Spirax Sarco S1 User manual

IM-P023-55 ST Issue 3 1
S1, S2, S3, S5, S6, S7, S8, S12 and S13
Separators
Installation and Maintenance Instructions
IM-P023-55
ST Issue 3
0231150/3
1. General
safety information
2. General
product information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. pare parts
Printed in the UK © Copyright 2002
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IM-P023-55 ST Issue 32
1. General safety information
Safe operation of these units can only be guaranteed if they are properly installed,
commissioned and maintained by a qualified person (see Section 11 of the attached
Supplementary Safety Information) in compliance with the operating instructions. General
installationandsafetyinstructionsforpipelineandplantconstruction,aswellastheproper
use of tools and safety equipment must also be complied with.
Warning
The inspection cap gasket on the S2, S3, S12, S13 and the bottom cover gasket on the S5
and S6 separators contain a thin stainless steel support ring which may cause physical
injury if not handled and disposed of carefully.
Isolation
Consider whether closing isolating valves will put any other part of the system or
personnel at risk. Dangers might include: isolation of vents, protective devices or
alarms. Ensure isolation valves are turned off in a gradual way to avoid system shocks.
Pressure
Before attempting any maintenance consider what is or may have been in the pipeline.
Ensure that any pressure is isolated and safety vented to atmospheric pressure before
attempting to maintain the product, this is easily achieved by fitting Spirax Sarco
depressurisationvalvestypeDV(see separate literaturefordetails).Donot assume thatthe
system is depressurised even when a pressure gauge indicates zero.
Temperature
Allow time for temperature to normalise after isolation to avoid the danger of burns and
consider whether protective clothing (including safety glasses) is required.
Disposal
These products are recyclable. No ecological hazard is anticipated with the disposal
of these products providing due care is taken.
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IM-P023-55 ST Issue 3 3
2. General product information
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 information see the following Technical Information Sheets.
Type Material Pressure rating Sizes Connections TI reference
S1 SG iron PN16 ½", ¾" and 1" Screwed TI-P023-02
S2 Cast iron PN16 1¼", 1½" and 2" Screwed TI-P023-07
S3 Cast iron PN16 DN40 - 200 Flanged TI-P023-24
Screwed
S5 Carbon steel PN50/ANSI 300 DN15 - 80 and TI-P023-11
Flanged
Austenitic stainless Screwed
S6 PN50/ANSI 300 DN15 - 80 and TI-P023-12
steel 316L Flanged
S7 Carbon steel PN16 and PN40 DN65 - 150 Flanged TI-P138-03
DN200 - 350 Flanged TI-P138-04
S8 Austenitic stainless PN16 and PN40 DN65 - 150 Flanged TI-P138-10
steel 316L DN200 - 350 Flanged TI-P138-11
S12 SG iron PN25 1¼", 1½" and 2" Screwed TI-P023-25
S13 SG iron PN25 DN40 - 200 Flanged TI-P023-26
Note: The S7 and S8 separators are designed and manufactured to BS 5500 Category 3.
Fig. 3 Fig. 4 Fig. 5
S3
S13
S5
S6 S7
S8
Fig. 2
S1
S2
S12
*
*
*
Fig. 1
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IM-P023-55 ST Issue 34
2.2 Limiting conditions for cast separators (ISO 6552)
Maximum PMA - Maximum TMA - Maximum Designed for a max.
Type body design allowable allowable cold hydraulic
conditions pressure temperature test pressure of:
exceeds bar g (psi g) °C (°F) bar g (psi g)
S1 PN16 16 (232) 300 (572) 24.0 (348.0)
S2 PN16 16 (232) 184 (363) 24.0 (348.0)
S3 PN16 16 (232) 184 (363) 24.0 (348.0)
JIS/KS 10K 20.6 (299.0)
ANSI 150 30.0 (435.0)
JIS/KS 20K 50.0 (725.0)
S5 ANSI 300/ 50 (725) 425 (767) DIN PN40 60.0 (870.0)
and PN50 ANSI 300 76.6 (1 111.0)
S6 Screwed,
Socket weld, 76.6 (1 111.0)
Butt weld
S12 PN25 25 (362) 350 (662) 37.5 (544.0)
JIS/KS 10K 20.4 (296.0)
S13 PN25 25 (362) 350 (662) PN16 24.0 (348.0)
PN25 37.5 (544.0)
JIS/KS 20K 37.5 (544.0)
Note: Flanged separators may be supplied with a lower pressure rating than that cast into the
body. Reference should be made to the appropriate operating chart to determine the actual
product limitations.
2.3 Operating ranges for cast separators
S1
S2 and S3
Temperature °C
300
250
200
150
100
50
00246810 12 14 16
13*
Steam
saturation
curve
Pressure bar g
Pressure bar g
Temperature °C
The product must
not be used in this region.
*PMO Maximum
operating pressure when
used for steam service.
The product must
not be used in this region.
*PMO Maximum
operating pressure when
used for steam service.
A-APN16/Table F/
Scrd BSP/NPT
A-BJIS/KS 10
A-CANSI 125
02468
10* 12 14 16
0
50
100
150
184
A
B, C
A
Steam
saturation
curve
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IM-P023-55 ST Issue 3 5
S5
S6
12.
5
010 20 30* 40 50
0
100
200
300
400
13.8* 35.9* 41.4*
425
Pressure bar g
Temperature °C
A
D C E
AD
C
Steam
saturation
curve
B
BE
12.5*
02030
40 50
0
100
200
300
400
425
23.5* 34.1*
25.8*
11.4 27.9*
9.9
Temperature °C
Pressure bar g
Steam
saturation
curve
B
BCDEF
FE
A
CD A
*
0 5 10 15 20 25
0
100
200
300
350
21.3*
Pressure bar g
Temperature °C
Steam
saturation
curve
S12
S13
The product must
not be used in this region.
*PMO Maximum
operating pressure when
used for steam service.
A-AJIS/KS 10K
B-BANSI Class 150
C-CJIS/KS 20K
D-DDIN PN40
E-EANSI Class 300,
Scrd BSP, NPT,
SW and BW
The product must
not be used in this region.
*PMO Maximum
operating pressure when
used for steam service.
A-AJIS/KS 10K
B-BANSI Class 150
C-CJIS/KS 20K
D-DDIN PN40
E-EANSI Class 300
F-FScrd BSP, NPT,
SW and BW
0510 15 20 25
0
100
200
300
350
12.3*
13.7* 21.3*
Pressure bar g
Temperature °C
A
B
Steam
saturation
curve A
C
BThe product must
not be used in this region.
*PMO Maximum
operating pressure when
used for steam service.
A-AJIS/KS 10K
B-BPN16
C-DPN25 and
JIS/KS 20K
The product must
not be used in this region.
*PMO Maximum
operating pressure when
used for steam service.
D
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IM-P023-55 ST Issue 36
2.4 Limiting conditions for fabricated separators
Type S7 Designed for a maximum cold
Size Flange Design Design hydraulic test pressure of:
standard pressure temperature Shop Site
bar g (psi g) °C °F bar g (psi g) bar g (psi g)
Class 150 14 (203) 198 (388) 26.2 (380) 23.0 (333)
DN65 PN16 24.0 (348) 23.0 (333)
Class 300 25 (362) 227 (441) 49.1 (712) 43.1 (625)
PN40
Class 150 14 (203) 198 (388) 25.7 (373) 23.0 (333)
PN16 24.0 (348) 23.0 (333)
DN80 Class 300 20 (290) 213 (415) 38.0 (550) 33.9 (491)
PN40
Class 150 14 (203) 198 (388) 25.7 (373) 23.0 (333)
DN100 PN16 24.0 (348) 23.0 (333)
Class 300 20 (290) 213 (415) 37.9 (549) 33.9 (491)
PN40
Class 150 14 (203) 198 (388) 25.7 (373) 23.0 (333)
DN125 PN16 24.0 (348) 23.0 (333)
Class 300 30 (435) 236 (457) 58.3 (845) 53.1 (770)
PN40
Class 150 14 (203) 198 (388) 25.7 (373) 23.0 (333)
DN150 PN16 24.0 (348) 23.0 (333)
Class 300 30 (435) 236 (457) 59.3 (860) 53.1 (770)
PN40
Class 150 6 (87) 165 (329) 10.7 (155) 9.0 (130)
PN16
DN200 Class 150 14 (203) 198 (388) 23.4 (339) 21.0 (304)
PN16
Class 300 30 (435) 236 (457) 52.7 (764) 47.4 (687)
PN40
Class 150 6 (87) 165 (329) 10.7 (155) 9.0 (130)
PN16
DN250 Class 150 14 (203) 198 (388) 22.7 (329) 21.0 (304)
PN16
Class 300 30 (435) 236 (457) 51.8 (751) 47.4 (687)
PN40
Class 150 6 (87) 165 (329) 10.3 (149) 9.0 (130)
PN16
DN300 Class 150 14 (203) 198 (388) 22.7 (329) 21.0 (304)
PN16
Class 300 30 (435) 236 (457) 51.8 (751) 47.4 (687)
PN40
Class 150 6 (87) 165 (329) 10.3 (149) 9.0 (130)
PN16
DN350 Class 150 14 (203) 198 (388) 22.7 (329) 21.0 (304)
PN16
Class 300 30 (435) 236 (457) 50.6 (734) 47.4 (657)
PN40
For pressures and temperatures that exceed these operating conditions please contact
Spirax Sarco for a bespoke product.
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IM-P023-55 ST Issue 3 7
Type S8 Design Design Designed for a maximum
Flange pressure temperature cold hydraulic test pressure of:
Size standard bar g (psi g) °C (°F) bar g (psi g)
Class 150 11 (159) 198 (388) 19.5 (283)
DN65 PN16 10 (145) 198 (388) 17.7 (257)
Class 300 27 (391) 236 (457) 50.2 (728)
PN40 25 (362) 236 (457) 46.5 (674)
DN80, Class 150 11 (159) 198 (388) 18.8 (273)
DN100, PN16 10 (145) 198 (388) 17.1 (248)
DN125, Class 300 27 (391) 236 (457) 48.5 (703)
DN150 PN40 25 (362) 236 (457) 44.9 (651)
Class 150 6 (87) 165 (329) 9.7 (141)
DN200,PN16 6 (87) 165 (329) 9.7 (141)
DN250, Class 150 11 (156) 198 (388) 18.8 (273)
DN300, PN16 10 (145) 198 (388) 17.1 (248)
DN350 Class 300 27 (391) 236 (457) 48.5 (703)
PN40 25 (362) 236 (457) 44.9 (651)
For pressures and temperatures that exceed these operating conditions please contact
Spirax Sarco for a bespoke product.
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IM-P023-55 ST Issue 38
3. Installation
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.
3.4 The separators may be lagged if required.
Important installation note
for the S1, S2, S3, S12 & 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.
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.
3.6 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.
4. Commissioning
After installation or maintenance, ensure that the system is fully functioning. Carry out tests on
any alarms or protective devices.
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Fig. 7 Compressed air distribution
Fig. 6 Heat transfer processes and valve protection
5. Operation
Separators are designed to gather together small droplets of entrainedliquidsand 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.
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IM-P023-55 ST Issue 310
Support
bracket
6. Maintenance
Note: Before actioning any maintenance programme
observe the 'Safety information' in Section 1.
Warning
There are no internal components that require maintenance.
Fig. 11 S7 and S8
➧
Fig. 10 S5 and S6
➧
5
➧
Fig. 8 S1
4
Fig. 9 S2, S3, S12 and S13
➧
2
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IM-P023-55 ST Issue 3 11
Table 1 Recommended tightening torques
or
Separator Item Size N m (lbf ft)
mm
½"7 / 16"¼" UNF x ¾" 12 - 14 (9 - 10)
S1 4¾"½"5
/ 16" UNF x ¾" 28 - 32 (21 - 24)
1" 9
/ 16"3 / 8" UNF x ¾" 40 - 50 (30 - 37)
S2 22" 60 A/F M72 190 - 210 (140 -155)
DN40 46 A/F M56 150 - 165 (110 -121)
DN50 60 A/F M72 190 - 210 (140 -155)
DN65 46 A/F M56 150 - 165 (110 -121)
DN80 60 A/F M72 190 - 210 (140 -155)
S3 2DN100 60 A/F M72 190 - 210 (140 - 155)
DN125 60 A/F M72 190 - 210 (140 -155)
DN150 60 A/F M72 190 - 210 (140 -155)
DN200 60 A/F M72 190 - 210 (140 -155)
S5 5 DN15-80 19 A/F M12 x 35 40 - 45 (30 -37)
S6 5 DN15-80 19 A/F M12 x 35 40 - 45 (30 -37)
S12 2 2" 46 A/F M56 150 - 165 (110 -121)
DN40 46 A/F M56 150 - 165 (110 -121)
DN50 46 A/F M56 150 - 165 (110 -121)
DN65 46 A/F M56 150 - 165 (110 -121)
S13 DN80 60 A/F M72 190 - 210 (140 -155)
2DN100 60 A/F M72 190 - 210 (140 -155)
DN125 60 A/F M72 190 - 210 (140 -155)
DN150 60 A/F M72 190 - 210 (140 -155)
DN200 60 A/F M72 190 - 210 (140 -155)
7. pare parts
There are no spare parts required or available for these components.
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IM-P023-55 ST Issue 312
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