Spirax Sarco FT12 User manual

IM-P020-02-EN-ISS1 CMGT 1
1. Safety information
2. General product information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
© Copyright 2018
Printed in GB
0849950/7
FT12
Cast Iron Float/Orice Trap
Installation and Maintenance Instructions
IM-P020-02-EN-ISS1
CMGT
PREVIOUS REFERENCE NO. IM-P084-02

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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.
Warning
The inner and outer gaskets used when installing/maintaining the UIB to a PC_ pipeline connector
contain thin stainless steel support rings 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.
The products listed below comply with the requirements of the Pressure Equipment Directive
(PED) and carry the mark when so required. The products fall within the following Pressure
Equipment Directive categories:
Product Group 2
Gases
Group 2
Liquids
FT12 DN150 1SEP
i) The products have 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 safet y 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 ex ternal 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 at tempting
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. Safety information

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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.
1.6 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?
Danger s mi ght includ e isolation of ve nts or protec tive devices or the renderin g inef fective of controls
or alarms. Ensure isolat ion valves are turned on and of f 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 vicinit y 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 'per mit 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 the product may reach temperatures
up to 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’).
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 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 practices required to
prevent waterhammer and ensure safe working conditions on a steam system.
Safe Handling
Cast Iron is a brittle material. If the product is dropped during
installation and there is any risk of damage the product
should not be used unless it is fully inspected and pressure
tested by the manufacturer.

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Prevention of waterhammer
Steam trapping on steam mains:
Steam Mains - Do's and Don'ts:
Steam Steam
Flow Flow
30 - 50 metre intervals
Gradient 1:100
Gradient 1:100
Trap set
Trap set
Trap set
Condensate
Condensate
Condensate
Steam
Steam

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Prevention of tensile stressing
Pipe misalignment:
Installing products or re-assembling after maintenance:
Thermal expansion:
Do not over tighten.
Use correct torque gures.
1
1
4 2
3
8
2
6
3
7
Flange bolts should be gradually tightened across
diameters to ensure even load and alignment.
Guides
Guides
Limit
rods
Limit rods
Fixing point
Medium
distance
Small lateral
movement
Small lateral
movement
Large lateral
movement
Large lateral
movement
Short
distance Fixing point
Axial
movement
Axial movement
Guides
Guides
5
4

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2.1 General description
The FT12 is a unique steam trap which utilises a large fixed orifice to handle very high condensate loads
up to differential pressures of 4 bar (58 psi). An integral float trap mechanism provides a variable capacity
in addition to the orifice. Minimum flowrates are required to avoid blowthrough and these depend on the
orifice selected A, B, C or D.
The FT12 is manufactured in cast iron with DN150 (6") flanged connections. It is designed specifically for
the sugar industry, which has inherently low pressure, high load steam systems.
Note: For additional information see the Technical Information Sheet TI-P020-01-EN-ISS1.
2.2 Size and pipe connections
DN150 flanged PN16 and ANSI 125 (Flanges to BS 10 Table D can be supplied to special order).
Fig. 1
2. General product information

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220
200
150
100
50
0
024* 6810 12 14 16
Temperature °C
Steam
saturation
curve
Pressure bar g
2.3 Pressure/temperature limits
The product must not be used in this region.
*PMO Maximum operating pressure recommended for saturated steam 4 bar g (58 psi g).
Body design conditions PN16
PMA Maximum allowable pressure 4 bar g (58 psi g)
TMA Maximum allowable temperature 220 °C (428 °F)
PMO Maximum operating pressure 4 bar g (58 psi g)
TMO Maximum operating temperature 220 °C (428 °F)
Designed for a maximum cold hydraulic test pressure of: 24 bar g (348 psi g)

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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.
3.4 The trap is designed for installation in a horizontal plane. A typical installation is shown in
Figure 2. Where air is present as part of the process cycle a separate thermostatic air vent can
be fitted in parallel.
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).
BSA1
Fig 33
SDCV3
FT12
BSA1
340
340 340
Fig. 2
3. Installation
Weight (approximate) 82 kg
Dimensions (approximate) in mm
After installation or maintenance ensure that the system is fully functional. Carry out tests on any alarms
or protective devices.
4. Commissioning

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Note: Before actioning any maintenance programme obser ve 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 main valve assembly:
-Remove the trap from the pipeline, using a suitable spanner, withdraw the eight body bolts (2).
-Remove the main valve assembly, by unscrewing the four bolts (6).
-Withdraw the main valve assembly and replace with a new one.
-Replace bolts and tighten evenly.
-Replace cover gasket and tighten cover bolts to the recommended torque (see Table 1).
6. Maintenance
5.1 General information
The ball float steam trap is a continuous discharge trap, removing condensate the instant it forms. On start-up,
the addition of a thermostatic air vent (if required) allows air to bypass the main valve preventing the system
air binding. Hot condensate will close the air vent tightly, but as soon as it enters the trap, the float rises and
the lever mechanism attached to it opens the main valve - keeping the system drained of condensate at all
times. When steam arrives, the float drops and closes the main valve. Float traps are renown for their high
start-up load handling capability, clean tight shut-off and resistance to waterhammer and vibration.
5.2 Trap operation
It is important that the FT12 is sized correctly to the running load of the plant being drained. See Technical
Information Sheet TI-P020-01-EN-ISS1 for full details on 'Capacities - How to select/size the trap'.
The fixed orifice (available in four different cross sectional areas A, B, C, or D) will pass a set amount of
condensate at any given differential pressure consequently it is important that loads are constant. If the
condensate load drops below the minimum value shown then steam will also pass through the trap. A separate
float trap mechanism provides additional capacity should the condensate level build up to the maximum
value shown on the graph. Correct sizing will ensure that the plant condensate flow is between the minimum
and maximum flowrates shown.
5. Operation

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6.2 How to fit the orifice plate:
-Remove the trap from the pipeline, using a suitable spanner, withdraw the eight body bolts (2).
-Remove the main valve assembly, by unscrewing the four bolts (6), and the four bolts (9) which secure
the orifice plate, and then remove.
-A new orifice plate should be fitted in the reverse order, and all screws tightened to the recommended
torque (see Table 1).
Table 1 Recommended tightening torques
Item Part
or
mm
N m (lbf ft)
2Cover bolts/nuts 32 A/F M22 x 90 160 - 180 (117 - 132)
6Main valve assembly bolts M8 x 20 20 - 24 (15 - 17)
9Orifice plate bolts M8 x 20 20 - 24 (15 - 17)
6
9 2
2

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6
9 8 23
2
745
Main valve assembly
The spare parts available are shown in heavy outline. Parts drawn in a grey line are not supplied as spares.
Available spares
Main valve assembly with float 4, 5, 6, 7, 8
Orifice plate (state A, B, C or D) 8, 9
Set of body gaskets (packet of 3) 3
Set of body nuts and bolts 2
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 - Main valve assembly for DN150 FT12-D float trap.
7. Spare parts