Spirax Sarco FTC80 User manual

IM-IBR16-32IN Issue 1 1
1. Safety information
2. General product
information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
© Copyright 2017
Printed in India
IM-IBR16-32IN
Issue 1
FTC80
Cast Steel Ball Float Steam Trap
Installation and Maintenance Instructions

IM-IBR16-32IN Issue 12

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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. The FTC80 complies with the requirements of the Indian Boiler
Regulations, 1950.
i) The product has 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.
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 minimize
them.
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.
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.
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. General safety information

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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 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.
1.12 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 may reach
temperatures 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').

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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.
1.17 Safe lifting of Spirax Sarco products
Please note that the Spirax Sarco model FTC80 comes complete with tapped holes
located in the cover, which may be used for lifting purposes at the sole risk and
responsibility of the purchaser.
The purchaser is responsible for the selection and use of the correct eye-bolt or
shackle combination and is, in whole, responsible for all lifting operations and
operator competency at their location. Spirax Sarco will ensure that any tapped hole
will have a spot face larger than the shoulder of a standard eye-bolt to allow seating
down to the shoulder. However, it should not be assumed that an eye-bolt is suitable
for lifting the product simply on the basis of shoulder size.
Spirax Sarco will accept no responsibility for loss or damage real or imagined,
caused by incorrect or inappropriate lifting of our products.
Spirax Sarco will ensure that the tapped holes provided are clearly marked with the
exact size and thread form. We will also carry out in conjunction with a third party,
a test on a sample of each product so provided and make available a copy of the
test procedure and test certificate on request.
Furthermore and without obligation Spirax Sarco will attach to each product
provided with such holes, threaded or otherwise, a disclaimer affixed to the product
explaining the purchaser's duty under the LOLER regulations for safe off loading
and lifting of the product at their premises.

IM-IBR16-32IN Issue 16
2. General product information
2.1 Description
As standard, the FTC80 ball float steam trap is supplied with a right to left (R-L) flow
configuration having horizontal connections and has provision for adding an air venting option;
Please note that the unit is supplied with a ¾" socket weld connection in the cover with a
plug screwed into the fitting. It has been designed for floor mounting and is suitable for most
high-pressure process and drainage applications. Its simple robust ball float mechanism
ensures excellent resistance to waterhammer. All internals are easily accessible for in-line
maintenance and a drain port allows full body drainage. It has a large maintainable strainer
screen that extends service intervals and is located in an accessible flanged chamber.
Standard
This product fully complies with the requirements of the Indian Boiler Regulations, 1950.
Certification
All certification / inspection requirements must be stated at the time of order placement.
Note: For further information see TI-IBR16-34IN.
2.2 Sizes and pipe connections
ASTM body
1½" and 2" ASME (ANSI) B 16.11
Class 6000 socket weld.
Note: Other connections
are available upon request but
may limit the operating range –
Please consult Spirax Sarco for
further information.
1½" and 2" ASME (ANSI) B 16.5
Class 600 flanges.
Drain plug connection is " screwed BSP or NPT as standard.
2.3 Available options
Factory fitted external BDV2 manual air vent having a ½" BSP or NPT screwed connection.
Note: As standard the unit is supplied with a ¾" socket weld connection in the cover with a
" NPT (ASTM body) screwed plug fitted.
Fig. 1 1½" and 2" FTC80 (R-L) having socket weld connections
Optional extra 1

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2.4 Pressure / temperature limits (ISO 6552)
The product must not be used in this region.
Body design conditions ASME (ANSI) 600
PMA Maximum allowable pressure 100 bar g @ 52 °C (1 450 psi g @ 125.5 °F)
TMA Maximum allowable temperature 425 °C @ 57 bar g (797 °F @ 826.5 psi g)
Minimum allowable temperature -29 °C (-20.2 °F)
PMO Maximum operating pressure 80 bar g (1 160 psi g)
for saturated steam service
TMO Maximum operating temperature 425 °C @ 57 bar g (797 °F @ 826.5 psi g)
Minimum operating temperature 0 °C (32 °F)
Maximum differential
FTC80-45 45 bar (653 psi)
∆PMXpressure FTC80-62 62 bar (899 psi)
FTC80-80 80 bar (1 160 psi)
Designed for a maximum cold hydraulic test pressure: 150 bar g (2 176 psi g)
Temperature °C
Pressure bar g
Steam
saturation
curve
Pressure psi g
Temperature °F

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3. Installation
Notes
Before conducting any maintenance activities 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 its intended use.
Warnings
The gaskets contained in this product incorporate a thin stainless steel support ring,
which may cause physical injury if not handled and disposed of carefully.
The strainer screen is manufactured from sheared perforated sheet which may cause
physical injury if not handled and disposed of carefully.
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.
Suitable isolation valves must be installed to allow for safe maintenance / replacement.
3.2 Appropriate high temperature jointing compound must be used on the drain plug and
air vent plug threads. Please see Section 6.7 of this document.
3.3 Determine the correct installation situation and direction of fluid flow. The flow direction
will be clearly marked on the trap cover. A typical installation is shown in Figure 2.
Where the trap discharges into a closed return system a non-return valve should be
specified downstream.
3.4 Remove protection covers from all connections and protective film from all
name-plates, where appropriate, before installation on steam or other high
temperature applications.
3.5 The trap is provided with integral feet for floor mounting or for being supported as
such. If for any reason the unit is not floor mounted then any surrounding structures
need to be capable of supporting the weight of the trap and the fluid it may contain.
Such structures or flooring must be level so that the float arm rises and falls vertically.
3.6 The trap should be fitted as close to the outlet of the plant to be drained as possible
otherwise the trap can steam lock and this could lead to the system becoming
waterlogged. The trap should be fitted below the outlet, with a small drop leg
immediately preceding the trap, typically 150 mm (6"). See Figure 2. If no drop leg is
allowed for then it may be possible (under low load conditions) for steam to flow over
the condensate in the bottom of the pipe and reach the trap.
3.7 Where steam traps are fitted in exposed conditions, the possibility of freezing damage
may be reduced by thermal insulation, draining and / or isolation. The trap is provided
with a drain point, blanked off by a " hexagon headed plug.
3.8 When a socket weld trap is being installed the welding should be carried out to an
approved procedure of a recognised standard.
3.9 Access and withdrawal distance for removal of the integral strainer screen and cover
should be provided.
3.10 Access to the cover bolts should receive due consideration as the recommended
torque value will require the use of a large torque wrench or torque multiplier / gear
headed wrench.
Note: If the trap is to discharge to atmosphere, ensure that it is to a safe place. The
discharging fluid may generate high noise levels and be at a temperature of 100 °C (212 °F).

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Fig. 2 Typical installation of FTC80
Commissioning with particular reference to venting air
It can take several hours or even days to bring a new system to normal operating pressure
and temperature. Even if the trap has replaced another one, while the main system has
remained running, it may still be necessary to vent air from the drop leg. If the trap is some
distance from the upstream isolation valve it could be possible to air lock the pipework between
the valve and the trap (i.e. the trap closes to air and does not readily allow steam to enter the
pipework). To overcome this on start-up, as an option, the trap can be supplied either with
an external operated air vent (BDV2) or with an internal fixed bleed. As standard the air vent
hole is supplied with a plug fitted allowing the user to determine the method of air venting.
To commission a new or replacement installation first read the advice given in Section 5.2
on how to operate the air vent and clear an air locked trap, then proceed as follows. If
an internal fixed bleed is present then manual air venting is not required. Ensure that
the upstream isolation valve is closed before opening the air vent as documented in
Section 5.2. With the air vent now open, slowly open the upstream valve. Note that in order
to vent air from the drop leg and trap the isolation valve does not need to be opened fully.
Air, steam and / or condensate will now be vented from the top of the trap. Once the air
has been fully discharged close and tighten the air vent to the recommended torque
(see Table 1, page 20). Once the air vent is closed the upstream valve may be slowly opened
fully and the trap will begin to function normally.
After installation or maintenance always open isolation valves slowly to mitigate system
shocks and check for leaks. Ensure that the system is fully functional and carry out tests on
any alarms or protective devices.
The trap can be cold hydraulic tested, up to and including 150 bar g (2 176 psi g) without the
need to remove any internals. At pressures beyond this limit, permanent damage may occur
to the float that would render the trap inoperative.
Note: After the trap has been in service at normal operating pressure and temperature for
24 hours, it is essential that the cover bolts be retightened (see Figure 5, page 13). This will
ensure the correct compression of the gasket under service conditions.
Steam supply
Liquid
out / in
Heat exchanger
FTC80
Condensate
4. Commissioning

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5. Operation
5.1 General information
The ball float steam trap is a continuous discharge device, removing condensate the instant
it forms. On start-up the external air vent or internal fixed bleed allows air to bypass the main
valve preventing the system from air binding. When condensate arrives at the trap in sufficient
quantity to cause the water level to rise, it generates buoyancy in the float which in turn actuates
the lever mechanism and opens the main valve, keeping the system drained of condensate at
all times. When the condensate level falls the float drops. This causes the main valve to close
before live steam can reach it. The mechanism is balanced to retain a constant water level
above the main valve at all times (unless the trap is drained or bypassed). This constant water
seal is what prevents the loss of live steam. Float traps are renown for their high start-up load
handling capability, clean tight shut-off and resistance to both waterhammer and vibration.
5.2 Air binding and steam locking
Traps can steam lock or air bind and fail closed. In both cases a gas or vapour is preventing
condensate from reaching the trap with the result that the float is no longer buoyant and the
trap closes. In some cases the steam may condense (and the trap open) but trapped air has
no means of escape and the trap will be permanently disabled. To mitigate this problem,
either an external manually operated air vent BDV2 (12) can be provided at the top of the
cover for the rapid removal of air or incondensable gases. As an option, an air vent can be
fitted or internal fixed bleed. The trap with the BDV2 may be vented by turning the bleed
screw anticlockwise taking adequate measures (including thermal insulating gloves, safety
glasses and a long handled spanner) to protect the operator from any hot discharge. The A/F
dimension of the bleed screw is 17 mm and torque figures are provided in Table 1, page 20.
During actuation of the bleed screw and / or while the trap is pressurised, the main body (12)
of the BDV2 manual air vent (with a A/F dimension of 24 mm) should not be loosened. The
bleed screw is principally provided as a manually operated air vent for use during start-up
however, it could also be used to relieve steam locking. The manually operated air vent (12)
has not been designed to be used as a permanent vent and should be closed tight once the
blockage has been removed. To close the bleed screw, turn it clockwise. Further venting
may be required if residual air in the system finds its way to the trap in sufficient quantity to
prevent the float from being immersed in condensate or, on start-up after a prolonged period
of shutdown. If an internal fixed bleed is present then manual air venting is not required.
Fig. 3 Manually operated air vent (BDV2)
Note: The bleed screw needs to be turned
only by one half turn to one whole turn for the
air vent to work.
12
Bleed
screw
5.3 Correct sizing
It is important that the FTC80 is correctly sized to the running load of the plant being drained.
See the following Technical Information Sheets for full details on capacities: TI-IBR16-33IN
for the ASTM body. If the trap is undersized then it will still attempt to operate correctly
however condensate will back up. This could lead to a drop in plant efficiency, a greater risk
of waterhammer, and failure of the trap to open if the increase in head exceeds the differential
pressure of the mechanism.

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5.4 How to size the condensate return line
Where high volumes of flash steam are involved, it is important to select the correct pipework
downstream of a steam trap.
Incorrectly sized pipework will lead to rapid erosion of the pipework and / or product and
may also generate excessive backpressure on the trap. Clearly DN40 and DN50 (1½" and
2") FTC80's condensate discharge line will need to be significantly larger than 40 mm or
50 mm when high pressures and high flowrates are involved.
The section of pipeline downstream of the steam trap will carry both condensate and flash
steam at the same pressure and temperature. This is referred to as two-phase flow, and the
mixture of liquid and vapor will have the characteristics of both steam and water in proportion
to how much of each is present.
The two-phase fluid in the trap discharge line will have much more in common with steam than
water, and it is sensible to size on reasonable steam velocities rather than use the relatively
small volume of condensate as the basis for calculation. If lines are undersized, the flash
steam velocity and backpressure will increase, which can cause waterhammer, reduce the
trap capacity, and flood the process.
Steam lines are sized with attention to maximum velocities.
For further information refer to:
-Module 14.3 of the Steam and Condensate Loop Book (SC-GCM-01).
alternatively:
-www.spiraxsarco.com/resources/steam-engineering-tutorials/condensate-recovery/
sizing-condensate-return-lines.asp
5.5 Waterhammer
Waterhammer is an impact load caused by starting and / or stopping liquid flow suddenly. Due
to the immense impulse pressures generated, the results of waterhammer can be devastating.
Permanent deformation or even catastrophic failure could occur to the pressure containing
shell in such situations. The risk of damage from waterhammer can be mitigated by correct
plant design and the slow opening or closing of isolation valves.

IM-IBR16-32IN Issue 112
6. Maintenance
Note
Before conducting any maintenance activities observe the 'Safety information' in
Section 1.
Warnings
The gaskets contained in this product incorporate a thin stainless steel support ring,
which may cause physical injury if not handled and disposed of carefully.
The strainer screen is manufactured from sheared perforated sheet which may
cause physical injury if not handled and disposed of carefully.
6.1 General information
With suitable isolation, maintenance or repairs can be completed with the trap in the pipeline
once the safety procedures have been observed. In particular, prior to any maintenance
ensure that the trap is isolated, that no pressure exists within the unit and that components
can be handled without the risk of causing burns, either by allowing the trap time to cool or
by wearing thermal insulating gloves. It is recommended that new gaskets and spares are
used whenever maintenance is undertaken and that when reassembling, all joint faces are
clean. Ensure that the correct tools and necessary protective equipment are used at all times
and recommended torque values documented in Table 1 (page 20) are adhered to. When
maintenance is complete open isolation valves slowly and check for leaks.
6.2 Recommended service intervals
If installed and maintained in accordance with these instructions the trap will give many
years of trouble free operation. However, it is recommended that the trap receives an annual
inspection to give early warning of any potential issues and save the plant from unscheduled
interruptions.
6.3 How to access, replace or clean the strainer screen
The strainer screen (8) is located on the inlet side of the trap and is housed in a pocket
which is covered by a circular strainer flange (7) and retained by 4 off strainer nuts (11).
- Ensure the trap is depressurised (see 'Section 6.1 - General information')
- Unscrew the 4 off strainer nuts (11), lift off the strainer flange (7) and remove the strainer
gasket (9).
- Withdraw the strainer screen (8) by pulling it out of its pocket wearing suitable gloves to
guard against physical injury.
- Clean the strainer screen (8) or replace it, as required.
- Fit the cleaned or new strainer screen (8) by pushing it back into the trap, with the opening
in the screen toward the inlet.
- Clean both gasket faces, fit a new strainer gasket (9), fit the strainer flange (7) and tighten
the 4 strainer nuts (11) to the recommended tightening torque (see Figure 5, page 13).
The recommended bolting sequence and procedure is also given in Figure 5.

IM-IBR16-32IN Issue 1 13
Fig. 4 Strainer screen
8
11
7
9
A. Install bolts hand tight then "snug-up" to 15 N m to 30 N m but not to exceed 20%
of the target torque. Check flange gap for uniformity.
B. Tighten to 20% to 30% of target torque. Check flange gap for uniformity.
C. Tighten to 50% to 70% of target torque. Check flange gap for uniformity.
D. Tighten to 100% of target torque. Check flange gap for uniformity.
E. Continue to tighten the bolts on a rotational clockwise pattern until no further rotation
occurs at the target torque.
Sequence Recommend target torque for strainer flange
N m lbf ft
A10 - 16 7 - 12
B16 - 24 12 - 18
C40 - 56 29 - 41
D80 59
E80 59
1
3
2
4
Fig. 5 Recommended bolting sequence (1-3-2-4) and torque

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6.4 How to access the mechanism assembly
To gain access to the mechanism assembly (13) the cover (2) needs to be removed. For
this, and any servicing, the trap may remain in the pipeline.
- Ensure the trap is depressurised (see 'Section 6.1 - General information')
- Unscrew the 14 off cover nuts (5) and remove the cover (2) and cover gasket (3). The
cover (2) weighs in the region of 35 kg (77 lb) and threaded connections are provided (one
at each end) for the use of M12 lifting eyes. Place the cover (2) down in such a manner
as not to damage the gasket face.
- The mechanism assembly (13) will now be clearly visible. It is retained to the body by
2 off M12 assembly studs and nuts (18a and 18b), Figure 7. These are located at the
opposite end to the float (14). Unscrew the 2 assembly nuts (18b) and remove the
mechanism assembly (13) and assembly gasket (19).
Fig. 6 Cover removal
5
Provision for
a lifting eye
2
3
13 and 14
Provision for
a lifting eye
Dowel

IM-IBR16-32IN Issue 1 15
Fig. 7 Mechansim assembly removal
- The mechanism assembly (13) can now be worked upon remotely from the body (1) allowing
good access to such features as the seat (15), the ball head (16), retainer (17) and the
float mechanism assembly (13 and 14).
- To refit the mechanism assembly (13) back into the body (1) locate on to the two M12
assembly studs (18a) and evenly tighten the 2 off M12 assembly nuts (18b) to the
recommended torque (see Table 1, page 20) having remembered to fit a new assembly
gasket (19) to the cleaned gasket faces.
- Clean the gasket faces on the body (1) and the cover (2), fit a new cover gasket (3),
reposition the cover (2) and tighten the 14 off cover nuts (5) to the recommended torque
(see Figure 8) to reassemble the trap. The four shorter bolts should be fitted at the outlet
end of the trap where the cover flange is thinnest. A dowel in the body (1) ensures that
the cover (2) can only be assembled to the body (1) the correct way round.
1413
2 x (18b) nuts
Dowel
19
1
16 and 17
152 x (18a) studs

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Fig. 8 Recommended bolting sequence (1–2–3–4–5–6–7–8–9–10–11–12–13–14)
and torque
A. Install bolts hand tight then "snug-up" to 15 N m to 30 N m but not to exceed 20%
of the target torque. Check flange gap for uniformity.
B. Tighten to 20% to 30% of target torque. Check flange gap for uniformity.
C. Tighten to 50% to 70% of target torque. Check flange gap for uniformity.
D. Tighten to 100% of target torque. Check flange gap for uniformity.
E. Continue to tighten the bolts on a rotational clockwise pattern until no further rotation
occurs at the target torque.
Sequence Recommend target torque for studs and cover nuts
N m lbf ft
A45 - 85 33 - 63
B085 - 127 63 - 94
C121 - 298 89 - 220
D425 313
E425 313
1
2
459
8
610 3 7
1
2
45
98
6
10
3
7
11
12
14
13
Spiral tightening
sequence
starting in the
middle for non-
circular bolt
patterns

IM-IBR16-32IN Issue 1 17
6.5 Servicing the mechanism assembly
(Mechanism seat (15) and ball head (16))
- Ensure the trap is depressurised (see 'Section 6.1 - General information').
- Follow the instructions under Section 6.4 to access and remove the mechanism assembly
(13 and 14).
- Once removed, the mechanism assembly (13) is easily disassembled by removing each
spring clip (20) at the end of each pivot pin (21). The pins may then be withdrawn.
- The valve seat (15) and ball head (16) can now be accessed and replaced if necessary.
- To replace the seat (15) unscrew the old one from the mounting bracket (22). Tighten the
new seat (15) to the recommended torque (see Table 1, page 20). There is no need to
remove the pressed steel pivot frame during this operation.
- To replace the ball head (16) simply remove the retainer (17). The old ball head (16) should
drop out of its frame. Fit the new ball head (16) through the pivot frame and refit the retainer
(17). Ensure that the ball head (16) and the tabs on the frame are on the same side as one
another. The retainer (17) should be on the opposite side to the tabs on the pivot frame
(as shown in Figure 9).
- Reassemble the mechanism assembly (13) as shown using the pivot pins (21) and spring
clips (20). Refit the mechanism assembly as instructed under Section 6.4.
Fig. 9 Seat and ball head replacement
14
Valve head assembly
22
20
Ball head mounting frame
17
21
Tabs
18 15 16
19
13
20

IM-IBR16-32IN Issue 118
6.6 How to replace the fixed bleed and mechanism assembly
To gain access to the mechanism assembly (13) the cover (2) needs to be removed. For this,
and any servicing, the trap may remain in the pipeline.
- Ensure the trap is depressurised (see 'Section 6.1 - General information').
- Unscrew the 14 off cover nuts (5) and remove the cover (2) and cover gasket (3). The cover
(2) weighs in the region of 35 kg (77 Ib) and threaded connections are provided (one at
each end) for the use of M12 lifting eyes on the PN100 flanged traps and ½" UNC on socket
weld and class 600 flanged traps. Place the cover (2) down in such a manner as not to
damage the gasket face.
- The mechanism (13) will now be clearly visible. The mechanism assembly (13) is retained
to the body by 2 off M12 assembly studs (18a) and nuts (18b). These are located at the
opposite end to the float (14). It is also connected to the fixed bleed assembly via the pipe
support.
- Unscrew the two assembly nuts (18b) and remove the mechanism assembly (13) and
assembly gasket (19).
- To fit a new mechanism assembly (13) into the body (1) locate on to the two M12 assembly
studs (18a) and evenly tighten the 2 off M12 assembly nuts (18b) to the recommended
torque (see Table 1, page 20) having remembered to fit a new assembly gasket (19) to the
cleaned gasket faces.
- Clean the gasket faces on the body (1) and the cover (2), fit a new cover gasket (3),
reposition the cover (2) and tighten the 14 off cover nuts (5) to the recommended torque
(see Figure 8, page 16) to reassemble the trap. The four shorter bolts should be fitted
at the outlet end of the trap where the cover flange is thinnest. A dowel in the body (1)
ensures that the cover (2) can only be assembled to the body (1) the correct way round.

IM-IBR16-32IN Issue 1 19
Provision for
a lifting eye
5
2
3
14
13
18b
18a
1
Dowel
Fig. 10 Replacement fixed and mechanism assembly
Provision for
a lifting eye
19

IM-IBR16-32IN Issue 120
Table 1 Recommended tightening torques - see Figure 12
Item Part or
mm
Torque
N m lbf ft
5Cover nuts 30 A/F M20 425 314
11 Strainer nuts 19 A/F M12 80 59
12
Air
vent
Body 24 A/F ½" BSP or NPT See note below
Bleed screw 17 A/F M12 22 – 25 17 - 19
15 Valve seat 24 A/F M16 60 45
18b Assembly nuts 19 A/F M12 80 60
27 Drain plug 22 A/F ½" BSP or NPT See note below
Joining compound on threads
A high temperature manganese thread jointing compound is applied to the FTC80 threads
on the drain plug (as standard) air vent connection (if screwed connection is required) and
fixed bleed stud ( if requested). The jointing compound can be used in the temperature range
of -20 °C to 600 °C (-4 °F to 1112 °F) and of a pressure up to 193 bar g (2 799 psi g). Following
application, the joining compound must be allowed to cure for 5 minutes before assembly
and 24 hours before testing. It is resistant to high temperatures and pressures. It also resists
vibration and thermal expansion. Hemp may be used as reinforcement, this must be fully
wetted with the compound prior to assembly of the joint. It is suitable for use with high pressure
steam, non potable water, compressed air, LPG, natural gas and alcohol, but it is not suitable
for oils or petroleum products.
How jointing compounds are applied
Prior to applying the jointing compound, it is most important that both the male and female
threads are clean i.e. all traces of cutting fluid, rust, paint, grease and any other contaminant
is removed. If a joint is being remade then all traces of previous jointing compound etc must
be removed before applying fresh material.
Under normal pipe fitting practice, jointing compound is applied to the male thread and is
usually reinforced with a small quantity of hemp. Any excess compound which extrudes
around the joint when it has been assembled should be wiped clean.
Note: The recommended procedure for tightening taper threads is to screw the connection
until it is hand tight and then proceed to screw the component another 2 to 3 complete turns
to effect a seal.
6.7 How to replace the manually
operated air vent BDV2
- Turn the bleed screw anticlockwise by one half or one whole
turn to check that the trap is depressurised.
- Unscrew the air vent plug (12) and remove it from the trap.
- Tighten the new BDV2 air vent (12) to the recommended
torque (see Table 1).
12
Bleed
screw
Fig. 11