Spirax Sarco 600 Series Manual de usuario

IIM-P067-06 CMGT Issue 4 1

1. Safety information

2. General product information

3. Installation

4. Commissioning

5. Operation

6. Maintenance

7. Spare parts

Printed in GB

0677450/4

600 and 900 Series

Inverted Bucket Steam Traps

Installation and Maintenance Instructions

IM-P067-06

CMGT Issue 4

IIM-P067-06 CMGT Issue 4

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1. Safety information

Safe operation of these products can only be guaranteed if they are properly installed,

commissioned, used and maintained by qualified personnel (see Section 1.11 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.

1.1 Intended use

Referring to the Installation and Maintenance Instructions, name-plate and Technical Information

Sheet, check that the product is suitable for the intended use/application.

The products listed below comply with the requirements of the Pressure Equipment Directive (PED)

and carry the mark when so required.

The products fall within the following Pressure Equipment Directive categories:

Product Group 2

Gases

Group 2

Liquids

621, 622, 623 and 624 DN15 - 40 1 SEP

626 DN50 2 SEP

921 and 922 DN15 - 20 1 SEP

923, 925 and 926 DN25 - 50 2 SEP

i) The products have been specifically designed for use on steam, air or water/condensate

which are in Group 2 of the above mentioned Pressure Equipment Directive. The products’ use

on other fluids may be possible but, if this is contemplated, Spirax Sarco should be contacted

to confirm the suitability of the product for the application being considered.

ii) Check material suitability, pressure and temperature and their maximum and minimum values.

If the maximum operating limits of the product are lower than those of the system in which it

is being fitted, or if malfunction of the product could result in a dangerous overpressure or

overtemperature occurrence, ensure a safety device is included in the system to prevent such

over-limit situations.

iii) Determine the correct installation situation and direction of fluid flow.

iv) Spirax Sarco products are not intended to withstand external stresses that may be induced

by any system to which they are fitted. It is the responsibility of the installer to consider these

stresses and take adequate precautions to minimise them.

v) Remove protection covers from all connections before installation.

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

Ensure adequate lighting, particularly where detailed or intricate work is required.

IIM-P067-06 CMGT Issue 4 3

1.4 Hazardous liquids or gases in the pipeline

Consider what is in the pipeline or what may have been in the pipeline at some previous time.

Consider: flammable materials, substances hazardous to health, extremes of temperature.

1.5 Hazardous environment around the product

Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of

temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.

1.6 The system

Consider the effect on the complete system of the work proposed. Will any proposed action (e.g.

closing isolation valves, electrical isolation) put any other part of the system or any personnel

at risk?

Dangers might include isolation of vents or protective devices or the rendering ineffective of

controls or alarms. Ensure isolation valves are turned on and off in a gradual way to avoid system

shocks.

1.7 Pressure systems

Ensure that any pressure is isolated and safely vented to atmospheric pressure.

Consider double isolation (double block and bleed) and the locking or labelling of closed valves.

Do not assume that the system has depressurised even when the pressure gauge indicates zero.

1.8 Temperature

Allow time for temperature to normalise after isolation to avoid danger of burns.

1.9 Tools and consumables

Before starting work ensure that you have suitable tools and/or consumables available. Use only

genuine Spirax Sarco replacement parts.

1.10 Protective clothing

Consider whether you and/or others in the vicinity require any protective clothing to protect

against the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling

objects, and dangers to eyes and face.

1.11 Permits to work

All work must be carried out or be supervised by a suitably competent person.

Installation and operating personnel should be trained in the correct use of the product according

to the Installation and Maintenance Instructions.

Where a formal 'permit to work' system is in force it must be complied with. Where there is no

such system, it is recommended that a responsible person should know what work is going on

and, where necessary, arrange to have an assistant whose primary responsibility is safety.

Post 'warning notices' if necessary.

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.

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1.13 Residual hazards

In normal use the external surface of the product may be very hot. If used at the maximum

permitted operating conditions the surface temperature of some products may reach temperatures

in excess of 300 °C (572 °F).

Many products are not self-draining. Take due care when dismantling or removing the product

from an installation (refer to 'Maintenance instructions').

1.14 Freezing

Provision must be made to protect products which are not self-draining against frost damage in

environments where they may be exposed to temperatures below freezing point.

1.15 Safety information - Product specific

See relevent Sections of the attached Installation and Maintenance Instructions for specific

details relating to these products.

1.16 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.

1.17 Returning products

Customers and stockists are reminded that under EC Health, Safety and Environment Law, when

returning products to Spirax Sarco they must provide information on any hazards and the

precautions to be taken due to contamination residues or mechanical damage which 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.

IIM-P067-06 CMGT Issue 4 5

2. General product information

2.1 Description

The Spirax Sarco 600 and 900 series alloy steel inverted bucket steam traps are designed for installation

in vertical pipework between anges. They are suitable for a wide range of pressures and applications and

include an integral check valve on the inlet.

Certification

The product is available with material certication to EN 10204 3.1.B as standard.

Certication must be specied at the time of order placement.

2.2 Sizes and pipe connections

600 series

DN15 - 621, DN20 - 622, DN25 - 623, DN40 - 625 and DN50 - 626

In all sizes the body and cover forgings form the inlet and outlet anges.

The drilled holes in both inlet and outlet anges are tapped to receive bolts.

ASME anges are tapped UNC. BS 4504 and DIN anges are tapped metric.

Flanges meet the requirements of ASME 150, 300 and 600, BS 4504 and DIN PN25 and PN40.

BS 10 anges can be supplied on request.

900 series

DN15 - 921, DN20 - 922, DN25 - 923, DN40 - 925 and DN50 - 926.

In all sizes the body and cover forgings form the inlet and outlet anges.

The drilled holes in both inlet and outlet anges are tapped to receive bolts.

ASME anges are tapped UNC. BS 4504 and DIN anges are tapped metric.

Flanges meet the requirements of ASME 600 or PN64. BS 10 anges can be supplied on request.

Fig. 1

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2.3 600 series

Limiting conditions (ISO 6552)

Maximum body design conditions Exceeds PN40

PMA Maximum allowable pressure 41 bar g @ 250 °C (595 psi g @ 482 °F)

TMA Maximum allowable temperature 400 °C @ 29 bar g (752 °F @ 420 psi g)

Designed for a maximum cold hydraulic test pressure of: 62 bar g (900 psi g)

DPMX - Maximum differential pressure

Size

DPMX - Maximum differential pressure bar (psi)

8.5 (123.3) 17 (246.5) 31 (449.6) 41 (594.6)

DN15 621/12 621/10 621/8 621/7

DN20 622/12 622/10 622/8 622/7

DN25 623/16 623/12 623/10 623/8

DN40 625/22 625/18 625/14 625/12

DN50 626/32 626/24 626/20 626/18

Note: The pressure limit on the ange specied should be greater than the pressure limit of the internal

mechanism. The table below offers guidance

Flange Pressure (at saturation) Mechanism available

ASME 150 13.8 bar g (200.1 psi g) 8.5 bar (123.3 psi)

ASME 300 42.0 bar g (609.0 psi g) all versions

ASME 600 84.0 bar g (1 218.3 psi g) all versions

PN25 25.0 bar g (362.5 psi g) 8.5, 17 bar (123.3, 246.5 psi)

PN40 40.0 bar g (580.0 psi g) 8.5, 17, 31 bar (123.3, 246.5, 449.6 psi)

IIM-P067-06 CMGT Issue 4 7

Dimensions/weights approximate in mm (ins) and kg (lb)

Size A B C D E Weight

DN15

½"

270 185 203 121 28 18 .1

(10.63) ( 7. 2 8) ( 7. 9 9) (4.76) (1.10) (39.91)

DN20

¾"

270 185 203 121 28 18 .1

(10.63) ( 7. 2 8) ( 7. 9 9) (4.76) (1.10) (39.91)

DN25

310 203 229 130 36 29.5

(12.20) ( 7.9 9) (9.02) (5.11) (1.41) (65.04)

DN40

1½"

410 248 305 168 45 50.0

(16.14) (9.76) (12.00) (6.61) (1.77) (110. 23)

DN50

452 301 330 213 52 79.4

(17.79) (11.8 5) (12.99) (8.38) (2.04) (175.07)

Fig. 2

C Withdrawal distance

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2.4 900 series

Limiting conditions (ISO 6552)

Maximum body design conditions Exceeds PN63

PMA Maximum allowable pressure 62 bar g @ 260 °C (900 psi g @ 500 °F)

TMA Maximum allowable temperature 400 °C @ 49 bar g (752 °F @ 710 psi g)

Designed for a maximum cold hydraulic test pressure of: 93 bar g (1 348 psi g)

DPMX - Maximum differential pressure

Size

DPMX - Maximum differential pressure bar (psi)

48 (696) 62 (899)

DN15 - 921/8

DN20 - 922/8

DN25 923/12 923/10

DN40 925/12 925/10

DN50 926/18 926/16

Note: The pressure limit on the ange specied should be greater than the pressure limit of the internal

mechanism. The table below offers guidance

Flange Pressure (at saturation) Mechanism available

ASME 600 84 bar g (1 218 psi g) all versions

PN40 60 bar g (870 psi g) 48 bar (696 psi)

PN64 64 bar g (928 psi g) 48 bar (696 psi)

IIM-P067-06 CMGT Issue 4 9

Dimensions/weights approximate in mm (ins) and kg (lb)

Size A B C D E Weight

DN15

½"

310 203 229 130 36 29.5

(12.20) ( 7.9 9) (9.02) (5.11) (1.41) (65.04)

DN20

¾"

310 203 229 130 36 29.5

(12.20) ( 7.9 9) (9.02) (5.11) (1.41) (65.04)

DN25

410 248 305 168 45 50.0

(16.14) (9.76) (12.00) (6.61) (1.77) (110. 23)

DN40

1½"

410 248 305 168 45 50.0

(16.14) (9.76) (12.00) (6.61) (1.77) (110. 23)

DN50

452 301 330 213 52 79.4

(17.79) (11.8 5) (12.99) (8.38) (2.04) (175.07)

Fig. 3

C Withdrawal distance

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Note: Before actioning any installation observe the 'Safety information' in Section 1.

Referring to the installation and maintenance instructions, name-plate and Technical Information Sheet,

check that the product is suitable for the intended installation:

3.1 Check materials, pressure and temperature and their maximum values. If the maximum operating

limit of the product is lower than that of the system in which it is being tted, ensure that a safety

device is included in the system to prevent overpressurisation.

3.2 Determine the correct installation situation and the direction of uid ow.

3.3 Remove protective covers from all connections.

3.4 The trap must be installed with the body upright so that the bucket is rising and falling vertically.

The inlet should be at the bottom with the trap installed below the drain point so that a water seal

can be maintained around the open end of the bucket. When superheat conditions exist the trap

body may need to be primed with water prior to steam being turned on to avoid steam blowing

through the trap.

Inve r te d bu cket ste am t ra ps d o no t pe rmit ra pi d re le ase of a ir. O n p ro ce ss ap pl ic at io ns, in p ar t ic ular,

this can lead to slow warm-up times and waterlogging of the steam space. A separate external air

vent is therefore required in parallel to vent air efciently. Any bypass should be positioned above

the trap. If it is below, and is leaking or left open, the waterseal could be blown away leading to

steam wastage. Where inverted bucket traps are tted in exposed conditions the possibility of

freezing damage can be reduced by thermal insulation.

3.5 Open the isolation valves slowly until the normal operating conditions are achieved.

3.6 Check for leaks and correct operation.

Note: If the trap is to discharge to atmosphere ensure it is to a safe place, the discharging uid may be at a

temperature of 100 °C (212 °F).

3. Installation

After installation or maintenance ensure that the system is fully functioning. Carry out tests on any alarms

or protective devices.

4. Commissioning

Under most conditions the trap will discharge condensate with a 'blast' type action. Under low load and/or

low pressure applications the discharge may tend to 'dribble'.

Condensate is discharged at steam temperature so due care must be given to the site of the discharge.

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