BPW32 DN15, DN20 and DN25 Balanced Pressure Wafer Steam Trap

BPW32 DN15, DN20 and DN25 Balanced Pressure Wafer Steam Trap
1263050/6
IM-P126-07
ST Issue 6
BPW32 DN15, DN20 and DN25
Balanced Pressure Wafer Steam Trap
Installation and Maintenance Instructions
1. Safety information
2. General
product information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
IM-P126-07
Printed in the ST
UKIssue 6
1
© Copyright 2007
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.
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 falls within category SEP and therefore does not carry the
mark.
Product
BPW32
i)
DN15 to DN25
Group 2
Gases
Group 2
Liquids
SEP
SEP
The product has been specifically designed for use on steam, air or water /
condensate which are 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 covers 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 pipeline at some
previous time. Consider: flammable materials, substances hazardous to health,
extremes of temperature.
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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.
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.
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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 in excess of 260°C (500°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.
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2. General product information
2.1 General description
The BPW32 is a compact wafer pattern stainless steel balanced pressure steam trap for
pressures up to 21 bar g (304.5 psi g). It has an internal strainer, is maintainable and is suitable
for installation between two pipeline flanges. It offers both weight and space saving over
conventional traps.
Capsule fill and operation
Standard capsules are marked with the letters 'STD' for operation at approximately 13°C
(23.4°F) below steam saturation temperature.
Optionally, the capsule can be supplied for sub-cooled operation with a 'SUB' fill which
operates at approximately 24°C (43.2°F) below steam saturation temperature or for
near-to-steam a 'NTS' fill which operates at approximately 6°C (10.8°F) below steam saturation
temperature.
Standards
This product fully complies with 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 further information see the following Technical Information sheet TI-P126-06.
Fig. 1
2.2 Sizes and pipe connections
DN15, DN20 and DN25 to fit between standard flanges PN40, ANSI 150, ANSI 300, JIS 10,
JIS 16 and JIS 20.
IM-P126-07 ST Issue 6
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Pressure psi g
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Steam
saturation
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Pressure bar g
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Temperature °F
Temperature °C
2.3 Pressure / temperature limits
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The product must not be used in this region.
The product should not be used in this region or beyond its operating range as
damage to the internals may occur.
Body design conditions
PMA Maximum allowable pressure
50 bar g @ 38°C
TMA Maximum allowable temperature
260°C @ 33 bar g
Minimum allowable temperature
0°C
PMO Maximum operating pressure
21 bar g @ 260°C
TMO Maximum operating temperature
260°C @ 21 bar g
Minimum operating temperature
0°C
Note: For lower operating temperatures consult Spirax Sarco.
Designed for a maximum cold hydraulic test pressure of: 75 bar g
6
PN50 /ANSI 300
(725 psi g @ 100°F)
(500°F @ 478 psi g)
(32°F)
(304 psi g @ 500°F)
(500°F @ 304 psi g)
(32°F)
(1088 psi g)
IM-P126-07 ST Issue 6
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.
3.3
Remove protective covers from all connections and the protective film from all
name-plates, where appropriate, before installation on steam or other high
temperature applications.
3.4
The BPW32 is intended for installation in a vertical line with flow from top to bottom,
this will ensure that it is self-draining. It can also be installed in other planes if required.
Standard flange gaskets to be used - supplied by customer.
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).
4. Commissioning
After installation or maintenance ensure that the system is fully functional. Carry out tests on
any alarms or protective devices.
5. Operation
The operating element is a capsule containing a small quantity of a special liquid with a boiling
point below that of water. In the cold conditions that exist at start-up, the capsule is relaxed.
The valve is off its seat and is wide open, allowing unrestricted removal of air. This is a feature
of all balanced pressure traps and explains why they are well suited to air venting.
As condensate passes through the balanced pressure steam trap, heat is transferred to the
liquid in the capsule. The fill liquid boils before steam reaches the trap. The vapour pressure
within the capsule causes it to expand and the trap shuts. Heat loss from the trap then cools
the water surrounding the capsule, the fill condenses and the capsule contracts, opening the
valve and releasing condensate until steam temperature approaches again at which the cycle
is repeated.
IM-P126-07 ST Issue 6
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6. Maintenance
Note: Before actioning any maintenance program observe
the 'Safety information' in Section 1.
6.1 General information
Before undertaking any maintenance on the trap it must be isolated from the supply line and
return line and any pressure allowed to safely normalise to atmosphere. The trap should then
be allowed to cool. When reassembling, ensure that all joint faces are clean. Always ensure the
correct tools, safety procedures and protective equipment are used at all times. When the
maintenance is complete open the isolation valves slowly and check for leaks.
6.2 Replacing the internals set:
- Unscrew the cap (2) from the body (1) and lift out the spacer plate (5), capsule (3), spring (4)
and screen (6). Lugs are provided on the side of the body for easy location during
disassembly.
-
Insert the new internal set (see Section 7) together with the spacer plate (5) which is reusable.
Refit the cap (2) using a two pin spanner. The thread should be coated with a small
amount of anti-seize lubricant.
If the end cap (2) is replaced then a new internals set should be fitted as detailed above.
Note: A suitable tool is manufactured by GEDORE 'Caliper face spanner', 635-456, Gedore
No. 44/7 pin diameter to be 4 mm. This is available to order through Spirax Sarco.
Table 1 Recommended tightening torques
or
Item
Connections Size
Nm
(Ibf ft)
mm
1 and 2
8
ANSI 150
All sizes
M45
10 - 15
(7.2 - 10.7)
PN40
ANSI 300
JIS 10
JIS 16
JIS 20
DN15
M45
10 - 15
(7.2 - 10.7)
DN20
M51
15 - 20
(10.7 - 14.3)
DN25
M59
20 - 25
(14.3 - 17.8)
IM-P126-07 ST Issue 6
7. Spare parts
The spare parts available are shown in solid outline. Parts drawn in broken line are not
supplied as spares
Available spares
3, 4, 5, 6, 7
2
Internal set
End cap
How to order spares
Always order spares by using the description given in the column headed 'Available spares'
and state the size, model no. and capsule option required.
Example: 1 - Internal set for a DN20 BPW32 balanced pressure wafer steam trap with 'STD'
fill capsule.
Note: The capsule can be identified from the letter stamped on the name-plate on the cap
(e.g. STD, SUB or a NTS).
A standard capsule (STD) will be supplied, unless specified otherwise on the order.
1
6
4
3
5
7
2
Fig. 2
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10
IM-P126-07 ST Issue 6
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IM-P126-07 ST Issue 6
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