IM-P117- 3 9 CMGT Issue 1
1
MSC04 shown
1. Safety information
2. General product
information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
© Copyright 2017
Printed in GB
IM-P117- 39
CMGT Issue 1
1170152 /1
MSC-125 and MSC-160 Manifolds for Steam
Distribution and Condensate Collection
Installation and Maintenance Instructions
IM-P117- 3 9 CMGT Issue 1
2
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, product markings 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 and falls within Category '1' and therefore carries the mark.
i) This product has been specifically designed for use on steam, air or
condensate / water, which is 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, where appropriate, before
installation on steam or other high temperature applications.
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: flammable materials, substances hazardous to health,
extremes of temperature.
IM-P117- 3 9 CMGT Issue 1
3
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 opened and closed
progressively 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 the 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.
IM-P117- 3 9 CMGT Issue 1
4
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 may reach
temperatures in excess of 425 °C (797 °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 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.
1.16 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.
IM-P117- 3 9 CMGT Issue 1
5
2. General product information
2.1 General description
A range of forged carbon steel compact manifolds with integral piston type stop valves
for steam distribution and condensate collection duty. MSC manifolds can be used for
either steam distribution duty or condensate collection duty depending on the way they
are installed.
Optional extras
The following are available at extra cost:
-
Mounting kit comprising of studs,
spacers and nuts.
-
Insulating jacket.
-
Fitted with steam traps for quick
installation projects.
Fig. 1 Type MSC04 socket weld version shown
Flow direction when
used for condensate
collection duty
Flow direction when
used for steam
distribution duty
Recommended alternatives
Standards
This product fully complies with the
requirements of the European Pressure
Equipment Directive 2014/68/EU.
Certification
The product is available with certification to EN 10204 3.1.
Note: All certification / inspection requirements must be stated at the time of order placement.
IM-P117- 3 9 CMGT Issue 1
6
2.2 Available types, sizes and pipe connections
MSC manifolds are available with 4, 8 or 12 connections, with and without integral piston
isolation valves designated:
MSC04-125, MSC08-125 and MSC12-125 with 125mm pitch respectively
DN15 and DN20 screwed BSP, NPT or socket weld to B16.11 Class 3000 tracer ports are
available as standard.
MSC04-160, MSC08-160 and MSC12-160 with 160mm pitch respectively
DN15 and DN20 screwed BSP, NPT or socket weld to B16.11 Class 3000 tracer ports are
available as standard.
The steam main / condensate return connection is DN40 socket weld to ASME B 16.11 as
standard.
Alternative connections, including flanged, are available on request.
IM-P117- 3 9 CMGT Issue 1
7
0
0 10 20
19.6
30 40 50
51
-46
100
200
300
400
0
200
400
600
100 200 300 400 500 600 700
2.3 Pressure / temperature limits
The product must not be used in this region.
A - B Flanged ASME Class 300, screwed and socket weld.
A - C Flanged ASME Class 150.
Body design conditions ASME B16.5 Class 300
PMA Maximum allowable pressure 51 bar g @ 38 °C 740 psi g @ 100 °F
TMA Maximum allowable temperature 425 °C @ 28 bar g 797 °F @ 406 psi g
Minimum allowable temperature -46 °C -50 °F
PMO
Maximum
operating
pressure for
saturated steam
service
ASME 150 14 bar g 203 psi g
ASME 300, SW, NPT 602 psi g
TMO
Maximum
operating
temperature
ASME 150 425 °C @ 5.5 bar g 797 °F @ 80 psi g
ASME 300,
SW, NPT
425 °C @ 28 bar g 797 °F @ 406 psi g
Minimum operating temperature 0 °C 32 °F
Note: For lower operating temperatures consult Spirax Sarco
Designed for a maximum cold hydraulic test pressure of: 76 bar g 1 102 psi g
2.4 Kv values
All sizes Kv 1.8
For conversion:
Cv (UK) = Kv x 0.963
Cv (US) = Kv x 1.156
The Kv stated is for each valve rather than the complete manifold.
Pressure bar g
Temperature °C
C B
A
Steam
saturation
curve
Pressure psi g
Temperature °F
IM-P117- 3 9 CMGT Issue 1
8
3. Installation
Note: Before actioning any installation observe the 'Safety information' in Section 1.
Referring to the Installation and Maintenance Instruction, 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.
Note: If the trap draining the manifold 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).
3.4 General information
The manifold has been designed for vertical installation. Ensure that there is sufficient
access to the handwheel to allow proper operation. The back is provided with threaded
connections M12 for attaching to a supporting structure.
For ease of insulation it is recommended that spacers are fitted to give the manifold a
stand-off of at least 50 mm.
For convenience the following sets of mounting kit are available:
-
A single set comprising 2 off each stud, nut and spacer suitable for installing one MSC04
or MSC08.
-
A single set comprising 4 off each stud, nut and spacer suitable for installing one MSC12.
-
A multiple set comprising 12 off each stud, nut and spacer suitable for installing 6 x MSC04,
6 x MSC08 or 3 x MSC12.
After installation it is recommended that the manifold is insulated to minimise radiated heat
losses and to protect personnel from burn risks. This is most easily done using the optional
insulating jacket.
3.5 Steam distribution duty
The recommended installation is with the steam inlet connection at the top of the manifold.
A trap set should be fitted to the bottom. The discharge from this trap set should ideally
be returned. If it is to be discharged to atmosphere we recommend that a diffuser is fitted.
3.6 Condensate collection duty
The recommended installation is with the condensate outlet at the top. The bottom of the
manifold should be fitted with a stop valve for blowdown purposes. Again, we recommend
that a diffuser is fitted.
3.7 Pipeline welding
Any welding provided by Spirax Sarco or our nominated sub-vendors will be in accordance
with our latest Weld Procedures and associated documentation. Copies are available, if
required, on request and should be approved before any orders are placed.
Any welding that is not being carried out by Spirax Sarco or their sub-vendors, will remain
the full responsibility of the customer, user or their own appointed contractors / sub-vendors.
IM-P117- 3 9 CMGT Issue 1
9
5. Operation
The integral piston valves should be either fully open or fully closed. They are not intended
for throttling duties.
During closing operation the piston ensures a permanent seal by means of the handwheel.
Therefore during service never remove the handwheel from the spindle. Due to the large
sealing area of the piston valve, it is not necessary to use a valve key to ensure leaktight
shut-off.
During opening operation the piston is stopped when the valve is fully open as its top
touches the inside of the bonnet.
Operation of the handwheel should always be light.
After installation or maintenance ensure that the system is fully functioning. Carry out tests
on any alarms or protective devices.
4. Commissioning
Fig. 2 Installation view from above
MSC manifold
M12 stud
M12 Nut
Structural steelwork
Spacer
50 mm
IM-P117- 3 9 CMGT Issue 1
10
6. Maintenance
Note: Before actioning any maintenance programme observe the 'Safety information'
in Section 1.
Warning
The graphite stem sealing rings (items 8 and 9) contain thin stainless steel support
rings which may cause physical injury if not handled and disposed of carefully.
6.1 Maintenance in service
After the manifold is first put into service or after a change of sealing rings (8 and 9), the
bonnet nuts (4) should be lightly followed up with the valve in the closed position. Ensure
the bonnet (2) is driven down straight during tightening and that care is taken with the
handwheel operation. This operation is to be repeated should any trace of leakage develop.
If perfect sealing cannot be achieved in this way, repack the valve following the procedure
below. The handwheel can be unscrewed from the piston valve assembly following the
removal of the top nut and domed lock-nut, (11). A washer is located under these nuts and
also one between the the handwheel and valve bonnet. During reassembly ensure that
these are refitted in the correct locations, by using a suitable anti-seize compound applied
to the washers and applying the recommended torque to the nuts - See Table 1.
The top nut and domed lock-nut (item 11) should be locked together by unscrewing the top
nut by an th of a turn whilst maintaining the position of the domed lock-nut.
6.2 Preparation of valve dismantling
Before starting work ensure that you have suitable tools and / or consumables available.
Before attempting to carry out any maintenance, ensure that the manifold is fully isolated
and safely depressurised. Do not assume the system is depressurised even when the
pressure gauge indicates zero. If performing maintenance whilst the pipework is hot, wear
appropriate protective clothing. Carefully remove insulation if fitted. When using the optional
insulation jacket, this is easily removed by undoing the fastenings.
6.3 Dismantling the valve:
-
Using the handwheel (10), fully open the valve.
-
Remove the bonnet nuts (4) and washers (5) from studs (3).
-
Carefully turn the handwheel in the closing direction to lift the bonnet (2).
-
Rotate the bonnet (2) to ensure that the flange bolt holes are misaligned with the studs (3).
-
Turn the handwheel in the opening direction to release the piston (6) from the upper and
lower sealing rings (8 and 9) and so release piston / bonnet sub-assembly from the body (1).
-
Examine the piston (6) for signs of scoring, corrosion etc. which could affect perfect
tightness of the valve.
-
Check other parts for wear / damage and replace if necessary.
Table 1 Recommended tightening torques
Item
or
mm
N m lbf ft
4 14 " x 18 UNC 12 8.9
11 10 M6 12 8.9
IM-P117- 3 9 CMGT Issue 1
11
Manifold
inlet
Extractor tool
Fig. 4 View showing valve
internals extractor tool
Fig. 3 View showing valve internals
1
6 2 7
3 + 4 + 5
10
8 9
12
Washer
Top nut
Domed
lock-nut
11
12
Washer
IM-P117- 3 9 CMGT Issue 1
12
6.4 Repacking the valve:
-
With the valve dismantled, insert the valve internals extractor tool through the upper and
lower sealing rings (8 and 9) and lantern bush (7) (See Figure 7).
-
Firmly tap to ensure that the tool bottoms out in the bore and with a quarter turn of
the handle carefully remove the two sealing rings (8 and 9) and the lantern bush (7).
-
Thoroughly clean the sealing rings housing and all the internals.
-
Fit new lower sealing ring (9), lantern bush (7) and upper sealing ring (8), ensuring they
fit perfectly. (Note: The lower and upper sealing rings are the same.)
-
Apply a thin layer of graphite based grease to threads only (not to internals and piston).
6.5 Reassembling the valve - See Figure 5:
-
Take the piston valve sub assembly (6,7,8 and 9), lightly inserting it into the pipeline
connector body (1) and applying an even downwards force using the bonnet
assembly (2) over the studs.
-
Fit the belleville washers (5) and nuts (4) and evenly tighten the bonnet assembly (2)
down to a torque of 12 Nm (8.9 lbf ft).
-
The valve handwheel can now be reinstalled as per the instructions in Section 6.1, paying
particular attention to the placement of the washers and torque figures.
-
At this point the backlash of the valve should be tested ensuring it is not more than ¼ of
a turn and that the securing nuts do not turn with the handwheel.
Table 1 Recommended tightening torques
Item
or
mm
N m lbf ft
4 14 " x 18 UNC 12 8.9
11 10 M6 12 8.9
IM-P117- 3 9 CMGT Issue 1
13
Manifold
inlet
Extractor tool
Fig. 6 View showing valve
internals extractor tool
Fig. 5 View showing valve internals
1
6 2 7
3 + 4 + 5
10
9
12
Washer
Top nut
12
Washer
8
Domed
lock-nut
11
IM-P117- 3 9 CMGT Issue 1
14
7. Spare parts
The spare parts available are detailed below.
To avoid any internal damage, the correct extractor tool must be used for removing the
sealing rings - Please order seperately.
Available spares
Sealing ring set 8 and 9
Piston valve assembly 2, 4, 5, 6, 7, 8, 9, 10, 11 and 12
Piston valve sub-assembly 6, 7, 8 and 9
Extractor tool See Figure 6 on page 13
Mounting kit See Figure 2 on page 9
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 manifold.
Example: 1 - Sealing ring set for an integral piston valve on a carbon steel manifold
MSC04-125 DN15 socket weld.
Fig. 7
1
6 2 7
3 + 4 + 5
10
9
12
Washer
Top nut
12
Washer
8
Domed
lock-nut
11
IM-P117- 3 9 CMGT Issue 1
15
IM-P117- 3 9 CMGT Issue 1
16
Loading...