IM-P150-07 ST Issue 4 1
TD120
Thermodynamic Steam Trap
Installation and Maintenance Instructions
IM-P150-07
ST Issue 4
1500050/4
1. Safety information
2. General
product information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
Printed in the UK © Copyright 2007
IM-P150-07 ST Issue 42
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.
Warning
The cover gasket contains 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.
This product complies with the requirements of the European Pressure Equipment
Directive 97/23 / EC and all falls within category 'SEP'. It should be noted that products
within this category are required by the Directive not to carry 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 and protective film from all name-
plates, where appropriate, before installation on steam or other high temperature
applications.
IM-P150-07 ST Issue 4 3
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.
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.
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-P150-07 ST Issue 44
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 of some products
may reach temperatures of 550°C (1 022°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-P150-07 ST Issue 4 5
2. General product information
2.1 General description
The TD120 is a maintainable medium high pressure thermodynamic steam trap with integral
strainer designed specifically for steam mains drainage applications up to 250 bar g
(3 625 psi g).
Standards
This product fully complies with the requirements of the European Pressure Equipment
Directive 97/23 / EC.
Certification
This product is available with certification to EN 10204 3.2. Note: All certification/ inspection
requirements must be stated at the time of order placement.
Note: For additional information see Technical Information Sheet TI-P150-01.
2.2 Sizes and pipe connections
½", ¾" and 1" Butt weld ends to suit Schedule 160 pipe.
½", ¾" and 1" Socket weld ends to ANSI B 16.11 Class 6000.
DN15 and DN25 standard integral flange DIN 2549 PN250.
DN15, DN20 and DN25 standard integral flanges: ANSI 600, ANSI 900, ANSI 1500,
DIN 2547 PN100 and DIN 2548 PN160.
Fig. 1 Thermodynamic steam trap
IM-P150-07 ST Issue 46
Pressure bar g
Temperature °C
A
B
C
DEG
Steam
saturation
curve
F
The product must not be used in this region.
A - B Socket weld and butt weld ends.
A - C Flanged to DIN 2549 PN250.
A - D Flanged to ANSI 1500.
A - E Flanged to DIN 2548 PN160.
A - F Flanged to ANSI 900.
A - G Flanged to ANSI 600 and DIN 2547 PN100.
2.3 Pressure/ temperature limits (ISO 6552)
Body design conditions PN250
PMA Maximum allowable pressure 250 bar g @ 522°C (3 626 psi g @ 972°F)
TMA Maximum allowable temperature 550°C @ 153 bar g (1 022°F @ 2 220 psi g)
Minimum allowable temperature -29°C (-20°F)
PMO
Maximum operating pressure
250 bar g (3 626 psi g)
for saturated steam service
TMO Maximum operating temperature 550°C @ 153 bar g (1 022°F @ 2 220 psi g)
Minimum operating temperature 0°C (32°F)
Note: For lower operating temperatures consult Spirax Sarco.
PMOB Maximum operating backpressure should not exceed 50% of the upstream pressure
Minimum operating differential pressure 8 bar g (116 psi g)
Designed for a maximum cold hydraulic test pressure of 375 bar g (5 439 psi g)
Pressure psi g
Temperature °F
IM-P150-07 ST Issue 4 7
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.
A typical installation is shown in Figure 2, page 9.
3.3 Remove protective covers from all connections and protective film from all name-plates,
where appropriate, before intallation on steam or other high temperature applications.
3.4 The preferred installation is in a horizontal pipe with the name-plate uppermost.
The trap will operate in other positions, but the service life may be affected! The
installation should have a small drop leg preceding the trap. Access for removal of
the integral strainer screen should also be provided.
3.5 Suitable isolation valves must be installed to allow for safe maintenance and trap
replacement.
Where the trap discharges into a closed return system a non-return valve should be fitted
downstream to prevent flow.
3.6 Always open isolation valves slowly until normal operating conditions are achieved - this
will avoid system shocks. Check for leaks and correct operation.
3.7 Always ensure the correct tools, safety procedures and protective equipment are used
at all times.
3.8 The disc and seating surfaces of these traps have been produced to a high degree of
flatness to achieve good shut-off under high pressure conditions. An integral strainer
helps prevent dirt and scale from entering the trap. If particles become entrapped between
the disc and seat, the high flow velocities can cause rapid wear and erosion. A separate
strainer and / or dirt pocket will provide additional protection.
3.9 When a socket weld or butt weld trap is being installed the welding should be carried
out to an approved proceedure of a recognised standard.
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).
IM-P150-07 ST Issue 48
5. Operation
The TD120 is a thermodynamic steam trap which uses a disc to control the release of
condensate and to trap steam. The trap cycles open and closed to discharge condensate,
close to steam temperature, and closes tight between discharges.
The disc, which is the only moving part, rises and falls in response to dynamic forces produced
by the partial re-evaporation (flashing) of hot condensate. Cool condensate, air and other
non-condensible gases enters the trap through the central orifice, lifts the disc, and discharges
through the outlet orifice. When the condensate approaches steam temperature, a portion of it
flashes as it enters the trap. The flash steam passes at high velocity over the underside of the
disc and collects in the control chamber above. The resulting pressure imbalance, forces the
disc downward onto the seating surfaces, stopping the flow. The trap remains tightly closed
until the loss of heat through the trap body lowers the control chamber pressure, allowing the
inlet pressure to raise the disc and repeat the cycle.
4.1 Commissioning with particular reference to venting air
Initial start-up can take several hours (or days) to bring the system to normal operating
pressure and temperature. Even if the trap has replaced another trap while the main system
has remained running, it may still be necessary to vent air from the drop leg. If the trap is
some distance from stop valve 'A' (Figure 2), it could be possible to air lock the pipework
between valve '
A' and the trap (i.e. the trap closes to air and does not readily allow steam to
enter the pipework). To overcome this on start-up the following procedure should be adopted.
With the stop valve '
B' closed, drain valve 'C' open, slowly and partially open stop valve 'A'.
This will discharge the air, condensate and any pipe debris.
Valve '
C' should then be fully closed, and valves 'A' and 'B' slowly opened to the fully open
position. When the trap is more than 2 m (6 ft) away from the vertical drain leg, a suitable drop
leg at the inlet to the trap can improve its service life by ensuring that the trap does not see a
mixture of steam and condensate.
Important note
After the trap has been in service at normal operating pressure and temperature for
24 hours, it is essential that the cover nuts be retightened (see Table 1, page 11). This will
ensure the correct compression of the gasket under service conditions.
4. Commissioning
IM-P150-07 ST Issue 4 9
Steam main
Drain valve 'C'
Stop valve 'A'
Stop valve 'B'
TD120
Strainer
(Optional)
Dirt pocket / dirt leg
To drain
or return
To drain
or return
Fig. 2 Typical installation
Alternative layout
Suggested drop leg if the
TD120 is located more
than 2 m (6') away from
the main drop leg.
To drain
IM-P150-07 ST Issue 410
Note:
Before actioning any maintenance programme observe the 'Safety information' in
Section 1.
Warning
The cover gasket contains a thin stainless steel support ring which may cause physical
injury if not handled and disposed of carefully.
6.1 How to fit the disc:
-
Unscrew the four nuts (8) and remove the top cover.
-
Lift off the disc (2).
-
Fit a new disc making sure that the body seating surface (6) is not unduly worn. If the body
seating surface is only slightly worn it can be refaced by lapping individually on a flat
surface such as a surface plate.
If the wear is too great to be rectified by simple lapping, the seating faces on the body must
be ground flat and then lapped. The total amount of metal removed in this way should not
exceed 0.25 mm.
-
Reassemble the cover using a new gasket (7), making sure that the gasket faces are perfectly
clean. Ensure that the name-plate is placed over the studs prior to reassembling nuts.
-
Retighten the cover nuts (8) to the recommended tightening torques (see Table 1).
-
After 24 hours in service, and when reassembling, the nuts should be tightened in a diagonally
opposite sequence.
-
Open the isolation valves slowly until normal operating conditions are achieved.
-
Check for leaks.
6.2 How to clean or replace the strainer:
-
Access to the strainer screen can be obtained by undoing the nuts (8) and removing the
bottom cover.
-
Remove the strainer screen (4).
-
Fit the new or cleaned strainer screen into the recess on the underside of the cover.
-
A new gasket (7) should be fitted and the cover refitted.
-
Retighten the cover nuts (8) to the recommended tightening torques (see Table 1).
-
After 24 hours in service, and when reassembling, the nuts should be tightened in a diagonally
opposite sequence.
-
Open the isolation valves slowly until normal operating conditions are achieved.
-
Check for leaks.
6.3 To replace the cover studs:
-
After removing the old cover studs, fit new cover studs until the studs bottom out. The use
of a thread lubricant is recommended.
Note: Two sets of studs are included when the spares are supplied. For traps with flat topped
covers, the long studs should be used. For traps with profiled forged covers, the shorter
studs should be used.
6. Maintenance
IM-P150-07 ST Issue 4 11
Table 1 Recommended tightening torques
or
Item Part N m (lbf ft)
mm
4 22 A / F 25 - 35 (18 - 26)
8 Nut 23 A / F M16 160 - 180 (118 - 132)
8 Stud M16 85 - 90 (62.5 - 66)
8
2
6
7
7
4
8
Fig. 3
IM-P150-07 ST Issue 412
7. Spare parts
The spare parts available are shown in solid outline. Parts drawn in broken line are not
supplied as spares.
Available spares
Set of internals 2, 7 (2 off), 4
Strainer screen 4, 7
Set of cover gaskets 7 (2 off)
Set of cover studs and nuts 8 (8 off), 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 trap.
Example: 1 - Strainer screen for a Spirax Sarco DN15 TD120 thermodynamic steam trap.
Fig. 3
8
8
4
7
2
7
8
8
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