Spirax Sarco TD120 Bedienungsanleitung

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

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

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Pressure bar g

Temperature °C

DEG

Steam

saturation

curve

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

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