Remote Pilot 25 TRM Pilot Operated Temperature

Remote Pilot 25 TRM Pilot Operated Temperature
INSTALLATION AND MAINTENANCE INSTRUCTIONS
IM-1-1116A-US
October 2015
Remote Pilot 25 TRM Pilot Operated
Temperature Regulator
Safety Information
1.6 The system
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.
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.
1.1 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.
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.
i) The products have been specifically designed for use on
steam, air or water/condensate. 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.
1.8 Temperature
Allow time for temperature to normalise after isolation to avoid
danger of burns.
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.
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
iii) Determine the correct installation situation and direction
of fluid flow.
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.
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.
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.
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.
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.
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.
Post ‘warning notices’ if necessary.
1.3 Lighting
1.12 Handling
Ensure adequate lighting, particularly where detailed or intricate
work is required.
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.
1.4 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.
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1.13 Residual hazards
Steam Mains - Do's and Dont's:
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 300°C (572°F).
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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.
Steam
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.
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 perfectly safe. However, because
of its mechanical properties, 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.
Prevention of tensile stressing
Pipe misalignment:
Installing products or re-assembling after maintenance:
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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.
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Do not over tighten.
Use correct torque figures.
Prevention of water hammer
Steam trapping on steam mains:
30 - 50 metre intervals
Gradient
Steam
1:100
Trap set
Condensate
Gradient
1:100
Trap set
Condensate
Steam
Trap set
Condensate
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3
2
1
3
5
6
4
2
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Flange bolts should be gradually tightened across
diameters to ensure even load and alignment.
Thermal expansion:
Guides
Limit rods
Guides
Medium
distance
Axial movement
Short
distance
Small
lateral
movement
Large
lateral
movement
Fixing point
Fixing point
Limit rods
Axial movement
Guides
Guides
Small
lateral
movement
Assembly Instructions
Start-Up
Caution: Installation should be performed by qualified service
personnel. Before installation or any maintenance is
performed, ensure that all main valve and pilot stop valves
are closed and that all internal pressure has been relieved.
When breaking any connection, piping/bolts should be
removed slowly so that if the line is under pressure, this
fact will be apparent before completely removing the pipe
or component. Always relieve pressure before breaking any
joint. Allow main valve and lines to cool before beginning
installation.
1. First make certain that all stop valves are closed.
1. If a pilot valve is mounted, remove the present pilot valve assembly from the main valve body. Leave the main valve cover
and the copper tubing connections intact.
Large
lateral
movement
2. Adjust the temperature pilot to the temperature required by
turning the red adjustment knob 3C. Caution: DO NOT loosen
Allen set-screw in the red temperature knob.
3. Open stop valves in the following order:
a. Open stop valves ahead of steam trap on steam supply line.
This will insure condensate free steam at the regulator inlet.
b. Open downstream stop valve.
c. Slowly open inlet stop valve.
4. After the system has stabilized itself, check thermometer temperature. Readjustment of the temperature pilot (red knob 3C)
may be necessary. Note: In the event the temperature indicated on the calibrated dial does not agree with the thermometer, the temperature pilot can be recalibrated to match the
thermometer. See Installation and Maintenance Instructions IMI 1.1116 for recalibration procedure.
2. Assemble the adapter (B) and cap (E) to the main valve body
using studs (C) and nuts (D) in the location which the pilot valve
assembly was removed in Step 1. Make sure that the locating
pin is properly entered into the locating pin hole. Place gaskets
(F) between castings as shown on the attached drawing.
5. Important - Retighten all pilot flange connections to insure
steam tight joints.
3. Assemble body (A) and pilot valve assembly as shown in the
attached drawing. Be sure to place gasket between pilot valve
and body (A). Make certain that the locating pin is properly entered into the locating pin hole.
4. Note direction of pilot flow indicated on the attached drawing.
Connect 5/16” copper tubing or 1/4” pipe between exit flow of
adapter (B) and inlet end of body (A) indicated with arrow on
casting.
5. Connect a similar pipe between outlet of body (A) to the inlet of
adapter (B) .
6. Carefully uncoil the flexible tubing avoiding sharp bends and
kinks.
7. Support flexile tubing to protect it against mechanical damage.
8. Keep flexible tubing away from hot pipe lines or other hot surfaces.
9. Install thermostatic bulb to unit to be controlled. Make certain
that the entire bulb is exposed to the medium being controlled.
Accuracy of regulation depends on the bulb being located in a
representative location with adequate circulation over it.
10. If a separable socket is used for the temperature bulb, it is
recommended that the socket be packed with a heat transfer
compound to minimize lag in response to temperature changes
caused by the insulating air layer between bulb and socket.
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5/16" Copper Tubing
or 1/4" Pipe
Steam
Supply
Moisture
Separator
Main
Control Valve
Strainer
Regulated
Steam to
Process
Strainer
Float &
Thermostatic
Steam Trap
E
C
B
D
Remote
Temp.
Pilot
1/2" Pipe
Check
Valve
Float &
Thermostatic
Steam Trap
Sensor
Check
Valve
Hook-up for 25 TRM Temperature Control
Remotely Mounted (within 15 ft. of Main Valve)
5/16"" copper or 1/4" pipe
F
Capillary Tubing
View of 25 Series Main Valve from
Inlet Connection
Temperature Pilot
A
1/2" Pipe
Use 1/2" pipe to anchor
assembly to a rigid surface
To Drip Station
(if required)
Remote Mounting Kit Components - Stock #99134
A
(1) 1/2" MP Valve Body
B
(1) Adapter Bracket
C
(4) Studs
D
(4) Nuts
E
(1) E Pilot Cap
F
(2) Pilot Gaskets
Sensing Bulb
Notes:
1. Piping shown in phantom lines to be supplied by
end user.
2. Remote pilot should not be more than 15 feet
from the main valve.
Spirax Sarco Applications Engineering Department
Toll Free at:
1-800-575-0394
SPIRAX SARCO, INC. • 1150 NORTHPOINT BLVD. • BLYTHEWOOD, SC 29016
PHONE 803-714-2000 • FAX 803-714-2200
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