Spirax Sarco S1 User manual

IM-F05-01-EN-ISS2 CMGT 1
1. Safety information
2. General product information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
© Copyright 2018
Printed in France
0231150/13
S1, S2, S3, S5, S6, S7, S8, S12 and S13
Separators
Installation and Maintenance Instructions
IM-F05-01-EN-ISS2
CMGT
PREVIOUS REFERENCE NO. IM-P023-55

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IM-F05-01-EN-ISS2 CMGT 3
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 inspection plug gasket on the S2, S3, S12 and S13 and the bottom cover gasket on the S5 and
S6 contain 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. 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 1
Gases
Group 2
Gases
Group 1
Liquids
Group 2
Liquids
S1 16 bar g
DN15 - DN20 SEP SEP SEP SEP
DN25 2 1 SEP SEP
S2 16 bar g
DN32 - DN40 1SEP SEP SEP
DN50 2 1 SEP SEP
S3 16 bar g
DN40 1SEP SEP SEP
DN50 - DN80 2 1 SEP SEP
DN100 - DN150 322SEP
DN200 212SEP
S5
and
S6
50 bar g
DN15 SEP SEP SEP SEP
DN20 - DN25 2 1 SEP SEP
DN32 - DN50 322SEP
1. Safety information

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Product Group 1
Gases
Group 2
Gases
Group 1
Liquids
Group 2
Liquids
S7
and
S8
14 bar g
DN65 - DN125 322SEP
DN150 - DN200 432SEP
DN250 - DN350 442SEP
20 bar g
and
23 bar g
DN65 - DN80 322SEP
DN100 - DN150 432SEP
DN200 - DN300 442SEP
DN350 4421
25 bar g
DN65 - DN80 322SEP
DN100 - DN150 432SEP
DN200 - DN250 442SEP
DN300 - DN350 4421
S12 25 bar g
DN32 - DN40 1SEP SEP SEP
DN50 2 1 SEP SEP
S13 25 bar g
DN40 1SEP SEP SEP
DN50 - DN80 2 1 SEP SEP
DN100 - DN125 322SEP
DN150 - DN200 322SEP
i) The product has been specifically designed for use on steam and compressed air which are
in Group 2 of the above mentioned Pressure Equipment Directive.
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) A number of products are supplied for the intention of the end user (or agent thereof) modifying
the flange configuration from that supplied. It is the responsibility of the organisation carrying
out the modification to do so in accordance with the internationally recognised flange
standards and to ensure that the design rating and operation of the product are not
compromised. Spirax Sarco will not be held responsible for any unapproved modification or
consequential liability resulting in failure to observe these requirements.
iv) Determine the correct installation situation and direction of fluid flow.
v) 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.
vi) Remove protection covers from all connections and protective film from all name-plates, where
appropriate, before installation on steam or other high temperature applications.

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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.
1.5 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.

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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 temperatures
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 Section 6 '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 water hammer
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 products detailed are all baffle type separators used for the removal of entrained liquids in steam,
compressed air and gas systems. We recommend the fitting of insulating jackets to improve the performance
of the separator.
Note: For additional product data see the following Technical Information Sheets.
Type Material Pressure rating Sizes Connections TI reference
S1 SG iron PN16 ½", ¾" and 1" Screwed TI-P128-01-EN-ISS1
S2 Cast iron PN16 1¼", 1½" and 2" Screwed TI-P129-01-EN-ISS1
S3 Cast iron PN16 DN40 - DN200 Flanged TI-P131-01-EN-ISS1
S5 Carbon steel PN50/ASME 300 DN15 - DN50 Screwed and
Flanged TI-P133-01-EN-ISS1
S6 Austenitic stainless
steel 316L PN50/ASME 300 DN15 - DN50 Screwed and Flanged TI-P134-01-EN-ISS1
S7* Carbon steel PN16 and PN40 DN65 - DN350 Flanged TI-P135 - 02-EN-ISS1
S8* Austenitic stainless PN16 and PN40 DN65 - DN350 Flanged TI-P136-01-EN-ISS1
S12 SG iron PN25 1¼", 1½" and 2" Screwed TI-P130-01-EN-ISS1
S13 SG iron PN25 DN40 - DN200 Flanged TI-P132-01-EN-ISS1
* Note: The S7 and S8 separators are designed and manufactured in accordance with EN 13445:2002 –
'Unfired Pressure Vessels'.
Fig. 3
Fig. 4 Fig. 5
S3
S13
S5
S6
S7
S8
Fig. 2
S1 S2
S12
Fig. 1
2. General product information

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Note: Before actioning any installation observe the 'Safety Information' in Section 1.
Referring to the Installation and Maintenance Instructions, body markings, name-plate (if fitted) 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 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 separators may be lagged if required.
Important installation note
for the S1, S2, S3, S12 and S13 separators:
Install in a horizontal pipeline with the drain directly below. To ensure that any separated liquid
is drained away quickly, a suitable liquid drainer or steam trap must be connected to the drain.
Isolation valve
Strainer
S13
separator
Float trap
Fig. 6 Separator on a steam line
3.5 Installation for the S5 and S6
Install in a horizontal pipeline with the drain directly below.
To ensure that any separated liquid is drained quickly, a suitable liquid drainer or steam trap must be connected
to the drain connection. A float type trap is recommended.
For those steam systems where air can be present, air can collect in the upper portion of the separator. In
this situation a suitable air vent should be connected to the air vent connection.
If an air vent is not being fitted then the connection must have the plastic transit protection plug removed
and must have a carbon steel class 3000 lb plug fitted.
3. Installation

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3.6 Installation for the S7 and S8
Install in a horizontal pipeline with the drain directly below. All sizes are fitted with support
brackets which can be used to minimise piping loads. Each bracket has two drilled holes.
To ensure that any separated liquid is drained quickly, a suitable liquid drainer or steam
trap must always be connected to the drain connection. A float type trap is recommended.
For those steam systems where air can be present, air can collect in the upper portion of the
separator. In this situation a suitable air vent should be connected to the air vent connection.
If an air vent is not being fitted then the connection must have the plastic transit protection
plug removed and a carbon steel class 3000 Ib plug fitted.
Air vent
Isolation valve
Strainer
S7 separator
FT
or
CA trap
S5 separator
Strainer
Float trap
Isolation
valve
Fig. 7
Fig. 8 Separator on a steam line

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Fig. 10 Compressed air distribution
Fig. 9 Heat transfer processes and valve protection
After installation or maintenance, ensure that the
system is fully functioning. Carry out tests on any
alarms or protective devices.
Separators are designed to gather together small droplets of entrained liquids and then separate them from
the gas/vapour flow. The relatively heavy droplets impinge on the internal baffles and are then directed to
the separator drain connection and removed from the system using a steam trap, or when used on air or gas
distribution system, a liquid drainer.
4. Commissioning
5. Operation

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Table 1 Recommended tightening torques
Separator Item Size
or
mm
N m (lbf ft)
S1 4
½"
¾"
1"
7/16"
½"
9/16"
¼" UNF x ¾"
5/16" UNF x ¾"
3/8" UNF x ¾"
12
28
40
-
-
-
14
32
50
(9
(21
(30
-
-
-
10)
24)
37)
Note: Before actioning any maintenance programme observe the 'Safety information' in Section 1.
Fig. 11
S1
4
*
6. Maintenance
Warning
There are no internal components that
require maintenance.

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Fig. 12
S2,S3,S12 and S13
2
*
Warning
There are no internal components that
require maintenance.
Table 2 Recommended tightening torques
Separator Item Size
or
mm
N m (lbf ft)
S2 22" 60 A/F M72 190 -210 (140 -155)
S3 2
DN40
DN50
DN65
DN80
DN100
DN125
DN150
DN200
46 A/F
60 A/F
46 A/F
60 A/F
60 A/F
60 A/F
60 A/F
60 A/F
M56
M72
M56
M72
M72
M72
M72
M72
150
190
150
190
190
190
190
190
-
-
-
-
-
-
-
-
165
210
165
210
210
210
210
210
(110
(140
(110
(140
(140
(140
(140
(140
-
-
-
-
-
-
-
-
121)
155)
121)
155)
155)
155)
155)
155)
S12 2 2" 46 A/F M56 150 -165 (110 -121)
S13 2
DN40
DN50
DN65
DN80
DN100
DN125
DN150
DN200
46 A/F
46 A/F
46 A/F
60 A/F
60 A/F
60 A/F
60 A/F
60 A/F
M56
M56
M56
M72
M72
M72
M72
M72
150
150
150
190
190
190
190
190
-
-
-
-
-
-
-
-
165
165
165
210
210
210
210
210
(110
(110
(110
(140
(140
(140
(140
(140
-
-
-
-
-
-
-
-
121)
121)
121)
155)
155)
155)
155)
155)

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Support
bracket
Fig. 14
S7 and S8
Fig. 13
S5 and S6
5
*
There are no spare parts required or available for these components.
Table 3 Recommended tightening torques
Separator Item Size N m (lbf ft)
S5 5DN15
- DN50 46 A/F 180 -200 (133 -150)
S6
7. Spare parts

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