Forbes Marshall Tracer Line Trap Manuale

FMTLT53-Y

Forbes Marshall Tracer Line Trap

with Integral Flange and Strainer

Forbes Marshall Tracer Line Trap with

Integral Flange and Strainer

FMTLT53-Y

Installation and Maintenance Manual

Energy Conservation | Environment | Process Efficiency www.forbesmarshall.com

1. Preface .................................................................................1

2. Important Safety Notes ........................................................1

3. Brief Product Information .....................................................3

4. Product Working Principle ...................................................5

5. Installation Guidelines ..........................................................6

6. Start-up and Commissioning ................................................6

7. Maintenance Guidelines .......................................................6

8. Troubleshooting .................................................................8

8. Available Spares .................................................................9

9. Warranty Period .................................................................9

Table of Contents

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.

Forbes MarshallTracer LineTrap with Integral Flange and Strainer

Preface:

This manual is intended for anyone using, commissioning, servicing, or disposing the below

mentionedproductssafelyandefficiently.

ForbesMarshallTracerLineTrapwithIntegralFlangeand Strainer[FMTLT53-Y]

Size:DN15(½”)andDN20(¾”)

PLEASENOTE:

Throughout this manual the following cautionary symbol is used to describe a potential damage

orinjurythatmightoccurifthesafetyconsiderationsareoverlooked.

ImportantSafetyNotes:

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

designedto performfor non-contaminatedfluids only. Acontamination inthe formof

chemical, foreign particle etc. can lead to problem with product performance and life

oftheproduct.

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

safetyofequipment's,pipelineandplantconstructionmustalsobecompliedwith.

2.1 Intendeduse:

Check if the product is suitable for intended use/application by referring to the installation

andmaintenanceinstructions,nameplatesandtechnicalinformationsheets.

i) Theproductissuitablefor useasdefined inthetechnical informationsheet.In casethe

need arises to use the product on any other fluid please contact Forbes Marshall for

assistance.

ii) Checkforthesuitabilityinconformancetothelimitingconditionsspecifiedintechnical

informationsheetoftheproduct.

iii) Thecorrectinstallationanddirectionoffluidflowhastobedetermined.

iv) Forbes Marshall products are not intended to resist external stresses, hence necessary

precautionstobetakentominimizethesame.

2.2 AccessibilityandLighting:

Safeaccessibilityandworkingconditionsaretobeensuredpriortoworkingontheproduct.

2.3 Hazardousenvironmentandmedia:

The product has to be protected from hazardous environment and check to ensure that no

hazardousliquidsorgasespassthroughtheproduct.

FMTLT53-Y

2.4 Depressurizingofsystemsandnormalizingoftemperature:

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.Toavoiddangerofburnsallowtemperaturetonormalizeafterisolation.

2.5 Toolsandconsumables:

Ensure you have appropriate tools and / or consumables available before starting the work.

UseoforiginalForbesMarshallreplacementpartsisrecommended.

2.6 Protectiveclothing:

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 falling objects.

2.7 Permitstowork:

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

knowledgeonwhatworkisgoingonandwhererequired,arrangetohaveanassistantwith

his primary goal and responsibility being safety. “Warning Notices” should be posted

wherevernecessary.

2.8 Handling:

There is a risk of injury if heavy products are handled manually. Analyze the risk and use

appropriatehandling method by takinginto considerationthe task,individual, theworking

environmentandtheload.

2.9 Freezing:

Provision should be made to protect systems which are not self-draining, against frost

damage(inenvironmentwheretheymaybeexposedtotemperaturesbelowfreezingpoint)

tobemade.

2.10 Returningproducts:

CustomersandStockistareremindedthat,whenreturningproductstoForbesMarshallthey

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

environmentalrisk.

This information must be provided in writing including Health and Safety data sheets

relatingtoanysubstancesidentifiedashazardousorpotentiallyhazardous.

Forbes MarshallTracer LineTrap with Integral Flange and Strainer

3. BriefProductInformation:

FMTLT53-Y

3.1 Description:

The Forbes Marshall Forbes Marshall Tracer Line Trap with Integral Flange and Strainer

with Integral flange and Strainer, FMTLT53-Y is a forged carbon steel maintainable

balance pressure trap with integral flanged connections and has a Y-type strainer screen

having 0.8 mm dia. perforation.

Standard Unit FMTLT53-Y Having ‘E’ /’STD’ fill thermopod

Also available FMTLT53-C Having ‘E’ /’STD’ fill thermopod

and inbuilt check valve

3.2 Thermopod fill and operation:

Standard Thermopod is marked with the letter “T” for operation at approximately 12°C

below steam saturation temperature.

Optionally, the thermopod can be supplied for under cooling “U” operation at

approximately 24°C below steam saturation temperature or close to saturation 'C'

operation at approximately 6°C below steam temperature

3.3 Sizes and Pipe Connections:

DN 15 ANSI 150, 300

DN 20 ANSI 150

Note: IBR approved FMTLT53-Y can be supplied on request.

3.4 Limiting Conditions:

3.5 Product Dimension and Drawing:

PMA-Max allowable pressure 50 bar g @ 50°C

TMA-Max. allowable temperature 400°C @ 35 bar g

PMO-Max. operating pressure 32 bar g

TMO-Max operating temperature 287°C

Cold hydraulic test pressure 42 bar g

Steam

Saturation

curve

400

300

200

100

00 10 20 21 30 32* 40 50

Temperature ºC

Pressure bar g

The product must not be used in this region

The product should not be used in this region or beyond its

operating range as damage to the internals may occur.

PMO Maximum Operating Pressure 32 bar g

4Forbes MarshallTracer LineTrap with Integral Flange and Strainer

Materials:

3.6 Product Dimensions and Drawing:

FMTLT53-C

Check

Valve

Figure 1: Forbes Marshall Tracer Line Trap with Integral Flange and Strainer

No Part Material Standard

1 Cover Forged Carbon Steel ASTM A105

2 Thermopad Stainless Steel

3 Valve Seat St. Steel Type 431 ASTM A276

4 Strainer Screen St. Steel Type 304 ASTM A240

5 Cover Gasket Reinforced exfoliated graphite

6 Body Forged Carbon Steel ASTM A105

7 Cover Bolts Carbon Steel –HT Gr 8.8 IS 1367

8 Strainer Cap Forged Carbon Steel BS 3146 PART2 ANC2

9 Spacer Plate St. Steel Type 304 ASTM A240

10 Spring St. Steel Type 302 ASTM A276

Withdrawal

Distance

Withdrawal

Distance

Figure 2: Dimensional Drawing of FMTLT53-Y

4. ProductWorkingPrinciple:

The Forbes Marshall Tracer Line Trap works on thermostatic principle operates on the steam

temperature difference from sub-cooled condensate and air. Steam increases the pressure inside

the thermostatic element i. e. thermopod, causing the trap to close. As condensate and non-

condensate gases surrounding the thermopod, the temperature begins to drop and the

thermopodcontractsandopensthevalve.

4.1. OperationsofForbesMarshallTracerLineTrap [FMTLT53-Y]:[Referfigure1]

1. Theoperatingthermostaticelementisathermopod(2)containingasmallquantityofa

hydrocarbonliquidwithaboilingpointbelowthatofwater.

2. Whensteam isturned onduringstart-up, airandsub-cooled condensateisdischarged

asthevalveisoffitsseat(3)andiswideopen.

3. As condensate passes through the Forbes Marshall Tracer Line Trap heat is transferred

tothehydrocarbonliquidinthethermopod(2). Thehydrocarbonliquidboils(based on

thermopod(2)selected)beforesteamreachesthetrap.

4. The vapour pressure within the thermopod (2) causes it to expand which closes the

valveseat(3)andtrapremainsshut.

5. Heat loss from the trap cools the water surrounding the thermopod (2), the

hydrocarbonliquidcondensesandthethermopod(2)contracts,openingthevalveseat

(3) and releasing condensate until steam temperature approaches again at which the

cycleisrepeated.

FMTLT53-Y

Dimensions (approx.) in mm:

3.7 Capacity Chart:

Size A B C D E Weight

DN 15 125 57 54 30 40 7.5Kg

DN 20 125 57 54 38 40 7.5Kg

Differential pressure bar g (x 100 = kPa)

Hot water capacity Cold water capacity

0.1 0.2 0.3 0.5 1 2 3 4 5 10 20 32

3000

2000

1000

500

400

300

200

100

Condensate kg/h

FMTLT53-Y

FMTLT53-C

FMTLT53-Y

FMTLT53-C

Installation Guidelines:

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.

1. Before installing the Forbes Marshall Tracer Line Trap, flush the inlet piping to remove dirt

andoil.

2. Removeprotectivecoversfromallconnectionswhereappropriate,beforeinstallation.

3. The FMTLT53-Y steam trap is designed for installation with the thermopod in a horizontal

planeandthecoveratthetop,preferablywithadriplegimmediatelyprecedingthetrap.

4. Suitable isolation valves must be installed to allow for safe maintenance and steam trap

replacement.Removeallprotectivecapspriortoinstallation.

5. Open isolation valves slowly until normal conditions are achieved. Check for leaks and

attendifany.

Start-upandCommissioning:

6.1. Flushingoflines:

As part of pre-installation all fluid handling equipment particularly piping should be

thoroughlycleanedofscaleandtheinternaldebriswhichaccumulatesduringconstruction.

This is accomplished by blowing or flushing with air, steam, water and other suitable

medium.

Followthesestepstocarryouttheflushing.

1. Closetheisolationvalveandopenthebypassisolationvalve.

2. Drain the condensate 10 -15 minutes or until clear condensate starts coming out,

whicheverisearlier.

3. Nowslowlyclosethebypassisolationvalveandopenthetrapisolationvalve.

Note:ForadetailedprocedureonflushingoflinespleasevisitForbesMarshallwebsite.

6.2. Commissioning:

After installation or maintenance ensure that the system is fully functioning by

confirming fluid is passing through it.

1. After flushing of lines is complete, ensure that bypass valve closed and isolation

valve is opened.

2. Check for leaks and attend if any.

Maintenance Guidelines:

Note: Before undertaking any maintenance of the product it must be isolated from

both supply line and return line and ensure pressure is normalized to atmosphere. The

productshouldthenbeallowedto cool.Whenre-assemblingensurethatalljointfaces

areclean.

Forbes MarshallTracer LineTrap with Integral Flange and Strainer

7.1 RoutineandPreventiveMaintenance:

Please refer to the maintenance schedule mentioned in the table below to undertake

routinemaintenanceoftheForbesMarshallTracerLineTrap/AirVent.

7.2. ToolKit:

To carry out any maintenance on the Forbes Marshall Tracer Line Trap use the tools

mentionedbelow:

7.3. Recommendedtighteningtorque:

Table1:Recommendedtighteningtorques

7.4. Proceduretofitanewthermopodandseat:[Referfigure1]

1. Removethecover(1)fromthebody(6)byunscrewingthecoverbolts(7).

2. Removethethermopodassembly(2)andunscrewthevalveseat(3)fromthebody(6).

3. Clean the thermopod assembly (2) and valve seat (3) if damaged replace with new

thermopod assembly (2) and valve seat (3) and tighten valve seat (3) from the body (6)

totherecommendedtorqueasmentioninTable1.

4. Reassemblethespacerplate(9),thermopod(2)andspring(10).

5. Fit new cover gasket and retighten cover bolts (7) evenly to the recommended torque

asmentioninTable1.

7.5. Proceduretocleanorreplacethestrainerscreen:[Referfigure1]

1. Unscrewthestrainercap(8)andremovethestrainerscreen(4).

2. Clean or replace as required and reassemble the strainer cap (8) into the body (6),

ensuringthestrainerscreen(4)islocatedcentrally.

3. Using anti – seize compound on the threads to recommended torque as mention in

Table1.

No. Parameters to be checked Frequency for checking various parameters

Immediate Daily Weekly Monthly Quarterly Half

Yearly Annually

1Check FMTLT53-Y Y

2Repair / Replace steam traps - when testing

shows leaks Y

3Clean internals of FMTLT53-Y Y

4 Visual inspection for leakages Y

5Arresting any other leaks Y

Size Component Tool used and size

DN 15 / 20 Cover Bolt Box spanner of 17 mm (A/F)

Valve seat Box spanner of 17 mm (A/F)

Strainer Cap Box spanner of 26 mm (A/F)

Part No. Component Torque Range

3 Valve Seat 25 -35Nm

7 Cover Bolts 35 Nm

8 Strainer Cap 120 -135 Nm

FMTLT53-Y

8. Troubleshooting:

If the expected performance is unachievable after installation of the Forbes Marshall Tracer

Line Trap, check the following points for appropriate corrective measures.

*Seat stamping procedure:

Place valve seat on the fixture with thermopod on the valve seat (thermopod ball side resting on

the valve seat orifice) and tap slightly on the center with a mallet. Due to stamping a seating

surfaceisformedonthevalveseatorifice.

Note: Never attempt to modify the product. When replacing part with new, use the spare parts

listedinSection9.

Failure Mode Possible Cause Remedy

No condensate

discharge

(blocked).

Strainer screen is clogged with rust or scale. Clean strainer screen if rusted

replace with new one.

Valve seat is blocked. Clean the valve seat and

thermopod ball surface then

re-assemble the steam trap.

Thermopod may be over extended due to

excessive internal pressure caused by

superheat steam making it impossible for the

thermopod ball (valve head) to lift off from

valve seat.

Replace the thermopod

assembly.

Steam leakage

or blowing

from the outlet.

Foreign material has built-up between

thermopod ball (valve head) and valve seat. Clean the valve seat and

thermopod ball surface then

re-assemble the steam trap;

check for any steam leak. If

valve seat damage replace the

seat assembly.

Valve seat and thermopod ball (valve head)

does not shut – off tightly. Clean both valve seat and

thermopod ball after that *seat

stamping should be done.

Check if the thermopod is in good condition.

Thermopod should not be compressible

when cool; any flabbiness indicates failure.

Replace with new thermopod.

Valve seat damage due to wire drawing. Replace valve seat.

Improper installation. Check installation i.e. cap to be

on top / flow direction same as

arrow on the steam trap body.

Steam leaks

from body and

top cover joint.

Improper tightening torque on nut. Tighten to the suitable torque.

Cover gasket deterioration or damage. Replace with new cover gasket.

8Forbes MarshallTracer LineTrap with Integral Flange and Strainer

Indice

Altri manuali Forbes Marshall Unità di controllo

Forbes Marshall

Forbes Marshall FMTD64 Manuale

Forbes Marshall

Forbes Marshall FMPRV41 Manuale

Manuali Unità di controllo popolari di altre marche

Festo

Festo Compact Performance CP-FB6-E Manuale elenco delle parti

Elo TouchSystems

Elo TouchSystems DMS-SA19P-EXTME Manuale utente

JS Automation

JS Automation MPC3034A Manuale utente

JAUDT

JAUDT SW GII 6406 Series Guida rapida

Spektrum

Spektrum Air Module System Manuale utente

BOC Edwards

BOC Edwards Q Series Manuale utente

KHADAS

KHADAS BT Magic Manuale utente

Etherma

Etherma eNEXHO-IL Manuale utente

PMFoundations

PMFoundations Attenuverter Manuale utente

GEA

GEA VARIVENT Manuale utente

Walther Systemtechnik

Walther Systemtechnik VMS-05 Manuale utente

Altronix

Altronix LINQ8PD Istruzioni per il montaggio

Eaton

Eaton Powerware Series Manuale utente

WAGO

WAGO 750-407/040-000 Manuale utente

Sony

Sony CCU-590 Manuale utente

Graco

Graco 25D614 Manuale utente

Task Force Tips

Task Force Tips YE-RF-900 Manuale di programmazione

Shini

Shini SPV-U Series Manuale utente