Spirax Sarco S1, S2, S7, S8, S3 Installation And Maintenance Instructions Manual

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PREVIOUS REFERENCE NO. IM-P023-55

IM-F05-01-EN-ISS2

CMGT

S1, S2, S3, S5, S6, S7, S8, S12 and S13

Separators

Installation and Maintenance Instructions

IM-F05-01-EN-ISS2 CMGT

1. Safety information

2. General product information

3. Installation

4. Commissioning

5. Operation

6. Maintenance

7. Spare parts

Printed in France

IM-F05-01-EN-ISS2 CMGT

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) 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 equipment must also be complied with.

Warning

The inspection plug gasket on the S2, S3, S12 and S13 and the bottom cover gasket on the S5 and S6 contain a thin stainless steel support ring which may cause physical injury if not handled and disposed of carefully.

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 li sted below

comply with t he requirements of the Pressure Equipment Direct ive (PED) and carry the mar k

when so required.

The products fall within the following Pressure Equipment Directive categories:

and

Product

16 bar g

50 bar g

Group 1

Gases

DN15 - DN20 SEP SEP SEP SEP

DN25 2 1 SEP SEP

DN32 - DN40 1 SEP SEP SEP

DN50 2 1 SEP SEP

DN40 1 SEP SEP SEP

DN50 - DN80 2 1 SEP SEP

DN100 - DN150 3 2 2 SEP

DN200 2 1 2 SEP

DN15 SEP SEP SEP SEP

DN20 - DN25 2 1 SEP SEP

DN32 - DN5 0 3 2 2 SEP

Group 2

Gases

Group 1

Liquids

Group 2

Liquids

IM-F05-01-EN-ISS2 CMGT

Product

DN65 - DN125 3 2 2 SEP

14 bar g

and

20 bar g

and

23 bar g

25 bar g

S12

S13

i) The product has been specifically designed for use on steam and compressed air which are

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

iii) A numbe r of product s are suppl ied for the in tention of t he end user (or a gent there of) modifying

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

v) Spirax Sarco products are not intended to wi thst and external stresses that may be induced by

vi) Re move protect ion covers from all connect ions and prot ective film f rom all name -plates, w here

25 bar g

in Group 2 of the above mentioned Pressure Equipment Directive.

If the maximum operating limits of the product are lower than those of the system in whic h it is being fitted, or if malfunction of t he product could result in a dange rous overpressure or overtemperature occurrence, ensure a safety device is included in the syst em to prevent such over-limit situations.

the fl ange conf iguratio n from that su pplied. It i s the respo nsibilit y of the organ isation c arrying out the modif ication to do so in accordance with the internationally recognised flange standards and to ensure that the design rating and operation of the product are not compromised. Spirax Sa rco will not be held responsible for any unapproved modification or consequential liability resulting in failure to observe these requirements.

any system to which they are fit ted. It is the responsibility of the installer to consid er these stresses and take adequate precautions to minimise them.

appropriate, before installation on steam or other high temperature applications.

DN150 - DN200 4 3 2 SEP

DN250 - DN350 4 4 2 SEP

DN65 - DN80 3 2 2 SEP

DN100 - DN150 4 3 2 SEP

DN200 - DN300 4 4 2 SEP

DN350 4 4 2 1

DN65 - DN80 3 2 2 SEP

DN100 - DN150 4 3 2 SEP

DN200 - DN250 4 4 2 SEP

DN300 - DN350 4 4 2 1

DN32 - DN40 1 SEP SEP SEP

DN50 2 1 SEP SEP

DN40 1 SEP SEP SEP

DN50 - DN80 2 1 SEP SEP

DN100 - DN125 3 2 2 SEP

DN150 - DN200 3 2 2 SEP

Group 1

Gases

Group 2

Gases

Group 1

Liquids

Group 2

Liquids

IM-F05-01-EN-ISS2 CMGT

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.

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 ri sk? Dange rs might inc lude isola tion of vents o r protect ive devices or t he render ing ineff ective of con trols or alar ms. Ensure isolation valves are turned on and of f 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 star ting work ensure that you have suitable tools and /or consumables available. Use only genuine Spirax Sarco replacement parts.

1.10 Protective clothing

Consi der whethe r you and/or oth ers in the vic inity req uire any prote ctive clot hing to prote ct 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 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 'permit to work' system is in force it must b e complied with. Where there is no such system, it is recommended that a responsible p erson should know what work is going on and, where n ecessar y, arrang e to have an assi stant whos e primar y respons ibility i s safety. Post ' warning notices' if necessary.

IM-F05-01-EN-ISS2 CMGT

1.12 Handling

Manual handling of large 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 ta sk, th e 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 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 of 300 °C (572 °F). Many pro ducts are not self- draining. Take due care when dismantling or removing the produc t from an installation (refer to Section 6 '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 Disposal

Unles s otherw ise stated in t he Install ation and Ma intenanc e Instruct ions, this p roduct is re cyclable and no ecological ha zard is anticipated with its disposal providing due care is taken.

1.16 Returning products

Custom ers 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 p resent a health, safety or environmental risk. This information must be provided in writing including Health and Safet y data sheets relating to any substances identif ied as hazardous or potentially hazardous.

1.17 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 per fectly safe. However, because of its mechanical proper ties, it is l ess forgiving compared to oth er materials such a s 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.

IM-F05-01-EN-ISS2 CMGT

Prevention of water hammer

Steam trapping on steam mains:

Steam

30 - 50 metre inter vals

Gradient 1:100

Tra p set

Condensate

Gradient 1:100

Tra p set

Condensate

Steam Mains - Do's and Don'ts:

Flow

Steam Steam

Steam

Tra p set

Condensate

Flow

IM-F05-01-EN-ISS2 CMGT

Prevention of tensile stressing

Pipe misalignment:

Installing products or re-assembling after maintenance:

Do not over tighten.

Use correct torque gures.

Thermal expansion:

Guides

Short distance

Guides

Fixing point

Guides

4 2

Flange bolts should be gradually tightened across

diameters to ensure even load and alignment.

Axial movement

Medium distance

Limit rods

Fixing point

Limit rods

Guides

Small

lateral

movement

Large

lateral

movement

Small lateral movement

Large lateral movement

IM-F05-01-EN-ISS2 CMGT

2. General product information

2.1 General description

The products detailed are all baffle type separators used for the removal of entrained liquids in steam, compressed air and gas systems. We recommend the fitting of insulating jackets to improve the performance of the separator.

Note: For additional product data see the following Technical Information Sheets.

Typ e Material Pressure rating Sizes Connections TI reference

S1 SG iron PN16 ½", ¾" and 1" Screwed T I-P128 -01- EN -ISS1

S2 Cast iron PN16 1¼", 1½" and 2" Screwed TI-P129-01-EN-ISS1

S3 Cast iron PN16 D N40 - DN200 Flanged TI-P131-01-EN -ISS1

S5 Carbon steel PN50/ASME 300 DN15 - DN50

Austenitic stainless

steel 316 L

S7* Carbon steel PN16 and PN40 DN65 - DN350 Flanged TI-P135- 0 2- EN -ISS1

S8* Austenitic stainless PN16 and PN40 DN65 - DN350 Flanged TI- P13 6 -01- EN -ISS1

S12 SG iron PN25 1¼", 1½" and 2" Screwed TI -P130 - 01-E N-ISS1

S13 SG iron PN25 DN40 - DN200 Flanged TI- P13 2- 01- EN- ISS1

* Note: The S7 and S8 separators are designed and manufactured in accordance with EN 13445:20 02 –

'Unfired Pressure Vessels'.

PN50/ASME 300 DN15 - DN50

Scr ewed and Flanged

TI-P133 - 01- EN- IS S1

TI-P134-01-EN-ISS1

S13

Fig . 1

Fig. 4

IM-F05-01-EN-ISS2 CMGT

S5 S6

Fig. 2

S12

Fig. 3

S7 S8

Fig. 5

3. Installation

Note: Before ac tioning any installation observe the 'Safety Infor mation' in Section 1.

Referring to the Installation and Maintenance Instructions, body markings, name-plate (if fitted) 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 fitted, ensure a safety devic e is included in the system to prevent overpressurisation.

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

3.2

Remove protective covers from all connections and the protective film from all name-plates, where

3.3

appropriate, before installation on steam or other high temperature applications.

The separators may be lagged if required.

3.4

Important installation note

for the S1, S2, S3, S12 and S13 separators:

Install in a horizontal pipeline with the drain directly below. To ensure that any separated liquid is drained away quickly, a suitable liquid drainer or steam trap must be connec ted to the drain.

Isolation valve

S13

separator

Strainer

Float trap

Fig. 6 Separator on a steam line

3.5 Installation for the S5 and S6

Install in a horizontal pipeline with the drain directly below. To ensure that any separated liquid is drained quickly, a suitable liquid drainer or steam trap must be connected to the drain connection. A float type trap is recommended. 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 c onnection. If an air vent is not being f itted then the connection must have the plastic transit protection plug removed and must have a carbon steel class 3000 lb plug fitted.

IM-F05-01-EN-ISS2 CMGT

S5 separator

Fig. 7

Isolation

valve

Strainer

Float trap

3.6 Installation for the S7 and S8

Install in a horizontal pipeline with the drain directly below. All sizes are fitted with suppor t brackets which can be used to minimise piping loads. Each bracket has two drilled holes. To ensure that any separated liquid is drained quickly, a suitable liquid drainer or steam trap must always be connected to the drain connection. A float type trap is recommended. 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 f itted then the c onnection must have the plastic transit protection plug removed and a carbon steel class 3000 Ib plug fitted.

Air vent

S7 separator

Fig. 8 Separator on a steam line

IM-F05-01-EN-ISS2 CMGT

Isolation valve

Strainer

CA trap

4. Commissioning

After installation or maintenance, ensure that the system is fully functioning. Carr y out tests on any alarms or protective devices.

Fig. 9 Heat transfer processes and valve protection

Fig. 10 Compressed air distribution

5. Operation

Separators are designed to gather together small droplets of entrained liquids and then separate them from the gas/ vapour f low. The relatively heavy droplets impinge on the internal baffles 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.

IM-F05-01-EN-ISS2 CMGT

6. Maintenance

Note: Before ac tioning any maintenance progr amme obser ve the 'Safety information' in Section 1.

Fi g. 11

Table 1 Recommended tightening torques

There are no internal components that

require maintenance.

Warning

Separator Item Size

IM-F05-01-EN-ISS2 CMGT

4½"¾"

7/16"

½"

9/16"

¼" UNF x ¾"

5/16" UNF x ¾"

3/8" UNF x ¾"

N m (lbf ft)

28 40

(9 (21 (30

10)

24)

37)

Fig. 12

S2, S3, S12 and S13

Table 2 Recommended tightening torques

There are no internal components that

Warning

require maintenance.

Separator Item Size

S12

S13

2 2" 60 A/F M72 190 - 210 (140 - 155)

DN40 DN50 DN65 DN80

DN100 DN125 DN150 DN200

2 2" 46 A/ F M56 150 - 165 (110 - 121)

DN40 DN50 DN65 DN80

DN100 DN125 DN150 DN200

46 A/ F 60 A/F 46 A/ F 60 A/F 60 A/F 60 A/F 60 A/F 60 A/F

46 A/ F 46 A/ F 46 A/ F 60 A/F 60 A/F 60 A/F 60 A/F 60 A/F

M56 M72 M56 M72 M72 M72 M72 M72

M56 M56 M56 M72 M72 M72 M72 M72

N m (lbf ft)

150

190 150 190 190 190 190 190

150 150 150 190 190 190 190 190

165

210

165

210

165

210

(110 (140 (110 (140 (140 (140 (140 (140

(110 (110 (110 (140 (140 (140 (140 (140

121)

155)

121)

155)

121)

155)

IM-F05-01-EN-ISS2 CMGT

Suppor t bracket

Fig. 13

S5 and S6

Fig. 14

S7 and S8

Table 3 Recommended tightening torques

Separator Item Size N m (lbf ft)

5 DN15 - DN50 46 A/F 180 - 200 (133 - 150)

7. Spare parts

There are no spare parts required or available for these components.

IM-F05-01-EN-ISS2 CMGT

Spirax Sarco S1, S2, S7, S8, S3 Installation And Maintenance Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual