Spirax Sarco TD120M User manual

IM-IBR17-47IN 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-IBR17-47IN
Issue 2
TD120M
Thermodynamic Steam Trap
with Replaceable Seat
Installation and Maintenance Instructions

IM-IBR17-47IN Issue 12
1. Safety information
Safe operation of this product can only be guaranteed if it is properly installed,
commissioned, used and maintained by qualied 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.
Warning
The cover gasket contains a thin stainless steel support ring which may cause
physical injury if not handled and disposed of carefully.
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 Indian Boiler Regulations, 1950.
i) This product has been specifically designed for use on steam, air or
condensate/water. 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 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: ammable materials, substances hazardous to health,
extremes of temperature.

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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, 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.
1.7 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 of 525 °C (977 °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 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.

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2. General product information
2.1 General description
The TD120M is a maintainable high pressure thermodynamic steam trap with integral strainer
and replaceable seat to ease maintenance. It has low capacity specically designed for
superheated mains drainage applications up to 250 bar g (3 625 psi g).
Standards
This product fully complies with the requirements of the Indian Boiler Regulations, 1950.
Note: All certication/inspection requirements must be stated at the time of order
placement.
Note: For additional information see Technical Information Sheet TI-IBR17-48IN.
2.2 Sizes and pipe connections
½", ¾" and 1" Butt weld ends to suit Schedule 160 pipe.
½", ¾" and 1" Socket weld ends to ASME (ANSI) B 16.11 Class 6000.
DN15 and DN25 standard integral ange EN 1092 PN160 and PN250.
DN15, DN20 and DN25 standard integral anges: ASME (ANSI) Class 600, 900 and 1500,
and EN 1092 PN100.
Fig. 1 TD120M with butt weld connections

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Pressure bar g
Temperature °C
A
B
C
Steam
saturation
curve
E
The product must not be used in this region.
A - BSocket weld and butt weld ends.
A - CFlanged to ASME (ANSI) Class 1500
A - DFlanged ASME (ANSI) 900.
A - E Flanged to ASME (ANSI) Class 600.
Body design conditions PN250
PMA Maximum allowable pressure 250 bar g @ 300 °C(3 625 psi g @ 572 °F)
TMA Maximum allowable temperature 550 °C @ 80 bar g (1022 °F @ 1160 psi g)
Minimum allowable temperature -29 °C(-20 °F)
PMO Maximum operating pressure for
saturated steam service
220 bar g @ 374 °C(3 190 psi g @ 705 °F)
TMO Maximum operating temperature 525 °C @ 114.9 bar g (977 °F @ 1 666 psi g)
Minimum operating temperature 0°C(32 °F)
Note: For lower operating temperatures consult Spirax Sarco.
PMOB Maximum operating backpressure should not exceed 50% of the upstream pressure
Minimum operating di󰀨erential pressure 8 bar g (116 psi g)
Designed for a maximum cold hydraulic
test pressure of
375 bar g (5 439 psi g)
2.3 Pressure/temperature limits (ISO 6552)
Pressure psi g
Temperature °F
D

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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 t ted,
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.
A typical installation is shown in Figure 2, page 9.
3.3 R e m o v e p r o t e c t i v e c ov e r s f r o m a l l c o n n e c t i o n s a n d p r o t e c t i v e  l m f r o m a l l n a m e - p l a t e s ,
where appropriate, before intallation on steam or other high temperature applications.
3.4 The preferred installation is in a horizontal pipe with the name-plate uppermost. The
t r a p w i l l o p e r a t e i n o t h e r p o s i t i o n s , b u t t h e s e r v i c e l i f e m a y b e a 󰀨 e c t e d ! T h e i n s t a l l a t i o n
should have a small drop leg preceding the trap. Access for removal of the integral
strainer screen should also be provided.
3.5 Suitable isolation valves must be installed to allow for safe maintenance and trap
replacement.
Where the trap discharges into a closed return system a non-return valve should
be tted downstream to prevent ow.
3.6 Always open isolation valves slowly until normal operating conditions are achieved -
this will avoid system shocks. Check for leaks and correct operation.
3.7 Always ensure the correct tools, safety procedures and protective equipment are
used at all times.
3.8 The disc and seating surfaces of these traps have been produced to a high degree of
atness to achieve good shut- o󰀨 under high pressure conditions. An integral strainer
helps prevent dirt and scale from entering the trap. If particles become entrapped
between the di sc an d seat, the hi gh ow velocities can cause rapid wear and er osion.
A separate strainer and/or dirt pocket will provide additional protection.
3.9 When a socket weld or butt weld trap is being installed the welding should be carried
out to an approved proceedure of a recognised standard.
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).

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The TD120M is a thermodynamic steam trap which uses a disc to control the release of
condensate and to trap steam. The trap cycles open and closed to discharge condensate,
close to steam temperature, and closes tight between discharges.
The disc, which is the only moving part, rises and falls in response to dynamic forces
produced by the partial re-evaporation (ashing) of hot condensate. Cool condensate, air
a n d o t h e r n o n - c o n d e n s i b l e g a s e s e n t e r s t h e t r a p t h r o u g h t h e c e n t r a l o r i  c e , l i f t s t h e d i s c , a n d
discharges through the outlet orice. When the condensate approaches steam temperature,
a portion of it ashes as it enters the trap. The ash steam passes at high velocity over the
underside of the disc and collects in the control chamber above. The resulting pressure
imbalance, forces the disc downward onto the seating sur faces, stopping the ow. The trap
remains tightly closed until the loss of heat through the trap body lowers the control chamber
pressure, allowing the inlet pressure to raise the disc and repeat the cycle.
4.1 Commissioning with particular reference to venting air
Initial start-up can take several hours (or days) to bring the system to normal operating
pressure and temperature. Even if the trap has replaced another trap 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 stop valve 'A' (Figure 2), it could be possible to air lock the pipework
between valve 'A' 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 the following procedure should be
adopted. With the stop valve 'B' closed, drain valve 'C' open, slowly and partially open
stop valve 'A'. This will discharge the air, condensate and any pipe debris.
Valve 'C' should then be fully closed, and valves 'A' and 'B' slowly opened to the fully
open position. When the trap is more than 2 m (6 ft) away from the vertical drain leg, a
suitable drop leg at the inlet to the trap can improve its service life by ensuring that the
trap does not see a mixture of steam and condensate.
Important note
After the trap has been in service at normal operating pressure and temperature
for 24 hours, it is essential that the cover nuts be retightened (see Table 1, page 11).
This will ensure the correct compression of the gasket under service conditions.
4. Commissioning
5. Operation

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Steam main
Drain valve 'C'
Stop valve 'A'
Stop valve 'B'
TD120M
Strainer
(Optional)
Dirt pocket/dirt leg
To drain or
return
To drain or
return
Fig. 2 Typical installation
Alternative layout
Suggested drop leg if the
TD120M is located more
than 2 m (6') away from
the main drop leg.
To drain

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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 How to fit the disc and seat:
-Remove the top cover (3) by unscrewing the four nuts (9) that are securing it in place.
-Lift o󰀨 the disc (2).
-Lift out the seat (6). The use of 2 screwdrivers inserted into the groove may ease removal.
Ensure that the location ferrule (12) is also removed.
-Carefully remove the seat gaskets (10 and 7) from the body of the trap. Ensure that no
damage is caused to the trap body.
-Ensure that the gasket contact surface in the body is clean and t new seat gaskets
(10 and 7).
-Fit the new seat (6) ensuring that the location ferrule (12) is rmly located in the body.
-Fit the new seat gasket (7) making sure that the gasket faces are perfectly clean and t
a new disc (2). Ensure that the disc is tted with the grooves facing the seat.
-Reassemble the top cover (3).
-Ensure that the name-plate is placed over the studs prior to reassembling the four nuts (9).
-Retighten the cover nuts (9) to the recommended tightening torques (see Table 1).
-After 24 hours in service, and when reassembling, the nuts should be tightened in a
diagonally opposite sequence.
-Open the isolation valves slowly until normal operating conditions are achieved.
-Check for leaks.
6.2 How to clean or replace the strainer:
-Access to the strainer screen can be obtained by removing the bottom cover (5) by
unscrewing the four nuts (9) that are securing it in place.
-Remove the strainer screen (4).
-Fit the new or cleaned strainer screen into the recess on the underside of the cover.
-A new gasket (11) should be tted and the cover retted.
-Retighten the cover nuts (9) to the recommended tightening torques (see Table 1).
-After 24 hours in service, and when reassembling, the nuts should be tightened in a
diagonally opposite sequence.
-Open the isolation valves slowly until normal operating conditions are achieved.
-Check for leaks.
-It is recommended that the strainer screen be inspected as part of a scheduled
maintenance programme.
6. Maintenance

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Fig. 3
TD120M with butt weld connections
8
9
7
2
6 + 12
7
10
11
4
9
8
Table 1 Recommended tightening torques
Item Part or
mm N m (lbf ft)
422 A/F 25 - 35 (18 - 26)
8Stud M16 85 - 90 (62.5 - 66)
9Nut 23 A/F M16 160 - 180 (118 - 132)
6.3 To replace the cover studs:
-After removing the old cover studs, t new
cover studs until the studs bottom out. The
use of a thread lubricant is recommended.

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7. Spare parts
Fig. 4
The spare parts available are shown in solid outline. Parts drawn in a grey line are not
supplied as spares.
Available spares
Set of cover studs and nuts 8 (8 off), 9 (8 off)
Strainer screen and gasket 4, 11
Set of gaskets 7 (2 off), 10, 11
Maintenance kit 2, 4, 7 (2 off), 10, 11, 6 +12
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 - Seat and disc assembly for a
Spirax Sarco DN15 TD120M high pressure
thermodynamic steam trap.
8
9
7
2
6 + 12
7
10
11
4
9
8