Spirax Sarco CA44, CA44S, CA44-32, CA46S, CA44S-4.5 Installation And Maintenance Instructions Manual
...
1484450/3
IM-P148-37
ST Issue 3
CA44, CA44S, CA46 and CA46S
Air and Gas Traps
Installation and Maintenance Instructions
1. Safety information
2. General
product information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
IM-P148-37 ST Issue 3 1
© Copyright 2015
Printed in GB
1. Safety information
Safe operation of this product can only be guaranteed if it is properly installed,
commissioned, used and maintained by qualified personnel (see Section 1.11)
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.
This product complies with the requirements of the European Pressure Equipment
Directive 97 / 23 / EC and falls within Category 'SEP'. It should be noted that products
within this category are required by the Directive not to carry the mark.
Product Size PED category CE marked
CA44 and CA46
CA44S and CA46S
i) This product has 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 re sult in a dangerous overpressure or over temperature 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 and protective film from all
name-plates, where appropriate, before installation on steam or other high
temperature applications.
DN15 - DN20 SEP No
DN25 2 Yes
DN15 - DN20 SEP No
DN25 - DN50 2 Ye s
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.
2
IM-P148-37 ST Issue 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.
Viton - CA44 and CA46 main valve cone:
If the the main valve cone (made of Viton) has been subjected to a temperature
approaching 315°C (599°F) or higher it may have decomposed and formed hydrofluoric
acid. Avoid skin contact and inhalation of any fumes as the acid will cause deep skin
burns and damage the respiratory system.
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 super vised 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.
IM-P148-37 ST Issue 3 3
1.12 Handling
Manual handling of large and / or heavy products may present a risk of injur y. Lifting,
pushing, pulling, carrying or supporting a load by bodily force can cause injur y
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 sur face of the 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 400°C (752°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 Disposal
Unless other wise 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, EXCEPT:
Viton - CA44 and CA46 main valve cone:
- Waste parts can be landfilled, when in compliance with National and Local regulations.
- Waste parts can be incinerated, but a scrubber must be used to remove Hydrogen
Fluoride, which is evolved from the product and with compliance to National and
Local regulations.
- Parts are insoluble in aquatic media.
1.16 Returning products
Customers and stockists are reminded that under EC Health, Safet y 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.
4
IM-P148-37 ST Issue 3
2. General product information
2.1 General description
CA44
DN15 and DN20 Flanged
The CA44 is a carbon steel ball float air and gas trap. It is available with a soft valve cone
and has horizontal flanged connections. The cover will be drilled and tapped ½" BSP or NPT
for the purpose of fitting a balance line.
Body and cover castings are produced by a TÜV approved foundry.
CA44S
DN15, DN20, DN25, DN40, DN50 Flanged and 1" screwed / socket weld
The CA44S is a carbon steel ball float air and gas trap. It is available with a metal valve
cone and has horizontal flanged, screwed or socket weld connections. With exception to
the DN40 and DN50, the cover will be drilled and tapped ½" BSP or NPT for the purpose
of fitting a balance line (also available for the socket weld version). The cover on the DN40
and DN50 wil be drilled and tapped ¾" BSP or NPT.
Body and cover castings are produced by a TÜV approved foundry.
CA46
DN15 and DN20 Flanged
The CA46 is an austenitic stainless steel ball float air and gas trap. It is available with a soft
valve cone and has horizontal flanged connections. The cover will be drilled and tapped
½" BSP or NPT for the purpose of fitting a balance line.
Body and cover castings are produced by a TÜV approved foundry.
CA46S
DN15, DN20, DN25, DN40 and DN50 Flanged
The CA46S is an austenitic stainless steel ball float air and gas trap. It has a metal valve cone
and is available with horizontal flanged connections. With exception to the DN40 and DN50,
the cover will be drilled and tapped ¾" BSP or NPT for the purpose of fitting a balance line.
The cover on the DN40 and DN50 will be drilled and tapped ¾" BSP or NPT.
Body and cover castings are produced by a TÜV approved foundry.
Note:
For additional information see the following Technical Information Sheets:
Product Sizes and connections Material Section TI reference
CA44 DN15 - DN20 Flanged Carbon steel Section 2.2 TI-P148-02
DN15 - DN25 Flanged Carbon steel Section 2.2 TI-P148-02
CA44S DN40 - DN50 Flanged Carbon steel Section 2.2 TI-P148-03
1" Screwed Carbon steel Section 2.2 TI-P148-23
CA46 DN15 - DN20 Flanged Austenitic stainless steel Section 2.3 TI-P148-04
DN15 - DN25 Flanged Austenitic stainless steel Section 2.3 TI-P148-04
CA46S
DN40 - DN50 Flanged Austenitic stainless steel Section 2.3 TI-P148-07
IM-P148-37 ST Issue 3 5
2.2 CA44 and CA44S - Carbon steel
Fig. 1
CA44 and CA44S
DN15 and DN20
DIN flange
Fig. 2
Sizes and pipe connections
DN40 and DN50
CA44
DN15 and DN20 flanged
CA44S
1" screwed BSP or NPT with BSP or NPT balance line.
1" socket weld BS 3799 class 3000 with NPT or socket weld balance line.
DN15, DN20, DN25, DN40 and DN50 flanged
Standard flanges are EN 1092 PN40 with DIN face-to-face dimensions and BS 1560 class
ASME 150, ASME 300 and JIS / KS 20K with extended face-to-face dimensions.
On request ASME 150 and ASME 300 flanges with drilled and tapped bolt holes with
DIN face-to-face dimensions can be provided. PN and JIS / KS flanges will be provided with
BSP balance line and ASME flanges with an NPT balance line.
CA44S
DIN flange
Limiting conditions
Maximum body design conditions PN40
PMA - Maximum allowable pressure 40 bar g (580 psi g)
TMA - Maximum allowable temperature 400°C (752°F)
PMO - Maximum operating pressure 40 bar g (580 psi g)
TMO - Maximum operating temperature 400°C (752°F)
PMX - Maximum differential pressure 32 bar g (464 psi g)
0°C (32°F)
Minimum operating temperature Screwed 60 bar g (870 psi g)
Socket weld 60 bar g (870 psi g)
PN40 60 bar g (870 psi g)
Designed for a maximum
cold hydraulic test pressure of:
JIS / KS 20K 60 bar g (870 psi g)
6
ASME 300 60 bar g (870 psi g)
ASME 150 30 bar g (435 psi g)
IM-P148-37 ST Issue 3
Operating range
A
CA44
Temperature °C
D
Pressure bar g
C
B
CA44S
A
Temperature °C
The product must not be used in this region.
A - B Flanged EN 1092 PN40, ASME 300, screwed and socket weld
A - C Flanged JIS/ KS 20K
A - D Flanged ASME 150
∆ PMX - Maximum differential pressure
Depending on the specific gravity of the liquid being drained.
Specific gravity
Trap 1.0 0.9 0.8 0.7 0.6
Maximum differential pressure bar (psi)
CA44-32 32.0 (464.00) 32.0 (464.00) 29.0 (420.50) 20.0 (290.00) 12.0 (174.00)
CA44S- 4.5 4.5 (65.25) 4.5 (65.25) 4.5 (65.25) 3.4 (49.30) 2.0 (29.00)
CA44S-10 10.0 (145.00) 9.5 (137.75) 6.8 (98.60) 5.5 (79.75) 3.4 (49.30)
CA44S-14 14.0 (203.00) 14.0 (203.00) 11.0 (159.50) 8.0 (116.00) 5.0 (72.50)
CA44S-21 21.0 (304.50) 19.0 (275.50) 15.0 (217.50) 10.0 (145.00) 6.5 (94.25)
CA44S- 32 32.0 (464.00) 30.0 (435.00) 23.0 (333.50) 16.5 (239.25) 10.0 (145.00)
D C
Pressure bar g
B
IM-P148-37 ST Issue 3 7
2.3 CA46 and CA46S - Austenitic stainless steel
Fig. 3
CA46 and CA46S
DN15 and DN20
DIN flange
Fig. 4
DN40 and DN50
Sizes and pipe connections
CA46
DN15 and DN20 flanged
CA46S
DN15, DN20, DN25, DN40 and DN50 flanged
Standard flanges are EN 1092 PN40 with DIN face-to-face dimensions and BS 1560 class
ASME 150 and ASME 300 and JIS / KS 20K with drilled and tapped bolt holes with
DIN face-to-face dimensions. PN and JIS / KS flanges will be provided with BSP balance
line and ASME flanges with an NPT balance line.
CA46S
DIN flange
Limiting conditions
Maximum body design conditions PN40
PMA - Maximum allowable pressure 40 bar g (580 psi g)
TMA - Maximum allowable temperature 400°C (752°F)
PMO - Maximum operating pressure 40 bar g (580 psi g)
TMO - Maximum operating temperature 400°C (752°F)
PMX - Maximum differential pressure 32 bar g (464 psi g)
Minimum operating temperature 0°C (32°F)
PN40 60 bar g (870 psi g)
Designed for a maximum
cold hydraulic test pressure of:
JIS / KS 20K 49 bar g (710.5 psi g)
8
ASME 300 60 bar g (870 psi g)
ASME 150 30 bar g (435 psi g)
IM-P148-37 ST Issue 3
Operating range
A
CA46 - DN15 and DN20 flanged
Temperature °C
C B
Pressure bar g
CA46S - DN15, DN20 and DN25 flanged
A
Temperature °C
C
Pressure bar g
B
CA46S - DN40 and DN50 flanged
A
D
Temperature °C
The product must not be used in this region.
A - B Flanged EN 1092 PN40 and ASME 300
A - C Flanged ASME 150 (DN15, DN20 and DN25 only) and JIS / KS 20K
D - D Flanged ASME 150 (DN40 and DN50 only)
∆ PMX - Maximum differential pressure
Depending on the specific gravity of the liquid being drained.
Specific gravity
Trap 1.0 0.9 0.8 0.7 0.6
Maximum differential pressure bar (psi)
CA46-32 32.0 (464.00) 32.0 (464.00) 29.0 (420.50) 20.0 (290.00) 12.0 (174.00)
CA46S- 4.5 4.5 (65.25) 4.5 (65.25) 4.5 (65.25) 3.4 (49.30) 2.0 (29.00)
CA46S-10 10.0 (145.00) 9.5 (137.75) 6.8 (98.60) 5.5 (79.75) 3.4 (49.30)
CA46S-14 14.0 (203.00) 14.0 (203.00) 11.0 (159.50) 8.0 (116.00) 5.0 (72.50)
CA46S-21 21.0 (304.50) 19.0 (275.50) 15.0 (217.50) 10.0 (145.00) 6.5 (94.25)
CA46S- 32 32.0 (464.00) 30.0 (435.00) 23.0 (333.50) 16.5 (239.25) 10.0 (145.00)
IM-P148-37 ST Issue 3 9
D
Pressure bar g
C
B
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:
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 fitted,
ensure that a safety device is included in the system to prevent overpressurisation.
3.2 Determine the correct installation situation and the direction of fluid flow.
3.3 Remove protective covers from all connections.
3.4 The trap should be fitted in the horizontal plane with the inlet at the top so that the float
mechanism is free to rise and fall in a vertical plane.
The trap must be fitted below what it is draining. Point the arrow on the name-plate
downwards. One of the advantages of the float trap for draining air systems is that no air
bleed is required for satisfactory operation. However, because the trap has no air bleed
it could under some circumstances become air or gas locked.
Make sure that the balance line is piped back to the upstream side.
A balance line is essential for the correct operation of this product.
For convenience of maintenance it is recommended that a union is fitted in the balance
line near to the trap cover.
Note: If the trap is to discharge to atmosphere ensure it is to a safe place, the discharging fluid
may be at a temperature of 100°C (212°F).
4. Commissioning
After installation or maintenance ensure that the system is fully functional. Carry out tests on
any alarms or protective devices.
5. Operation
The CA44(S) and CA46(S) float traps are continuous discharge traps, removing liquid from
air and gas systems. As soon as liquid enters the main chamber of the trap, the float rises
and the lever mechanism attached to it opens the main valve - keeping the system drained
of liquid at all times. When air or gas arrives, the float drops and shuts the main valve tightly
against the seat. The balance line is necessary to prevent the trap from becoming air locked.
Float traps are renowned for their instantaneous load handling capability, clean tight shut-off
and resistance to waterhammer and vibration.
10
IM-P148-37 ST Issue 3
Balance line
Air receiver
CA14
air trap draining
small receiver
Fig. 5 Installation with balance line arrangement
IM-P148-37 ST Issue 3 11
Strainer
6. Maintenance
Note:
Before actioning any maintenance programme observe the 'Safety information' in
Section 1.
Warning
The cover gasket and the main valve gasket (DN40 and DN50) contains a thin stainless
steel support ring which may cause physical injury if not handled and disposed of
carefully.
Servicing:
- With suitable isolation, repairs can be carried out with the trap in the pipeline.
- When reassembling, make sure that all joint faces are clean and the dowel locates in the
cover.
How to fit the main valve assembly (CA44S and CA46S):
- Undo the cover bolts (2) and lift off the cover.
- Remove the float assembly (8 + 9 CA44 and CA46 only) by extracting the pivot pin (16).
- Remove the support (14), pivot frame (15) and the valve seat (5) by unscrewing the set
screws (7).
- Ensure seat /gasket faces are clean and dry.
- Fit a new valve seat (5) into the body using a new gasket (6).
- Attach the support frame (14) and pivot frame (15) to body with assembly set screws (7)
but do not tighten.
- Fit the float arm (8) to the pivot frame (15) using the pin (16) and by moving the complete
assembly, centre the valve head (9) onto the seat orifice.
- Tighten the assembly set screws (7) to the recommended torque (see Table 1).
- Check the operation by raising and lowering the float (8) several times making sure that
the valve head is centering properly on the seat (5).
- Make sure that all joint faces are clean and refit the cover, ensuring the dowel locates in
the cover, by using a new gasket (3) and apply a thin coating of an anti-seize compound to
the cover bolts (2).
- Tighten the cover bolts (2) uniformly to the recommended torques (see Table 1).
- Open up the isolating valve slowly until the full system pressure is achieved.
- Check for leaks.
How to fit valve cone (CA44 and CA46):
- Withdraw the pivot pin (6) to release the float and lever. Push out the soft valve cone (9)
and replace with a new one.
- Reassemble the float and lever into the pivot frame (15) and replace the pin (16).
- Check the operation by raising and lowering the float (8) several times making sure that
the valve head is centering properly on the seat (5).
- Make sure that all joint faces are clean and refit the cover, ensuring the dowel locates in
the cover, by using a new gasket (3) and apply a thin coating of an anti-seize compound to
the cover bolts (2).
- Tighten the cover bolts (2) uniformly to the recommended torques (see Table 1).
- Open up the isolating valve slowly until the full system pressure is achieved.
- Check for leaks.
12
IM-P148-37 ST Issue 3
23Dowel
DN40 and DN50
CA44S and CA46S only
DN40 and DN50
CA44S and CA46S only
2
6
Main valve assembly with float
Fig. 6 CA44S and CA46S DN40 and DN50
Note: The trap shown is the DN40 and DN50 CA44S / CA46S. However the type of internals
and the method of maintenance is no different from that used in the smaller sizes of CA44(S)
and CA46 (S).
165
15 14 7
9*
8
*CA44 and CA46 only
Table 1 Recommended tightening torques
or
Item Size N m (lbf ft)
mm
DN15 to DN25 17 A/ F M10 x 60 19 - 22 (14 - 16)
2 DN40 24 A/ F M16 x 85 60 - 66 (44 - 48)
DN50 (CA44S and CA46S) 24 A/ F M16 x 85 80 - 88 (56 - 65)
5 17 A/ F M12 x 8 50 - 55 (37 - 40)
7 Cheesehead M5 x 20 2.5 - 2.8 (1.8 - 2.1)
DN40 10 A/ F M6 x 20 10 - 12 (7 - 9)
19
DN50 13 A/ F M8 x 20 20 - 24 (15 - 17)
IM-P148-37 ST Issue 3 13
7. Spare parts
The spare parts available are shown in heavy outline. Parts drawn in broken line are not
supplied as spares.
Available spares
Soft valve cone CA44 and CA46 (packet of 3) 9
Main valve assembly with float*
CA44S and CA46S 5, 6, 7, 8 , 14, 15, 16
Complete set of gaskets (packet of 3 sets) 3, 6
*The CA44 and CA46 use a soft Viton valve head, where as the CA44S and CA46S use a
stainless steel valve head.
Note: The trap shown is the DN40 and DN50 CA44S/CA46S. However the type of internals
and the method of maintenance is no different from that used in the smaller sizes of CA44(S)
and CA46 (S).
How to order spares
Always order spares by using the description given in the column headed 'Available spares'
and state the size and type of trap.
Example: 1 - Main valve assembly for a Spirax Sarco DN25, CA46S-32 air and gas trap.
CA44 and CA46 5, 6, 7, 8+9, 14, 15, 16
14
IM-P148-37 ST Issue 3
3
DN40 and 50
CA44S and CA46S only
6
Main valve assembly with float
Fig. 7 CA44S and CA46S DN40 and 50 (see note under 'Available spares')
IM-P148-37 ST Issue 3 15
165
15 14 7
9*
8
*CA44 and CA46 only
16
IM-P148-37 ST Issue 3
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