INSTALLATION AND MAINTENANCE INSTRUCTIONS
IM-7-000-US
OCTOBER 2017
Separators for Steam, Air and Gas Systems
Types S1, S2, S3 Cast Iron Separators
S4A Fabricated Steel Separators
Safety Information
Safe operation of these products can only be guaranteed if
they are properly installed, commissioned, used and maintained
by qualied 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
prope r use of tools a nd safety e quipmen t must also be c omplied
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.
i) The products have been specically designed for use on
steam, air or water/condensate. 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.
i v ) S p i ra x S a rc o p ro d u c t s a re n o t i n te n de d t o wi t hs t an d e x te r na l
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 and
protective lm from all name-plates, 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
p i pe l in e a t s om e p re vi o us t i me . C on s id e r: a mm a bl e m a te r ia l s,
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.
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
c o m p li e d w it h . W h e re t h e r e i s n o s u ch s y st e m , i t is r e co m m e nd e d
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 injur y. 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
1.13 Residual hazards
I n n or m a l u se t h e ex te r n al s u r f a c e o f th e p ro d uc t
may be very 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 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,
wh en retu rning prod uct s to Sp ira x Sar co th ey
must provide information on any hazards and
the pre cauti ons to be t aken due to c ontam inatio n
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.
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 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.
7
Steam Mains - Do's and Dont's:
4
Steam
4
4
4
4
Prevention of tensile stressing
Pipe misalignment:
Installing products or re-assembling after maintenance:
Do not over tighten.
Use correct torque gures.
1
4 2
Flange bolts should be gradually tightened across
diameters to ensure even load and alignment.
3
7
7
7
7
7
7
3
6
2
1
5
4
8
Prevention of water hammer
Steam trapping on steam mains:
30 - 50 metre intervals
Gradient 1:100
Steam
Trap set
Condensate
Gradient 1:100
Trap set
Condensate
Trap set
Steam
Condensate
2
Thermal expansion:
Guides
Guides
Limit rods
Smal l
lateral
movement
Larg e
lateral
movement
Axial movement
Short
distance
Fixing point
Axial movement
Guides
Description
Moisture separators are used to improve the quality of steam
or compressed air either within the distribution system or on
the supply inlet to equipment. Removal of moisture is by a
series of bafes on which the suspended water droplets impinge and fall out by gravity to the drain, which must be piped
to a trap. The Model S1, S2, and S3 are cast iron construction. The Model S4A is of fabricated steel construction in accordance with Section VIII, Division I of the ASME Boiler and
Pressure Vessel Code.
Limiting Conditions
Model PMO TMO
S1 200 psig 388°F
S2, S3 145 psig 363°F
1/2” to 2” S4A 600 psig 650°F
2-1/2” to 6” S4A ANSI 150 lb 150 psig 650°F
2-1/2” to 6” S4A ANSI 300 lb 300 psig 650°F
2-1/2” to 6” S4A ANSI 600 lb* 600 psig 650°F
*optional
PMO - Maximum Operating Pressure
TMO - Maximum Operating Temperature.
Medium
distance
Fixing point
Limit rods
Guides
Smal l
lateral
movement
Operation
The separator’s simple, robust design requires no maintenance other than periodic vessel inspection. Trap and strainer should be maintained in accordance with recommended
procedures for each product.
Installation
A separator is required for proper removal of moisture from
steam, air and gas systems. Locate separator as close to
equipment to be protected as possible. Install in a horizontal
pipeline with ow direction to match arrow located on
separator with drainport at bottom for vertical downline discharge. Proper drainage to be provided through use of a
Spirax Sarco steam trap or liquid drain trap and Y strainer
as outlined below. Proper pipework support and provision for
thermal expansion should be used consistent with good engineering practice. 2-1/2” and larger sized S4A provide built
in pipe supports for ease of installation.
Recommended steam hook-up as shown in Fig. 1, 2 and
3 using a oat and thermostatic steam trap, Y strainer and
isolation valve. Figure 4 provides proper installation for compressed air or gas systems with liquid drain trap and pressure balance line.
Larg e
lateral
movement
Fig. 1
Typical installation
showing S4A anged
separator with reex
sight glass.
Fig. 2
Optional installation showing
screwed or socket weld S4A
separator with strainer prior
to separator inlet.
Fig. 3
Typical installation
showing S3
separator.
Fig. 4
Typical installation for
compressed air or gas,
showing an S1 separator
with liquid drain trap and
pressure balance line.
3
For any additional information you may require, contact: Spirax Sarco Applications Engineering Department
SPIRAX SARCO, INC. • 1150 NORTHPOINT BLVD. • BLYTHEWOOD, SC 29016
PHONE 803-714-2000 • FAX 803-714-2222
Toll Free 1-800-883-4411
SPIRAXSARCO.COM/GLOBAL/US
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