SP80 and SP100 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. General installation and safety requirements 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, nameplate and Technical Information Sheet to verify 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 when required.

This product falls within the following Pressure Equipment Directive categories:

i) This product has been specifically designed for use with steam, air or water/condensate in Group 2 of the above Pressure Equipment Directive. The product may be suitable for use with other fluids, but if this is contemplated, Spirax Sarco should be contacted to confirm the suitability of the product for the intended application.
ii) Check material suitability, pressure, temperature and 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 a product failure could result in dangerous overpressure or overtemperature, ensure that the system includes a safety device to prevent such limit exceedances.
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) Before installation in steam or other high-temperature applications, remove protective covers from all connections and, where applicable, protective film from all nameplates.

1.2 Access

Ensure safe access before working on the product. If necessary, provide a safe working platform with suitable protection. If lifting is required, provide suitable lifting equipment.

1.3 Lighting

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

1.4 Hazardous Liquids or Gases in the Pipeline

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

1.5 Hazardous Environment Around the Product

Consider: potentially explosive areas, oxygen-deficient environments such as tanks and pits, hazardous gases, extreme temperatures, hot surfaces, fire hazards such as 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 switching off electrical isolation, put another part of the system or any personnel at risk?

Hazards may include the isolation of vents or protective devices, or the rendering ineffective of controls or alarms. Open and close isolation valves slowly to avoid system shocks.

1.7 Pressure Systems

Ensure that all pressure is isolated and safely vented to atmospheric pressure. Consider double isolation, using two valves with a vent in between, and lock or tag closed valves. Do not assume that the system has been depressurised even when the pressure gauge indicates zero.

1.8 Temperature

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

1.9 Tools and Consumables

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

1.10 Protective Clothing

Consider whether you and/or others nearby require protective clothing to prevent injury from chemicals, high/low temperatures, radiation, noise, falling objects, and eye and face hazards.

1.11 Permits to Work

All work must be carried out by suitably competent persons or under their supervision. 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 force, it must be complied with. Where no such system exists, it is recommended that a responsible person is made aware of the work being carried out and, where necessary, that an assistant whose primary responsibility is safety is appointed.

Post “Warning Notices” if necessary.

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 by physical effort can cause injury, particularly to the back. It is recommended that you assess the risks, taking into account the task, the individual, the load and the working environment, and use an appropriate handling method based on the specific circumstances of the work.

1.13 Residual Hazards

Under normal operating conditions, 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 300 °C (572 °F).

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

1.14 Freezing

Products that are not self-draining and are exposed to temperatures below freezing must be protected against frost damage.

1.15 Disposal

Unless otherwise stated in the Installation and Maintenance Instructions, this product is recyclable and no ecological hazard is anticipated with appropriate care during disposal. This product can be safely recycled and/or disposed of provided that appropriate care is taken. Always comply with local recycling and disposal regulations.

1.16 Returning Products

Customers and distributors are reminded that, under EU 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 for any substances identified as hazardous or potentially hazardous.

2. Product Information

2.1 Description

The Spirax Sarco SP80 and SP100 are pilot-operated bimetallic steam traps manufactured from cast steel and designed for high-capacity process applications.

They are unaffected by superheat and use a bimetallic pilot valve arrangement to control the main valve through a large-diameter piston.

Both the SP80 and SP100 incorporate an integral strainer to protect the pilot valve and feature an external adjustment facility for setting the condensate discharge temperature.

Available Models

Standards

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

Certification

This product is available with EN 10204 3.1 certification. Note: All certification/inspection requirements must be specified at the time of order.

Note: For further product data, see Technical Information Sheet TI-P624-02.

Figure 1

2.2 Sizes and Pipeline Connections

DN80 SP80 or DN100 SP100, with EN 1092 PN40, ASME 150 or ASME 300 flanged connections.

2.3 Pressure/Temperature Limits

The product must not be used in this area.

A - B ASME 150 flanges

A - C PN40 flanges

A - D ASME 300 flanges

3. Installation

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

Refer to the Installation and Maintenance Instructions, nameplate and Technical Information Sheet to verify that the product is suitable for the intended installation conditions:

3.1 Check the materials, pressure and temperature, including 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 the system includes a safety device to prevent overpressure.
3.2 Determine the correct installation position and fluid flow direction.
3.3 Before installation in steam or other high-temperature applications, remove protective covers from all connections and, where applicable, protective film from all nameplates.
3.4 Install the steam trap downstream of the equipment to be drained and ensure that it is readily accessible for inspection and maintenance.
3.5 Before installing the steam trap, ensure that the pipeline is clean and free of debris.
3.6 Install the steam trap horizontally, with the arrow on the body pointing in the direction of fluid flow.
3.7 The steam trap may be welded directly into the pipeline without removing internal components. For socket-weld traps, follow qualified welding procedures. Internal components do not need to be removed during welding, but overheating should be avoided.
3.8 The steam trap is factory-set.

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

Figure 2 Recommended installation - Note: The pipeline should slope in the direction of flow.

4. Commissioning

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

5. Operation

The Spirax Sarco SP80 and SP100 are bimetallic steam traps.

These traps operate based on two opposing forces acting on the valve: an opening force generated by system pressure and a closing force generated by condensate temperature acting on the bimetallic element.

These steam traps can be serviced in line. They operate without steam loss and automatically and rapidly discharge air, non-condensable gases and large quantities of cold condensate during start-up.

6. Maintenance

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

Warning

The bonnet gasket and main valve assembly gasket contain thin stainless steel support rings which may cause personal injury if handled or disposed of incorrectly.

Safety instructions

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

The equipment required for carrying out any maintenance procedure is listed in Table 1.

SP steam traps are fitted with an external adjustment screw that can be used to flush the valve seat and set the condensate discharge temperature in the inlet line.

Provided that the 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 completing maintenance, open the isolation valve slowly and check for leaks.

Table 1 Recommended tightening torques

Item	Component		or mm	N m	(lbf ft)
-	Locknut on adjustment screw	13 A/F
8	Upper bonnet bolts	22 A/F		72 - 78	(53 - 57)
10	Bimetallic element	36 A/F		120 - 132	(88 - 97)
14	Pilot valve bonnet bolts	17 A/F		45 - 55	(33 - 40)
16	Plug nut	29 A/F		78 - 88	(53 - 65)
20	Lower bonnet bolts	19 A/F		54 - 66	(40 - 49)
-	Main valve locknut	19 A/F		45 - 55	(33 - 40)

6.1 Flushing the valve seat in service

If the steam trap is to be cleaned while in service, it is recommended that the steam inlet valve be closed before turning the adjustment screw, followed by the procedure below. In a closed condensate return system, close the discharge line and open the test valve:

• Remove the plug nut (16) and loosen the locknut on the adjustment screw.
• Using a screwdriver, tighten the adjustment screw clockwise by several turns. This will fully disengage the valve inlet.
• Slightly open the upstream isolation valve. This produces a powerful flushing action to remove any debris that may have accumulated in the steam trap.
• Move the adjustment screw upwards counter-clockwise until the valve contacts the seat.
• Tighten the locknut. Replace the plug nut gasket (15) and plug nut (16), and tighten to the recommended torque shown in Table 1.

Figure 4a

6.2 Adjusting the discharge temperature

• Remove the plug nut (16) and loosen the locknut on the adjustment screw.
• Using a screwdriver, tighten the adjustment screw clockwise by several turns. This will fully disengage the valve inlet.
• The condensate discharge temperature is adjusted by moving the adjustment screw a greater or smaller distance upwards from the point where the valve contacts the seat. Standard adjustment: turn the screw a further 1/4 to 1/2 turn counter-clockwise.
• After adjustment, tighten the locknut on the adjustment screw.
• Replace the plug nut gasket (15) and plug nut (16), and tighten to the recommended torque shown in Table 1.
• Close the test valve and open the discharge line valve. In a closed condensate return system, a test tee and valve must be used to observe steam trap operation. The steam trap should regulate condensate discharge according to the inlet temperature and pressure.
• After adjustment, fully open the upstream isolation valve.

Figure 4b

6.3 Replacing the bimetallic element

Spare parts for serviceable steam traps are listed in Section 7.

6.3.1 Disassembly and assembly of the steam trap

Before disassembling the steam trap, observe all safety information provided in this installation and maintenance guide and use all recommended torques where applicable, as shown in Table 1.

• Isolate the steam trap before disassembly, observing the safety instructions.
• Unscrew the upper bonnet bolts (8) and remove the upper bonnet assembly.
• Unscrew the lower bonnet bolts (20) and remove the lower bonnet assembly (19).
• Remove the spring (17).
• Secure the main valve (3) using the flats, taking care not to damage the valve seat sealing surface.
• Unscrew the locknut from the main valve.
• The main valve (3), main piston (4) and piston cylinder (2) can now be removed for cleaning and inspection for wear.
• Assembly of the lower bonnet and main valve assembly is the reverse of disassembly.
• The locknut securing the main valve to the piston can now be retightened, as shown in Table 1. Apply one drop of Loctite 620 to the threads to secure it firmly.

6.3.2 Disassembly and assembly of the pilot valve bimetallic assembly, N or E type

• Remove the plug nut (16) and plug nut gasket (15), then loosen and remove the locknut from the adjustment screw.
• Unscrew and remove the bolts (14) from the pilot valve bonnet (13).
• Remove the strainer (11).
• Using the specified pipe wrench, unscrew the bimetallic element assembly (10) from the bonnet (7).
• Assembly of the bonnet is the reverse of disassembly.

6.3.3 Adjustment

• Slightly open the downstream isolation valve and steam inlet valve.
• Tighten the adjustment screw clockwise by several turns, then wait briefly for the steam trap to reach the required temperature and for steam to appear.
• Move the adjustment screw upwards counter-clockwise until the valve contacts the seat.
• The condensate discharge temperature is adjusted by moving the adjustment screw a greater or smaller distance upwards from the point where the valve contacts the seat. To increase the condensate temperature, turn the adjustment screw clockwise in increments of 1/2 turn, pausing between each adjustment to allow the temperature to stabilise. Continue adjusting until the required performance is achieved.
• After adjustment, fit the locknut onto the adjustment screw.
• Replace the plug nut gasket (15) and plug nut (16), and tighten to the recommended torque shown in Table 1.
• After adjustment, fully open the upstream isolation valve.

7. Spare parts

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

Available spare parts

How to order spare parts

When ordering spare parts, always use the descriptions given in the Available spare parts column and specify the size and model of the bimetallic steam trap.

Example: 1 gasket set for a Spirax Sarco DN80 SP80 bimetallic steam trap.

Figure 5

8. Troubleshooting