact with product outlets. Failure to do so may result in burns or other injury from the discharge of fluids.

CAUTION

Indicates that there is a possibility of injury, or equipment/product damage.

• When disassembling or removing the product, wait until the internal pressure equals atmospheric pressure and the surface of the product has cooled to room temperature. Disassembling or removing the product when it is hot or under pressure may lead to discharge of fluids, causing burns, other injuries or damage.
• Be sure to use only the recommended components when repairing the product, and NEVER attempt to modify the product in any way.
• Use only under conditions in which no freeze-up will occur.
• Use under conditions in which no water hammer will occur. The impact of water hammer may damage the product, leading to fluid discharge.

Configuration

No.	Description	Material	DIN*	ASTM/AISI*
1	Body	Alloy Steel A182 F22 Cl.3 / Alloy Steel (9%Cr - 1%Mo)	1.7380 / 1.4903	- / -
2	Cover	Stainless Steel SUS420J2	1.4031	AISI420
3	Module Valve Seat	Stainless Steel SUS440C	1.4125	AISI440C
4	Disc	Stainless Steel SUS440C	1.4125	AISI440C
5	Eye Nut	Carbon Steel SS400	1.0037	A6
6	Spacer	Carbon Steel SS400	1.0037	A6
7	Module Gasket	Graphite/Stainl. Stl. SUS309S+Cb	-/1.4833	-/AISI309S+Cb
8	Module Gasket	Graphite/Stainl. Stl. SUS309S+Cb	-/1.4833	-/AISI309S+Cb
9	Screen inside/outside	Stainless Steel SUS430/304	1.4016/4301	AISI430/304
10	Body Bolt	Alloy Steel SNB16	1.7711	A193 Gr.B16
11	Cover Nut	Alloy Steel SNB7	1.7225	A193 Gr.B7
12	Cap	Carbon Steel SPCC	1.0330	A109
13	Guide Pin	Stainless Steel SUS304	1.4301	AISI304
14	Nameplate	Stainless Steel SUS304	1.4301	AISI304
15	Hexagon Nut	Carbon Steel SS400	1.0037	A6

(M) maintenance parts, (R) repair parts available in replacement kits.

Dimensions

HR260A Socket Welded

DN	L (mm)	H (mm)	H1 (mm)	φD (mm)	φC (mm)	h (mm)	Weight (kg)
15	160	208	179	53.5	21.8	14	18
20	160	208	179	53.5	27.7	14	18
25	160	208	179	53.5	33.9	14	18

ASME B16.11-2005, other standards available. DN 20 dimensions based on regional specifications.

HR260A Butt Welded

DN	L (mm)	H (mm)	H1 (mm)	φD (mm)	φD1 (mm)	φd (mm)	h (mm)	Weight (kg)
15	165	208	179	28	22	16	20	18
25	165	208	179	40	35	27	20	18

DIN 3239 Form C (PN250), other standards available.

Discharge Capacity

1. Differential pressure is the difference between the inlet and outlet pressure of the trap.
2. Recommended safety factor: at least 2.

Proper Installation

1. The trap can be installed either horizontally or vertically, but make sure the arrow on the trap points in the direction of flow.
2. Before installation, be sure to remove all protective seals.
3. Before installing the trap, blow out the inlet piping to remove all dirt and oil.
4. Install the trap in the lowest part of the pipeline or equipment so the condensate flows naturally into the trap by gravity. The inlet pipe should be as short and have as few bends as possible.
5. Support the pipes properly within 800 mm (2.5 ft) on either side of the trap.
6. Install a bypass valve to discharge condensate, and inlet and outlet valves to isolate the trap in the event of trap failure or maintenance.
7. Install a check valve at the trap outlet whenever more than one trap is connected to the condensate collection pipeline.
8. In order to avoid excessive back pressure, make sure the discharge pipes are large enough; (the outlet back pressure allowance should be no more than 50% of the inlet steam pressure).
9. We recommend unions to facilitate connection and disconnection of screwed models.

Piping Arrangement

Check to make sure that the pipes connected to the trap have been installed properly.

1. Is the pipe diameter suitable?
2. Has sufficient space been secured for maintenance?
3. Have maintenance valves been installed at inlet and outlet? If the outlet is subject to back pressure, has a check valve been installed?
4. Is the inlet pipe as short as possible, with as few bends as possible, and installed so that the condensate will flow naturally down into the trap?
5. Has the piping work been done properly as shown in the table below?

Requirement	Incorrect Condition
Install a catchpot with the proper diameter.	Diameter is too small.
Make sure the flow of condensate is not obstructed.	Diameter is too small and inlet protrudes into pipe.
To prevent rust and scale from flowing into the trap, connect the inlet pipe 25 - 50 mm (1 - 2 in) above the base of the T-pipe.	Rust and scale flow into the trap with the condensate.
When installing on the blind end, make sure nothing obstructs the flow of condensate.	Condensate collects in the pipe.

Start-up Procedure

IMPORTANT START-UP PROCEDURE

To ensure proper operation, slowly open the inlet valve slightly. Initially OPEN THE VALVE ONLY 1/32 TURN in order to supply steam to the trap very slowly, then WAIT FOR AT LEAST 30 SECONDS for air to vent before fully opening the inlet valve.

Operational Check

A visual inspection can be carried out to aid in determining the necessity for immediate maintenance or repair, if the trap is open to atmosphere. If the trap does not discharge to atmosphere, use diagnostic equipment such as TLV TrapMan (within its pressure and temperature measuring range).

Status	Description
Normal	Condensate is discharged in a short blast followed by a longer period of no drainage. During the discharge, flash steam may be seen. A small amount of flash steam may be visible after the discharge.
Blocked	No condensate is discharged. The trap is quiet and makes no noise. The surface temperature of the trap is low.
Blowing	Live steam continually flows from the outlet, and there is a continuous metallic sound.
Steam Leakage	Live steam is discharged through the trap outlet together with condensate, accompanied by a high-pitched sound.
Chattering	The trap does not close properly. Steam is discharged from the trap in short rapid bursts.

(When conducting a visual inspection, flash steam is sometimes mistaken for steam leakage. For this reason, the use of a steam trap diagnostic instrument is highly recommended.)

Inspection and Maintenance

Operational inspections should be performed at least twice per year, or as called for by trap operating conditions. Steam trap failure may result in temperature drop in the equipment, poor product quality or losses due to steam leakage.

WARNING

Before attempting to open the trap, close the inlet and outlet isolating valves and wait until the trap has cooled completely. Failure to do so may result in burns.

Parts Inspection Procedure

Part	Inspection Item
Sealing surfaces	Check for damage or dirt on the sealing surfaces
Screen	Check for clogging or corrosion damage
Disc	Check for wear and damage, scratches, on the surface where it contacts the valve seat, and dirt or oil film
Module valve seat	Check discharge channel and grooves for rust and scale inside
Body, Cover	Check inside for erosion, dirt, grease, rust or scale

Disassembly/Reassembly

Part	Disassembly	Reassembly
Cap / Eye Nut	Remove the eye nut and then the cap.	Adjust length of spacer, if necessary.
Cover nut / Cover	Use a socket wrench to remove nuts at diagonal positions sequentially. Apply liquid penetrant for at least 5 minutes to loosen the nuts, if necessary. Lift up and remove cover.	Tighten nuts at diagonal position sequentially after having applied antiseize to the threads. It is recommended to use new nuts for the assembly. Tighten to the proper torque.
Module gasket (large)	Remove the gasket and clean the sealing surfaces.	Replace with a new gasket even if no damage can be seen.
Disc	Remove, being careful not to scratch the lapped surface.	Make sure that the seat surface (the lapped side with groove) is facing down, toward the valve seat.
Module valve seat and Guide pin	Remove from the body.	Insert the guide pin into the hole in the body and make sure it fits properly into the respective hole of the module valve seat.
Module gasket (small)	Remove the gasket and clean the sealing surfaces.	Replace with a new gasket even if no damage can be seen.
Screen	Be careful not to bend the screen.	Be careful not to bend the screen.

Tightening Torque

Part	Torque N·m (lb-ft)	Distance Across Flats (mm)
Cover nut HR260A	280 (205)	27 (1 1/16 in)

Troubleshooting

If the expected performance is unachievable after installation of the trap, check the following points for appropriate corrective measures.

Problem	Cause	Remedy
No condensate is discharged (blocked) or discharge is poor	Screen is clogged with rust or scale	Clean
	Disc is sticking to valve seat (due to oil, etc.)	Clean
	Steam-locking has occurred	Perform a bypass blow-down, or close the trap inlet valve and allow the trap to cool. Piping correction may also be required.
	Trap capacity is insufficient	Change to trap of suitable capacity
	Differential pressure is low	Study inlet/outlet pressure, including rise in outlet pipe
Steam leakage or blowing (from valve seat)	Valve closure is obstructed by scale, etc.	Clean or replace screen
	Disc or valve seat is worn	Replace worn parts
	Back pressure exceeds allowable value	Use within pressure range
	Trap is being used below minimum operating pressure	Use within pressure range
	Disc is sticking to top of cover (due to oil, etc.)	Clean
Valve chattering (Leakage)	Foreign matter or oil film on disc or valve seat	Clean
	Scratches on disc or valve seat	Replace disc or module valve seat
	Disc or valve seat is worn	Replace disc or module valve seat
Leakage from a location other than valve seat	Bypass valve is damaged or open	Replace or close bypass valve
	Cover is loose or module gaskets are damaged	Tighten cover or replace module gaskets