Installation and Maintenance Instructions for Steam Traps with Integral Spiratec Sensor (ITD32, IBP21, IBP21S, IBP30, ISM21, IFT14)

1. Safety information
2. Product information
3. Installation
4. Maintenance
5. Spare parts

1. Safety information

The safe operation of these products can only be guaranteed when they are properly installed, commissioned, used and maintained by qualified personnel (see Section 11 of this document) in accordance with the operating instructions. The general installation and safety instructions for pipeline and plant construction must also be followed, together with the correct use of tools and safety equipment.

1.1 Intended use

Refer to the Installation and Maintenance Guide, name-plate and Technical Information Sheet to verify that the product is suitable for the intended use/application.

The products listed below comply with the requirements of the European Pressure Equipment Directive 97/23/EC and carry the mark where required.

These products fall within the following categories of the Pressure Equipment Directive:

i) These products have been specifically designed for use with steam, air or water/condensate, which are included in Group 2 of the above-mentioned Pressure Equipment Directive. The products’ use 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, pressure and temperature and their maximum and minimum values. If the product’s maximum operating limits are lower than those of the system in which it is being installed, or if product failure could result in a dangerous overpressure or overtemperature, ensure that a safety device is included in the system to prevent such an over-limit condition.

iii) Determine the correct installation location 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 installer’s responsibility to consider these stresses and take adequate precautions to minimise them.

v) Remove all protective covers from connections before installation.

1.2 Accessibility

Ensure safe access and, if necessary, provide a safe working platform with suitable protection. Arrange suitable lifting equipment if 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 environments around the product

Consider: explosion-risk areas, lack of oxygen (for example, tanks and pits), hazardous 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 work proposed on the entire system. Could any proposed action (for example, 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 making control or alarm devices ineffective. Ensure that isolation valves are opened and closed slowly to prevent 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 been 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, and consider whether protective clothing, including safety glasses, is required. FTS14 is fitted with fluoroelastomer seals and must not be exposed to temperatures above 315 °C (599 °F). Above this temperature, toxic fumes may be released. Avoid inhalation of fumes and skin contact.

1.9 Tools and consumables

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

1.10 Protective clothing

Consider whether you and/or others 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 Guide.

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

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 loads by bodily force can cause injury, particularly to the back. You are advised to assess the risks, considering the task, the individual, the load and the working environment, and use appropriate handling methods 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 permitted operating conditions, the surface temperature of some products may exceed 250 °C (482 °F).

Many products are not self-draining. Exercise 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 and are exposed to environments below freezing point.

1.15 Safety information

For specific details relating to these products, refer to the relevant sections of the accompanying Installation and Maintenance Guide.

1.16 Disposal

Unless otherwise stated in the Installation and Maintenance Guide, this product is recyclable and its disposal will not cause ecological hazard, provided it is disposed of with due care.

FTS14 is fitted with fluoroelastomer seals. Particular care must be taken to avoid potential health hazards associated with the decomposition or combustion of the seals.

1.17 Returning products

Customers and distributors are reminded that, under EC Health, Safety and Environmental Laws, 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.

2. Product Information

Warning

The cover gaskets of IBP21, IBP21S, IBP30, ISM21 and IFT14 contain a very thin stainless steel support ring, which may cause personal injury if handled or treated incorrectly.

The Spirax Sarco range of steam traps with integral sensors is designed for direct installation in steam lines without the need for an additional sensor chamber.

The following options are available:-

They can be fitted with integral sensors for detecting condensate and steam leakage (WLS1), or steam leakage only (SS1). All steam trap types can be easily integrated into an existing Spiratec monitoring system.

When connecting to an R1C (IM-P087-33) or R16C (IM-P087-21 and IM-P087-22) automatic monitor, refer to the relevant installation and maintenance instructions.

Limiting Conditions (ISO 6552)

IBP21 and IBP21S IBP30 ITD32

IFT14 ISM21

3. Installation

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

All steam traps must be installed in horizontal pipework, preferably with a short drop leg upstream. Suitable isolation valves must be installed to allow safe maintenance or replacement of the steam trap. When the steam trap discharges into a closed condensate return system, a check valve should be installed downstream to prevent reverse flow (for ITD32, the check valve should be located 1 metre downstream of the steam trap outlet). Remove all packaging and protective covers, and ensure that all connection ports are free from obstructions. Always open the isolation valves slowly until normal operating conditions are reached - this will prevent system shock. Check for leaks and correct operation. Always ensure that the correct tools, safety procedures and protective equipment are used. When welding IBP21, IBP21S, IBP30 and ISM21 steam traps to pipework, it is not necessary to remove the components/capsule provided that the arc welding method is used.

Note: The steam traps are supplied with a plug in the sensor connection. It is recommended that the steam trap be operated under normal conditions for 24 hours before removing the plug. This will allow any pipe debris to be cleared from the strainer before installing the sensor. Failure to complete this commissioning process may affect sensor operation. Before installing the sensor, the steam trap must be isolated from the steam supply and condensate return lines, and any pressure must be safely released to atmospheric pressure. Then allow the steam trap to cool. Remove the plug from the connection, ensure that the steam trap is securely supported, and then replace it with the sensor. Ensure that the gasket is centred when screwing the sensor into the connection. Tighten to the recommended tightening torque. If a condensate sensor is to be installed, the installation procedure in IM-P087-34 supplied with the sensor must be followed.

4. Maintenance

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

4.1 General information

Maintenance can be carried out while the steam trap remains in the pipeline. It is recommended that new gaskets and spare parts be used whenever maintenance is carried out (see Section 5). Always ensure that the correct tools and necessary protective equipment are used. After completing maintenance, slowly open the isolation valve and check for leaks.

Note: The sensor should be removed periodically for inspection and cleaning of the insulation, as an accumulation of pipeline residue may affect sensor operation. The inspection frequency will depend on condensate quality. If pitting is found on the insulation, a new sensor should be fitted.

More detailed service information is provided in the following sections:

4.2 Service information for IBP21, IBP21S, IBP30, and ISM21

How to fit the flat screen, capsule, and seat assembly (IBP21, IBP21S, and ISM21)

Remove the cover nuts and bolts. On IBP21 and IBP21S, loosen the clamp securing the capsule to the support bracket, remove the capsule and support plate, and unscrew the seat from the body. Replace with new gaskets, support bracket, and seat, using a suitable thread sealant such as STAG. Ensure that the flat screen is centred when tightening to the recommended torque (see Table 2). On ISM21, the element assembly can be removed by unscrewing the seat. Refit the new capsule and support plate, then replace the clamp or complete element. Ensure that the flat screen is correctly centred. Fit a new cover gasket and evenly retighten the cover nuts to the recommended tightening torque.

How to fit the Y-type strainer screen

If a waterlogging sensor is fitted, it is necessary to disconnect the wiring at the terminal. Unscrew and remove the sensor connector; it is not necessary to remove the sensor from the connector. Clean or replace the screen as required. Refit the screen and sensor assembly, ensuring that the screen is centred, and fit a new gasket (IBP21S and IBP30 only), ensuring that the mating faces are clean. Apply a small amount of molybdenum disulphide grease to the first few threads. Tighten to the recommended tightening torque (see Table 1). Reconnect the waterlogging sensor in accordance with the instructions in IM-P087-34.

How to replace or clean the sensor

If a waterlogging sensor is fitted, it is necessary to disconnect the wiring at the terminal. Remove the sensor from the connector. This can be done online provided that the connector is securely held. Clean the sensor insulation. If pitting is found on the insulation, a new sensor should be fitted. Fit the new sensor and screw it into the connector, ensuring that the gasket is centred. Tighten to the recommended tightening torque. Reconnect the waterlogging sensor in accordance with the instructions in IM-P087-34.

Ensure that any sensor fitted to IBP30 has the letter “L” marked on the hexagon. Sensors marked with “L” on the hexagon must not be fitted to IBP21, IBP21S, or ISM21 steam traps.

Table 1 Recommended tightening torque

4.3 ITD32 service information

Servicing the disc and seat

If a jacket is fitted, remove it and use a suitable socket or spanner to unscrew the cap. Do not use a pipe wrench or similar type of spanner, as this may distort the cap.

If the disc and body seating surfaces are only slightly worn, they can be individually lapped and reconditioned on a flat surface such as a surface plate. A figure-eight motion with a small amount of grinding paste will produce the best results.

If the wear is too extensive to be corrected by simple lapping, the seating surface on the body must be machined flat before lapping. The disc should be replaced. The total amount of metal removed in this way must not exceed 0.25 mm (0.010”).

When reassembling, the disc normally contacts the seating surface with the grooved side facing the seat. The screw-in cap does not require a gasket, but a suitable high-temperature anti-seize grease should be applied to the threads. Tighten to the recommended torque (see Table 2).

How to fit the strainer screen

If a waterlogging sensor is fitted, it is necessary to disconnect the wiring at the terminal.

Unscrew and remove the sensor connector; it is not necessary to remove the sensor from the connector. Clean or replace the screen as required. Refit the screen and sensor assembly, ensuring that the screen is centred. Fit a new gasket and ensure that the mating faces are clean. Apply a small amount of molybdenum disulphide grease to the first few threads. Tighten to the recommended tightening torque. Reconnect the waterlogging sensor in accordance with the instructions in IM-P087-34. ITD32L and ITD32H are fitted with a 0.8 mm perforated screen. ITD32LA and ITD32HA are fitted with a 100 mesh screen.

How to replace or clean the sensor

If a waterlogging sensor is fitted, it is necessary to disconnect the wiring at the terminal.

Remove the sensor from the connector. This can be done online provided that the connector is securely held. Clean the sensor insulation. If pitting is found on the insulation, a new sensor should be fitted. Fit the new sensor and screw it into the connector, ensuring that the gasket is centred. Tighten to the recommended tightening torque (see Table 2). Reconnect the waterlogging sensor in accordance with the instructions in IM-P087-34.

Ensure that any sensor fitted to ITD32 has the letter “L” marked on the hexagon.

Table 2 Recommended tightening torque

ITD32LA and ITD32HA anti-air-binding discs

Groove identification for LA and HA versions

4.4 IFT14 service information

How to fit the main valve assembly

Unscrew the cover bolts and remove the cover. Remove the complete float assembly by unscrewing the two screws. Remove the main valve seat. Ensure that the seat and gasket surfaces are clean and dry. Fit the new seat and gasket and tighten to the recommended tightening torque (see Table 3). Fit the complete float assembly by tightening the assembly retaining screws to the recommended tightening torque. Refit the cover using a new gasket and evenly retighten the cover bolts to the recommended tightening torque.

How to fit the air vent valve assembly

Remove the spring clip, capsule, and support plate, then unscrew the seat. Fit the new seat, gasket, and bracket and tighten to the recommended tightening torque. Assemble the support plate, fit the new capsule, and install the clip. Align the complete air vent horizontally so that the bracket does not interfere with the cover. Refit the cover using a new gasket and evenly retighten the cover bolts to the recommended tightening torque.

How to replace or clean the sensor

If a waterlogging sensor is fitted, it is necessary to disconnect the wiring at the terminal. Remove the sensor from the steam trap. Clean the sensor insulation. If pitting is found on the insulation, a new sensor should be fitted. Fit the new sensor, ensuring that the gasket is centred. Tighten to the recommended tightening torque. Reconnect the waterlogging sensor in accordance with the instructions in IM-P087-34.

Sensors marked with “L” on the hexagon must not be fitted to IFT14 steam traps.

\*Item 7 (main valve assembly screw) is not shown

Table 3 Recommended tightening torque

5. Spare parts

5.1 How to order spare parts

When ordering spare parts, always use the description provided in the “Available spare parts” column and specify the size, model, and pressure rating of the steam trap.

Example 1: Strainer and gasket for a ½” ITD32 steam trap with integral sensor from Spirax Sarco.

Example 2: Capsule and seat assembly for a ½” IBP21 steam trap with integral sensor from Spirax Sarco, with “E” filling.

5.2 Available spare parts for the ITD32 series

The following options are available:-

• ITD32L with integral sensor, low capacity

• ITD32H with integral sensor, high capacity

• ITD32A with integral sensor, low capacity and anti-air-binding disc

• ITD32HA with integral sensor, high capacity and anti-air-binding disc

Spare parts are listed below.

No other parts are available as spare parts.

5.3 Available spare parts for IBP21, IBP21S, IBP30 and ISM21

Spare parts are listed below.

5.4 Available spare parts for IFT14

Spare parts are listed below. No other parts are available as spare parts.

* Item 7 (main valve assembly screws) is not shown.

IFT14