HP45 Bimetallic Steam Trap Installation and Maintenance Instructions

1. Safety information
2. Product information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
8. Troubleshooting

1. Safety information

Safe operation of this product can only be guaranteed if it is properly installed, commissioned, used and maintained by qualified personnel (see Section 1.11 of this document) in accordance with the operating instructions. The general installation and safety instructions for pipeline and plant construction, as well as the correct use of tools and safety equipment, must also be observed.

1.1 Intended use

Referring to the Installation and Maintenance Instructions, the name-plate and the Technical Information Sheet, check that the product is suitable for the intended use/application.

This product fully complies with the requirements of the European Pressure Equipment Directive 2014/68/EU and carries the Ⓒ mark where applicable.

This product falls within the following categories of the Pressure Equipment Directive:

i) This product has been specifically designed for use with steam, air or water/condensate, which are included in Group 2 of the Pressure Equipment Directive referred to above. Use of the product with 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 the suitability of the materials, and the maximum and minimum pressure and temperature values. If the maximum operating limits of the product are lower than those of the system in which it is installed, or if product failure could result in a dangerous overpressure or overtemperature condition, ensure that a safety device is included in the system to prevent such an occurrence.
iii) Determine the correct installation position and the direction of fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses that may be induced by the system in which they are installed. It is the responsibility of the installer to consider these stresses and take adequate precautions to minimise them.
v) Remove protective covers from all connections before installation.

1.2 Access

Ensure safe access and, if necessary, provide a safe working platform with suitable protection. Arrange suitable lifting equipment where required.

1.3 Lighting

Ensure adequate lighting, particularly where detailed or complex work is required.

1.4 Hazardous liquids or gases in the pipeline

Consider what is in the pipeline or what may previously have been in it. Consider: flammable materials, substances hazardous to health and extreme temperatures.

1.5 Hazardous environment around the product

Consider: explosion risk areas, lack of oxygen (for example, tanks or pits), dangerous gases, extreme temperatures, hot surfaces, fire hazards (for example, during welding), excessive noise and moving machinery.

1.6 The system

Consider the effect of the proposed work on the entire system. Could any proposed action, such as closing isolation valves or electrical isolation, put any other part of the system or any personnel at risk?

Hazards may include isolating vents or protective devices, or rendering controls or alarms ineffective. Ensure that isolation valves are opened and closed slowly 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 locking or labelling closed valves. Do not assume that the system has depressurised even when the pressure gauge indicates zero.

1.8 Temperature

Allow time for the temperature to normalise after isolation to avoid the risk of burns.

1.9 Tools and consumables

Before starting work, ensure that suitable tools and/or consumables are available. Use genuine Spirax Sarco replacement parts only.

1.10 Protective clothing

Consider whether you and/or other people in the vicinity require protective clothing to protect against, for example, chemicals, high or low temperatures, radiation, noise, falling objects and hazards to the eyes and face.

1.11 Permits to work

All work must be carried out by, or under the supervision of, appropriately qualified personnel. Installation and operating personnel should be trained in the correct use of the product in accordance with the Installation and Maintenance Instructions.

Where a formal “permit to work” system is in operation, it must be complied with. Where no such system is in operation, it is recommended that a responsible person is aware of the work being carried out and, where necessary, that an assistant whose primary responsibility is safety is appointed.

If necessary, post “warning notices”.

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 using 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 an appropriate handling method according to the circumstances of the work being performed.

1.13 Residual hazards

During normal use, the external surface of the product may be very hot. If used at the maximum allowable operating conditions, the surface temperature of some products may reach temperatures of 425 °C (797 °F).

Many products are not self-draining. Take particular care when dismantling or removing the product from an installation (refer to the Maintenance Instructions).

1.14 Freezing

Provision must be made to protect products that are not self-draining from damage caused by freezing when they are exposed to temperatures below freezing point.

1.15 Disposal

Unless otherwise stated in the Installation and Maintenance Instructions, this product is recyclable and its disposal does not present an ecological hazard provided that it is handled with care.

If no additional information is provided on the Spirax Sarco product compliance web page, this product can be safely recycled and/or disposed of provided that it is handled with care. Always comply with local recycling and disposal regulations.

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 about any hazards and the precautions to be taken due to contamination residues or mechanical damage that 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.

2. Product information

2.1 Description

The Spirax Sarco HP45 bimetallic steam trap is manufactured from forged steel and is designed to discharge condensate from high-pressure, high-temperature steam mains and process systems.

The trap is specifically designed for high-pressure steam applications. It features a reinforced stainless steel internal liner and can be serviced in line. It operates without steam loss and rapidly discharges air, non-condensable gases and large quantities of cold water during start-up. The valve is fail-open and incorporates a check valve, an integral strainer and an external adjustment device for regulating the condensate discharge temperature.

Standards

This product fully complies with the requirements of the European Pressure Equipment Directive 2014/68/EU.

Certification

An EN 10204 3.1 certification can be provided for this product.

Note: All certification/inspection requirements must be stated at the time of order.

Note: For further information, refer to the Technical Information Sheet TI-P623-02.

2.2 Sizes and pipe connections

1/2”, 3/4” and 1” threaded connections BSP T Rp (ISO 7-1) / NPT, socket weld ends to ANSI B 16.11 and butt weld ends to ANSI B 16.25. DN15, DN20 and DN25 flanged connections PN63, PN100 and ANSI 600.

Fig. 1

2.3 Pressure/temperature limits

A-B-B flanges Class 600, threaded BSP/NPT, socket weld and butt weld ends

A-C-C flanges PN100

A-D-D flanges PN63

The product must not be used in this region.

The product should not be used in this region or beyond its operating range, as this may damage the internal components.

3. Installation

Note: Before carrying out any installation, observe Section 1, “Safety information”.

Referring to the Installation and Maintenance Instructions, the name-plate and the Technical Information Sheet, check that the product is suitable for the intended installation:

3.1 Check the materials, pressure and temperature, and their maximum values. If the maximum operating limits of the product are lower than those of the system in which it is installed, ensure that a safety device is included in the system to prevent overpressure.
3.2 Determine the correct installation position and the correct direction of fluid flow.
3.3 Before installation in steam or other high-temperature applications, remove protective covers from all connections and remove all protective film from the name-plates.
3.4 Install the trap downstream of the equipment being drained, ensuring that it is easily accessible for inspection and maintenance.
3.5 The trap may be installed in any position, but the discharge outlet must not point vertically upwards.
3.6 Before installing the trap, ensure that all connecting pipework is clean and free from debris.
3.7 When installing the trap, the arrow on the body must point in the direction of fluid flow.
3.8 The trap may be welded directly into the pipeline without removing the internal components. Where pipeline freezing may occur, the trap cover axis should be installed horizontally. For socket weld traps, qualified welding procedures must be followed. It is not necessary to remove the internal components during welding, but overheating must be avoided.
3.9 The trap is factory set.

Note: If the trap discharges to atmosphere, ensure that the discharge is directed to a safe location. The discharged fluid may be at a temperature of up to 100 °C (212 °F).

Fig. 2 Recommended installation - Note: The pipework should slope in the direction of flow.

4. Commissioning

After installation or maintenance, ensure that the system is fully operational. Test any alarms or protective devices.

5. Operation

The Spirax Sarco HP45 is a bimetallic steam trap.

The trap operates using two opposing forces acting on the valve: the opening force generated by system pressure and the closing force generated by the temperature of the condensate acting on the bimetallic element.

During operation, the HP45 steam trap discharges without steam loss and automatically discharges air, non-condensable gases and large quantities of cold water rapidly during start-up.

6. Maintenance

Note: Before carrying out any maintenance procedure, observe Section 1, “Safety information”.

Safety Information

These steam traps are installed in high-pressure steam lines. Personnel carrying out adjustment work should wear thick gloves, long-sleeved shirts, and other personal protective equipment intended to protect the wearer, such as safety glasses and face shields, to guard against leakage.

The equipment required for any maintenance procedure is listed in Table 1. The HP45 steam trap has an external adjustment screw for flushing the valve seat and setting the condensate discharge temperature in the inlet line.

Provided that safety procedures are followed, maintenance can be carried out while the steam trap remains installed in the pipeline. New gaskets and spare parts are recommended whenever maintenance is performed. Always ensure that the correct tools and necessary protective equipment are used. After maintenance is complete, slowly open the isolation valve and check for leaks.

6.1 Flushing the Valve Seat in Service

To clean or adjust the steam trap while it is in service, it is recommended that the upstream isolation valve be closed before turning the adjustment screw. Proceed as follows: (in a closed-loop return system, close the discharge line and open the test valve):

• Remove the cap nut (9) and loosen the locknut (10) on the adjustment screw.
• Using a screwdriver, tighten the adjustment screw clockwise by several turns. This will completely disengage the valve inlet.
• Slightly open the upstream isolation valve. This produces a strong flushing action to remove any debris that may have accumulated in the steam trap.
• Move the adjustment screw upward counter-clockwise until the valve comes into contact with the valve seat.

6.2 Adjusting the Discharge Temperature

• Remove the cap nut (9) and loosen the locknut (10) on the adjustment screw.
• The condensate discharge temperature is adjusted by moving the adjustment screw upward by a greater or lesser amount from the point where the valve contacts the valve seat (standard adjustment: turn the screw a further 1/4 to 1/2 turn counter-clockwise).
• After adjustment, tighten the locknut (10) on the adjustment screw.
• Replace the cap nut (9) and gasket (8), and tighten to the specified torque (see Table 1).
• Close the test valve and open the discharge line valve. In a closed-loop return system, a test tee and valves must be used to observe steam trap operation. The steam trap should regulate condensate discharge according to the inlet temperature and pressure.
• After adjustment is complete, fully open the upstream isolation valve.

Table 1 Spanner sizes and recommended tightening torques

6.3 Replacing the Bimetallic Element

Serviceable spare parts are listed in Section 7.

6.3.1 Dismantling the Steam Trap

• Isolate the steam trap.
• Remove the cap nut (9), the locknut (10) on the adjustment screw, and the cover nuts (7) on the cover (6).
• Using a screwdriver with a maximum blade diameter of 7 mm to allow insertion into the thread in the cover, tighten the adjustment screw on the assembly so that it disengages from the cover.
• Remove the strainer (4).
• Remove the bimetallic element (3) using a pipe wrench. A dedicated 36 mm A/F pipe wrench is recommended for this operation.
• Insert the bimetallic element into the pipe wrench. Use a 17/16” (36 mm) hexagonal wrench to unscrew the valve seat from the body and remove the internal component (3).
• Inspect all parts, particularly the gaskets and sealing surfaces.

6.3.2 Reassembling the Steam Trap

• New gaskets supplied in the spare parts replacement kit must be used (see Section 7).
• Apply grease to the sealing surfaces of the valve seat, adjustment screw, and valve seat gasket.
• Place the valve seat gasket (2) into the valve body.
• Screw in the bimetallic element (3) using a pipe wrench and tighten to the recommended torque (see Table 1).
• Install the strainer (4) and cover gasket (5).
• Using a screwdriver inserted into the cover, screw the cover onto the adjustment screw and move the adjustment screw counter-clockwise until it is positioned above the cover.
• Apply grease to the cover studs, replace the cover nuts (7), and tighten to the recommended torque (see Table 1).
• Install the locknut (10) on the adjustment screw, then carry out the final adjustment (see Section 6.3.3).

6.3.3 Adjustment

• In a closed-loop return system, close the discharge line and open the test valve.
• Slightly open the upstream isolation valve.
• Tighten the adjustment screw clockwise by several turns, then wait briefly for the steam trap to reach the required temperature and produce steam.
• Move the adjustment screw upward counter-clockwise until the valve comes into contact with the valve seat.
• The condensate discharge temperature is adjusted by moving the adjustment screw upward by a greater or lesser amount from the point where the valve contacts the valve seat (standard adjustment: turn the screw a further 1/4 to 1/2 turn counter-clockwise).
• After adjustment is complete, screw the locknut (10) onto the adjustment screw.
• Replace the cap nut (9) and gasket (8), and tighten to the specified torque (see Table 1).
• Close the test valve and open the discharge line valve. In a closed-loop return system, a test tee and valves must be used to observe steam trap operation. The steam trap should regulate condensate discharge according to the inlet temperature and pressure.
• After adjustment is complete, fully open the upstream isolation valve.

7. Spare Parts

Available spare parts are listed below. No other parts are supplied as spare parts.

Available Spare Parts

Bimetallic assembly kit

2, 3, 4, 5, 8

How to Order Spare Parts

When ordering spare parts, always use the description in the “Available Spare Parts” column and specify the size and model of the bimetallic steam trap.

Example: 1 bimetallic assembly kit for a Spirax Sarco DN20 HP45 bimetallic steam trap.

8. Troubleshooting