Forbes Marshall Tracer Line Trap
Contents
1. A d Installation and Maintenance Manual f Boden Trusted Partners Innovative Solutions Forbes Marshall Tracer Line Trap Forbes Marshall Air Vent FMTLT53 FMAV53 Energy Conservation Environment Process Efficiency www forbesmarshall com Forbes Marshall Forbes Marshall Arca Codel International Krohne Marshall Forbes Solar Forbes Vyncke Forbes Marshall Steam Systems 4 Forbes A lay Innovative Solutions Table of Contents i NES Ee 1 2 Important Safety Notes zeideg 1 3 Brief Product Description ssc catsuecscdeasexcsassinenseddvinwsas asenueadvesess 3 4 Product Working Principle ss sssssssssseiissiirsssrrieserrrnrrrrrnrrrrr 5 5 Installation Guidelines delabr iert s rie 6 6 Start up and Een BEE 7 7 Maintenance Guidelines EE 7 8 TOUDIESHOOING capere erent rE A ENERE 8 8 Available Spares Attentater 9 9 Warranty le ME 9 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 4 Forbes i Marshall Trusted Partners Innovative Solutions D Preface This manual is intended for anyone using commissioning servicing or disposing the below mentioned products safely and efficiently Forbes Marshall Tracer Line Trap FMTLT53 Forbes Marshall Air Vent FMAV53 Size DN15 2 and DN20 34 PLEASE NO2. radiation dangers to eyes and face noise and falling objects Permits to work 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 knowledge on what work is going on and where required arrange to have an assistant with his primary goal and responsibility being safety Warning Notices should be posted wherever necessary Handling There is a risk of injury if heavy products are handled manually Analyze the risk and use appropriate handling method by taking into consideration the task individual the working environment and the load Freezing Provision should be made to protect systems which are not self draining against frost damage in environment where they may be exposed to temperatures below freezing point to be made Returning products Customers and Stockist are reminded that when returning products to Forbes Marshall 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
3. 411 034 INDIA Tel 91 02135 393400 Tel 91 0 20 27145595 39858555 CIN No U27109PN1959PTCO1 1334 www forbesmarshall com Email seg forbesmarshall com
4. FMAV53 having screwed BSPT connections How to Order Spares Always order spares by using the description given in the column above headed Available Spares and stating the size and type of steam trap For codes refer user manual Warranty Period As per ordering information and agreements in the contract DN LVVESAVWS ESLILWIS N S LOS au nb suod e se paiJndul asiMuay 20 JUBLUNDON SIU JO s ua4U02 y Jo Aue Jo UOeDI dde 10 asn ay Jo AjauIpUL 10 p o 10 JeUosJad seu 10 sassoy saiqiigel Aue wiepsip Ajjerijoads pue suolssiwo 10 saipeindzeul 104 Aljiqisuodsal ou auunsse sajuedwo gt dnoJy pue sagt sajepossy saLeIpIsqns S JO WI dou yoyy m auey o palqns s JUBWNIOD sjy u UOEUOJU ay GALIGIHOUd SI NOISSIW ddd NALLIYM YOlYd LNOHLIMIYNSOTDSIC YO NOILNIYLSIG NOLLINGOYdIY ANY SLHOIY ALYIdOYd TWALDITISLNI JHL Y3GNN NOILDJLOYd ONIAVH ANY 29 AVI ISV JHL SY CAdSSIN4 03 UI ALVAIYd SWJLSAS Wis TIVHSYV S39404 YO LW QILINI JLVAIYd TIVHSYYIN 3900 20 ALY3dOYd JHL JYV NIJYJH SLNJLNOD TIY Formerly Spirax Marshall Pvt Ltd Forbes Marshall Steam Opp 106th Milestone Systems Pvt Ltd a ay o 2 o g i 2 e e Ae ae xog TES cya V S 2 eS a os OH a X oo D EE i DS oS H anbe bei S EE U e bei T S z Val Forbes Marshall Forbes Marshal Trusted Partners Innovative Soluti Bombay Poona Road Kasarwadi Pune
5. and 4 respectively wee Lines l gt FMTLT53 ve U Figure 3 Installation of Forbes Marshall Tracer Line Trap in tracer line Goes Ss v e Air Out SA es Steam in J Condensate Out Figure 4 Installation of Forbes Marshall Air Vent for air vent 4 Forbes i Marshall Trusted Partners Innovative Solutions D Start up and Commissioning 6 1 Flushing of lines As part of pre installation all fluid handling equipment particularly piping should be thoroughly cleaned of scale and the internal debris which accumulates during construction This is accomplished by blowing or flushing with air steam water and other suitable medium Follow these steps to carry out the flushing 1 Close the isolation valve and open the bypass isolation valve 2 Drain the condensate 10 15 minutes or until clear condensate starts coming out whichever is earlier 3 Now slowly close the bypass isolation valve and open the trap isolation valve Note For a detailed procedure on flushing of lines please visit Forbes Marshall website 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
6. must be isolated from both supply line and return line and ensure pressure is normalized to atmosphere The product should then be allowed to cool When re assembling ensure that all joint faces are clean 7 1 Routine and Preventive Maintenance Please refer to the maintenance schedule mentioned in the table below to undertake routine maintenance of the Forbes Marshall Tracer Line Trap Air Vent FREQUENCY FOR CHECKING VARIOUS PARAMETERS No PARAMETER TO BE CHECKED Immediate Daily Weekly Monthly Quarterly Half Yearly Annually 1 Test trap Y 2 Repair Replace steam traps when testing shows leaks 3 Clean internals of FMTLT53 FMAV53 Y 4 Visual Inspection for leakages Yy 5 Arresting any other leaks 7 2 Tool Kit To carry out any maintenance on the FMTLT53 FMAV53 please use the tools mentioned below Size Component Tool used amp size Fixture 86139 0 8mm perforated screen in the body DN 15 20 Rocol on threads of the seat Valve seat Box spanner of 17mm A F 4 M8 bolts and nuts Box spanner of 13mm A F 4 Forbes i Marshall Trusted Partners Innovative Solutions 7 3 Recommended tightening torques Item Torques Cover Bolts 7 25 35 Nm Table1 Recommended tightening torques 7 4 Procedure to fit or replace thermopod and seat assembly Refer Figure 1 1 Remove the cover from body by unscrewing t
7. 40 0 2 0 3 0 5 1 2 345 10 21 Differential pressure bar g x100 kPa Hot water capacity Cold water capacity D Product Working Principle The Forbes Marshall Tracer Line Trap Air Vent works on thermostatic principle operates on the steam inside non c therm 4 1 temperature difference from sub cooled condensate and air Steam increases the pressure the thermostatic element i e thermopod causing the trap to close As condensate and ondensate gases surrounding the thermopod the temperature begins to drop and the opod contracts and opens the valve Operations of Forbes Marshall Tracer Line Trap Air Vent Refer Figure 1 The operating thermostatic element is a thermopod 2 containing a small quantity of a hydrocarbon liquid with a boiling point below that of water When steam is turned on during start up air and sub cooled condensate is discharged as the valve is off its seat 3 and is wide open As condensate passes through the tracer line trap heat is transferred to the hydrocarbon liquid in the thermopod 2 The hydrocarbon liquid boils based on thermopod 2 selected before steam reaches the trap The vapour pressure within the thermopod 2 causes it to expand which closes the valve seat 3 and trap remains shut Heat loss from the trap cools the water surrounding the thermopod 2 the hydrocarbon liquid condenses and the thermopod 2 contracts opening the valve seat 3 a
8. TE Throughout this manual the following cautionary symbol is used to describe a potential damage or injury that might occur if the safety considerations are overlooked Important Safety Notes 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 designed to perform for non contaminated fluids only A contamination in the form of chemical foreign particle etc can lead to problem with product performance and life of the product 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 safety of equipment s pipeline and plant construction must also be complied with 2 1 Intended use Check if the product is suitable for intended use application by referring to the installation and maintenance instructions name plates and technical information sheets i The product is suitable for use as defined in the technical information sheet In case the need arises to use the product on any other fluid please contact Forbes Marshall for assistance
9. al plane ightening torque on cover nut Replace with new valve seat The trap is designed for installation with the thermopod in a horizontal plane with the drip leg immediately preceding the trap Tighten to the proper torque as mention in table 1 Cover gasket deterioration or damage Replace with new cover gasket 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 surface is formed on the valve seat orifice Note Never attempt to modify the product When replacing part with new use the spare parts isted in Section 9 9 Available Spares The spare parts available are shown in heavy outline Parts drawn in broken line are not supplied as spares Spares Part No Spare Code Thermopod amp seat assembly set State thermopod filling U STD fill A 2016338 Thermopod amp seat assembly set State thermopod filling T SUB fill A 2016280 Thermopod amp seat assembly set State thermopod filling C SUB fill A 2031914 Strainer screen amp gasket kit Pack of 5 B C 2016367 Figure 5 Parts available as spares Heavy line of FMTLT53 FMAV53 How to Order Example Forbes Marshall Tracer Line Trap DN15 FMTLT53 having screwed BSPT connections with Thermopod U filling Or Forbes Marshall Air Vent DN15
10. as hazardous or potentially hazardous 4 Forbes i Marshall Trusted Partners Innovative Solutions D Brief Product Description 3 1 3 2 3 3 3 4 Description The Forbes Marshall Tracer Line Trap FMTLT53 Air Vent FMAV53 can be used for air venting application from steam mainlines or as a steam trap for tracer line application for removal of sub cooled condensate It comes with an inbuilt flat strainer screen having 0 8 mm diameter perforations Size and End Connections DN 15 and DN 20 Screwed BSPT NPT socket weldable ends Note Available with IBR certificate on request Limiting Conditions PMA Max allowable pressure 50 bar g 50 C TMA Max allowable temperature 400 C 35 barg PMO Max operating pressure 32 barg TMO Max operating temperature 287 C Cold hydraulic test pressure 64 bar g Operating Range A A oO CH CO N Q CH Temperature C Y N oO CH 0 10 20 30 32 40 50 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 A B Screwed amp Socket Weld Ends Thermopod Filling for FMTLT53 As a standard the FMTLT53 trap is supplied with filling U which will operate approximately 24 C below steam saturation temperature As an optional alternative the trap can be supplied with filling T
11. ed with rust or scale Clean Strainer Screen if screen rusted replace with new one Valve seat is blocked Clean the valve seat and thermopod ball surface then No re assemble the Tracer Line Trap Air Vent condensate Thermopod may be over extended due to excessive discharge internal pressure caused by superheat steam making it n blocked impossible for the thermopod ball valve head to lift off Replace the thermopod assembly from valve seat improper installati n Check installation fluid flow direction same as arrow prop on the Tracer Line Trap Air Vent Body 4 Forbes i Marshall Trusted Partners Innovative Solutions Failure Mode Steam leakage or blowing from the outlet Steam leaks from body amp top cover joint Possible Cause Foreign material has built up between thermopod ball valve head and valve seat Remedy 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 valveseat assembly Valve sea and thermopod ball valve head does not shut off tightly Check if the thermopod is in good condition Thermopod should not be compressible when cool any flabbiness indicates failure Clean both valve seat and thermopod ball after that seat stamping should be done Replace with new thermopod assembly Valve sea Steam trap Improper is wire drawing installation in vertic
12. he cover bolts amp nuts 7 using box spanner of 13mm Unscrew the thermopod and0 valve seat assembly set Remove the restraining clip from the thermopod and seat assembly and lift the thermopod 2 and spacer upwards amp outwards Remove the gasket 5 and clean the internals using WD40 liquid spray and clean with lint free cloth After cleaning refit the thermopod amp seat assembly and insert new cover gasket 5 make sure that the strainer screen 4 is correctly located Ensure that the cover blots are tightened evenly The recommended torques for tightening as shown in table 1 When maintenance is complete open isolation valves slowly until the normal pressure is obtained Checks for leaks and attend if any 7 5 Procedure to clean or replace the strainer screen Refer Figure 1 1 4 D Troubleshooting Remove the cover from body by unscrewing the cover bolts and nuts 7 using a 13mm box spanner Replace with new strainer screen 4 Ensure that the cover bolts are tightened evenly The recommended torques for tightening as shown in Table 1 When maintenance is complete open isolation valves slowly until normal pressure is obtained Checks for leaks and attend if any If the expected performance is unachievable after installation of the FMTLT53 FMAV53 check the following points for appropriate corrective measures Failure Mode Possible Cause Remedy Strainer Screen is clogg
13. ii Check for the suitability in conformance to the limiting conditions specified in technical information sheet of the product iii The correct installation and direction of fluid flow has to be determined iv Forbes Marshall products are not intended to resist external stresses hence necessary precautions to be taken to minimize the same 2 2 Accessibility and Lighting Safe accessibility and working conditions are to be ensured prior to working on the product 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 4 Forbes Marshall Trusted Partners Innovative Solutions Hazardous environment and media The product has to be protected from hazardous environment and check to ensure that no hazardous liquids or gases pass through the product Depressurizing of systems and normalizing of temperature 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 To avoid danger of burns allow temperature to normalize after isolation Tools and consumables Ensure you have appropriate tools and or consumables available before starting the work Use of original Forbes Marshall replacement parts is recommended Protective clothing 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
14. nd releasing condensate until steam temperature approaches again at which the cycle is repeated 4 Forbes Marshall Trusted Partners Innovative Solutions D 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 TI Before installing the Forbes Marshall Tracer Line Trap Air Vent flush the inlet piping to remove all dirt and oil 2 Remove protective covers from all connections where appropriate before installation 3 The Forbes Marshall Tracer Line Trap Air Vent should be installed on horizontal plane and the cover at the top preferably with a drip leg immediately preceding the steam trap when installed on tracer line 4 Itis recommended that a non return valve is fitted when discharging condensate into return lines where backpressure is experienced It is also recommended that a diffuser is fitted when discharging to atmosphere 5 Suitable isolation valves must be installed to allow for safe maintenance and steam trap replacement 6 Open isolation valves slowly until normal operating conditions are achieved Check for leaks and correct operation 7 Installation locations for Forbes Marshall Air Vent FMAV53 when used in tracer lines and air vent applications as shown in figure 3
15. which will operate approximately 12 C below steam saturation temperature or filling C which will operate approximately 6 C below the steam saturation curve Note If the alternative thermopod is required this must be clearly stated in the order e g capsule to have U fill or T fill Thermopod Filling for FMAV53 As a standard the FMAV53 is supplied with filling U 4 Forbes i Marshall Trusted Partners Innovative Solutions Figure 1 Forbes Marshall Tracer Line Trap Forbes Marshall Air Vent Material No Part Material Standard 1 Cover Forged Carbon Steel ASTM A105 2 Thermopod Stainless Steel AISI 304 3 Valve Seat St Steel Type 316 ASTM A276 4 Strainer Screen St Steel Type 304 ASTM A240 5 Cover Gasket Body Reinforced Exfoliated Graphite 6 Forged Carbon Steel ASTM A105 7 Cover Bolts and Nuts Carbon Steel H T IS 1367 3 5 Product Dimension and Drawing Withdrawal distance ic KEE Sal Figure 2 Dimensional drawing of FMTLT53 FMAV53 Dimensions approx in mm Size DN A c D E H Weight kg 15 92 EA 70 26 40 2 20 92 80 70 26 40 2 4 Forbes i Marshall Trusted Partners Innovative Solutions 3 6 Capacity Chart 3000 2000 1000 T lt o e 500 SZ 400 on 300 gt amp 200 100 50
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