Spirax Sarco TD42S2 User manual

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IM-IBR16-30IN Issue 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-IBR16-30IN
Issue 1
TD42S2
Thermodynamic Steam Trap
Installation and Maintenance Instructions

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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.
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 Regulation, 1950.
i) This product has been specifically designed for use on steam, air or
condensate / water. The products’ use on other uids may be possible but, if this
is contemplated, Spirax Sarco should be contacted to conrm the suitability of
the product for the application being considered.
ii) Check material suitability, pressure and temperature and their maximum and
minimum values. If the maximum operating limits of the product are lower than
those of the system in which it is being tted, or if malfunction of the product
could result in a dangerous overpressure or 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 and protective lm from all name-
plates, where appropriate, before installation on steam or other high temperature
applications.
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded)
before attempting to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous 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.
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, re 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.

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1.12 Handling
Manual handling of large and /or heav y products may present a risk of injur y. Lif ting,
pushing, pulling, carrying or supporting a load by bodily force can cause injury
particularly to the back. You are advised to assess the risks taking into account the
task, the individual, the load and the working environment and use the appropriate
handling method depending on the circumstances of the work being done.
1.13 Residual hazards
In normal use the external surface of the product may be very hot. If used at the
maximum permitted operating conditions the surface temperature of some products
may reach temperatures of 400 °C (752 °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
U n l e s s o t h e r w i s e s t a t e d i n t h e I n s t a l l a t i o n a n d M a i n t e n a n c e I n s t r u c t i o n s , t h i s p r o d u c t
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
h a z a r d s a n d t h e p r e c a u t i o n s t o b e t a k e n d u e t o c o n t a m i n a t i o n r e s i d u e s o r m e c h a n i c a l
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 General description
The TD42S2 is a thermodynamic steam trap with forged steel body and socket weld ends.
Optional extras
Insulating cover To prevent the trap being unduly influenced by excessive heat loss such
as when subjected to low outside temperatures, wind, rain etc.
Standards
This product fully complies with the requirements of the Indian Boiler Regulation, 1950.
Certification
Note: All certification/inspection requirements must be stated at the time of order placement.
Note: For addtional information see Technical Information Sheet TI-IBR16-31IN.
Fig. 1 TD42S2 thermodynamic steam trap
2.2 Sizes and pipe connections
½"LC, ¾"LC, 1"LC, ½", ¾" and 1".
Socket weld ends to ASME (ANSI) B 16.11 Schedule 80 / BS 3799 Class 3000 lb.

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Pressure bar g
Temperature °C
The product must not be used in this region.
The product should not be used in this region.
Note: Upon prolonged exposure to temperatures above 425 °C (797 °F), the carbide phase
of steel may be converted to graphite. Permissible but not recommended for prolonged use
above 425 °C (797 °F).
Body design conditions ASME / ANSI 300
PMA Maximum allowable pressure 51 bar g @ 38 °C (739 psi g @ 100 °F)
TMA Maximum allowable temperature 427 °C @ 28 bar g (800 °F @ 406 psi g)
Minimum allowable temperature 0°C (32 °F)
PMO Maximum operating pressure for
saturated steam service 42 bar g (609 psi g)
TMO Maximum operating temperature 400 °C @ 34 bar g (752 °F @ 493 psi g)
Minimum operating temperature
Note: For lower operating temperatures consult Spirax Sarco. 0°C (32 °F)
DPMX Maximum differential pressure 42 bar (609 psi)
PMOB Maximum operating backpressure should not exceed 80% of the upstream pressure
Minimum operating differential pressure for satisfactory
operation 0.25 bar (3.6 psi)
Designed for a maximum cold hydraulic test pressure of: 76.5 bar g (1109.5 psi g)
Pressure psi g
Temperature °F
Steam
saturation
curve
2.3 Pressure / temperature limits (ISO 6552)

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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 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 protective film from all name
plates, where appropriate, before installation on steam or other high temperature
applications.
3.4 The trap should preferably be installed in the horizontal plane, with a small drop leg
preceding it. Suitable isolation valves must be installed to allow for safe maintenance
and trap replacement. Consideration should be given to a suitable method for testing
the correct operation of the trap. This may be a sight glass or a Spiratec system. Sight
glasses must be positioned a minimum of 1 m (3 ft) downstream of any blast-action
traps. Where the trap discharges into a closed return system, a non-return valve should
be fitted downstream to prevent return flow.
3.5 Isolation valves must be installed to allow for safe maintenance and trap replacement.
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 Welding into the pipeline - 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, the discharging
fluid may be at a temperature of 100 °C (212 °F).

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Note: Before actioning any maintenance programme observe the 'Safety information'
in Section 1.
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.
6.2 How to service
-Remove the insulating cover (7) , if fitted, and unscrew the cap (2) using a suitable spanner
or socket. Do not use stillsons or a wrench of similar type which may cause distortion of
the cap.
-If the seating faces on the body are only slightly worn, they can be refaced by lapping on a
flat surface, such as a surface plate. A figure-of-eight motion and a little grinding compound,
such as 'Carborundum Co's Compound I.F.' gives the best results.
If the wear is too great to be rectified by simple lapping, the seating faces on the body must
be ground flat and then lapped.
Note: the disc (3) should always be replaced with a new one. The total amount of
metal removed in this way should not exceed 0.25 mm (0.010").
-When reassembling, the disc (3) is normally placed in position with the grooved side in
contact with the body seating face (1).
-Screw on the cap (2) to the recommended tightening torque (see Table 1); no gasket is
required but a suitable high temperature anti-seize grease should be applied to the threads.
6.3 How to clean or replace the strainer:
-Unscrew the strainer cap (5) using a suitable spanner.
-Withdraw the screen (4) and clean or, if damaged, replace with a new one.
-To reassemble, insert the screen (4) into the strainer cap (5), then screw the strainer cap
into place. A fine smear of 'Molybdenum Disulphide' grease should be applied to the first
few threads. Care should be taken to ensure that the gasket and gasket faces are clean.
-Tighten to the recommended torque (see Table 1).
-When maintenance is complete open isolation valves slowly and check for leaks.
After installation or maintenance ensure that the system is fully functional. Carry out tests on
any alarms or protective devices.
The thermodynamic steam trap will discharge condensate with a blast type action at a few
degrees below steam saturation temperature, due care must be given to the site of the
discharge.
6. Maintenance
4. Commissioning
5. Operation

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Table 1 Recommended tightening torques
or
Item Part Size N m lbf ft
mm
½" LC 36 A/F 87 - 97 62 - 69
¾" LC 36 A/F 87 - 97 62 - 69
2Cap 1" LC 36 A/F 87 - 97 62 - 69
½" 41 A/F 100 - 110 72 - 79
¾" 41 A/F 100 - 110 72 - 79
1" 55 A/F 140 - 160 100 - 114
5Strainer cap (all sizes) 27 A/F M24 120 - 135 88 - 100
1
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The spare parts available are shown in solid outline. Parts drawn in broken line are not
supplied as spares.
Available spares
Disc (packet of 3) 3
Strainer screen and gasket 4, 6
Strainer cap gasket (packet of 3) 6
Insulating cover 7
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 - Strainer screen and gasket for a Spirax Sarco ½" TD42S2 thermodynamic steam trap.
7. Spare parts
Fig. 3

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