Spirax Sarco BPM21L User manual

IM-P124-09 ST Issue 1 1
BPM21L Carbon Steel
Balanced Pressure Thermostatic Steam Trap
Installation and Maintenance Instructions
1. Safety information
2. General
product information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
Printed in the UK © Copyright 2005
IM-P124-09
ST Issue 1
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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.
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 Group 2 Group 2
Gases Liquids
BPM21L SEP SEP
i) 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 before installation.
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. Safety information

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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 300°C (572°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 Safety information - Product specific
The cover gasket contains a thin stainless steel support ring which may cause
physical injury if not handled and disposed of carefully.
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.
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 identified as hazardous or potentially
hazardous.

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2. General product information
2.1 Description
The BPM21L is a compact, carbon steel, balanced pressure steam trap, having an
internal strainer. It is ideally suited for applications where space is important such as OEM
machinery.
Options
Capsule fill and operation - As standard, the capsule fitted will operate at approximately
13°C (55°F)below steam saturation temperature (STD). Alternatively, a near-to-steam
(NTS) capsule can be fitted that will operate at approximately 6°C (43°F) below steam
saturation temperature or a sub-cooling (SUB) capsule can be fitted that will operate at
approximately 24°C (75°F) below steam saturation temperature.
Non-return / check valve - All versions can be supplied with an integral check valve and
are designated BPM21LCV.
Standards
The product fully complies with the requirements of the European Pressure Equipment
Directive 97 / 23 / EC.
Certification
The product is available with a manufacturers Typical Test Report.
Note: All certification / inspection requirements must be stated at the time of order placement.
Note: For all additional information see Technical Information Sheet, TI-P124-08.
2.2 Sizes and pipe connections
and ½" screwed BSP (BS 21 parallel) or NPT.
Socket weld ends (½"only).
Fig. 1 BPM21L

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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.
Steam
saturation
curve
Temperature °C
Body design conditions PN25
PMA Maximum allowable pressure 25 bar g @ 120°C (362 psi g @ 248°F)
TMA Maximum allowable temperature 242°C @ 20 bar g (467°F @ 290 psi g)
Minimum allowable temperature -10°C (14°F)
PMO Maximum operating pressure 21 bar g @ 217°C (304 psi g @ 422°F)
TMO Maximum operating temperature 242°C @ 20 bar g (467°F @ 290 psi g)
Minimum operating temperature 0°C (32°F)
Designed for a maximum cold hydraulic test pressure of: 38 bar g (551 psi g)
2.3 Pressure / temperature limits (ISO 6552)
Pressure psi g
Temperature °F

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BPM21L
DVC41 Condensate out
150 mm (6") minimum
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 trap is designed for installation in any position, horizontal or vertical, preferably
with a drop leg immediately preceding the trap - typically 150 mm (6") see Figure 2.
Caution: If no drop leg is allowed 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.
3.5 Unless the BPM21LCV is used, always fit a non-return (check) valve downstream of
any steam traps which discharge into condensate return lines where backpressure is
experienced. This is most commonly caused by a rising condensate line. The check
valve will prevent the steam space flooding when the inlet pressure is reduced or the
steam is shut off. Use a suitable valve such as the Spirax Sarco DCV41, see Figure 2.
3. Installation
Steam
in
Fig. 2 Small process equipment

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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.
3.6 When the trap is discharging to atmosphere, it is strongly recommended to install a
diffuser on the outlet side of the trap. This reduces any problem of noise and erosion
by cushioning high velocity discharge. See TI-P155-02 for further information.
3.7 Isolation valves must be installed to allow for safe maintenance and trap replacement.
3.8 Open isolation valves slowly until normal operating conditions are achieved.
3.9 Check for leaks and correct operation.
3.10 Ensure adequate space is left to remove the cover from the body for maintenance.
Minimum withdrawal distance for the cover is 20 mm (¾").
3.11 Welding into the pipeline - There is no need to remove the operating capsule from the
product providing the welding is performed using the electric arc method. For specific
weld procedures consult the relevant National and International welding standards.
Note: If the trap is to discharge to atmosphere ensure it is to a safe place as the discharging
fluid may be at a temperature of 100°C (212°F).

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Table 1 Recommended tightening torques
Item Part or N m (lbf ft)
mm
3 Valve seat 17 A / F 50 - 55 (37 - 41)
7 Cover bolts M8 x 25 14 - 18 (11 - 13)
6. Maintenance
Note: Before actioning any maintenance programme observe
the ‘Safety information’ in Section 1.
Warning
The cover gasket contains a thin stainless steel support ring which may
cause physical injury if not handled and disposed of carefully.
6.1 General information
Before undertaking any maintenance on the trap it must be isolated from both 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.
Maintenance can be completed with the trap in the pipeline, once the safety procedures have
been observed. It is recommended that new gaskets and spares are used whenever maintenance
is undertaken. Ensure that the correct tools and necessary protective equipment are used at
all times. When maintenance is complete open isolation valves slowly and check for leaks.
6.2 How to fit a new capsule and seat:
- Remove the cover (1) and spring (10) from the body (6) by unscrewing the cover bolts (7).
- Remove the capsule (2) and spacer plate (9).
- Unscrew the valve seat (3) from the body (6).
- Clean or replace the strainer screen (4).
- Replace the valve seat (3) and tighten to the recommended torque (see Table 1).
- It is recommended to fit a new cover gasket (5) reassemble the spacer plate (9) ensuring
that it is located centrally on the valve seat (3).
- Reassemble the capsule (2), spring (10) and cover (1). Make sure the spring is positioned
with the narrow end downwards.
Note: Care must be taken to ensure the cover bolts (7) are progressively tightened to the
recommended torque (see Table 1).
6.3 How to clean or replace the strainer screen:
- Remove the cover (1) and spring (10) from the body (6) by unscrewing the cover bolts (7).
- Remove the capsule (2) and spacer plate (9).
- Unscrew the valve seat (3) from the body (6).
- Clean or replace the screen (4) as required.
- Replace the valve seat (3) and tighten to the recommended torque (see Table 1).
- It is recommended to fit a new cover gasket (5), reassemble the spacer plate (9) ensuring
that it is located centrally on the valve seat (3).
- Reassemble the capsule (2), spring (10) and cover (1). Make sure the spring is positioned
with the narrow end downwards.
Note: Care must be taken to ensure the cover bolts (7) are progressively tightened to the
recommended torque (see Table 1).

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7
5
4
3
2
Fig. 3
10
9
8
6
1

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Spare parts
The spare parts available are shown in solid outline. Parts drawn in broken are not supplied
as spares.
Available spares
Capsule and seat assembly set 2, 3, 5, 8, 9, 10
Gasket set 5, 8
Strainer screen (packet of 3) 4
How to order spares
Always order spares by using the description given in the column headed 'Available spares'
and state the size and type of trap.
Example: 1 off Capsule and seat assembly set for a Spirax Sarco ½" BPM21L balanced
pressure thermostatic steam trap having STD operation at 13°C below steam saturation
temperature.
7. Spare parts
7
5
9
2
3
(not an
available
spare)
10
Fig. 4
8
4