Spirax Sarco 5953 Series User manual

3.562.5275.200
© Copyright 2018
EXPER
TISE SOLUTIONS SUST
AINABILITY
CTLS Issue 3 - 2019
5953 and 5954 Series Self-Operated Valves
Installation and Maintenance Instructions
1. General Safety information
2. General Product information
3. Installation
4. Maintenance
5. Spare parts
6. Faultnding

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Safeoperationoftheunitcanonlybeguaranteedifitisproperlyinstalled,commissionedand
maintainedbyaqualiedperson(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.Theproductslistedbelow
complywiththerequirementsoftheEuropeanPressureEquipmentDirective2014/68/EU(PED)
andcarrythemark whensorequired.TheproductsfallwithinthefollowingPressureEquipment
Directivecategories:
Unit Connection Group 1
Gases
Group 2
Gases
Group 1
Liquids
Group 1
Liquids
Actuator
mod. 595/596
Direct - SEP - SEP
Water pot IT - SEP SEP SEP
I) TheproductshavebeenspecicallydesignedforuseonsteamwhichisinGroup2oftheabove
mentionedPressureEquipmentDirective.Theproduct'suseonotheruidsmaybepossible
but,ifthisiscontemplated,SpiraxSarcoshouldbecontactedtoconrm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tted,orifmalfunctionoftheproductcouldresultinadangerousoverpressureorover
temperature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uidow.
IV)Spirax Sarcoproducts arenot intendedto withstandexternal stressesthat maybeinduced
byanysystemtowhichtheyaretted.Itistheresponsibilityoftheinstallertoconsiderthese
stressesandtakeadequateprecautionstominimizethem.
V) Removeprotectioncoversfromallconnectionsandprotectivelm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 substances in the pipeline
Considerwhatis inthe pipelineorwhat mayhave beeninthe pipelineat someprevious time.
Consider:ammable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,rehazard(e.g.duringwelding),excessivenoise,movingmachinery.
1.6 The system
Considerthee󰀨ect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ine󰀨ectiveofcontrols
oralarms.Ensureisolationvalvesareturnedonando󰀨inagradualwaytoavoidsystemshocks.
1. General Safety information

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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thedangerofburnsandconsider
whetherprotectiveclothing(includingsafetyglasses)isrequired.
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.
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250°C
(482°F).Manyproductsarenotself-draining.Takeduecarewhendismantlingorremovingtheproduct
fromaninstallation(referto'Maintenanceinstructions').Self-actingvalvesmayoperateunexpectedly
duringnormalservice.Theriskofpersonalinjuryshouldbeassessedforeachinstallation.Where
appropriate,suitableguardingshouldbetted.
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 Safetyinformation–Productspecic
ThesevalvescontainaPTFEcomponent.WithinitsworkingtemperaturerangePTFEisacompletely
inertmaterial,butwhenheatedtoitssinteringtemperatureitgivesrisetogaseousdecomposition
productsorfumeswhichcanproduceunpleasante󰀨ectsifinhaled.Theinhalationofthesefumes
iseasilypreventedbyapplyinglocalexhaustventilationtoatmosphereasneartotheirsourceas
possible.Smoking shouldbeprohibited inworkshopswherePTFEis handledbecausetobacco
contaminatedwithPTFEwillduringburninggiverisetopolymerfumes.Itisthereforeimportanttoavoid
contaminationofclothing,especiallythepockets,withPTFEandtomaintainareasonablestandardor
personalcleanlinessbywashinghandsandremovinganyPTFEparticleslodgedunderthengernails.
1.16 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.

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Caution
Iftheproductisnotusedinthemannerspeciedbytheseinstructions,theprotection
provided may be impaired.
1.17 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identiedashazardousorpotentiallyhazardous.
1.18 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.
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.
Pleaseremovelabelbeforecommissioning.
Prevention of water hammer
Steamtrappingonsteammains:
30÷50m.intervals
Steam
Condasate
Trapset
Gradient1:100
Gradient1:100
Trapset
Condasate
Condasate
Trapset
Steam

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Steam Mains - Do's ( ) and Dont's ( ):
Donotovertighten.
Usecorrecttorquegures.
Flangeboltsshouldbegraduallytightenedacross
diameterstoensureevenloadandalignment.
Prevention of tensile stressing
Pipemisalignment:
Installing products or re-assembling after maintenance:

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Thermal expansion:
Examplesshowingtheuseofexpansionbellows.Itishighlyrecommendedthatexpertadviseis
soughtfromthebellowsmanufacturer.
Guides
Short
distance
Medium
distance
Guides
Fixing
point
Fixing
point
Axialmovement
Limit
rods
Limitrods
Guides
Small
lateral
movement
Small
lateral
movement
Large
lateral
movement
Large
lateral
movement
Axialmovement
Guides

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2. General product information
2.1 Description
Series5953e5954PressureReducingandReliefValvesisarangeofdirectactingself-powered
valveofrobustconstruction,designedtooperateunderarduousconditionsbeingidealtocontrol
thepressureinwater,steam,airandinertgascircuits.
Asoft-seatedPTFEversionisavailable("G"su󰀩x)forair/gasapplicationsthatrequiretightshut-o󰀨
(limitedto200°C).Itisrecommendedthatfortheseapplications,amaximumpressureturndown
ratioof10:1isobserved.
Thevalveiscontrolledbythedownstreampressurewhichactsdirectlyonthediaphragm,opposing
theforcetowhichthespringiscalibrated.Understableconditionsdiaphragmforceandspringforce
areinastateofbalance,butanincreaseordecreaseindemandraisesorlowersthedownstream
pressurewhichinturnactsagainstthespringtocloseoropenthevalvetoadjusttheowrateand
maintainaconstantdownstreampressure.
Series5953and5954Valvesareperiodicmaintenancefree.
Note: Whenoperatingapressurereductiononliquids,itispossiblethatcavitationoccurs.Insuch
situations,itisessentialtousecontrolvalveswhicharespecicallydesignedtoavoiddamagesthat
cavitationmaycausebothtothevalveinternalpartsandtothecomponentsmountedimmediately
downstream.
Fig. 1 - 5953 Reducing Valve Fig.2-5954OverowValve

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2.2 Valve Body - Technical data
ValveBodyTechnicaldetailswithvaluesexpressedinbaraccordingtoANSIstandards,forvalves
inASTMA216Gr.WCBcarbonsteelandinASTMA351Gr.CF8Mstainlesssteel.
2.3 595-596 Actuators - Technical data
Available types 595 Reverse-acting CastSteel DiaphragmDimensions 150/250
596 Direct-acting SG Iron DiaphragmDimensions 150/250
Body design conditions
595-150 595-250
PMA - Maximumdesignpressure 15 bar 4,5bar
TMA -Temperaturamassimaammissibile 110°C *
Minimumdesigntemperature 0°C 0°C
Note: Watersealpotisusedfortemperatures>110°C.
Watersealpotisfilleduptomaximumlevelasshowninthepicture.
Foruseonsteam,itissuggestedtousewaterasthefillingliquid.Forotherworkingfluidsissuggested
tousewaterorglycerine,consistentwiththenatureoftheprocessfluid.
Caution: Thefillfluidshouldhaveadensitygreaterthantheprocessfluid.
Fig. 3 - IT Water seal pot
DN
Waterlling
connection
DN
Actuatorpressure
signal
DNConnection
to the pipeline
DN
MaxLevel
Fillingliquid
2.4 Water seal pot - Technical data

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Technical data
Connections
Version IT
Connection to the pipeline Buttweld 3/8”BW
Connection to the actuator Screwed 1/8”gas
Materials pot housing Carbonsteel
Pressure / temperature limits
IT
Bodydesigncondition PN16
PMA - Maximumallowablepressure @250°C15bar
TMA - Maximumallowabletemperature @15bar250°C
Minimumallowabletemperature 0°C
PMO - Maximumoperatingpressureforsaturatedsteamservice 15 bar
TMO - Maximumoperatingtemperature* 250°C
Minimumoperatingtemperature 0°C
Designedforamaximumcoldhydraulictestpressureof 24 bar
Pressure bar
Temperature°C
IT
0
50
100
150
200
250
0 5 10 15
Steam
saturation
curve
TheITWatersealpotcanbeusedintheentireareaofthechart
Pressure - temperature limits

3.562.5275.200
10
Nota: Before actioning any installation observe the 'Safety information' in Section 1.
3.1 General information
Thevalveshouldbeinstalledverticallyinahorizontalpipeline.
Foroperatingtemperaturesbelow110°Cthevalvemaybeinstalledwiththeactuatoreithervertically
upwardsorverticallydownwards(seeFig.4).
Foroperatingonsteamortemperaturesabove110°Cthevalvemustbeinstalledverticallydownwards
withthespring/actuatorbelowthepipeworkwithawatersealpotttedonthedownstreamcontrol
signallinetotheactuator,atypicalinstallationisshowninFig.5.
Fullattentionmustbegiventocorrectlyinstallthevalveasindicatedbytheowdirectionarrowon
thevalvebody.
* minimum of 1 m or 15 times the pipe diameter
**
Fig.4-Typicalinstallationfordownstreamtemperaturesbelow110°C,inwhichthevalvecan
also be installed with the actuator upwards.
**
*minimum of 1 m or 15 times the pipe diameter
ITWatersealpot
Fig. 5 - Typical installation for downstream temperatures higher than 110°C
3. Installation