Spirax Sarco FTC23 User manual

3.341.5275.241 CH Issue 3 - 2013
© Copyright 2013
FTC23
Carbon Steel Ball Float Trap
Installation and Maintenance Instructions
1. Safety information
2. General product information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
The PED Directive 97/23/EC is repealed and replaced by the new
PED Directive 2014/68/EU with effect from 19 July 2016.

ATTENZIONE
Lavorare in sicurezza con apparecchiature
in ghisa e vapore
Working safely with cast iron products on steam
Informazioni di sicurezza supplementari - Additional Informations for safety
Lavorare insicurezza conprodotti
in ghisa per linee vapore
I prodotti di ghisa sono comunemente presenti
in molti sistemi a vapore.
Se installati correttamente, in accordo alle
migliori pratiche ingegneristiche, sono dispositivi
totalmente sicuri.
Tuttavia la ghisa, a causa delle sue proprietà
meccaniche, è meno malleabile di altri materiali
come la ghisa sferoidale o l’acciaio al carbonio.
Di seguito sono indicate le migliori pratiche
ingegneristiche necessarie per evitare i colpi
d'ariete e garantire condizioni di lavoro sicure
sui sistemi a vapore.
Movimentazione in sicurezza
La ghisa è un materiale fragile: in caso di
caduta accidentale il prodotto in ghisa non è
più utilizzabile. Per informazioni più dettagliate
consultare il manuale d'istruzioni del prodotto.
Rimuovere la targhetta prima di effettuare la
messa in servizio.
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 prac-
tices required to prevent waterhammer and
ensure safe working conditions on a steam
system.
Safe Handling
Cast Ironis abrittle material.If theproduct isdropped
during installation and there is any risk of damage
the product should not be used unless it is fully
inspected andpressure testedby themanufacturer.
Please remove label before commissioning

Vapore
Steam
Flusso
Flow
Esempi di esecuzioni corrette ( ) ed errate ( ) sulle linee vapore:
Steam Mains - Do's and Dont's:
Flusso
Flow
Prevenzione dai colpi d’ariete - Prevention of water hammer
Scarico condensa nelle linee vapore - Steam trapping on steam mains:
Intervalli di 30÷50 m. intervals
Pendenza - Gradient 1:100
Vapore
Steam Gruppo di scarico
Trap set
Condensa - Condasate
Pendenza - Gradient 1:100
Gruppo di scarico
Trap set
Gruppo di scarico
Trap set
Condensa - Condasate
Condensa - Condasate
Vapore
Steam

Prevenzione delle sollecitazioni di trazione
Prevention of tensile stressing
Evitare il disallineamento delle tubazioni - Pipe misalignment:
Installazione dei prodotti o loro rimontaggio post-manutenzione:
Installing products or re-assembling after maintenance:
Evitare l’eccessivo serraggio.
Utilizzare le coppie di serraggio
raccomandate.
Do not over tighten.
Use correct torque gures.
Per garantire l’uniformità del carico e dell'allineamento,
i bulloni delle ange devono essere serrati in modo
graduale e in sequenza, come indicato in gura.
Flange bolts should be gradually tightened across
diameters to ensure even load and alignment.

Dilatazioni termiche - Thermal expansion:
Gli esempi mostrano l’uso corretto dei compensatori di dilatzione. Si consiglia di richiedere una
consulenza specialistica ai tecnici dell’azienda che produce i compensatori di dilatazione.
Examples showing the use of expansion bellows. It is highly recommended that expert advise is
sought from the bellows manufacturer.
Guide
Guides
Distanza breve
Short distance
Punto di ssaggio
Fixing point
Movimento assiale
Axial movement
Distanza
media
Medium
distance
Tiranti limitatori
Limit rods
Piccolo
movimento
laterale
Small
lateral
movement
Piccolo
movimento
laterale
Small
lateral
movement
Ampio
movimento
laterale
Large
lateral
movement
Ampio
movimento
laterale
Large
lateral
movement
Guide
Guides
Guide
Guides
Guide
Guides
Punto di ssaggio
Fixing point
Tiranti limitatori
Limit rods
Movimento assiale
Axial movement

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1. Safety information
Safe operation of these products can only be guaranteed if they are properly installed, commissio-
ned, used and maintained by qualied personnel (see Section 1.11 on this document) 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. These products comply with
the requirements of the European Pressure Equipment Directive 97/23/EC and carry the mark
when so required. The products fall within the following Pressure Equipment Directive categories:
Product Group 1
Gases
Group 1
Liquids
Group 2
Gases
Group 2
Liquids
FTC23 DN40 2 SEP 1 SEP
FTC23 DN50 2 2 1 SEP
I) The product has been specically designed for use on steam, air or condensate which are
in Group 2 of the Pressure Equipment Directive. It has been also categorized for mediums
which are in Group 1 of the above mentioned Directive. In case of use with mediums of Group
1, please contact Spirax Sarco in order to conrm suitability of the product for the intended
application.
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
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 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 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. Con-
sider: 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.

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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 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 ope-
rating 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 very high temperatures
(350°C). 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specic
See the specic details relating to the product in the following "Maintenance" section.

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1.16 Disposal
The product is recyclable. No ecological hazard is anticipated with the disposal of this product
providing due care is taken.
In the event that, during the operation, the trap comes into contact with harmful substances, you will
need to dispose it in accordance with regulations under the current legislation.
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.

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2. General product information
2.1 Description
The FTC23 is a carbon steel ball oat steam trap having stainless steel cover and internals it is suitable
for use with saturated and superheated steam, on process equipments, and is the rst choice for drainage
of temperature controlled systems. This trap is ideal to solve problems caused by dirt steam carrying
solid and incondensable contaminants (salts and gasses), that lead quickly to fouling and accumulation
of sediment and debris, resulting in failure of the internal mechanism (This trap is typically used on
geothermal steam). The main feature is the innovative self-cleaning oating closure mechanism, which
allows automatic safe operation even in cases of severe contamination of the steam. Furthermore, the
position and size of main valve and seat makes easier the discharge of the condensate and of any
solid contaminant. The trap is able to modulate the condensate ow adapting immediately to sudden
and large variations of ow and pressure. Another key feature is the external manual lever that allows
to fully open the plug regardless of the presence or absence of condensate in the device. In this way
it is allowed both the removal of any sediment interior and checking the proper operation of the unit.
Standards
This product fully complies with the requirements of the European Pressure Equipment 97/23/EC
and carries the mark when so required.
Approvals
This product is available, on request, with certication as dened in EN 10204 2.2 or EN 10204 3.1.
Note: all certication/inspection requirements must be stated at the time of order placement.
Versions
FTC23-07, FTC23-23
Special executions available on request.
Sizes and pipe connections
Flanged EN 1092 PN 40
Flanged ASME B16.5, Class 150
Flanged ASME B16.5, Class 300, standard
DN 40 and 50 - 1½" and 2"
2.2 Pressure/temperature limits
PMA - Maximum allowable pressure @ 350°C 50 bar g*
TMA - Maximum allowable temperature @ 32 bar g 425°C*
Minimum allowable temperature -10°C
PMO - Maximum operating pressure @ 350°C 23 bar g*
Minimum operating temperature, danger of freezing considered 0°C
∆PMX - Maximum differential pressure FTC23-7 7 bar
FTC23-23 23 bar g*
Designed for a maximum cold hydraulic test pressure of 75 bar g
* Note: maximum operating pressure can be limited by the rating chosen for the anges.
2.3 Dimensions/weights (approximate) in mm and kg
DN A B C D E* Weight
1½" e 2" - 40 and 50 320 220 305 310 560 40,0
* Withdrawal distance for cover removal
A
B
C
D
E*

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35910 13
1421
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11
12
8
7
6
4
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2.4 Materials
N° Parts Material Designation
1Body Carbon steel ASTM A216 WBC
Stainless steel ASTM A351 CF8 (on request)
2Studs Carbon steel ASTM A193 B7
3Body gasket Exfoliated graphite reinforced steel
4Seat gasket Exfoliated graphite reinforced steel
5Seat Stainless steel ASTM A479 316
6Seat screws Stainless steel AISI 304
7Ball Stainless steel AISI 316
8Float lever Stainless steel ASTM A240 316
9Float lever pin Stainless steel ASTM A479 316
10 Float Stainless steel AISI 316
11 Washer Stainless steel AISI 304
12 Screw Stainless steel AISI 304
13 Cover Stainless steel ASTM A351 CF8
14 Plug (½") Carbon steel ASTM A105
15 Internal lever Stainless steel AISI 316
16 Graphite packing seals Graphite Graphite
17 Spacer Stainless steel AISI 316
18 Gland nut Stainless steel AISI 316
19 Manual lever Stainless steel ASTM A240 304
20 Nut and locknut Stainless steel AISI 304
21 Nut Carbon steel ASTM A194 8M

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2.5 Capacities
Capacities (kg/h)
The condensate discharge capacities shown below are based on the actual temperature of operation.
Differential pressure (bar g) FTC23-7 FTC23-23
0,3 310 n.a.
0,5 490 330
0,7 590 500
11.000 700
1,5 1.400 830
21.820 1.080
42.510 1.550
73.000 2.050
10 2.340
13 2.540
15 2.680
18 2.880
21 3.070
23 3.160
The choice of trap should be based on the following data:
a) Hourly amount of condensate to be discharged,
b) Effective differential pressure
Safety factor: 1,25 ÷ 1,5 with continuous duty; 2 ÷ 3 with intermittent duty.
3. Installation
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 tted, ensure
that a safety device is included in the system to prevent overpressurisation.
3.2 Determine the correct installation situation and the direction of uid ow.
3.3 Remove protection covers from all connections before installation.
3.4 The FTC23 trap must be installed below the draining point and respecting the ow direction
as shown on the body and with the oat lever positioned on an horizontal plane so that it
can verticallyu rise and lower freely.
3.5 Insert a strainer with an adequate capacity immediately ahead of the trap to prevent damage
to the device’s internal components; in systems with steam recovery, it is recommended to
mount a ow indicator downstream of the trap to check that it is working.
3.6 In order to allow a safe inspection for cleaning or maintenance purpose, install suitable
shut-off valve.

3.341.5275.241
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3.7 Avoid long pipe lenghts, especially if arranged horizontally or rising.
3.8 With minimum operating pressures, leave a hydrostatic head of at least one meter between
the drainage outlet and the trap.
3.9 If the device to be drained is tted with automatic temperature control, add a vacuum breaker.
3.10 If the condensate has to be raised to a height above the trap, install a check valve downstream
of the trap.
3.11 In case condensate return is at a higher level and operating pressure is low (< 1 bar g) or the
system is temperature controlled, please consider the adoption of a steam recovery pump.
3.12 In order to ensure an efcient discharge of incondensable, it is recommended to connect the
balancing connection of the trap to the drained system. For convenience of maintenance it
is recommended that a union is tted in the balance line near to the trap cover.
Note: If the trap is to discharge to atmosphere ensure it is to a safe place, the discharging uid may
be at a temperature of 100°C (212°F).
4. Commissioning
After installation or maintenance ensure that the system is fully functioning. Carry out tests on any
alarms or protective devices. Always open isolation valves slowly until normal operating condition
are achieved. Check for leaks and correct operation.
5. Operation
Ball oat steam traps quickly remove air, have continuous, modulating condensate discharge, and
can adapt immediately even to large or sudden variations of ow and pressure.
Given the absence of air eliminator, the drainage of incondensable can be ensured by connecting
a balance line to the drained system.
Drainage of Heat Exchangers
FTC23 is not tted with internal air eliminator
due to his high sensibility to contaminants.
For this reason the trap must be vented to
the H.E. (Fig. 1).
Fig. 1 Fig. 2
Drip Trap
In this case, it is not mandatory to vent the
trap. It depends on the specic working
conditions (Fig. 2).

3.341.5275.241 9
6. Maintenance
Note: Before performing any maintenance programme observe the "Safety information" in
Section 1.
Safety note: These traps are installed in medium and high pressure steam lines. Personnel
doing the maintenance should wear heavy gloves, long sleeve shirt and other equipment
designed to protect the wearer (goggles, face shield, etc...) in the event of a leak.
6.1 General information
To ensure the device’s long-term, safe operation, an adequate maintenance schedule should be
prepared, involving regular inspection and cleaning, for which some important instructions are given
below. All work must be carried out or be supervised by a suitable competent person.
Before actioning any maintenance on the trap it must be isolated from both the supply line and return
line and any pressure allowed to safely vented to atmosphere. The trap should then be allowed to
cool. In case of dangerous contaminants inside condensate, ensure that piping is completely drained
before removing the trap. When reassembling, ensure that all joint faces are clean.
6.2 Routine Maintenance
-Clean accurately the insides from sediments and deposits, with regard to seals housings and
mechanical components.
- Check that the ball oat is not demaged and does not contain water; in case of replacement, do
not force the oat lever, but remove it by dissasembling the split pin and properly blocking it before
unscrewing the oat nut.
-Check that the mechanism works properly and that the ball plug moves freely to a completely
closed position. To replace the main valve assembly, unscrew the four nuts from the bolts. When
mounting the new set, check its integrity and the position of the cover gasket, and tighten the nuts
uniformly.
- Tighten to the recommended tightening torques (see table below).
- Assemble the body correctly (with down arrow) in accordance with oat movement, then slowly
open the shut-off valve and gradually reach the normal operating conditions.
-Check for leaks and correct operation. Check periodically that bolts are properly tightened in order
to avoid leakage. This check must be performed specially after each cycle start and stop of the
palnt. In order to avoid risk of leakage from anges we recommend the adoption of proper ange
shields. In case of dangerous contaminants inside condensate, check chemical compatibility of
gaskets.
6.3 Use of the manual lever
The manual lever placed on the body of the trap is used to fully open the plug, independently from the
presence of condensate in the unit.
This action allows to verify that ow section is free and allows the removal of any sediment. Operate
the hand lever for a few seconds by turning from the vertical position of normal operation to horizontal
exhaust open. For effective action always bring the lever from one limit position to the opposite (120 °)
without forcing the mechanism. In case of leakage from the lever pivot, tighten the packing nut. If such
action were not enough, it is necessary to replace the seals.
Tab. 1 - Recommended tightening torques
Item o
mm N m
Stud M 16 x 70
Cover nuts 24 90
Seat bolts 13 M 8 x 20 15

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6.4 HowtottheSeatAssembly
- Unscrew the 8 cover nuts (21), remove the cover (13) keeping the lever (19) in vertical position
downwards and remove the body gasket (3).
- Extract the oat lever pin (9) and remove the complete group lever + oat.
- Unscrew the 4 seat screws (6), remove the seat (5) and the gasket (4).
- Fit the new seat (5) and gasket (4), tighten the screw (6) to the recommended tightening torques
Tab 1.
- Connect the assembly lever + oat to the seat with the pin lever (9).
- Fit the new gasket (3).
- Fit the cover (13) with the lever (19) in in vertical position downwards.
- Tighten the nuts (21) to the recommended tightening torques Tab 1.
- Check the proper operation of the lever (19) turning it 90° anticlockwise.
6.5 HowtotthePlugBall
- Unscrew the 8 cover nuts (21), remove the cover (13) keeping the lever (19) in vertical position
downwards and remove the body gasket (3).
- Extract the oat lever pin (9) and remove the complete group lever + oat.
- Remove from the lever (8) the plug ball (7) and replace it with a new one.
- Connect the assembly lever + oat to the seat with the pin lever (9).
- Fit the new gasket (3).
- Fit the cover (13) with the lever (19) in in vertical position downwards.
- Tighten the nuts (21) to the recommended tightening torques Tab 1.
- Check the proper operation of the lever (19) turning it 90° anticlockwise.
6.6 HowtotFloatLeverandPinAssembly
- Unscrew the 8 cover nuts (21), remove the cover (13) keeping the lever (19) in vertical position
downwards and remove the body gasket (3).
- Extract the oat lever pin (9) and remove the complete group lever + oat.
- Remove from the lever (8) the plug ball (7).
- Disconnect the Float (10) from the Lever (8) by unscrewing the screw (12). Remove the washers (11).
- Connect the new Lever (8) to the oat (10) using the screw (12) and the washers (11).
- Place the Plug Ball into the lever and then connect the assembly lever + oat to the seat with the
pin lever (9).
- Fit the new gasket (3).
- Fit the cover (13) with the lever (19) in in vertical position downwards.
- Tighten the nuts (21) to the recommended tightening torques Tab 1.
- Check the proper operation of the lever (19) turning it 90° anticlockwise.
6.7 Howtottheoatassembly
- Unscrew the 8 cover nuts (21), remove the cover (13) keeping the lever (19) in vertical position
downwards and remove the body gasket (3).
- Extract the oat lever pin (9) and remove the complete group lever + oat.
- Remove from the lever (8) the plug ball (7).
- Disconnect the Float (10) from the Lever (8) by unscrewing the screw (12). Remove the washers (11).
- Connect the Lever (8) to the new oat (10) using the new screw (12) and the new washers (11).
- Place the Plug Ball into the lever and then connect the assembly lever + oat to the seat with the
pin lever (9).
- Fit the new gasket (3).

3.341.5275.241 11
- Fit the cover (13) with the lever (19) in in vertical position downwards.
- Tighten the nuts (21) to the recommended tightening torques Tab 1.
- Check the proper operation of the lever (19) turning it 90° anticlockwise.
6.8 Howtotthemanuallever
- Unscrew the 8 cover nuts (21), remove the cover (13) keeping the lever (19) in vertical position
downwards and remove the body gasket (3).
- Unscrew nut and locknut (20) and remove lever (19).
- Unscrew the Gland nut (18) and remove the spacer (17) and the graphite packing seals (16).
- Extract the item (15) from the internal side of the cover.
- Insert the new lever (15) from the internal side of the cover.
- Insert on the pin of the lever the graphite packing seals (16), the spacer (17) and nally tighten
the gland nut 18.
- Place the lever (19) and then tighten nut and locknut (20).
- Fit the new gasket (3).
- Fit the cover (13) with the lever (19) in in vertical position downwards.
- Tighten the nuts (21) to the recommended tightening torques Tab 1.
- Check the proper operation of the lever (19) turning it 90° anticlockwise.
6.9HowtotStufngboxandmanualleverspacerassembly
- Unscrew the 8 cover nuts (21), remove the cover (13) keeping the lever (19) in vertical position
downwards and remove the body gasket (3).
- Unscrew nut and locknut (20) and remove lever (19).
- Unscrew the Gland nut (18) and remove the spacer (17) and the graphite packing seals (16).
- Insert on the pin of the lever the graphite packing seals (16), the spacer (17) and nally tighten
the gland nut 18.
- Place the lever (19) and then tighten nut and locknut (20).
- Fit the new gasket (3).
- Fit the cover (13) with the lever (19) in in vertical position downwards.
- Tighten the nuts (21) to the recommended tightening torques Tab 1.
- Check the proper operation of the lever (19) turning it 90° anticlockwise.

3.341.5275.241 CH Issue 3 - 2013.09
Spirax-Sarco S.r.l. - Via per Cinisello, 18 - 20834 Nova Milanese (MB) - Tel.: [phone] - Fax: [phone]
7. Spare parts
The spare parts available are shown in solid outline. Parts drawn in broken line are not supplied
as spares.
Available spares
Seat assembly 5, 6
Plug ball 7
Float lever and pin assembly 8, 9
Float assembly 10, 11, 12
Manual lever kit 15, 16, 17, 18, 19, 20
Stufng box and manual lever spacer assembly 16, 17
Gaskets set (3 + 3 units) 3, 4
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How to order spares
Always order spare parts by using the description given in the table and state the size and type of
trap, including pressure range and type of the connections.
Example: N° 1 Ball oat and cover gasket assembly for a ball oat steam trap Spirax Sarco
FTC23-07, DN 1½".
REPAIRS
Please contact our nearest Branch Ofce or Agent, or directly Spirax-Sarco S.r.l.
Via per Cinisello, 18 - 20834 Nova Milanese (MB) - ITALY - Tel.: [phone] - Fax: [phone]
LOSS OF GUARANTEE
Total or partial disregard of above instructions involves loss of any right to guarantee.