PC20, IPC20 and IPC21 Pipe Connector Installation and Maintenance Instructions

PC20

Contents

1. Safety Information
2. Description
3. Installation
4. Maintenance
5. Available Spare Parts

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 1.12 of this document) in accordance with the operating instructions. General installation and safety instructions for pipeline and plant construction must also be observed, together with the correct use of tools and safety equipment.

1.1 Intended Use

Refer to the Installation and Maintenance Instructions, product markings and Technical Information Sheet to check that the product is suitable for the intended use/application. This product complies with the requirements of the European Pressure Equipment Directive (PED) and falls within the “SEP” category.

Please note that, under the Directive, products in this category must not bear the CE mark.

i) This product has been specifically designed for use with steam, air or condensate/water, which are in Group 2 of the above-mentioned Pressure Equipment Directive. 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 material suitability and the pressure and temperature limits, including their maximum and minimum 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 dangerous overpressure or overtemperature conditions, ensure that safety devices are included in the system to prevent such limits from being exceeded.
iii) Determine the correct installation position and fluid flow direction.
iv) Spirax Sarco products are not designed to withstand external stresses that may be imposed 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 and protective film from all nameplates, where applicable, before installation in steam or other high-temperature applications.

1.2 Access

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

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 have been in the pipeline previously. Consider flammable materials, substances hazardous to health and extreme temperatures.

1.5 Hazardous Environment Around the Product

Consider explosive areas, oxygen-deficient atmospheres such as tanks or pits, hazardous gases, extreme temperatures, hot surfaces, fire hazards such as during welding, excessive noise and moving machinery.

1.6 The System

Consider the effect of the proposed work on the complete system. Could any proposed action, such as closing isolation valves or electrical isolation, put other parts of the system or 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 progressively to avoid system shock.

1.7 Pressure Systems

Before carrying out any maintenance on the pipe connector, ensure that all pressure is isolated and safely vented to atmospheric pressure before proceeding with any maintenance work. This can be easily achieved by using a Spirax Sarco blowdown valve fitted to the unit (see Sections 1.7.1 and 5 below). Do not assume that the system has been depressurised even when a pressure gauge indicates zero.

1.7.1 Blowdown Valves and Depressurisation Valves

Blowdown valves and depressurisation valves are generally used to depressurise systems/vessels before maintenance or dismantling. Do not assume that the system has been depressurised even when a pressure gauge indicates zero. Consider the direction of the discharge flow and ensure that it will not create a hazard to yourself or others.

1.8 Temperature

Allow time for the temperature to return to normal after isolation to avoid the risk of burns, and consider whether protective clothing, including safety glasses, is required.

1.9 Isolation

Consider whether closing isolation valves will put other parts of the system or personnel at risk. Hazards may include isolating vents, protective devices or alarms. Ensure that isolation valves are opened and closed slowly to avoid system shock.

1.10 Tools and Consumables

Before operating valves, ensure that suitable tools are available. Before carrying out any maintenance, refer to the relevant tool reference table and correct torque settings.

1.11 Protective Clothing

Consider whether you and/or others nearby require protective clothing to protect against hazards such as chemicals, high/low temperatures, radiation, noise, falling objects, and hazards to the eyes and face.

1.12 Permits to Work

All work must be carried out by suitably qualified personnel or under their supervision. 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 no such system exists, it is recommended that a responsible person be aware of the work in progress and, where necessary, arrange for an assistant whose primary responsibility is safety.

Post “warning notices” where necessary.

1.13 Handling

Manual handling of large and/or heavy products may present a risk of injury. Lifting, pushing, pulling, carrying or supporting a load using physical effort can cause injury, particularly to the back. It is recommended that the risk be assessed by considering the task, the individual, the load and the working environment, and that an appropriate handling method be used for the specific circumstances of the work being undertaken.

1.14 Residual Hazards

Under normal operating conditions, the external surface of the product may be very hot. When used at the maximum permitted operating conditions, surface temperatures may exceed 425 °C (797 °F).

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

1.15 Freezing

Provision must be made to protect products that are not self-draining against frost damage when they are exposed to environments below freezing point.

1.16 Disposal

Unless otherwise stated in the Installation and Maintenance Instructions, this product is recyclable and no ecological hazard is anticipated with its disposal, provided due care is taken.

1.17 Returns

Customers and distributors are reminded that, under EC Health, Safety and Environment Law, 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 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. Description

2.1 General

PC and IPC pipe connectors are designed for use with universal connector steam traps. Their principle is that the pipe connector can be installed in either a horizontal or vertical pipeline. The steam trap can then be fitted to the connector and rotated through 360° to ensure that the steam trap is in a horizontal plane. PC20, IPC20 and IPC21 are fitted with an integral strainer. Available steam trap types are detailed in separate literature.

2.1.1 Identification

Figure 1 PC20

Note: The integral sensor is supplied as standard with IPC20 and IPC21, but can also be retrofitted to existing PC20 connectors provided that a blowdown valve is not installed.

A blowdown valve is available as an optional accessory for the PC20 to periodically remove pipeline debris. Note: Not available for IPC20 or IPC21.

Figure 2 IPC20 and IPC21

2.3 PC20, IPC20 and IPC21 - Pressure/Temperature Limits

Pressure psi g

This product must not be used in this area.

A - C PC20

B - C IPC20 and IPC21

*PMO Recommended maximum operating pressure for saturated steam service.

3. Installation

Note: Read Section 1, “Safety Information”, before commissioning.

3.1 General

To ensure the correct operation of the universal connector steam trap and effective removal of condensate, two conditions must be met:

• PC and IPC units must be installed in the direction of the arrow.
  The PC20 may be installed in either a horizontal or vertical pipeline, provided that the fitted steam trap is installed in the correct plane.
• IPC20 and IPC21 must be installed in a horizontal pipeline with the sensor facing downward.
  The connection face for the universal connector steam trap must always be in a vertical plane.

After installation, it is recommended that the pipe connector be insulated to minimise radiant heat losses and protect personnel from the risk of burns.

Note: Certain steam trap types should not be insulated.

The PC/IPC and steam trap are joined using a high-integrity spiral-wound gasket. It is important not to damage the steam trap gasket face, for example through welding, weld spatter or impact.

Therefore, particular care is required when installing the PC/IPC in the pipeline. It is recommended that the steam trap be fitted to the PC/IPC as soon as it is installed in the pipeline. Alternatively, the steam trap can be connected to the PC before installation.

3.2 Pipeline Welding for Socket Weld Types

It is difficult to provide a general welding procedure that covers the requirements of different national and international standards and codes, particularly with regard to welding procedures, welding conditions such as number of passes, filler material size, current, voltage and polarity, filler material storage, and filler material manufacturer/type, because many suitable filler material suppliers are available.

Welding recommendations can be provided in accordance with British Standards. Contact Spirax Sarco to discuss your welding requirements further. Welding may be carried out in accordance with the applicable ASME IX or BS EN standards.

4. Maintenance

Note: Read Section 1, “Safety Information”, before commissioning.

4.1 Introduction

All work must be carried out by suitably qualified personnel. Ensure that suitable tools are available before starting work. Use only Spirax Sarco replacement parts.

4.2 Maintenance

After observing the safety procedures, maintenance can be carried out while the connector remains in the pipeline. It is recommended that new gaskets and spare parts are used whenever maintenance is performed. Always ensure that the correct tools and necessary protective equipment are used. On completion of maintenance, slowly open the isolation valves and check for leaks.

How to Replace the Strainer Screen

Before starting, ensure that the pipe connector is isolated from main line pressure, both steam and condensate, and that any residual pressure has been vented to atmosphere. Allow it to cool before starting work.

Remove the strainer cap, or blowdown valve, and separate it from the strainer screen. After cleaning or replacing the strainer screen, locate it in the recess in the cap, fit the cap gasket, and insert it into the body. Lightly tighten to ensure correct positioning of the strainer screen and gasket.

Tighten to the recommended tightening torque. Always use a new gasket.

How to Blow Down the Strainer

Regular blowdown will remove most debris from the strainer. Larger debris may require the strainer to be removed completely as described above. Loosen the small retaining screw by half a turn. Slowly open the valve screw counterclockwise until condensate is discharged.

Note: Ensure that blowdown from the blowdown valve is discharged to a safe location. Close the valve screw after a few seconds and tighten it to the recommended tightening torque.

Under no circumstances should the small locking screw be removed. Always use the correct protective equipment and tools during operation.

How to Replace or Clean the Sensor

Before starting, ensure that the pipe connector is isolated from the main pipeline pressure (steam and condensate) and that any residual pressure has been vented to atmosphere. Allow it to cool before starting work.

If a waterlogging sensor is installed, disconnect the wiring at the connection terminals.

Remove the sensor from the adapter. This can be carried out online provided that the adapter is securely fixed. Clean the sensor insulation. If pitting is present on the insulation, install a new sensor. Clean or replace the strainer, as appropriate for its condition. Install the new sensor and screw it into the adapter, ensuring that the gasket and strainer are centred. Tighten to the recommended tightening torque.

Reconnect the waterlogging sensor as described in IM-P087-34.

5. Available Spare Parts

The available spare parts are listed below. No other parts are supplied as spares.

Available spare parts

How to Order Spare Parts

Always order spare parts using the description in the “Available spare parts” section and specify the model.

Example: 1 - Strainer and gasket for a 1/2” PC20 connector.

The blowdown valve (item 4) is available as an optional accessory for periodically removing debris from the pipeline on PC20.

PC20 with blowdown valve

Recommended tightening torques

Item		or mm	(3ZZS)	N m	(lbf ft)
3	32 A/F		M28 x 1.5P	170 - 190	(125 - 140)
5	32 A/F		M28 x 1.5P	170 - 190	(125 - 140)
6	19 A/F			45 - 50	(33 - 36)
8	24 A/F			50 - 55	(36 - 40)

* Note: Items 3 and 6 are not available as spare parts.

IPC20 and IPC21