121621, 413 PM manual viewer nw Rese Cue Gt Mein yeaa enc Forbes, Single Orifice Float Trap With SLR and/ or TV SOFT31 (DN15-25) Energy Conservation | Environment hitpssImanuslzz.comidoci7451086/single-fficeoatrap-with-si-and-ortv 16.121621, 4:13 PM hitpssmanualzz.comidoci7451086/single-orice-ost-rap-with a’ Forbe: & Warshan Table of Contents we arnannawn PLEASE describe Preface ........ Important Safety Notes Brief Product Information Product Working Principle 3 5 Installation Guidelines 6 Start-up and Commissioning 7 8 Maintenance Guidelines Troubleshooting Available Spares 13 Warranty Period... NOTE - Throughout this manual this cautionary symbol is used to 2 potential damage or injury that might occur if the safety Considerations are overlooked. Ths symbol denotes CAUTION, WARNING of DANGER. 26121621, 4:13 PM a’ Forbe: & Warshan Preface: This manual is intended for anyone using, commissioning, servicing, or disposing the below ‘mentioned products safelyandeficiently, ‘Single Orifice Float Trap With SLR and/or TV [SOFT31 (ON15-25)] ‘Sizes: DN15(1/2"), DN20 3/4"), DN2S (1") PLEASE NOTE: ‘Throughout this manual the following cautionary symbolis used to describe a potential damage ‘orinjury that might accurifthe safely considerations are overlooked Important Safety Notes: W Read this section carefully before instaling/operating/maintaining the product. The precautions lsted in this manual are provided for personnel and equipment safety. Furthermore, Forbes Marshall accepts no responsibility for accidents or damage ‘occuring asa result of failure to observe these precautions. Note thatthe products designed to perform for non-cantaminated fluids only. contamination in the form of ‘chemical, foreign paride etc. can lead to prablem with product performance and life of theproduct. HF these products in compliance with the operating instructions are, propery installed, ‘commissioned, maintained and installed by qualified personnel (eter Section 2.7) the safely ‘operations ofthese products can be guaranteed. General instructions for proper use of tools and safety of equipments, pipeline and plant construction must also be complied with 2.1 Intendeduse: Check i the product is suitable for intended use” application by referring to the instalation ‘and maintenance instructions, name plates and technicalinformationsheets, ’) The product issuitable for useas defined inthe technical information sheet. Incase the reed arises to use the product on any other fluid please contact Forbes Marshall for assistance i) Check forthe suitabiliyin conformance tothe limiting conditions specfiedin techrical information sheetof the product. li) The comect instalation and direction of fluid flow has tobe determined, 1N) Forbes Marshal products are not intended to resst extemal stresses, hence necessary precautions tobe taken to minimize the same 22 Accessibility and Lighting: Sale accessibilily and working conditions are to be ensuted prior to working on the product hitpssImanuslzz.comidoci7451086/single-fficeoatrap-with-si-and-ortv 36121621, 4:13 PM 23 24 25 26 27 2.10 Av Forbe F Wershat Hazardous environment and media: The producthas tobe protected from hazardous environment and check to ensure that no hazardous iquidsor gases pas through the product Depressurizing of systems and normalizing of temperature: Ensure isolation and safety venting of any pressure tothe atmospheric pressure. Even if the pressure gauge indicates zero, do not make an assumption that the system has been depressurized, Toavoid danger of burns allow temperature to normalize afte isolation. Tools and consumables: Ensure you have appropriate tools and/or cansumables available before starting the work. Use of orginal Forbes Marshall replacement parsisrecommenided Protective dothi Consider forthe requirement of any protective dlathing for your or others in the vic for protection against hazards of temperature (high or low), chemicals, radiation, dangers to ‘es and face, noise and faling objects. Permits to work: {Al 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 thissystem a responsible person should have complete information and knowledge on what work is going on and where eequired, arrange to have an asistant vith his primary goa and responsibiity being safely, "Waring Notices” should be posted wherevernecessary Handling: ‘There i a risk of injury if heavy products are handled manually. Analyze the risk and use ‘appropriate handling method by taking nto consideration the task, individual, the working environment and the load. Freezing: Provsion should be made to protect systems which are not self-draning, against frost damage (in environment where they may be exposed to temperatures below freezing point) tobe made. Returning products: Customers and Stockst are rerninded 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, safely or ‘environmental ik This information must be provided in wetting including Health and Safety data sheets relating to any substances identified as hazardous or potentially hazardous. hitpssImanuslzz.comidoci7451086/single-fficeoatrap-with-si-and-ortv ane121621, 4:13 PM EB riefProductinformation 34. Description: Av Forbe F Wershat “The Forbes Marshall Single Orifice Float Trap, SOFT3I, isa castiron single orice oat tap _2valiable with an integral automatic alr venting facilty. ts available with hotzontalor vertical connections with Now downwards, As an atematve a manual needie valve canbe added and Used. asteamlockrelease 32. Sizesand Pipe Connection: DN 15, 20and25 Serowed BSPTINP. Note: Available with IBR cerfficate onrequest 33 Available Types: [SOFT3I-TTV with Thermostatic air Vent (TV) ‘SOFT31-Swith Steam LockRelessa (SLR) ‘SOFTS1-ST combined TVand: 3.4 Limiting Conditions : SLR FMA Maximum allowable presure Tbargatz20"C TMA Maximum allowable temperature 220°C at 13 bar g VO Maximum operating pressure 1Bbarg TMO Maximum operating temperature 220°C at 13 bar g Minimum operating temperature ore "APM Maximum SOMTST-AS ‘a5 bare diferental pressure | Srsag 10bag SOFST-13 1Bbarg Cold hydraulic test pressure 26barg 35. Operating Range: 3 180 ° Temperature °C > 2 hitpssImanuslzz.comidoci7451086/single-fficeoatrap-with-si-and-ortv ew as Prossure bar 516121621, 4:13 PM Av Forbe F Wershat Figuret: Single Orifice Float Trap with SLR and / or TV Material: See iat aera Sandan 7 Cove ation Baran z Coro Taon et TRUST, z ov gale ‘bes ree gabe ie “ tae Gaston STOR 5 Ton het Sas sel ype 308 FSIWAT,GaCRTD 6 Min vake seat o an abe asonby Sas ie ape 30F et @ al fost ard iver Stones el Np 308 Astana a “arent enn Stones el ype 316 SIMD io Sika Stossel ype 410, SIMA i Sunt gsi Stale tel9pe 308 ASIA 7 Tre fame ype 306 Sins ste ASTM 1 Sal Gaphte 3.6 ProductDimension and Drawing: sorts! Figure 2: Dimensional Drawing of SOFT31 Dimensions (approx, in mm: sien) [a [es [c fo |e |e [wei 15/20 eum) 121 | 107 | 67 | 147] 105) 30 [25 1s20.08% [130] 109] 72 | 152| 120] 20 [29 25 sense) 1a1 | 10a] 72 | 160] 135] 20 [40 General Tol: 13 hitpssImanuslzz.comidoci7451086/single-fficeoatrap-with-si-and-ortv ene121621, 4:13 PM ‘manual viewer a’ Forbe: & Warshan 3.7 Capacity Chart: bane Covet a TE Product Working Principe: Rater to Figure 3) Figure3 shows a simple float trap operational representation. float trap works an the Buoyancy Principle. Condensate enters the trap body and raises the loat (1). The postion ofthe float (1) depends upon the levelfoad of condensate (flowrate). The float trap continues to discharge condensate continuously and doesn tallow back up of condensate aslongas the loadis within the discharge capacity. When the condensate load drops, the float (1) lowers in position and closes the outlet valve (3) with the ball(6)resting on theeifice (7) SUR (4) sa needle valve which releases steam that can steam lock the trap during start-up or in operation ifthe steam reaches the trap before the condensate. (On the start up the air present in the pipelinelprocess equipment is released through the thermostatic vent (5). Figure 3: Single Orifice Float trap working ‘The wap inthe gue 3 shows a TVSLR assembly. SOFT31(DN1S-25) also comes wth only TV o SLR assembly hitpssImanuslzz.comidoci7451086/single-fficeoatrap-with-si-and-ortv 76121621, 4:13 PM ‘manual viewer a’ Forbe: & Warshan FE instalation Guidelines: (Refer to Figure 4,5, and 6) Note: ere mpementng ay atlas oben he mprtant aly noes in secten2 Relea to theltslaton and Maintenance ssucios, ame ae and Techni Infomaton Shee, check hat te prodiet sutale fo he ended rsalaion Installation checks and Steps 1. Check coretinsalaionocationoston and te dectonof id How 2. pemove protective coves romal connects whee apr, beerinstalaton 3. Ensure the avalabilty ofall components as shown in Figure 5, to ensue the operation ofthe trap. Figure 4: Single Orifice Float trap module Typicad Representative Installation and may vary based on application and site Tem No. Description 1__| Spring Loaded Check Valve 26 Stop Vale 3 View Glass 4 Single Onfice Float Tap 5 strainer 4, Ifthe tap is to discharge to atmosphere ensure its to a safe place, the discharging fluid may be ata temperature of 100°C (212°F) 5. Install the trap such thatthe arrow on the name plate points downward to achieve proper ‘orientation of the trap. Figure 5: Single Orifice Float trap name plate 6. Thearrowan the casting should bein the direction of the flow. hitpssImanuslzz.comidoci7451086/single-fficeoatrap-with-si-and-ortv ane121621, 4:13 PM a’ Forbe: & Warshan Figure 6: Cover casting with the arrow Gh stereupand commissioning: 61 63 Flushing of Lines (Refer to Figure) 4s part of pre-installtion all fluid handling equipment particulatly piping should be thoroughly cleaned of scale and the intemal debris which accumulates during ‘onstruction, This is accomplished by blowing or flushing with air, steam, water and other suitable medium, Follow these steps to carryout the flushing. 1. Close thestop valve (2) and open the bypass stop valve (6). 2. Let the condensate drain for at least 10-15 minutes or until clear condensate starts comingout, whicheveris earlier 3. Nowslowiy close the bypass stop valve (6) and open thestop valve (2). Commissioning (Refer to Figure 4) {iter installation or maintenance ensure that the system is fully functioning by confirming ‘condensate s passing throughit. i) After fishing of lines is complete, ensure stop by-pass valve (6) closed and stop valve @)opened. i Checkforleaksandattendif ary. Setting of steam lock release (SLA); (Refer to Figure 7) Only SLR Assembly: 1. Loosen the gland nut (1 by one thread 2. Rotatethe stem (2)in clockwise direction. Thismovesthe stem (2) towardsSLRseat 3. Once the tem touches the SLR seat, rotate the stem (2) in anti-clockwise direction by 18" ofatuen hitpssImanuslzz.comidoci7451086/single-fficeoatrap-with-si-and-ortv one121621, 4:13 PM Av Forbe F Wershat A cL0se ROTATE STEM 7 clockwise {// ig TO CLOSE SLR “>: Figure 7: SLR setting for only SLR and SLR+TV configuration SLRSTV Assembly: Loosen the oland nut by one thread, Rotate the stem inanti-lockwise rection. Thismoves ‘thestem towards thermopod. Once the ste touches the thermopod bal otateitfurther by /8"ofatum. 4. Cheek for normeleischargepattem and easif any. Note: The SLR unit should only be used to prevent steam locking‘ and thereforeis designed to pass a small amount of steam, it is not recommended that the SLR be leftin the fully open condition as thismay lead to premature trap failure and more frequent maintenance schedules. Maintenance Guidelines: Before undertaking any maintenance on the product it must be isolated from both TZN) Si ie ot en ean an presale slowed sty roma ‘atmosphere. The product should then be allowed to cool. With suitable isolation repairs canbe carried outwith the producti the ine. When reassembling, make sure thatall joint faces are dean, Once completed open solation valves sly an check or leaks 7A Routine and preventive maintenance: Please refer to the maintenance schedule mentioned inthe table below to undertake routine maintenance ofthe rap. se No Parameters to be checked Frequency for checking and maintaining alt Single orice oat rap_| medi] Day | weakly] Monty] Quarter pins Anowally Test mum presse SOFT31 (G5bargto 175 ba) Rep Replace SOFT he ttn shows ks ‘lan stars of SOFT3T Y (Geant ol SOFT ¥ "Vil inspecon fr leakages ¥ “anesing any ote eke Y Ct hitpssImanuslzz.comidoci7451086/single-fficeoatrap-with-si-and-ortv 106121621, 4:13 PM ‘manual viewer F forbes aoa 72 Toolkit: To carry out any maintenance on the SOFTS1 please use the tools mentioned below: ‘Components Tool Too! Size SLR seat Box Spanner 17 mm Valve seat Imm 1D) Box Spanner 17mm (AM SUR Stern Sot Screw Driver [6 mm Gland nt Ring Spanner | 16 mn TM screw (valve sat) @NO) | Screw Driver Gained ‘M0 Bolt for ous covering | Box Spanner 17 mm (i) 7.3 Recommended tightening torques: ‘Components Torque Range SIR seat 35 Nev Valve seat (tr 1D) 35No SUR Stem 40-50 Nin (MIO Bolt for outside covering 25-35 NM 7.4 Maintaining / Replacing the main valve assembly : (Refer to Figure 8) Unscrew cover bolts (1) and lift off the base (2). Unscrew the assembly set screws (5), and dismantle the pivot frame (6). Remove the main valve seat (7) along with the metal gasket (8). Replace the main valve assembly (9) and the gasket (10) with a new one, Refit the cover (14) by using the cover bolts (1). hitpssImanuslzz.comidoci7451086/single-fficeoatrap-with-si-and-ortv 8121621, 4:13 PM ‘manual viewer a’ Forbe: & Warshan 7.5 Procedure to fit the steam lock release (SLR) assembly: (Refer to Figure 9) 1. Unscrew the complete SLR assembly 2. Remove the SLR gasket. (not shown inthe figure 9.) 3. Replace the SLR assembly and gasket with 4 Reset the SIR. Sy vat Figure 9: SLR assembly 7.6 Inspection and maintenance of air vent assembly (Refer to Figure 10) ‘Thermopod ball xX Valve seat Mounting ame Spocer pate ) OS Thermopod Pa ein ip Figure10: Maintaining the air vent assembly 1. Remove locking clip, thermopod and spacer plate. 2. Fit new gasket between mounting frame and body of the trap. (not visible in the figure 11), valve seat and mounting frame. 3. Acsemble spacer plate, thermopod and fit the locking clip. 7.7 Steam trap testing: Following methods can be used to determine the operating condition of a trap and determine ifits working propery 1,Testing traps through visual inspection Testing traps using temperature qurvequipments “Testing traps using sound/ultrasound “esting traps through online monitoring hitpssImanuslzz.comidoci7451086/single-fficeoatrap-with-si-and-ortv rae121621, 4:13 PM BY troubleshooting : tne expected peonnceis uaciveble ater the salto ofthe single fice ft Check theflownng parlor apport conectie essa. a’ Forbe: & Warshan Faitre Mode [Possible Cause femedy ick he wala, Chak Torte flow direction frou on Ye coer casing ane area orouron these casing Check or ocage the staner 1s [lft act tere presi igher than the Nocondensateis, | desgn. the steam Vap out hae aed in _ closed position as the float buoyancy will not be surface temperature of | secuste to open the valve seat. Not the trap is low. 7 ~ discharging at Pr falidied Check forthe valve and seat assembly for blockage. heck fe al oat punctured, 0 pace i Fost replacement check for water haretg in proces 10 vod reaccurence No condensates, | The wap geting steam locked Adjust he team Ghar and he | ek rose sett by rt cls fal an then sata ipa operingitby 1th tun, Check he wstalaion. The row on he name slate should pont owas Check vlan seat assem fr any deposton Live steam continunsty | and leant Inking tough the aut 9 Glan and lp the seating ae fadibg ight stomp on 5 lone seating ea — Check for SLR leakage/setting check for air vent iatage Tighten de covers and bls to the ‘Steam leaking from the | ecommended torque. tap body Check the gasket or any posse damage and tele req hitpssImanuslzz.comidoci7451086/single-fficeoatrap-with-si-and-ortv 1316121621, 4:13 PM a’ Forbe: & Warshan Frallure Mode Possible Cause Remedy Not discharging ‘enough condensate. Reduced condensate ‘carrying capacity of the trap, Check parameters and trap sizing. The wap will not cischarge enough condensate if the actual size is below the recommended size based on the condensate load, Check for back pressure and corresponding discharge capacities as per the capacity charts. 1) Replacertepair the leaking and non- working traps with working traps, the leak traps may createfinrease the back pressure on the ether working traps connected to the same return line or, i) ifthere are more than one tap discharging in a single condensate return line, then ensure all the raps have an NAV installed on the outlet of each trap 07 li) Ensure al the by-pass valve are closed, if by-pass vale is leaking or if itis kept ‘open in closed loop condition which createvincreases back pressure on the ‘other working traps, connected to the same return line Flooding of condensate, CCheck whether the inlet strainer is partially blocked CCheck thermostatic valve seat orifice for blockage If blocked, clean and lap Check main valve seat office for blockage. I blocked, clean and lap. hitpssImanuslzz.comidoci7451086/single-fficeoatrap-with-si-and-ortv sane121621, 4:13 PM Fer wee BA Avatobie Spares: (Refer to Figure 8) = These ats oie en nein abe a = ras sane 7 [ Mv Asenbiy Ka tar ONISO = 2_ [MW Asem Ybor ONS20 oats! 3 _ [MV Asn bar ONS 20 szo3iess @ | MV Assembly Kit aS bar DNS Slams 3 [Mv Asti Oba OS Sone 6 _ [Mv AsenbiyK 13a NOS oan 7 [Fest sendy 5 bor NISON2D Som 3 [Fes sendy 1b ONISONZD 200365 9 | Fest sey tar ONION = 10 | Float Assembly 4.5 bar DN25_ ‘ 2005485 Tr | Pest Aserby Ober DNDS Som 72 | Rost arb ber DES mee 13 A vet seb Ki ONTSO2S) Tz | sono va] over Gat Gt 5) 70 | sears 1 Secen Fok of 5 20056 ve) anu it smncODNES CWO ccomeun v7 _| SURE ASH He DMTSONAOINAS CLR oy ™ [eee tow t Onder DN 15 Single Orifice loa Tap, SOFT31-F-4.5 bar g, Ty, screwed BSPT How to Order Spares: ‘Always order spares by using the description given in the column above and stating the size of the trap, Example : Main valve assembly for DN 15 Single Oritice Float Tap SOPT31-F4.5 TD warranty Period As per the ordering information and agreements in the contract. hitpssImanuslzz.comidoci7451086/single-fficeoatrap-with-si-and-ortv 156121621, 413 PM manual viewer sre mmateninths ZW Forbes Forbes Marshall Forbes Marshall Steam TNA a ore ST nei ein Nac eee reat) : on etree Pear tee yy Sail eae cd Eee SP ee ee eee ea) Reto hitpssImanuslzz.comidoci7451086/single-fficeoatrap-with-si-and-ortv 1616