I&M SOFT31-O- Single Orifice Float Trap with SLR
Contents
1. A d Installation and Maintenance Manual f Boden Trusted Partners Innovative Solutions Single Orifice Float Trap With SLR SOFT31 O Energy Conservation Environment Process Efficiency www forbesmarshall com Forbes Marshall Forbes Marshall Arca Codel International Krohne Marshall Forbes Solar Forbes Vyncke Forbes Marshall Steam Systems 4 Forbes i Marshall Trusted Partners Innovative Solutions Table of Contents i PLE E 1 2 Important Safety Notes EE 1 3 Brief Product INfOrmation asa dacsca2 cieesexcnassinenseddvnwsas sseeeearveeaess 3 4 Product Working Principle cxsccuvcsrdcvsatsraaaueates temas aeseueneaie 5 5 Installation Guidelines media biede gierung 6 6 Start up and COMMISSIONINQ BEE 7 7 Maintenance Guidelines E 8 8 TOUBIESKNOOUN Geaen E 11 g Available Spares sesining aana 13 10 Warranty A sorsoran aa eege ie 13 PLEASE NOTE Throughout this manual this cautionary symbol is used to describe a potential damage or injury that might occur if the safety considerations are overlooked This symbol denotes CAUTION WARNING or DANGER 4 Forbes Marshall Trusted Partners Innovative Solutions Preface This manual is intended for anyone using commissioning servicing or disposing the below mentioned products safely and efficiently Single Orifice Float Trap With SLR SOFT31 O Size DN15 1 2 PLEASE NOTE Throughout this manual the following cauti2. EE U e bei T S z Val Forbes Marshall Forbes Marshal Trusted Partners Innovative Soluti Bombay Poona Road Kasarwadi Pune 411 034 INDIA Tel 91 02135 393400 Tel 91 0 20 27145595 39858555 CIN No U27109PN1959PTCO1 1334 www forbesmarshall com Email seg forbesmarshall com
3. Float 10barg 4 S2005483 S2005484 2031849 SLR unit kit 2017200 How to Order Example DN15 Single Orifice Float Trap SOFT31 O 14 bar g SLR BSPT How to Order Spares Always order spares using the description given in the column above headed Available Spares and stating the size and type of the trap For codes refer the user manual Ho Warranty Period As per the ordering information and agreements in the contract 13 OW LAVO LELIOS WIN S LOS 200 JUBLUNDOD SIU JO s ua4U02 y Jo Aue Jo UOeDI dde 10 asn ay Jo AjauIpUL 10 p a2u nb suo e se PadINDUI asian JO eUOSJad ee 10 Soss s j qer Aue wiepsip Ajjeryinads pue suoIssiwWo 10 saDeanddeul 10 Ayi iqisuodsal ou auunsse sajuedwo gt dnoJy pue sagt sajepossy saLeIpIsqns S JO WI dou yoyy m auey o palqns s JUBWNIOD sjy u UOEUOJU ay GALISIHOUd SI NOISSINY3d ND LUNA HOI LAOH LIMIYNSO1ISIC YO NOILNIYLSIG NOLLINGOYdIY ANY SLHOIY ALYIdOYd TWALDITISLNI JHL Y3GNN NOILDJLOYd ONIAVH ANY 29 AVI ISV JHL SY CAdSSIN4 03 UI JLVAIYd SWALSAS WVALS TIVHSYYIN S389404 YO LW QILINI JLVAINd TIVHSYYN S39Y04 4O ALYIdOYd JHL JUV NISYIH SLNILINOD TIY Formerly Spirax Marshall Pvt Ltd Forbes Marshall Steam Opp 106th Milestone Systems Pvt Ltd a ay o 2 o g i 2 e e Ae ae xog TES cya V S 2 eS a os OH a X oo D EE i DS oS H anbe bei S
4. Trusted Partners Innovative Solutions 6 3 Setting of Steam Lock Release SLR Refer to Figure 7 1 4 Loosen the gland nut 1 by one thread Rotate the stem 2 in clockwise direction This moves the stem 2 towards SLR seat Once the stem touches the SLR seat rotate the stem 2 in anti clockwise direction by 1 4 of aturn Check for normal discharge pattern and leaks if any Note The SLR unit should only be used to prevent steam locking and therefore is designed to pass a small amount of steam it is not recommended that the SLR be left in the fully open condition as this may lead to premature trap failure and more frequent maintenance schedules CZ CLOSE ROTATE STEM 77 clockwise 2 Ki TO CLOSE SLR 17 NS Figure7 SLR setting Maintenance Guidelines Before undertaking any maintenance on the product it must be isolated from both supply line and return line and any pressure should be allowed to safely normalise to atmosphere The product should then be allowed to cool With suitable isolation repairs can be carried out with the product in the line When re assembling make sure that all joint faces are clean Once completed open isolation valves slowly and check for leaks 7 1 Routine and Preventive Maintenance Please refer to the maintenance schedule mentioned in the table below to undertake routine maintenance of the product Sr Parameters to be checked Frequ
5. a needle valve which releases steam that can steam lock the trap during start up or in operation if the steam reaches the trap before the condensate INLET INLET 3 3 7 OUTLET BEER 3 a Trap Discharge Open 3 b Trap Discharge Closed Figure3 Float trap working The trap in the figure 3 shows a TV SLR assembly SOFT31 O comes with only SLR assembly 4 Forbes i Marshall Trusted Partners Innovative Solutions sl Installation Guidelines Refer to Figure 4 5 and 6 AI Note Before implementing any installations observe the Important Safety notes in section 2 Referring to the Installation and Maintenance Instructions name plate and Technical Information Sheet check that the product is suitable for the intended installation Installation checks and Steps 1 Check the correct installation location position and the direction of fluid flow 2 Remove protective covers from all connections where appropriate before installation 3 Ensure the availability of all components as shown in Figure 4 to ensure the operation of the OUTLETY Figure4 Single Orifice Float trap module Typical Representative Installation and may vary based on application and site Item No Description 1 Spring Loaded Check Valve 2 6 Stop Valve 3 View Glass 4 Single Orifice Float Trap 5 Strainer 4 Ifthe trap is to discharge to atmosphere ensure it is to a safe place the discharging fluid may beata tempe
6. embly Stainless Steel Type 410 ASTM A276 9 Ch Hd Screw Stainless Steel Type 304 l S 1364 10 Float assembly Stainless Steel type 304 ASTM A240 11 Hex Hd Bolt Carbon steel H T Gr 8 8 3 6 Product Dimensions and Drawing SECTION A A Figure 2 Dimensional Drawing of SOFT31 O Dimensions approx in mm Size A B Cc D E Weight DN15 151 46 58 90 118 2 5kg 4 Forbes Marshall Trusted Partners Innovative Solutions 6 Capacity Chart 1500 1000 a 3 r 3 6 8 8 K OF Bte LZ D pai D N 5 200 S P a gt Ei Ki e ee E tas fo paal e OH O 100 50 40 304 1 0 1 0 2 0 3 0 4 0 5 H S 3 4 5 10 13 Differential pressure bar g x100 kPa D Product Working Principle Refer to Figure 3 Figure 3 shows a simple float trap operational representation A float trap works on the Buoyancy Principle Condensate enters the trap body and raises the float 1 The position of the float 1 depends upon the level load of condensate flowrate The float trap continues to discharge condensate continuously and doesn t allow back up of condensate as long as the load is within the discharge capacity When the condensate load drops the float 1 lowers in position and closes the outlet valve 3 with the ball 6 resting on the orifice 7 SLR 4 is
7. ency for checking and maintaining BS Single Orifice float trap Immediately Daily Weekly Monthly Quarterly Annually 1 Test low pressure SOFT31 0 for leakage operation Repair Replace SOFT31 0O when 2 y testing shows leaks Clean strainers of Single Orifice 3 Float Traps Clean internals of Single Orifice 4 Float Traps 5 Visual inspection for leakages Y 6 Arresting any other leaks Y 4 Forbes i Marshall Trusted Partners Innovative Solutions 7 2 Tool Kit To carry out any maintenance on the trap please use the tools mentioned below Component Tool Used Size SLR seat Box Spanner 17 mm A F 19mm A F Valve seat 4 1mm ID Box Spanner 7 mm A F SLR Stem Slot Screw Driver Gland nut Open Spanner 13 mm A F M4 screw valve seat 4No Screw Driver 12 inch M10 Bolt for outside covering Box Spanner 13 mm A F 7 3 Recommended tightening torques Component Torque Range SLR seat 35 Nm Valve seat 4 1mm ID 35 Nm SLR Stem 60 70 Nm M10 Bolt for outside covering 25 35 Nm 7 4 Maintaining Replacing the main valve assembly Refer to Figure 8 Unscrew cover bolts 1 and lift off the cover 11 Dismantle the pivot pin 3 and remove the float 4 Unscrew the assembly set screws 5 and dismantle the pivot frame 6 Remove the main valve seat 7 along with the metal gasket 8 Replace the main valve assembly 9 and the gasket 10
8. limiting conditions specified in technical information sheet of the product iii The correct installation and direction of fluid flow has to be determined iv Forbes Marshall products are not intended to resist external stresses hence necessary precautions to be taken to minimize the same 2 2 Accessibility and Lighting Safe accessibility and working conditions are to be ensured prior to working on the product 2 3 Hazardous environment and media The product has to be protected from hazardous environment and check to ensure that no hazardous liquids or gases pass through the product 2 4 2 5 2 6 2 7 2 8 2 9 2 10 4 Forbes Marshall Trusted Partners Innovative Solutions Depressurizing of systems and normalizing of temperature Ensure isolation and safety venting of any pressure to the atmospheric pressure Even if the pressure gauge indicates zero do not make an assumption that the system has been depressurized To avoid danger of burns allow temperature to normalize after isolation Tools and consumables Ensure you have appropriate tools and or consumables available before starting the work Use of original Forbes Marshall replacement parts is recommended Protective clothing Consider for the requirement of any protective clothing for you or others in the vicinity for protection against hazards of temperature high or low chemicals radiation dangers to eyes and face noise and fal
9. ling objects Permits to work All work to be carried out under supervision of a competent person Training should be imparted to operating personnel on correct usage of product as per Installation and Maintenance instruction Permit to work to be complied with wherever applicable in case of absence of this system a responsible person should have complete information and knowledge on what work is going on and where required arrange to have an assistant with his primary goal and responsibility being safety Warning Notices should be posted wherever necessary Handling There is a risk of injury if heavy products are handled manually Analyze the risk and use appropriate handling method by taking into consideration the task individual the working environment and the load Freezing Provision should be made to protect systems which are not self draining against frost damage in environment where they may be exposed to temperatures below freezing point to be made Returning products Customers and Stockist are reminded that when returning products to Forbes Marshall 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 4 Forbes i Ma
10. nsate carrying capacity of the trap Check parameters and trap sizing The trap will not discharge enough condensate if the actual size is below the recommended size based on the condensate load iii Check for back pressure and corresponding discharge capacities as per the capacity charts working traps with working traps working traps connected to the Replace repair the leaking and non he leak traps may create increase he back pressure on the other same return line or if there are more than one trap discharging in a single condensate return line then ensure all the raps have an NRV installed on the outlet of each trap or ensure all the by pass valve are closed if by pass valve is leaking or if it is kept open in closed loop condition which creates increases back pressure on the other working raps connected to the same return line Flooding of condensate Check whether the inlet strainer is partially blocked Check main valve seat orifice for blockage If blocked clean and lap D Available spares Refer to Figure 8 The spare parts available are given in the following table 4 Forbes i Marshall Trusted Partners Innovative Solutions Float 13barg Gasket size kit pack of 5 Sr No SPARE PART PART No SPARE CODE 1 MV Assembly 4 5barg S2031851 2 MV Assembly 10barg 9 S2031852 3 MV Assembly 13barg S2031853 4 Float 4 5barg S2005482 5
11. onary symbol is used to describe a potential damage or injury that might occur if the safety considerations are overlooked Important Safety Notes Read this section carefully before installing operating maintaining the product The precautions listed in this manual are provided for personnel and equipment safety Furthermore Forbes Marshall accepts no responsibility for accidents or damage occurring as a result of failure to observe these precautions Note that the product is designed to perform for non contaminated fluids only A contamination in the form of chemical foreign particle etc can lead to problem with product performance and life of the product If these products in compliance with the operating instructions are properly installed commissioned maintained and installed by qualified personnel refer Section 2 7 the safety operations of these products can be guaranteed General instructions for proper use of tools and safety of equipments pipeline and plant construction must also be complied with 2 1 Intended use Check if the product is suitable for intended use application by referring to the installation and maintenance instructions name plates and technical information sheets i The product is suitable for use as defined in the technical information sheet In case the need arises to use the product on any other fluid please contact Forbes Marshall for assistance ii Check for the suitability in conformance to the
12. rature of 100 C 212 F 5 Install the trap such that the arrow on the name plate points downward to achieve proper orientation of the trap 4 Forbes i Marshall Trusted Partners Innovative Solutions EE e ef Forbes A Marshall EE sor E Sr No TMA A PMX PMA Size e e L J Figure5 Single Orifice Float trap name plate The arrow on the casting should be in the direction of the flow Figure6 Cover casting with the arrow A Start up and Commissioning 6 1 6 2 Flushing of Lines Refer to Figure 4 As part of pre installation all fluid handling equipment particularly piping should be thoroughly cleaned of scale and the internal debris which accumulates during construction This is accomplished by blowing or flushing with air steam water and other suitable medium Follow these steps to carry out the flushing 1 Close the stop valve 2 and open the bypass stop valve 6 2 Letthe condensate drain for 10 15 minutes or until clear condensate starts coming out whichever is earlier 3 Nowslowly close the bypass stop valve 6 and open the stop valve 2 Commissioning Refer to Figure 4 After installation or maintenance ensure that the system is fully functioning by confirming condensate is passing through it i After flushing of lines is complete ensure stop by pass valve 6 closed and stop valve 2 opened ii Check for leaks and attend if any 4 Forbes i Marshall
13. rshall Trusted Partners Innovative Solutions ES Brief Product Information 3 1 Description The Forbes Marshall Single Orifice Float Trap with SLR SOFT31 O is a condensate drain trap of cast iron body and stainless steel internals 3 2 Sizes and Pipe Connections DN15 Screwed BSPT NPT Note Available in Non IBR only 3 3 Available Types SOFT31 O with Steam Lock Release SLR only 3 4 Limiting Conditions PMA Maximum allowable pressure 13 bar g TMA Maximum allowable temperature 220 C 13 barg PMO Maximum operating pressure 13 bar g TMO Maximum operating temperature 220 C 13 barg Minimum operating temperature 0 C SOFT31 O0 4 5 4 5 barg SOFT31 O 10 10 bar g SOFT31 O 13 13 bar g Cold hydraulic test pressure 26 bar g APMX maximum differential pressure 3 5 Operating Range 220 200 150 Steam 100 S saturation 50 Temperature C Figure 1 Single Orifice Float Trap With SLR 4 Forbes A Marshall e scone Material S No Part Material Standard 1 Base Cast Iron IS 210Gr FG 260 2 Cover Cast Iron IS 210Gr FG 260 3 Cover Gasket Reinforced exfoliated graphite 4 Valve Seat Stainless Steel type 410 ASTM A276 5 Valve Seat Gasket Stainless Steel Type 304 ASTM A240 6 Pivot Frame Stainless Steel Type 304 ASTM A240 7 Pivot pin Stainless Steel Type 304 ASTM A276 8 SLR Ass
14. the cover casting and the name plate arrow on the base casting Check for blockage in the strainer If the actual differential pressure is higher than the design P the steam trap would have failed in closed position as the float buoyancy will not be adequate to open the valve seat Check for the valve and seat assembly for blockage Check if the ball float is punctured if so replace it Post replacement check for water hammering in process to avoid reoccurrence No condensate is discharged and the surface temperature of the trap is high The trap is getting steam locked Adjust the steam lock release setting by first closing it fully and then opening it by 1 4th turn Leaking steam Live steam continuously leaking through the outlet Check the installation The arrow on the name plate should point downwards Check valve and seat assembly for any deposition and clean it i Clean and lap the seating area ii Lightly stamp an SS ball on the seating area Check for SLR leakage setting check for air vent leakage Steam leaking from the trap body Tighten the cover nuts and bolts to the recommended torque Check the gasket for any possible damage and replace it if required 11 4 Forbes i Marshall Trusted Partners Innovative Solutions Failure Mode Possible Cause Remedy Not discharging enough condensate 12 Reduced conde
15. with a new one Refit the cover 11 by using the cover bolts 1 A OO a Cover Bolts 1 Gasket 10 Set Screws 5 Pivot Pin 3 Fioati4y 7 Main Valve Assembly 9 Base 2 Figure8 Maintaining the main valve assembly 10 4 Forbes i Marshall Trusted Partners Innovative Solutions 7 5 Procdure to fit the Steam Lock Release SLR assembly Refer to Figure 9 1 Er OM Unscrew the complete SLR assembly Remove the SLR gasket not shown in the figure 9 Replace the SLR assembly and gasket with new ones Reset the SLR SLR stem Gland Packing a Gland nut SLR seat Figure 9 SLR assembly 7 6 Steam trap testing Following methods can be used to determine the operating condition of a trap and determine if its working properly L pee IS Testing traps through visual inspection Testing traps using temperature gun equipment Testing traps using sound ultrasound Testing traps through online monitoring D Troubleshooting 4 Forbes i Marshall Trusted Partners Innovative Solutions If the expected performance is unachievable after the installation of the single orifice float trap check the following points for appropriate corrective measures Failure Mode Possible Cause Remedy Not discharging at all No condensate is discharged and the surface temperature of the trap is low Check the installation Check for the flow direction arrow on
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