Spirax Sarco 5800 Series, 5800, 5800Z, 9800, 9800Z Installation And Maintenance Instructions Manual
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3.324.5275.205
EXPER
AINABILITY
Issue 3 - 2014
5800 and 9800 Series Separators
Installation and Maintenance Instructions
The PED Directive 97/23/EC is repealed and replaced by the new
PED Directive 2014/68/EU with effect from 19 July 2016.
1. General safety information
TISE SOLUTIONS SUST
2. General product information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Inspections
8. Spare parts
© Copyright 2014
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ATTENZIONE
Lavorare in sicurezza con apparecchiature
in ghisa e vapore
Working safely with cast iron products on steam
Informazioni di sicurezza supplementari - Additional Informations for safety
Lavorare in sicurezza con prodotti
in ghisa per linee vapore
I prodotti di ghisa sono comunemente presenti
in molti sistemi a vapore.
Se installati correttamente, in accordo alle
migliori pratiche ingegneristiche, sono dispositivi
totalmente sicuri.
Tuttavia la ghisa, a causa delle sue proprietà
meccaniche, è meno malleabile di altri materiali
come la ghisa sferoidale o l’acciaio al carbonio.
Di seguito sono indicate le migliori pratiche
ingegneristiche necessarie per evitare i colpi
d'ariete e garantire condizioni di lavoro sicure
sui sistemi a vapore.
Movimentazione in sicurezza
La ghisa è un materiale fragile: in caso di
caduta accidentale il prodotto in ghisa non è
più utilizzabile. Per informazioni più dettagliate
consultare il manuale d'istruzioni del prodotto.
Rimuovere la targhetta prima di effettuare la
messa in servizio.
Working safely with cast iron
products on steam
Cast iron products are commonly found on steam
and condensate systems.
If installed correctly using good steam
engineering practices, it is perfectly safe.
However, because of its mechanical properties,
it is less forgiving compared to other materials
such as SG iron or carbon steel.
The following are the good engineering practices required to prevent waterhammer and
ensure safe working conditions on a steam
system.
Safe Handling
Cast Iron is a brittle material. If the product is dropped
during installation and there is any risk of damage
the product should not be used unless it is fully
inspected and pressure tested by the manufacturer.
Please remove label before commissioning
Prevenzione dai colpi d’ariete - Prevention of water hammer
Scarico condensa nelle linee vapore - Steam trapping on steam mains:
Vapore
Steam
Intervalli di 30÷50 m. intervals
Pendenza - Gradient 1:100
Gruppo di sca rico
Trap set
Condensa - Condasate
Pendenza - Gradient 1:100
Gruppo di sca rico
Trap set
Condensa - Condasate
Gruppo di sca rico
Condensa - Condasate
Trap set
Vapore
Steam
Esempi di esecuzioni corrette ( ) ed errate ( ) sulle linee vapore:
Steam Mains - Do's and Dont's:
Vapore
Steam
Flusso
Flow
Flusso
Flow
Prevenzione delle sollecitazioni di trazione
Prevention of tensile stressing
Evitare il disallineamento delle tubazioni - Pipe misalignment:
Installazione dei prodotti o loro rimontaggio post-manutenzione:
Installing products or re-assembling after maintenance:
Evitare l’eccessivo serraggio.
Utilizzare le coppie di serraggio
raccomandate.
Do not over tighten.
Use correct torque gures.
Per garantire l’uniformità del carico e dell'allineamento,
i bulloni delle ange devono essere serrati in modo
graduale e in sequenza, come indicato in gura.
Flange bolts should be gradually tightened across
diameters to ensure even load and alignment.
Dilatazioni termiche - Thermal expansion:
Gli esempi mostrano l’uso corretto dei compensatori di dilatzione. Si consiglia di richiedere una
consulenza specialistica ai tecnici dell’azienda che produce i compensatori di dilatazione.
Examples showing the use of expansion bellows. It is highly recommended that expert advise is
sought from the bellows manufacturer.
Guide
Guides
Movimento assiale
Axial movement
movimento
movement
Piccolo
movimento
laterale
Small
lateral
movement
Ampio
laterale
Large
lateral
Movimento assiale
Axial movement
Ampio
movimento
laterale
Large
lateral
movement
Distanza breve
Short distance
Guide
Guides
Distanza
media
Medium
distance
Punto di ssaggio
Fixing point
Tiranti limitatori
Limit rods
Punto di ssaggio
Fixing point
Tiranti limitatori
Limit rods
Guide
Guides
Guide
Guides
movimento
movement
Piccolo
laterale
Small
lateral
1. General safety information
Safe operation of these products can only be guaranteed if they are properly installed, commissio-
ned, used and maintained by qualied 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 European Pressure Equipment Directive 97/23/EC and carry
the mark when so required. The products fall within the following Pressure Equipment Directive
categories:
Product
DN15 - 32 - 1 - SEP
5800
9800
5800/Z
9800/Z
i) The products have been specically designed for use on propane or methane gases which are
in Group 1 of the above mentioned Pressure Equipment Directive. They can also be used on
steam, air or condesate wich are in Group 2 of the Pressure Equipment Directive. The products'
use on other uids may be possible but, if this is contemplated, Spirax Sarco should be contacted
to conrm 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 tted, 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 uid ow.
iv) Spirax Sarco products are not intended to withstand external stresses that may be induced
by any system to which they are tted. 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.
25 bar g
13 bar g
DN40 - 65 - 2 - SEP
DN80 - 125 - 3 - SEP
DN125 - 250 - 4 - SEP
DN65 - 80 - 2 - SEP
DN100 - 150 - 3 - SEP
DN200 - 250 - 4 - SEP
Group 1
Gases
Group 2
Gases
Group 1
Liquids
Group 2
Liquids
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.
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: ammable 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, re hazard (e.g. during welding), excessive noise, moving machinery.
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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.
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 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 section 6 ‘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 Safetyinformation-Productspecic
See the relevant Section in the attached Installation and Maintenance Instructions for specic details
relating to this product.
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 identied as hazardous or potentially hazardous.
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2. General product information
2.1 General description
The products detailed are all bafe type separators used for the removal of entrained liquids in
steam, compressed air and gas systems. We recommend the tting of insulating jackets to improve
the performance of the separator.
Note: For additional information see the following Technical Information Sheets.
Type Material Pressure rating Sizes Connections TI reference
5800 Carbon Steel PN16 and PN40 DN15-DN350 Flanged 3C.400-E
Carbon Steel
9800
Fig. 1
Zinc Plated
PN16 and PN40 DN15-DN250 Flanged 3D.200-E
5800 and 5800Z pressure / temperature limits
Type
5800
5800Z
* ANSI anges are also available on request
9800 and 9800Z pressure / temperature limits
Type
9800
9800Z
* ANSI anges are also available on request
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Size
DN
15-250 EN 1092 PN40* 25 300 37,5
>250 to be specied to be specied on design
65-250 EN 1092 PN16* 13 250 19,5
>250 to be specied to be specied on design
Size
DN
15-250 EN 1092 PN40* 25 300 37,5
>250 to be specied to be specied on design
65-250 EN 1092 PN16* 13 150 19,5
>250 to be specied to be specied on design
Flange
standard
Flange
standard
Design
pressure
bar g
Design
pressure
bar g
Design
temperature
°C
Design
temperature
°C
Designed for a
maximum cold hydraulic
test pressure of
bar g
Designed for a
maximum cold hydraulic
test pressure of
bar g
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3. Installation
Note: Before actioning any installation observe the ‘Safety Information’ in Section 1.
Referring to the Installation and Maintenance Instructions, body 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
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, before installation.
3.4 The separators may be lagged if required.
3.5 Important installation note
Install in a horizontal pipeline with the drain directly below.
Provide suitable support to the system to minimise piping loads.
To ensure that any separated liquid is drained quickly, a suitable liquid drainer or steam trap must
be connected to the drain connection.
For those steam systems where air can be present, air can collect in the upper portion of the separator.
In this situation a suitable air vent should be connected to the air vent connection.
If an air vent is not being tted then the connection must have the plastic transit protection plug
removed and must have a carbon steel class 3000 lb plug tted.
Air vent
Separator
Fig. 2 Separator on a stem or compressed air line feeding a machine
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Isolation valve
Strainer
FT or CA trap
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4. Commissioning
After installation or maintenance, ensure that the system is fully functioning. Carry out tests on any
alarms or protective devices.
Fig. 3 Heat transfer processes and valve protection
Fig. 4 Compressed air distribution
5. Operation
Separators are designed to gather together small droplets of entrained liquids and then separate
them from the gas /vapour ow. The relatively heavy droplets impinge on the internal bafes and
are then directed to the separator drain connection and removed from the system using a steam
trap, or when used on air or gas distribution system, a liquid drainer.
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6. Maintenance
Note: Before actioning any maintenance programme
observe the ‘Safety information’ in Section 1.
Warning
There are no internal components that require maintenance.
Periodically blow-off the discarge line to clean the system and control the regular working of the
automatic draining group.
Fig. 5
7. Inspections
If used at the best operating conditions, these separators are designed to last for more than 10
years, provided that:
1) all the recommendations and requirerments of this document are observed
2) the maximum design conditions on the separetor's nameplate are never exceeded
3) scheduled maintenance is carried out in accordance with the table below
4) Spirax Sarco Service Department is contacted whenever an excess scale is detected during
the 2 yearly inspection as this could cause functional problems with the product
Recommended inspection schedule
Description 1 month 2 years 10 years
Remove any scale
Check for leaks on all connections
Internal/external tank control
Integrity Testing
√
√
√
√
8. Spare parts
There are no spare parts required or available for these components.
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REPAIRS
Please contact our nearest Branch Ofce or Agent, or directrly Spirax Sarco S.r.l.
Via per Cinisello 18 - 20834 Nova Milanese (MB) - Tel. +39 0362 49 17.1 - Fax. +39 0362.49 17 307
LOSS OF WARRANTY
Total or partial disregard of above instructions involves loss of any right to guarantee.
Spirax-Sarco S.r.l. - Via per Cinisello, 18 - 20834 Nova Milanese (MB) - Tel.: 0362 49 17.1 - Fax: 0362 49 17 307
3.324.5275.205 Issue 3 - 2014.01
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