Forbes Marshall Tracer Line Trap Manual

FMTLT53-Y
Forbes Marshall Tracer Line Trap
with Integral Flange and Strainer
Forbes Marshall Tracer Line Trap with
Integral Flange and Strainer
FMTLT53-Y
Installation and Maintenance Manual
Energy Conservation | Environment | Process Efficiency www.forbesmarshall.com

1. Preface .................................................................................1
2. Important Safety Notes ........................................................1
3. Brief Product Information .....................................................3
4. Product Working Principle ...................................................5
5. Installation Guidelines ..........................................................6
6. Start-up and Commissioning ................................................6
7. Maintenance Guidelines .......................................................6
8. Troubleshooting .................................................................8
8. Available Spares .................................................................9
9. Warranty Period .................................................................9
Table of Contents
PLEASE NOTE - Throughout this manual this cautionary symbol is used to
describe a potential damage or injury that might occur if the safety
considerations are overlooked. This symbol denotes CAUTION, WARNING or
DANGER.
Forbes MarshallTracer LineTrap with Integral Flange and Strainer

1
1.
2.
Preface:
This manual is intended for anyone using, commissioning, servicing, or disposing the below
mentionedproductssafelyandefficiently.
ForbesMarshallTracerLineTrapwithIntegralFlangeand Strainer[FMTLT53-Y]
Size:DN15(½”)andDN20(¾”)
PLEASENOTE:
Throughout this manual the following cautionary symbol is used to describe a potential damage
orinjurythatmightoccurifthesafetyconsiderationsareoverlooked.
ImportantSafetyNotes:
Read this section carefully before installing/operating/maintaining the product. The
precautions listed in this manual are provided for personnel and equipment safety.
Furthermore, Forbes Marshall accepts no responsibility for accidents or damage
occurring as a result of failure to observe these precautions. Note that the product is
designedto performfor non-contaminatedfluids only. Acontamination inthe formof
chemical, foreign particle etc. can lead to problem with product performance and life
oftheproduct.
If these products in compliance with the operating instructions are, properly installed,
commissioned, maintained and installed by qualified personnel (refer Section 2.7) the safety
operations of these products can be guaranteed. General instructions for proper use of tools and
safetyofequipment's,pipelineandplantconstructionmustalsobecompliedwith.
2.1 Intendeduse:
Check if the product is suitable for intended use/application by referring to the installation
andmaintenanceinstructions,nameplatesandtechnicalinformationsheets.
i) Theproductissuitablefor useasdefined inthetechnical informationsheet.In casethe
need arises to use the product on any other fluid please contact Forbes Marshall for
assistance.
ii) Checkforthesuitabilityinconformancetothelimitingconditionsspecifiedintechnical
informationsheetoftheproduct.
iii) Thecorrectinstallationanddirectionoffluidflowhastobedetermined.
iv) Forbes Marshall products are not intended to resist external stresses, hence necessary
precautionstobetakentominimizethesame.
2.2 AccessibilityandLighting:
Safeaccessibilityandworkingconditionsaretobeensuredpriortoworkingontheproduct.
2.3 Hazardousenvironmentandmedia:
The product has to be protected from hazardous environment and check to ensure that no
hazardousliquidsorgasespassthroughtheproduct.
FMTLT53-Y

2
2.4 Depressurizingofsystemsandnormalizingoftemperature:
Ensure isolation and safety venting of any pressure to the atmospheric pressure. Even if the
pressure gauge indicates zero, do not make an assumption that the system has been
depressurized.Toavoiddangerofburnsallowtemperaturetonormalizeafterisolation.
2.5 Toolsandconsumables:
Ensure you have appropriate tools and / or consumables available before starting the work.
UseoforiginalForbesMarshallreplacementpartsisrecommended.
2.6 Protectiveclothing:
Consider for the requirement of any protective clothing for you/ or others in the vicinity
for protection against hazards of temperature (high or low), chemicals, radiation,
dangers to eyes and face, noise and falling objects.
2.7 Permitstowork:
All work to be carried out under supervision of a competent person. Training should be
imparted to operating personnel on correct usage of product as per Installation and
Maintenance instruction. “Permit to work” to be complied with (wherever applicable), in
case of absence of this system a responsible person should have complete information and
knowledgeonwhatworkisgoingonandwhererequired,arrangetohaveanassistantwith
his primary goal and responsibility being safety. “Warning Notices” should be posted
wherevernecessary.
2.8 Handling:
There is a risk of injury if heavy products are handled manually. Analyze the risk and use
appropriatehandling method by takinginto considerationthe task,individual, theworking
environmentandtheload.
2.9 Freezing:
Provision should be made to protect systems which are not self-draining, against frost
damage(inenvironmentwheretheymaybeexposedtotemperaturesbelowfreezingpoint)
tobemade.
2.10 Returningproducts:
CustomersandStockistareremindedthat,whenreturningproductstoForbesMarshallthey
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
environmentalrisk.
This information must be provided in writing including Health and Safety data sheets
relatingtoanysubstancesidentifiedashazardousorpotentiallyhazardous.
Forbes MarshallTracer LineTrap with Integral Flange and Strainer

3
3. BriefProductInformation:
FMTLT53-Y
3.1 Description:
The Forbes Marshall Forbes Marshall Tracer Line Trap with Integral Flange and Strainer
with Integral flange and Strainer, FMTLT53-Y is a forged carbon steel maintainable
balance pressure trap with integral flanged connections and has a Y-type strainer screen
having 0.8 mm dia. perforation.
Standard Unit FMTLT53-Y Having ‘E’ /’STD’ fill thermopod
Also available FMTLT53-C Having ‘E’ /’STD’ fill thermopod
and inbuilt check valve
3.2 Thermopod fill and operation:
Standard Thermopod is marked with the letter “T” for operation at approximately 12°C
below steam saturation temperature.
Optionally, the thermopod can be supplied for under cooling “U” operation at
approximately 24°C below steam saturation temperature or close to saturation 'C'
operation at approximately 6°C below steam temperature
3.3 Sizes and Pipe Connections:
DN 15 ANSI 150, 300
DN 20 ANSI 150
Note: IBR approved FMTLT53-Y can be supplied on request.
3.4 Limiting Conditions:
3.5 Product Dimension and Drawing:
PMA-Max allowable pressure 50 bar g @ 50°C
TMA-Max. allowable temperature 400°C @ 35 bar g
PMO-Max. operating pressure 32 bar g
TMO-Max operating temperature 287°C
Cold hydraulic test pressure 42 bar g
Steam
Saturation
curve
400
300
200
100
00 10 20 21 30 32* 40 50
Temperature ºC
Pressure bar g
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.
PMO Maximum Operating Pressure 32 bar g

4Forbes MarshallTracer LineTrap with Integral Flange and Strainer
Materials:
3.6 Product Dimensions and Drawing:
FMTLT53-C
Check
Valve
4
5
7
1
10
2
9
3
6
88
Figure 1: Forbes Marshall Tracer Line Trap with Integral Flange and Strainer
No Part Material Standard
1 Cover Forged Carbon Steel ASTM A105
2 Thermopad Stainless Steel
3 Valve Seat St. Steel Type 431 ASTM A276
4 Strainer Screen St. Steel Type 304 ASTM A240
5 Cover Gasket Reinforced exfoliated graphite
6 Body Forged Carbon Steel ASTM A105
7 Cover Bolts Carbon Steel –HT Gr 8.8 IS 1367
8 Strainer Cap Forged Carbon Steel BS 3146 PART2 ANC2
9 Spacer Plate St. Steel Type 304 ASTM A240
10 Spring St. Steel Type 302 ASTM A276
Withdrawal
Distance
Withdrawal
Distance
Figure 2: Dimensional Drawing of FMTLT53-Y

5
4. ProductWorkingPrinciple:
The Forbes Marshall Tracer Line Trap works on thermostatic principle operates on the steam
temperature difference from sub-cooled condensate and air. Steam increases the pressure inside
the thermostatic element i. e. thermopod, causing the trap to close. As condensate and non-
condensate gases surrounding the thermopod, the temperature begins to drop and the
thermopodcontractsandopensthevalve.
4.1. OperationsofForbesMarshallTracerLineTrap [FMTLT53-Y]:[Referfigure1]
1. Theoperatingthermostaticelementisathermopod(2)containingasmallquantityofa
hydrocarbonliquidwithaboilingpointbelowthatofwater.
2. Whensteam isturned onduringstart-up, airandsub-cooled condensateisdischarged
asthevalveisoffitsseat(3)andiswideopen.
3. As condensate passes through the Forbes Marshall Tracer Line Trap heat is transferred
tothehydrocarbonliquidinthethermopod(2). Thehydrocarbonliquidboils(based on
thermopod(2)selected)beforesteamreachesthetrap.
4. The vapour pressure within the thermopod (2) causes it to expand which closes the
valveseat(3)andtrapremainsshut.
5. Heat loss from the trap cools the water surrounding the thermopod (2), the
hydrocarbonliquidcondensesandthethermopod(2)contracts,openingthevalveseat
(3) and releasing condensate until steam temperature approaches again at which the
cycleisrepeated.
FMTLT53-Y
Dimensions (approx.) in mm:
3.7 Capacity Chart:
Size A B C D E Weight
DN 15 125 57 54 30 40 7.5Kg
DN 20 125 57 54 38 40 7.5Kg
Differential pressure bar g (x 100 = kPa)
Hot water capacity Cold water capacity
0.1 0.2 0.3 0.5 1 2 3 4 5 10 20 32
3000
2000
1000
500
400
300
200
100
50
Condensate kg/h
FMTLT53-Y
FMTLT53-C
FMTLT53-Y
FMTLT53-C

6
5.
6.
7.
Installation Guidelines:
Note: Before implementing any installations observe the 'Important Safety notes” in
section 2. Referring to the Installation and Maintenance Instructions, name-plate and
Technical Information Sheet, check that the product is suitable for the intended
installation.
1. Before installing the Forbes Marshall Tracer Line Trap, flush the inlet piping to remove dirt
andoil.
2. Removeprotectivecoversfromallconnectionswhereappropriate,beforeinstallation.
3. The FMTLT53-Y steam trap is designed for installation with the thermopod in a horizontal
planeandthecoveratthetop,preferablywithadriplegimmediatelyprecedingthetrap.
4. Suitable isolation valves must be installed to allow for safe maintenance and steam trap
replacement.Removeallprotectivecapspriortoinstallation.
5. Open isolation valves slowly until normal conditions are achieved. Check for leaks and
attendifany.
Start-upandCommissioning:
6.1. Flushingoflines:
As part of pre-installation all fluid handling equipment particularly piping should be
thoroughlycleanedofscaleandtheinternaldebriswhichaccumulatesduringconstruction.
This is accomplished by blowing or flushing with air, steam, water and other suitable
medium.
Followthesestepstocarryouttheflushing.
1. Closetheisolationvalveandopenthebypassisolationvalve.
2. Drain the condensate 10 -15 minutes or until clear condensate starts coming out,
whicheverisearlier.
3. Nowslowlyclosethebypassisolationvalveandopenthetrapisolationvalve.
Note:ForadetailedprocedureonflushingoflinespleasevisitForbesMarshallwebsite.
6.2. Commissioning:
After installation or maintenance ensure that the system is fully functioning by
confirming fluid is passing through it.
1. After flushing of lines is complete, ensure that bypass valve closed and isolation
valve is opened.
2. Check for leaks and attend if any.
Maintenance Guidelines:
Note: Before undertaking any maintenance of the product it must be isolated from
both supply line and return line and ensure pressure is normalized to atmosphere. The
productshouldthenbeallowedto cool.Whenre-assemblingensurethatalljointfaces
areclean.
Forbes MarshallTracer LineTrap with Integral Flange and Strainer

7
7.1 RoutineandPreventiveMaintenance:
Please refer to the maintenance schedule mentioned in the table below to undertake
routinemaintenanceoftheForbesMarshallTracerLineTrap/AirVent.
7.2. ToolKit:
To carry out any maintenance on the Forbes Marshall Tracer Line Trap use the tools
mentionedbelow:
7.3. Recommendedtighteningtorque:
Table1:Recommendedtighteningtorques
7.4. Proceduretofitanewthermopodandseat:[Referfigure1]
1. Removethecover(1)fromthebody(6)byunscrewingthecoverbolts(7).
2. Removethethermopodassembly(2)andunscrewthevalveseat(3)fromthebody(6).
3. Clean the thermopod assembly (2) and valve seat (3) if damaged replace with new
thermopod assembly (2) and valve seat (3) and tighten valve seat (3) from the body (6)
totherecommendedtorqueasmentioninTable1.
4. Reassemblethespacerplate(9),thermopod(2)andspring(10).
5. Fit new cover gasket and retighten cover bolts (7) evenly to the recommended torque
asmentioninTable1.
7.5. Proceduretocleanorreplacethestrainerscreen:[Referfigure1]
1. Unscrewthestrainercap(8)andremovethestrainerscreen(4).
2. Clean or replace as required and reassemble the strainer cap (8) into the body (6),
ensuringthestrainerscreen(4)islocatedcentrally.
3. Using anti – seize compound on the threads to recommended torque as mention in
Table1.
No. Parameters to be checked Frequency for checking various parameters
Immediate Daily Weekly Monthly Quarterly Half
Yearly Annually
1Check FMTLT53-Y Y
2Repair / Replace steam traps - when testing
shows leaks Y
3Clean internals of FMTLT53-Y Y
4 Visual inspection for leakages Y
5Arresting any other leaks Y
Size Component Tool used and size
DN 15 / 20 Cover Bolt Box spanner of 17 mm (A/F)
Valve seat Box spanner of 17 mm (A/F)
Strainer Cap Box spanner of 26 mm (A/F)
Part No. Component Torque Range
3 Valve Seat 25 -35Nm
7 Cover Bolts 35 Nm
8 Strainer Cap 120 -135 Nm
FMTLT53-Y

8. Troubleshooting:
If the expected performance is unachievable after installation of the Forbes Marshall Tracer
Line Trap, check the following points for appropriate corrective measures.
*Seat stamping procedure:
Place valve seat on the fixture with thermopod on the valve seat (thermopod ball side resting on
the valve seat orifice) and tap slightly on the center with a mallet. Due to stamping a seating
surfaceisformedonthevalveseatorifice.
Note: Never attempt to modify the product. When replacing part with new, use the spare parts
listedinSection9.
Failure Mode Possible Cause Remedy
No condensate
discharge
(blocked).
Strainer screen is clogged with rust or scale. Clean strainer screen if rusted
replace with new one.
Valve seat is blocked. Clean the valve seat and
thermopod ball surface then
re-assemble the steam trap.
Thermopod may be over extended due to
excessive internal pressure caused by
superheat steam making it impossible for the
thermopod ball (valve head) to lift off from
valve seat.
Replace the thermopod
assembly.
Steam leakage
or blowing
from the outlet.
Foreign material has built-up between
thermopod ball (valve head) and valve seat. Clean the valve seat and thermopod ball surface then
re-assemble the steam trap;
check for any steam leak. If
valve seat damage replace the
seat assembly.
Valve seat and thermopod ball (valve head)
does not shut – off tightly. Clean both valve seat and thermopod ball after that *seat
stamping should be done.
Check if the thermopod is in good condition.
Thermopod should not be compressible
when cool; any flabbiness indicates failure.
Replace with new thermopod.
Valve seat damage due to wire drawing. Replace valve seat.
Improper installation. Check installation i.e. cap to be
on top / flow direction same as
arrow on the steam trap body.
Steam leaks
from body and
top cover joint.
Improper tightening torque on nut. Tighten to the suitable torque.
Cover gasket deterioration or damage. Replace with new cover gasket.
8Forbes MarshallTracer LineTrap with Integral Flange and Strainer

9. Available Spares:
The spare parts available are shown in heavy outline. Parts drawn in broken line are not
supplied as spares.
Figure 3: Parts available as spares (Heavy outline) of FMTLT53-Y
How to order:
Example: 1 no. DN 15 Forbes Marshall Forbes Marshall Tracer Line Trap with Integral Flange
and Strainer with Integral flange and strainer, FMTLT53-Y Carbon steel body maintainable
trap. Flanged Class 150 with 'T' fill Thermopod.
How to Order Spares:
Always order spares by using the description given in the column headed “Available spares'
and state the trap size and Thermopod fill type.
Example: Refer user manual for appropriate code numbers.
Warranty Period:
As per ordering information and agreements in the contract.
10.
Spares Part No. Spare Code
Thermopod & seat assembly set (State thermopod filling) ‘T’/ SUB fill 2,3,9,10 S2016280
Thermopod &seat assembly set ( State thermopod filling) ‘U’/ SUB fill 2,3,9,10 D2016281
Thermopod &seat assembly set ( State thermopod filling) ‘C’/ SUB fill 2,3,9,10 S2016283
Screen and gasket kit (Pack of 3) 4,5 S2016282
10
9
FMTLT53-Y

Forbes Marshall Pvt Ltd
Manufacturing: B-85, Phase II Chakan Indl Area, Sawardari, Chakan
Tal. Khed, Dist, Pune 410 501. Tel: [phone]
Sales: Opp 106th Milestone, Bombay Pune Road, Kasarwadi,
Pune 411034 Tel.: [phone]
CIN No: U28996PN1985PTC037806
Disclaimer:
This information is strictly proprietary and legally privileged. All contents herein shall be the property of Forbes
Marshall Pvt Ltd and having protection under the intellectual property rights. No part of this information or data may
be distributed or disclosed in any form to any third party. Any dissemination, use, review, distribution, printing or
copying is strictly prohibited, if you are not the intended recipient or user of this information.
Email : [email protected] www.forbesmarshall.com