Separators: For Steam, Air and Gas Systems
Separators: For Steam, Air and Gas Systems
Separators: For Steam, Air and Gas Systems
Protect your investment in process plant and pipeline products whilst increasing productivity
Heat transfer applications
Water is an extremely effective barrier to heat transfer in steam systems. Whilst careful drainage and trapping will remove much of the water, it will not deal with water droplets in suspension. Wet steam can, and will, cause one or more of the following problems: Reduction in heat transfer efficiency as shown opposite.
Scale film Condensate film Air film
Increased erosion and possible corrosion within the steam system. Increased scaling of pipework and heating surfaces from impurities carried in the water droplets.
Steam
Stagnant film
Metal wall
n Erratic operation of control valves and flowmeters. n Eroded valve seats and fittings due to high velocity water droplets, (a condition known as wire drawing). n Ultimate failure due to rapid wear or waterhammer (e.g. broken turbine blades on air tools).
1 2
Type Size
Available in cast iron and SG iron, the S1, S2, S3, S12 and S13 separators are offered for general purpose applications. Designed for simplicity, they are relatively compact yet efficient for non-critical applications. The S5, S6, S7 and S8 series of high efficiency separators are specifically designed to maintain separation efficiency over a wide range of pipeline velocities and pressures. These separators are available in both carbon steel and austenitic stainless steel for specialist process systems.
The Spirax Sarco separator provides the total solution for all pipelines carrying steam, air or gas where water droplets are in suspension.
Separator range
Material
Cast iron S2
(Page 8)
Note: Certification will be provided to the requirements of the Pressure Equipment Directive.
Cast iron S3
(Page 8)
SG iron S13
(Page 9)
SG iron S1
(Page 10)
SG iron S12
(Page 11)
Carbon steel S5
(Page 12)
Carbon steel S7
(Page 14)
DN32 - 50 Screwed
DN15 - 25 Screwed
DN32 - 50 Screwed
Connections
Optional extras
Insulation jacket Air vent 2
AV30 AV45 AV30 AV45 AV21 AV30 AV21 AV30
Full range of separators in the following materials: cast iron, SG iron, carbon steel and austenitic stainless steel to cover all applications.
Air vent
See the 'Air vents for steam systems' brochure for more details.
Baffle designed to direct all moisture down to the outlet, ensuring no moisture is carried over into the steam line.
Dry steam
Wet steam
Large internal volume to reduce flow / velocity, providing efficient moisture separation and reducing the risk of moisture re-entrainment.
See the 'Ball float steam traps' and 'Liquid drainers for air and gas lines' brochures for suitable drain traps.
Condensate outlet
User benefits
Improves process plant productivity and product quality. Reduces maintenance cost and downtime. Increases plant and control valve life. Removes risk of waterhammer damage and subsequent maintenance bills. Simple, robust and effective separator design requiring no maintenance. Wide choice of materials and connections. Ensures only steam, air or gas is actually metered. (When fitted to protect flowmeters). Spirax Sarco's worldwide guarantee of knowledge, service and technical support. 3
n Using insulation jackets, ensures that dryness fraction and efficiency is maintained. n Using insulation jackets, prevents heat transfer losses. n Safety - Using insulation jackets, protects people from the possibility of injury from burns.
Due to their design the Spirax Sarco range of insulation jackets are clean (no messy application techniques), user friendly and resistant to water, fire and abuse. With Pressure System Regulations, inspection of wall thickness in order to monitor internal and external corrosion is becoming commonplace. Wall thickness can be quickly measured in service, (using for example an ultrasonic sensor) by simply undoing a velcro fastening or strap. This would be much more awkward with traditional lagging. 4
Typical applications
Steam distribution
Modern package boilers have limited steam space and evaporation surfaces which may give rise to very high steam take-off velocities and the production of wet steam under certain circumstances. When this happens the water carried over can contain impurities and water treatment chemicals all of which cause problems in the distribution system, control valves and process plant. The baffle separator removes all moisture ensuring a dry steam supply to process whilst reducing scaling in valves and on heat transfer surfaces.
Steam meters
Removes all excess moisture prior to metering, ensuring metered figures reflect the flow of dry steam. Also ensures meter components are not subjected to damage by waterhammer.
Steam sizing chart for the S5, S6, S7 and S8 separator up to DN150
Steam sizing example 1. Plot point A where the steam pressure and flowrates cross, e.g. 12 bar g / 500 kg / h. Draw a horizontal line. 2. Select line size. Any separator curve that is bisected by this line within the yellow area will operate at near 100% efficiency, e.g. DN32, point B. 3. Ascertain velocity. Line velocity for any size can be determined by dropping a vertical line from this intersection. From point B this line crosses the velocity axis at 18 m / s. 4. Pressure drop. Where the line extended from point B crosses the line C - C, plot a horizontal line. Now drop a vertical line from point A. The point of intersection, D, is the pressure drop across the separator, i.e. less than 0.05 bar. 5. Separators should be selected on the basis of the best compromise between line size, velocity and pressure drop for each application. The yellow area denotes recommended selection for 100% separation efficiency
Steam pressure psi g (approximate) 0 20 40 60 80 100 120 150 180 200 250
300
10 000 (22
350
20
Flow velocity ft / s 50 80
000)
5 000 (11
Steam flowrate kg / h (lb / h)
Separator size
2 000 (4 1 000 (2
500 (1 1 00)
2 0 (4
4)
50 (110)
14
16
18
20
22
24 25 5
10
15
20 25 30 35 Flow velocity m / s
40
0.002
(0.03
)
0.01 (
0 .0 2
0.15) (0 .3 )
0.05
(1 )
) 0.1 (2
) 0.2 (3
Note: For larger sizes and alternative, metals and pressure and temperatures that exceed these operating conditions please contact Spirax Sarco for a bespoke product. 6
Independent research carried out by Liverpool University in England, provided the experimental data from which the above graph was derived.
For critical applications, where flowmeters or control valves have to be protected to ensure their accuracy and stability, the Spirax Sarco range of high efficiency separators are recommended. The sizing charts below can be used to economically select the correct separator with known efficiency and pressure drop for steam. The sizing charts allow you to select a separator based upon different sizing criteria:
Given a pressure and flowrate a separator can be selected to provide a required velocity or acceptable pressure drop. If these factors are considered to be less important than pipe size a separator can be selected which will increase the velocity and pressure drop in order to reduce the size of the separator. Considering all these variables it is always possible to ensure that the separator will provide 100% efficiency.
Air sizing chart for the S5, S6, S7 and S8 separator up to DN150
Air sizing example 1. Plot point E where the compressed air pressure and flowrate cross, e.g. 8 bar g / 500 dm / s. Draw a horizontal line. 2. Select line size. Any separator curve that is bisected by this line within the yellow area will operate at near 100% efficiency, e.g. DN100, point F. 3. Ascertain velocity. Line velocity for any size can be determined by dropping a vertical line from this intersection. From point F this line crosses the velocity axis at 7 m / s. 4. Pressure drop. Where the line extended from point F crosses the line G - G, plot a horizontal line. Now drop a vertical line from point E. The point of intersection, H, is the pressure drop across the separator, i.e. less than 0.01 bar. 5. Separators should be selected on the basis of the best compromise between line size, velocity and pressure drop for each application. The yellow area denotes recommended selection for 100% separation efficiency
Air pressure psi g (approximate) 0 20 40 60 80 100 120 150 180 200 250 300 350 10 Flow velocity ft / s 20 30 40 50 60 65 DN150 DN125 DN100 DN80 DN65 DN50 DN40 DN32 DN25 DN20 DN15
2 000 (4 2 38)
Separator size
1 000 (2
Free flow air dm / s (cfm)
119)
500 (1059 )
200 (424 )
5 (1 1
0 2 4 6 8
20 (42)
)
12 14 16 18
10 (21)
20 22 24 25 2 4 6 8 10 12 14 16 18 20 Flow velocity m / s
0.002 (0.03) 0.005 (0.075) 0.01 (0.15)
10
0.02 (0.3
(1) 0.05
2) 0.1 (
Note: For larger sizes and alternative, metals and pressure and temperatures that exceed these operating conditions please contact Spirax Sarco for a bespoke product.
Independent research carried out by Liverpool University in England, provided the experimental data from which the above graph was derived.
S2
Cast iron
Sizes and pipe connections
1", 1" and 2" screwed BSP, NPT with screwed BSP or NPT drain.
S3
Cast iron
Materials
Body Plug DN40 to DN100 Gasket DN40 to DN100 Drain reducing bush (not DN200)
DN40, 50, 65, 80, 100, 125, 150 and JIS / KS 10 and AS2129 Table F (DN40 and BS 1560 class 125 wit
Mate
Body Plug 2" only Gasket 2" only Drain reducing bush
Cast iron DIN 1691 GG 20 / ASTM A126 CI B SG iron DIN 1693 GGG 40 Reinforced exfoliated graphite Forged carbon steel ASTM A105N
Operating range
Temperature C
Operatin
*PMO - Maximum operating pressure for steam.
12 14 16
Temperature C
The product must not be used in the red area. *PMO - Maximum operating pressure for steam.
A, B,
Limiting conditions
Body design conditions PN16 PMA - Maximum allowable pressure 16 bar g TMA - Maximum allowable temperature 184C Designed for a maximum cold hydraulic test pressure of 24 bar g
Limiting c
Body design co PMA - Maximum allowa TMA - Maximum allowa Designed for a maximum cold hy
Dimensions, weig
A 111 146 184 187 238 232 232 305 B 156 206 232 264 337 409 409 505 C 89 117 146 152 197 381 381 426 D 365 456 406 483 692 706 706 762
(approximate) in m
Inspection opening
S13
SG iron
Body Plug DN40 to DN80 DN100 to DN200 Gasket Drain reducing bush
e connections
d 200 flanged BS 4504 (DIN) PN16, d DN100 only) with screwed BSP drain and h screwed NPT drain.
erials
Materials
SG iron DIN 1693 GGG40 / ASTM A395 SG iron DIN 1693 GGG40 Carbon steel DIN 17425 GS C25N Reinforced exfoliated graphite Forged carbon steel ASTM A105N
DIN 1691 GG 20 / ASTM A126 CI B DIN 1693 GGG 40 ed exfoliated graphite arbon steel ASTM A105N
ng range
C
Operating range
*PMO - Maximum operating pressure for steam.
B, C A 14 16 10* 12
Temperature C
Pressure bar g
A 12.3* 13.7*
B 15 20 21.3*
D 25 24.4*
Pressure bar g
conditions
Limiting conditions
Maximum body design conditions PN25 PMA - Maximum allowable pressure 25 bar g TMA - Maximum allowable temperature 350C Designed for a maximum cold hydraulic test pressure of:
PN16 24 bar g, PN25 38 bar g, JIS / KS 10 19.6 bar g JIS / KS 20 38 bar g
onditions PN16 able pressure 16 bar g able temperature 184C ydraulic test pressure of 24 bar g
Inspection opening
Drain E 9
S1
SG iron
Sizes and pipe connections
", " and 1" screwed BSP, NPT with screwed BSP or NPT drain.
Materials
Body and cover Gasket Bolts Bush Baffle SG iron Semi-rigid graphite laminate Steel " - " Malleable iron 1" Forged carbon steel Cast iron ASTM A105N DIN 1691 Gr. GG20 BS 1768 Gr. 5 DIN 1693 Gr. GGG 40
Operating range
198
Temperature C
The product must not be used in the red area. *PMO - Maximum operating pressure for steam.
Limiting conditions
Body design conditions PN16 PMA - Maximum allowable pressure 16 bar g TMA - Maximum allowable temperature 300C Designed for a maximum cold hydraulic test pressure of 24 bar g
(approximate) in mm, kg and litres E " " " F 1" 1" 2" Weight 2.7 4.2 8.1 Volume 0.53 1.13 3.15
S12
SG iron
Sizes and pipe connections
1", 1" and 2" screwed BSP, NPT with screwed BSP or NPT drain.
Materials
Body Plug Gasket 2" only 2" only SG iron SG iron Reinforced exfoliated graphite Forged carbon steel ASTM A105N DIN 1693 GGG 40 / ASTM A395 DIN 1693 GGG 40
Operating range
Temperature C
The product must not be used in the red area. *PMO - Maximum operating pressure for steam.
10
15
Pressure bar g
20 21.3*
25
Limiting conditions
Body design conditions PN25 PMA - Maximum allowable pressure 25 bar g TMA - Maximum allowable temperature 350C Designed for a maximum cold hydraulic test pressure of 38 bar g
(approximate) in mm, kg and litres F 1" 1" 1" G 60 60 71 Weight 9.0 9.0 17.0 Volume 1.5 1.5 3.2
S5
Carbon steel
Sizes and pipe connections
", ", 1", 1", 1", 2", 2" and 3" screwed BSP or NPT, butt weld (BW) or socket weld (SW). DN15, 20, 25, 32, 40, 50, 65 and 80 flanged BS 4504 (DIN) PN40, JIS / KS 10K and 20K with screwed BSP drain and air vent and BS 1560 (ANSI B 16.5) Class 150 or 300 with screwed NPT drain and air vent.
Materials
Body Flange Cover Cover gasket Bolt PN ANSI / JIS / KS Carbon steel Carbon steel Carbon steel Carbon steel Reinforced exfoliated graphite Steel BS 3692 DIN 17245 GS C25N / ASTM A216 WCB DIN 17243 C22.8 ASTM A105N DIN 17245 C22.8 (1.0460) / ASTM A105N
Operating range
Temperature C
The product must not be used in the red area. *PMO - Maximum operating pressure for steam. A-A B-B C-C D-D E-E Flanged JIS / KS 10K Flanged ANSI Class 150 Flanged JIS / KS 20K Flanged DIN PN40 Flanged ANSI Class 300, Screwed BSP / NPT, SW, BW
B A
D, C
Limiting conditions
Maximum body design conditions PN50 / ANSI 300 PMA - Maximum allowable pressure 50 bar g TMA - Maximum allowable temperature 425C Designed for a maximum cold hydraulic test pressure of:
JIS / KS 10K - 20 bar g, JIS / KS 20K - 49 bar g, DIN PN40 - 60 bar g ANSI Class 150 - 30 bar g, ANSI Class 300 - 76 bar g, Screwed, SW, BW - 76 bar g.
G Air vent
DN32 - 1" 190 DN40 - 1" 220 DN50 - 2" DN80 - 3" 12 214 379 DN65 - 2" 319
274 209 438 90 " 14.0 310 221 508 90 1" 22.0 310 221 558 90 1" 23.0 419 270 663 90 " 65.0 489 329 764 90 " 82.0
S6
Austenitic stainless steel
S5 carbon steel model shown
Materials
Body Flange Cover Cover gasket Bolt PN Austenitic stainless steel 316L DIN 17445 Gx5 CrNi MoNb 1810 (werkstoff no. 1.4581)/ASTM A351 CF3M Austenitic stainless steel Stainless steel Reinforced exfoliated graphite Stainless steel BS ENO 150 35 08 - 1: 1998 Grade A4-80 DIN 17440 x2CrNi Mo 17 13 2 stainless steel (werkstoff no. 1.4404) ASTM A182 F316L DIN 17440 x2CrNi Mo (1.4404) / ASTM A182 F316L ANSI / JIS / KS Austenitic stainless steel
Operating range
Temperature C
The product must not be used in the red area. *PMO - Maximum operating pressure for steam. A-A B-B C-C D-D E-E F-F Flanged JIS / KS 10K Flanged ANSI Class 150 Flanged JIS / KS 20K Flanged DIN PN40 Flanged ANSI Class 300 Screwed BSP / NPT, SW, BW
B A
CD E
Pressure bar g
Limiting conditions
Maximum body design conditions PN50 / ANSI 300 PMA - Maximum allowable pressure 50 bar g TMA - Maximum allowable temperature 425C Designed for a maximum cold hydraulic test pressure of:
JIS / KS 10K - 20 bar g, JIS / KS 20K - 49 bar g, DIN PN40 - 60 bar g ANSI Class 150 - 30 bar g, ANSI Class 300 - 76 bar g, Screwed, SW, BW - 76 bar g.
G Air vent
DN32 - 1" 190 DN40 - 1" 220 DN50 - 2" DN80 - 3" 214 379 DN65 - 2" 319
274 209 438 90 " 14.0 310 221 508 90 1" 22.0 310 221 558 90 1" 23.0 419 270 663 90 " 65.0 489 329 764 90 " 82.0
S7
Carbon steel
Sizes and pipe connections
DN65, 80, 100, 125, 150, 200, 250, 300 and 350 flanged BS 4504 (DIN) PN16 or PN40 with screwed BSP drain and air vent and flanged BS 1560 (ANSI B 16.5) Class 150 or 300 with screwed NPT drain and air vent.
Materials
Carbon steel throughout
Limiting conditions
Size DN65 Flange Design pressure standard bar g Class 150 14 PN16 14 PN40 / Class 300 25 Class 150 14 PN16 14 PN40 / Class 300 20 Class 150 14 PN16 14 PN40 / Class 300 20 Class 150 14 PN16 14 PN40 / Class 300 30 Class 150 14 PN16 14 PN40 / Class 300 30 PN16 / Class 150 6 PN16 / Class 150 14 PN40 / Class 300 30 PN16 / Class 150 6 PN16 / Class 150 14 PN40 / Class 300 30 PN16 / Class 150 6 PN16 / Class 150 14 PN40 / Class 300 30 PN16 / Class 150 6 PN16 / Class 150 14 PN40 / Class 300 30 Design temperature C 198 198 225 198 198 213 198 198 213 198 198 236 198 198 236 165 198 236 165 198 236 165 198 236 165 198 236 Designed for a maximum cold hydraulic test pressure of: bar g Shop Site 26.2 23.0 24.0 23.0 49.1 43.1 25.7 23.0 24.0 23.0 38.0 33.9 25.7 23.0 24.0 23.0 37.9 33.9 25.7 23.0 24.0 23.0 58.3 53.1 25.7 23.0 24.0 23.0 59.3 53.1 10.7 9.0 23.4 21.0 52.7 47.4 10.7 9.0 22.7 21.0 51.8 47.4 10.3 9.0 22.7 21.0 51.8 47.4 10.3 9.0 22.7 21.0 50.6 47.4
DN80
DN100
DN125
DN150
DN200
DN250
DN300
DN350
(approximate) in mm, kg and litres J K Weight Volume J 263 30 47 18 G 263 30 49 18 Air vent
368 30 368 30 384 40 384 40 416 44 416 44 466 60 466 60 560 60 560 60 568 60 688 72 688 72 698 72 688 72 688 72 698 72 816 108 80 88 98 106 115 134 154 172 275 280 280 475 475 475 500 500 500 550 33 33 51 51 67 67 96 96 185 185 230 333 333 333 330 330 330 537
F D A
DN250
E B
DN300 DN350
14
S8
Austenitic stainless steel
S7 carbon steel model shown
Materials
Austenitic stainless steel throughout
Limiting conditions
Flange Design pressure Design temperature Designed for a maximum cold hydraulic test pressure of: standard bar g C bar g PN16 10 198 17.1 DN65 DN80 Class 150 11 198 18.8 DN100 PN40 25 236 44.9 DN125 Class 300 27 236 48.5 DN150 PN16 / Class 150 6 165 9.7 DN200 PN16 10 198 17.1 DN250 Class 150 11 198 18.8 DN300 PN40 25 236 44.9 DN350 Class 300 27 236 48.5 Note: For pressures and temperatures that exceed these operating conditions please contact Spirax Sarco for a bespoke product. Size
G Air vent
F D A
E B
K 15
Available types
The IJ-S1, IJ-S2, IJ-S3, IJ-S12 and IJ-S13 are a range of one piece design insulation jackets available with velcro fastenings for fitting to S1, S2, S3, S12 and S13 separators.
Available types
The IJ-S5 and IJ-S6 are one piece design insulation jackets for fitting to all S5 and S6 separators available in two versions: IJ-S5 / 6 a low temperature version (with velcro fastenings) or IJ-S5/6-H a high temperature version (with strap/ buckle fastening).
Materials
Inner and outer face Insulation Stitching Sealing Drawcords Label Silicone rubber coated glass fibre Mineral fibre Polyester cotton Velcro Nylon Nylon Inner and outer face Insulation Stitching Sealing Drawcords Label
Materials
IJ-S5 / 6 IJ-S5 / 6-H IJ-S5 / 6 IJ-S5 / 6-H IJ-S5 / 6 IJ-S5 / 6-H IJ-S5 / 6 IJ-S5 / 6-H IJ-S5 / 6 IJ-S5 / 6-H IJ-S5 / 6 and IJ-S5 / 6-H Silicone rubber coated glass fibre Glass fibre Mineral fibre Mineral fibre Polyester cotton Kevlar cotton Velcro Glass fibre / stainless steel buckles Nylon Kevlar Nylon
Limiting conditions
Maximum metal surface temperature 220C Thermal conductivity 0.044 W / mK at 100C
Limiting conditions
IJ-S5 / S6 - Maximum metal surface temperature 220C IJ-S5 / S6-H - Maximum metal surface temperature 425C Thermal conductivity 0.044 W / mK at 100C
Note: Other insulation jackets may be available on request. Please contact Spirax Sarco for more information
SEP
16
SB-S33-01
ST Issue 6