Spirax Sarco 600 Series, 900 Series, 621, 622, 623 Installation And Maintenance Instructions Manual
...
06 7745 0 /4
IM-P067-06
CMGT Issue 4
600 and 900 Series
Inverted Bucket Steam Traps
Installation and Maintenance Instructions
1. Safety information
IIM-P067-06 CMGT Issue 4
2. General product information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
© Copyright 2018
Printed in GB
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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 construct ion, as well as t he proper use of tools and safety equipm ent 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 car ry the mark when so required.
The products fall within the following Pressure Equipment Directive categories:
Pro du ct Group 2
Gases
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 speci fically designed for use on steam, air o r water/condensate
which are in Group 2 of the above mentioned Pressure Equipment Directive. The produc ts’ use
on other fluids may be possible but, if this is contemplated, Spirax Sarco should be contacted
to conf irm 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 t he product could result in a dangerous overpressure or
overtemperature occurrence, ensure a saf ety device is included in the system to prevent such
over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spira x Sarco products are not intended to withstand external stresses that may be induced
by any system to which they are fitted. It is the responsibilit y of the installer to c onsider these
stresses and take adequate precautions to minimise them.
v) Remove protection covers from all connections before installation.
Group 2
Liquids
1.2 Access
Ensure safe access and if necessa ry a safe working platform (suitably guarded) before attempting
to work on the product. Arrange suitable lifting gear i f required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
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1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipelin e 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, pit s), 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 wor k proposed. Will any proposed act ion (e.g.
closing isolation valves, electrical isolation) put any ot her part of t he 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 lab elling 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 star ting 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
objec ts, and dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be sup ervised by a suitably competent person.
Installation and operating personnel should be t rained in the correct use of the product according
to the Installation and Maintenance Instructions.
Where a formal 'per mit to work' system is in force it must b e complied with. Where there is no
such syst em, it is recommended that a resp onsible person should know what work is going on
and, where necessary, arrange to have an assistant whose primar y responsibilit y is safety.
Post 'warning notices' if necessary.
1.12 Handling
Manual handling of la rge and/or heavy products may present a risk of injur y. Lift ing, pushing,
pulling, car rying or suppor ting a load by bodily force can cause injur y par ticularly to the back.
You are advised to assess the risks taking into account the task, the individual, the load and t he
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 t he product may be ver y 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 pro duct s 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 b e made to protect products which are not self- draining against frost damag e 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 Inst allation 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
Custom ers and stockists are reminded that under EC Health, Safety and Environment L aw, when
returning products to Spirax Sarco they must provid e information on any hazards and the
precautions to be taken due to contamination residues or mechanical damage which may present
a healt h, safety or environmental risk. This information must b e provided in writing including
Health and Safety data sheets relating to any substances identifi ed as ha zardous or potentially
hazardous.
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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 cer tication to EN 10204 3.1.B as standard.
Certication must be specied 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 ASM E 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 ASM E 600 or PN 64. 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
DPMX - Maximum differential pressure bar (psi)
Size
DN15 621/12 621/10 621/8 621/7
DN20 622/12 622/10 62 2/ 8 622/7
DN25 623 /16 623/12 623 /10 623/8
DN40 625/ 22 625/18 6 25/14 625/12
DN50 626/32 626/24 626/2 0 626 /18
Note: The pressure limit on the ange specied should be greater than the pressure limit of the internal
mechanism. The table below offers guidance
Fla ng e Pressure (at saturation) Mechanism available
ASM E 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 (58 0.0 psi g) 8.5, 17, 31 bar (123.3, 246.5, 449.6 psi)
8.5 (12 3. 3) 17 (246.5) 31 (449.6) 41 (594.6)
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Dimensions/weights app roximate in mm (ins) and kg (lb)
Size A B C D E Weight
DN15
½"
DN20
¾"
DN25
1"
DN40
1½"
DN50
2"
270 18 5 203 121 28 18 .1
(10. 63) (7. 2 8) (7.9 9) (4.76) (1.10) ( 39. 91)
270 18 5 203 121 28 18 .1
(10. 63) (7. 2 8) (7.9 9) (4.76) (1.10) ( 39. 91)
310 20 3 22 9 130 3 6 29.5
(12. 20) (7.9 9) (9.02) (5 .11) (1. 41) (6 5. 04)
410 248 3 05 16 8 45 50.0
(16 .1 4) (9.76) (12.00) (6. 61) (1.77 ) (110 . 2 3)
452 3 01 330 213 52 79.4
(17. 7 9 ) (11. 8 5 ) (12. 9 9) (8.3 8) (2.04) (175.07)
Fig. 2
E
A
D
B
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
DPMX - Maximum differential pressure bar (psi)
Size
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 specied should be greater than the pressure limit of the internal
mechanism. The table below offers guidance
Fla ng e Pressure (at saturation) Mechanism available
ASME 600 84 bar g (1 218 psi g) all versions
PN4 0 60 bar g (870 psi g) 48 bar (696 psi)
PN6 4 64 bar g (928 psi g) 48 bar (696 psi)
48 (6 96) 62 (899)
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Dimensions/weights app roximate in mm (ins) and kg (lb)
Size A B C D E Weight
DN15
½"
DN20
¾"
DN25
1"
DN40
1½"
DN50
2"
310 20 3 22 9 130 3 6 29.5
(12. 20) (7.9 9) (9.02) (5 .11) (1. 41) (6 5. 04)
310 20 3 22 9 130 3 6 29.5
(12. 20) (7.9 9) (9.02) (5 .11) (1. 41) (6 5. 04)
410 248 3 05 16 8 45 50.0
(16 .1 4) (9.76) (12.00) (6. 61) (1.77 ) (110 . 2 3)
410 248 3 05 16 8 45 50.0
(16 .1 4) (9.76) (12.00) (6. 61) (1.77 ) (110 . 2 3)
452 3 01 330 213 52 79.4
(17. 7 9 ) (11. 8 5 ) (12. 9 9) (8.3 8) (2.04) (175.07)
Fig. 3
E
A
D
B
C Withdrawal distance
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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, name-plate and Technical Information Sheet,
check that the product is suitable for the intended installation:
Check materials, pressure and temperature and their maximum values. If the maximum operating
3.1
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.
Determine the correct installation situation and the direction of uid ow.
3.2
Remove protective covers from all connections.
3.3
The trap must be installed with the body upright so that the bucket is r ising and falling vertically.
3.4
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.
Inv e r ted bucke t st e a m traps do n o t pe r m i t ra p i d re l e a s e of ai r. On pr oc e s s ap p l i c a t i o n s , in pa r ticular,
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 efciently. 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.
Open the isolation valves slowly until the nor mal operating c onditions are ac hieved.
3.5
Check for leaks and correct operation.
3.6
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).
4. Commissioning
After installation or maintenance ensure that the system is fully functioning. Carry out tests on any alarms
or protective devices.
5. Operation
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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Air vent
Air vent
Bucket trap
Fig. 4 Typical installation - Oil storage tanks
Bucket trap
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6. Maintenance
Note: Before ac tioning any maintenance observe the 'Safety information' in Section 1.
Warning:
The body/cover gasket contains a thin stainless steel suppor t ring which may cause physic al
injury if not handled and disposed of carefully.
Before undertaking any maintenance on the trap it must be isolated from both the supply line and return line
and any pressure allowed to safely normalise to atmosphere. The trap should then be allowed to cool. It is
re com me nde d tha t new gasket s and spares ar e use d whe ne ve r m ai nt ena nc e is u nd erta ke n. Ensu re th at th e
correct tools and necessary protective equipment are used at all times. When reassembling, ensure that
all joint faces are clean. When maintenance is complete, open isolation valves slowly and check for leaks.
6.1 How to fit the valve and seat assembly:
Disconnect the outlet c onnection and after undoing the bolts (2) remove the cover (1) and valve seat
-
together with bucket assembly from the body.
Unhook the bucket (5) from the valve lever (11).
-
Remove the valve guide plate (7) by undoing the two screws (6).
-
Remove the valve seat (9). The valve seat is spherically ground so that a seal is made at the sealing
-
face . W he n tti ng a ne w val ve seat , it is ex treme ly im por t an t to en sur e tha t the jo int fac e s are cl ea n, an d
STAG jointing compound should be applied to the threaded por tion.
Screw in a new valve seat (9) (see Table 1 for the rec ommended tightening torques).
-
Fit a new valve guide plate ( 7) and lever (11), using new screws (6) supplied. Tighten these after checking
-
that the valve head is properly aligned to the valve seat orice (see Table 1 for the recommended
tightening torques).
Hook the bucket (5) onto the valve lever (11).
-
Using a new gasket (8), ret the cover (see Table 1 for the recommended tightening torques) and
-
reconnect the outlet to the pipework.
Open the isolation valves slowly until the nor mal operating c onditions are ac hieved.
-
Check for leaks and correct operation.
-
6.2 How to fit the check valve assembly:
Disconnect the outlet c onnection and after undoing the bolts (2) remove the cover (1) and valve seat
-
together with bucket assembly from the body.
Remove the check valve (12, 13 and 14) and adaptor (where tted).
-
Note: The DN15, DN20 and DN40 units have the check valve screwed directly into the body whereas
the DN25 and DN50 sizes use an adaptor between the body and check valve.
Prior to 1996 the 600 and 900 series used a 'mushroom' pattern check valve.
The new 'ball' design can be tted into all traps and does not require the spacer tubes tted on the
earlier 'mushroom' pattern valves.
Screw in a new check valve assembly (12, 13 and 14).
-
Using a new gasket (8), ret the cover (see Table 1 for the recommended tightening torques) and
-
reconnect the outlet to the pipework.
Open the isolation valves slowly until the nor mal operating c onditions are ac hieved.
-
Check for leaks and correct operation.
-
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1
8
2
6
9
10
Fig. 5
7
11
Table 1 Recommended tightening torques
Item Part
(621/622) M16 x 2.0P x 45 75 - 85 (55 - 63)
(623/921/922) M20 x 2.5P x 65 90 - 100 (66 - 74)
2
(625) (923/925) M20 x 2.5P x 65 120 - 135 (89 - 100)
(626) (926) M22 x 2.5 P x 70 150 - 165 (111 - 122)
(621/625) (921/925) 10 ¼" whit. x ½" 15 - 20 (11 - 16)
6
(626) (926) 13 " whit. x ½" 20 - 25 (16 - 19)
(621/622/623) (921/922) " A/F " 14 UNF 80 - 88 (60 - 65)
9
(625) (923/925) 1¼" A / F 1¼" x 12 UNF 180 - 200 (133 - 148)
(626) (926) 1½" A / F 1½" x 12 UNF 270 - 300 (200 - 222)
(621/623) (921/922) 1 " A /F 200 - 220 (148 - 163)
12
(625/626) (923/925 /926) 2" A/F 300 - 330 (222 - 244)
or
mm
N m (lbf ft)
4
5
14
12
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7. Spare parts
The spare parts available are shown in solid outline. Parts
drawn in a grey line are not supplied as spares.
Available spares
Valve and seat assembly
(state pressure range)
Bucket 5
Check valve assembly 12, 13, 14
Cover gasket (packet of 3) 8
How to order spares
Always order spares by using the description given in
the column headed 'Available spares' and state and full
denition of the trap e.g. 622/10.
Example: 1 - Valve and seat assembly for a Spirax Sarco
DN20, 622/10 alloy steel inverted bucket steam trap
(having a PMX of 17 bar g).
6 (2 off ), 7, 9, 10, 11
7
6
9
10, 11
5
Valve and
seat assembly
14
12, 13 , 14
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