PC10HP Pipeline Connector ANSI/ASME 600

IM-P128-13
1280051/2
ST Issue 2
PC10HP
Pipeline Connector (ASME 600)
Installation and Maintenance Instructions
1.Safety information
2.General
product information
3.Installation
4.Commissioning
5.Spare parts and
Maintenance
IM-P128-13 ST Issue 2
© Copyright 2014
1
Printed in GB
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 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. These products comply with the requirements of the European Pressure
Equipment Directive 97 / 23 / EC and all fall within category 'SEP'. It should be noted that
products within this category are required by the Directive not to carry the mark.
i) These products have 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.
1.2Access
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.
1.3Lighting
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 opened and closed progressively to
avoid system shocks.
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IM-P128-13 ST Issue 2
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.
1.8Temperature
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.
1.12Handling
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').
1.14Freezing
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.
1.15Disposal
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-P128-13 ST Issue 2
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2. General product information
Steam trap options:
- UBP32
- UTD30L
- UTD30H
- UTDS46M
- UTD52L
- UIB30
- UIB45
- UFT32
- USM21 and
- USM32
The universal trap gaskets are supplied with the trap
Fig. 1 The PC10HP has been designed for use with the above listed steam trap options
2.1 General description
The PC10HP pipeline connector is designed for use with the above listed swivel connector
steam traps up to the maximum pressure / temperature limitations of the selected steam trap. The
connector can be fitted into any vertical or horizontal pipeline and the trap can also be rotated
through 360º to ensure their correct orientation for operation.
The principle is that the pipeline connector can be fitted into the pipeline without the trap fitted
and the trap is connected afterwards using just two bolts. The trap can be simply and quickly
removed / replaced to minimise system downtime and reduce maintenance resource.
Standards
These products fully comply with the requirements of the European Pressure Equipment
Directive 97 / 23 / EC.
Certification
This product is available with certification to EN 10204 3.1. Note: All certification / inspection
requirements must be stated at the time of order placement.
Note: For additional information see the following Technical Information sheet TI-P128-10.
2.2 Sizes and pipe connections
Condensate inlet / outlet DN15, DN20 and DN25
½", ¾" and 1" screwed BSP or NPT
Socket weld ends to ASME B 16.11 / BS 3799 Class 3000.
Flanged versions are also available upon request. Please contact Spirax Sarco for further details.
2.3Kv values
Size
DN15 Kv1.1
DN20 1.1
For conversion: Cv (UK) = Kv x 0.963 Cv (US) = Kv x 1.156
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DN25
1.1
IM-P128-13 ST Issue 2
2.4 Pressure / temperature limits (ISO 6552)
Steam
saturation
curve
Pressure bar g
Temperature °F
Temperature °C
Pressure psi g
The product must not be used in this region.
Notes:
-If flange connections are fitted then these will limit the maximum design conditions of the
pipeline connector.
- The maximum operating limits of the complete assembly will be dictated by the steam trap
of choice. Reference the specific steam trap Technical Information sheet for its maximum
pressure / temperature limitations.
Body design conditions
PMA Maximum allowable pressure
TMA Maximum allowable temperature
ASME Class 600
99.3 bar g @ 38°C
(1 440 psi g @ 100°F)
425°C @ 56 bar g
(797°F @ 812 psi g)
Minimum allowable temperature
0°C(32°F)
Maximum operating pressure
PMO
for saturated steam service
64 bar g @ 281°C
(928 psi g @ 538°F)
TMO Maximum operating temperature
425°C @ 56 bar g
(797°F @ 812 psi g)
Minimum operating temperature 0°C(32°F)
ote: For lower operating temperatures consult Spirax Sarco
N
PMOB Maximum operating backpressure should not exceed 80% of the upstream pressure
Designed for a maximum cold hydraulic test pressure of 149 bar g
Size AWeight
½" 61.50.6
¾" 73.50.7
1"
90.0
ä
2.5Dimensions / weights (approximate) in mm and kg
(2 161 psi g)
A
ä
0.7
IM-P128-13 ST Issue 2
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3. Installation
Note: Before actioning any installation observe the 'Safety information' in Section 1.
There are a number of criteria which must be satisfied to ensure that the swivel connector
trap will operate correctly and ensure effective condensate removal. Referring to the
Installation and Maintenance Instructions, product markings and Technical Information
Sheet, check that the product is suitable for the intended installation:
3.1
Check materials and maximum pressure / temperature 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
The correct steam trap and end connection must be selected to meet the system design
conditions.
3.3
3.4
Steam trap connector bolts are supplied with the selected steam trap.
3.5
Determine the correct installation situation and direction of fluid flow. The PC10HP
must be installed with flow in the direction of the arrow. Flow can be horizontal (either
direction), vertical or inclined. The flow direction is clearly marked on the trap body
or pipeline connector.
Caution: The connection face for the swivel connector steam trap of choice must
always be in the vertical plane unless stated on the product specific steam trap
Installation and Maintenance Instructions provided with the product.
The joint between the PC10HP and trap is sealed with high integrity spirally wound gaskets.
During installation the gasket faces must be protected from damage caused by weld
splatter, knocks, etc.. to the trap gasket face. Hence care must be taken when installing
the PC10HP into the pipework. It is recommended that the trap is installed immediately
the PC10HP is in the pipework. Alternatively, the trap can be joined to the PC10HP prior
to installation.
3.6 Remove
protection covers from all connections, where appropriate, before
installation on steam or other high temperature applications.
3.7
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 back flow.
3.8
Always open isolation valves slowly until normal operating conditions are achieved –
this will avoid system shocks. Check for leaks and correct operation.
3.9
Always ensure the correct tools, safety procedures and protective equipment are
used at all times.
3.11When a socket weld version is being installed the welding should be carried out to
an approved procedure of a recognised standard. Guidance instructions regarding
welding socket weld versions are provided in Section 3.12
Notes:
1. If the trap is to discharge to atmosphere, ensure that it is to a safe place. The discharging
fluid may be at a temperature of 100°C (212°F).
2.After installation it is recommended that the PC10HP pipeline connector is insulated to
minimise radiated heat losses and to protect personnel from burns risk. Please note that
there are some trap types that should not be insulated.
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IM-P128-13 ST Issue 2
3.12 Welding into pipeline of socket weld variants
A universal weld procedure covering the requirements of different national and international
standards and practices is difficult to provide - specifically regarding the welding procedure, welding
conditions (run number, consumable size, current, voltage, polarity), storage of consumables
and make / type of consumables due to the abundance of appropriate consumable suppliers.
Therefore, this is only advice based on British standards to be used for guidance on the essential
requirements of welding socket weld pipeline connectors into the pipeline.
This will allow a user to select an appropriate weld procedure from those available to that user.
This advice is not intended to be a substitute for a weld procedure: it is for guidance only.
The welding of pipeline connector DN15, DN20, DN25
socket weld to pipe DN15, DN20 and DN25 Schedule 80
Parent material(s)
Description
PC10HP - Austenitic stainless steel with
minimum tensile strength up to and including
485 N /mm².
Pipe - Carbon steel with minimum tensile
strength up to and including 430 N / mm².
Specification(s)
ASTM A351 CF8 - PC10HP
ASTM A106 Gr. B - pipe
Material group(s)
R - PC10HP
A1- Pipe
Parent material(s) dimensions
DN15
DN20
DN25
PC10HP Pipe PC10HP Pipe PC10HPPipe
Thickness (mm)
8.85 3.73 5.50 3.91 5.04.55
O / D (mm)
39.00
21.30
39.00
26.70
45.0
33.40
Pipe is to BS 1600 Schedule 80
Joint type
Socket joint to ANSI B16.11 Class 3000 lb (This is equivalent to BS 3799)
Welding process(es)
Manual Metal Arc (MMA)
Weld preparation
Welding position(s)
Dimensioned sketch
All: site welded Diametrical clearance 1.0 mm maximum
t
Pipe
PC10HP
1.5 mm approximately
Ref.- BS 2633 : 1987 : Section 3.1 and Fig. 9
Continued on page 8
IM-P128-13 ST Issue 2
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3.12 Welding into pipeline of socket weld variants continued
Welding consumables
Filler material: Composition - Low C: 23% Cr: 12% Ni:
Specification - BS 2926: 1984: 23-12 L BR
Method of preparation and
cleaning
Socket : As supplied and wire brushed.
Pipe : Mechanically cut and wire brushed.
Shielding gas / flux:
Not applicable
Additional information
Parent material temperature
Run sequence and completed
weld dimensions
1. Fit-up using tack welds.
Sketch
Interpass temperature
Not applicable
Post-weld
heat treatment
This edge is not to be
completely melted away
1.4t minimum
Preheat temperature
Only required when ambient is below 5°C then
'warm to touch'
None required
1.4t minimum
Pipe
PC10HP
Ref.- BS 806 : 1990 : Section 4 : Clause 4.7.3
4. Commissioning
After installation and maintenance ensure that the system is fully functional. Carry out tests
on any alarms or protective devices.
5. Spare parts and Maintenance
Please note that there are no spare parts for the PC10HP pipeline connector.
If spare parts are required for the steam trap that is connected to the PC10HP we
recommend that you use the product specific Installation and
Maintenance Instructions for that particular product.
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IM-P128-13 ST Issue 2