Spirax Sarco APT10-2 User manual

IM-P612-18 ST Issue 3 1
APT10-2
Automatic Pump Trap
Installation and Maintenance Instructions
IM-P612-18
ST Issue 3
6120050/3
Printed in the UK © Copyright 2003
1. General
safety information
2. Product information
3. Installation
• Closed loop steam systems only
4. Commissioning
5. Operation
6. Maintenance
7. Replacementofspares(1):
• Cover gasket
• Inlet swing check valve
• Spring and actuator arm
• Float
8. Replacementofspares(2):
• Trap and outlet check valve
mechanism
• Steam inlet / exhaust valves
and seats
9. Fault finding guide

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IM-P612-18 ST Issue 3 3
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 in compliance with the operating
instructions.Allworkmustbecarriedoutorbesupervisedbyasuitablycompetentperson.
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 responsibilty
is safety.
Post 'warning notices' if necessary.
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.
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(seeseparateliteraturefordetails).Donotassumethatthe
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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2. Product information
Description
TheSpiraxSarcoautomaticpumptrapisadisplacementreceiverpressureratedtoPN10.Theunit
iscapableofautomaticallytrappingorpumping,dependingonlineconditions.Theunitisoperated
by steam and is used to remove condensate from process and heating plant under all pressure
conditions including vacuum.
Sizes and pipe connections
Size DN20 x DN20
Fluid connections
Inlet Outlet Motive/Exhaust
DN20 (¾") DN20 (¾") DN15 (½")
BSP - BS 21 parallel BSP
NPT NPT
Limiting conditions
Body design conditions PN10
Maximum motive inlet pressure 2.0 bar g (29 psi g)
Maximum operating pressure 2.0 bar g (29 psi g)
Maximum back pressure 1.9 bar g (27 psi g)
Maximum operating temperature 133°C (271°F)
Minimum operating temperature -10°C(14°F)
Designed for a maximum cold hydraulic test pressure of: 15.0 bar g (217 psi g)
Minimum installation head (from base of pump) 0.2 m (8")
Recommended minimum installation head (from base of pump) 0.3 m (12")
Technical specification - Nominal capacities
For full capacity details for a specific application consult Spirax Sarco.
To accurately size the pump trap, the following data is required.
1. Installationheadavailable,fromthebaseofthepumptraptothecentrelineoftheheatexchanger/
process condensate outlet (m). If the outlet is mounted vertically, then this should be from the
base of the pump to the face of the outlet.
2. Motive steam pressure available to power the pump trap (bar g).
3. Total back pressure in the condensate return system (barg). See note below.
4. Heat exchanger full load operating pressure (bar g).
5. Heat exchanger maximum steam load (kg/h).
6. Minimum temperature of secondary fluid. (°C).
7. Maximum controlled temperature of secondary fluid (°C).
Size DN20 x DN20
Pump discharge/cycle 2.1 litres
1 metre installation head Maximum trapping capacity 735 kg/h
At: 2.0 bar g (29 psi g) motive
0.5 bar g (7 psi g) total back pressure Maximum pumping capacity 405 kg/h
Note: Total lift or back pressure BP (static head plus pressure head in the return system) must be
below the motive fluid inlet pressure to allow pump capacity to be achieved.
BP (back pressure) = (H x 0.0981) + (P) + (Pf)
Height(H)in metresx 0.0981pluspressure (P)barg inthe returnline, plus downstream piping
friction pressure drop (Pf) in bar.
(Pfcanbeignoredifthedownstreampipeworkisless than100metresto anon-floodedcondensate
returnandhasbeensizedtotakeintoaccounttheeffectofflashsteamattheheatexchanger'sfull
load operating conditions.)

IM-P612-18 ST Issue 3 5
Fig. 1
Fig. 2
Dimensions / weights (approximate) in mm and kg
Size A B C D E F G H I Weight
DN20 x DN20 187 23 223 266 273 194 57 225 171 14
I
B
D
E
H
G
C
Motive
steam
supply Exhaust
A
F
OUT
IN

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Materials
No. Part Material
1Cover SG iron DIN 1693 GGG 40.3 / ASTM A395
2Cover gasket Graphite laminated with stainless steel insert
3Body SG iron DIN 1693 GGG 40.3 / ASTM A395
4Cover bolts Stainless steel BS EN ISO 3506 Gr. A2 70
5Pump trap lever Stainless steel BS 1449 304 S15
6Float Stainless steel BS 1449 304 S16
7Pivot shaft Stainless steel BS 970 431 S29 / ASTM A276 431
8Washer Stainless steel BS 1449 316
9Trap housing Stainless steel BS 970 431 S29 / ASTM A276 431
10 Ball ASTM A276 440 B
11 Seat (inlet check valve) Stainless steel AISI 420
12 Flap (inlet check valve) Stainless steel BS 3146 ANC 4B
13 Pump mechanism Stainless steel BS 3146 ANC 4B
bracket
14 Spring (pump) Stainless steel BS 2056 302 S26 Gr. 2
15 Split pin Stainless steel BS 1574
16 Exhaust seat Stainless steel BS 970 431S29 / ASTM A276 431
17 Inlet valve and seat assembly Stainless steel
18 Exhaust valve Stainless steel BS 3146 ANC 2
19 Valve seat gasket Stainless steel BS 1449 409 S19
20 Pump mechanism bolt Stainless steel BS EN ISO 3506 Gr. A2-70
21 Float bolt Stainless steel BS EN ISO 3506 Gr. A2-70
22 Trap 1st stage valve Stainless steel BS 970 431 S29 / ASTM A276 431
23 Trap gasket Stainless steel BS 1449 409 S19
24 Actuator arm Stainless steel BS 3146 ANC 2
25 Name-plate Stainless steel BS 1449 304 S16
26 Drain plug Stainless steel DIN 17440 1.4571
Disposal
There are no hazardous materials used in the construction of this product.
Any unwanted material should be recycled or disposed of in an environmentally friendly manner.

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Fig. 3
3
12
4
6
21
12
17
13
20
14 11
24
18
5
25
26
16
Trap and
outlet check valve
mechanism
9
8
22
23
10
7
15
19

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Important - safety note
Before any installation or maintenance procedure, always ensure that all steam or
condensate lines are isolated.
Ensure any residual internal pressure in the product or connecting lines is carefully
relieved. Also ensure any hot parts have cooled to prevent risk of injury from burns. Always
wear appropriate safety clothing before carrying out any installation or maintenance work.
Always use suitable lifting gear and ensure the product is safely secured.
3.1 Inlet piping
To prevent condensate backing up into the equipment being drained, it is recommended that the
inlet pipework is sufficiently sized to accumulate condensate during the pump’s discharge cycle.
Generally a length and diameter of pipe to accommodate 2 litres of condensate will be sufficient.
Itisrecommendedthiscondensatereservoirissituatedatleast1pipediameterbelowtheprocess
outlet but as high as possible above the APT10-2 inlet. It is essential that a Spirax Sarco Y-type
strainer with a maximum 0.8 mm perforation screen size is fitted at the condensate inlet of the
APT10-2, as shown in Fig. 5.
3.2 Recommended installation head
An installation head of at least 0.3 m (12 ins) from the base of the unit is recommended. Minimum
0.2m(8ins)withreducedcapacity.Note:Duringcoldstart-upconditions,itispossibleforhydraulic
pulsingoftheinletcheckvalvetooccur.Itisadvisableinthiscasetoinstallathrottlingisolationvalve
to reduce the filling pressure.
3.3 Connections (refer to installation diagram Fig. 4 opposite)
The APT10-2 has four connection ports. The DN20 (¾") port marked (IN) should be connected to
theoutletoftheequipmentbeingdrained.TheDN20(¾")portmarked(OUT)shouldbeconnected
to the condensate return line. A flow arrow indicates the correct direction of flow. The DN15 (½")
port marked (S) - steam should be connected to a trapped motive steam supply. * It is important
toensure thislineisdrained of condensateatall times usingaSpirax Sarco steamtrapand
filteredusing a 100 mesh strainer. ThescrewedDN15(½")port marked(E)-exhaustshouldbe
balanced back as close as possible to the condensate outlet of the equipment. This balance line
must always be connected to the top of the condensate pipe; as shown in Fig. 5.
Note: The APT10-2 can be secured to a level stable surface using the 2 x Ø12 mm holes drilled
into the base of the cover.
3.4 Outlet piping
It is important for the outlet piping to be correctly sized to prevent excessive back pressure on the
APT10-2.This pipeworkshould be sizedto takeinto accountthe effects offlash steamat theheat
exchangersfullloadoperatingconditions.RefertoTR-GCM-05forSpiraxSarco'smethodofsizing
this pipe.
3. Installation
4. Commissioning
4.1 After ensuring the inlet and outlet pipe connections and steam motive/exhaust connections
arecoupledinaccordancewithFig.4/5,slowlyopenthemotivesteaminletlinetosupplypressure
to the APT10-2. Ensure the exhaust /balance line is open and not restricted in any way.
4.2 Slowly open the isolation valves in the condensate inlet and discharge lines, allowing
condensate to fill the body of the APT10-2.
4.3 The APT10-2 is now ready to operate.
4.4 When the process plant is operational, the APT10-2 will discharge condensate under all
pressure conditions into the return line.
4.4 Ifanyirregularitiesareobserved,rechecktheinstallationaccordingtotherecommendations.
If the unit fails to operate, then consult the fault finding guide Section 9.

IM-P612-18 ST Issue 3 9
Steam
motive 'S'
Trapped motive
steam supply
line
Removable flanged or
union section for ease
of maintenance
Spirax Sarco
APT10-2
Fig. 4 Suggested coupling of motive supply and exhaust lines.
•Ensure this steam
line is correctly
drained of
condensate at
all times using a
Spirax Sarco
steam trap and a
100 mesh strainer
is used to prevent
debris entering the
pump mechanism.
Fig. 5
➤
➤
Minimum installation
head 0.2 m
from base of pump
Spirax Sarco sized lengthof
pipe to act as a reservoir
➤
➤
➤
Recommended the reservoir is installed at least 1 pipe diameter
below the process outlet, but as high as possible above the APT10-2 inlet.
Balance line
* Trapped motive
steam supply
Exhaust 'E'
Condensate
outlet
Condensate
inlet
Strainer
Soft sealing
flanged or
screwedDCV
➤
➤
Strainer
fitted with
100 mesh
screen
IN
OUT
250 mm minimum
withdrawal distance

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5. Operation
Step 1 (Fig. 6)
The APT10-2 automatic pump trap
operates on a positive displacement
principle. Condensate enters the body
through the inlet swing check valve
causing the float to rise. The float is
connected to the trap mechanism via
a lever to pivot arrangement. If the
upstream system pressure PS is
sufficient to overcome the back
pressure PB (Fig. 6), the build up of
condensate will be discharged
through the opening trap mechanism.
In this way, the float will automatically
modulate according to the rate of
condensate entering the APT10-2,
controlling the rate of opening and
closure of the trap.
Step 3 (Fig. 8)
However, with the APT10-2, the condensate
simply fills the main chamber - lifting
the float until the changeover linkage
is engaged, opening the motive inlet
and closing the exhaust valve.
Step 2 (Fig. 7)
With some temperature controlled
equipment, it is possible for the
system pressure PS to be lower than
the back pressure at PB (Fig. 7).
If this occurs a standard trap will stall
allowing the condensate to flood the
equipment being drained.
Fig. 6
Fig. 7
Fig. 8
Condensate
inlet PS
Exhaust
Condensate
outlet PB
Condensate
inlet PS
Exhaust
Condensate
outlet PB
Motive
steam
inlet
Larger APT14
shown for illustration