4041050/5 IM-P404-10

EMM Issue 5

FV
Flash Vessel
Installation and Maintenance Instructions

1. Safety information

2. Specific product safety

information

3. Product information

4. Installation

5. Commissioning

6. Operation

7. Maintenance

8. Spare parts
FV6 shown

© Copyright 2017
IM-P404-10 EMM Issue 5 1
Printed in GB
2 IM-P404-10 EMM Issue 5
1. Safety information
Safe operation of the unit can only be guaranteed if it is properly installed,
commissioned and maintained by a qualified person (see Section 1.10) in compliance
with the operating instructions. General installation and safety instructions for
pipeline and plant construction, as well as the proper use of tools and safety
equipment must also be complied with.

1.1 Intended use

Referring to these Installation and Maintenance Instructions, name-plate and
Technical Information Sheet, check that the product is suitable for the intended
use / application.
The products listed below comply with the requirements of the Pressure Equipment
Directive (PED) and carry the mark. The products fall within the following
Pressure Equipment Directive categories:

Group 2
Product
Gases

Flash vessel, FV6 and FV8 Category 2

Flash vessel, FV12, FV15 and FV18 Category 3

i) The products have been specifically designed for use with steam which is in
Group 2 of the above mentioned Pressure Equipment Directive. The products’
use on other fluids may be possible but, if this is contemplated, Spirax Sarco
should be contacted to confirm the suitability of the products for the application
being considered.

ii) Check material suitability, pressure and 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 being fitted, or if malfunction of the product
could result in a dangerous overpressure or over temperature occurrence,
ensure a safety device is included in the system to prevent such over-limit
situations.

iii) Determine the correct installation situation and direction of fluid flow.

iv) Spirax Sarco products are not intended to withstand external stresses that may
be induced by any system to which they are fitted. It is the responsibility of the
installer to consider these stresses and take adequate precautions to minimise
them.

v) Remove transit protection covers from all connections before installation.

1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded)
before attempting to work on the product. Arrange suitable lifting gear if required.

IM-P404-10 EMM Issue 5 3

1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.

1.4 Hazardous liquids or gases in the pipeline

Consider what is in the pipeline or what may have been in the pipeline at some
previous time. Consider: flammable materials, substances hazardous to health,
extremes of temperature.

1.5 Hazardous environment around the product

Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases,
extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive
noise, moving machinery.

1.6 The system

Consider the effect on the complete system of the work proposed. Will any proposed
action (e.g. closing isolation valves, electrical isolation) put any other part of the
system or any personnel at risk?
Dangers might include isolation of vents or protective devices or the rendering
ineffective of controls or alarms. Ensure isolation valves are turned on and off in
a gradual way to avoid system shocks.
Ensure that any pressure is isolated and safely vented to atmospheric pressure.
Consider double isolation (double block and bleed) and the locking or labelling of
closed valves. Do not assume that the system has depressurised even when the
pressure gauge indicates zero.

1.7 Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.

1.8 Tools and consumables

Before starting work ensure that you have suitable tools and / or consumables
available. Use only genuine Spirax Sarco replacement parts.

1.9 Protective clothing

Consider whether you and / or others in the vicinity require any protective clothing
to protect against the hazards of, for example, chemicals, high / low temperature,
radiation, noise, falling objects, and dangers to eyes and face.

1.10 Permits to work

All work must be carried out or be supervised by a suitably competent person.
Installation and operating personnel should be trained in the correct use of the
product according to these installation and maintenance instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where
there is no such system, it is recommended that a responsible person should know
what work is going on and, where necessary, arrange to have an assistant whose
primary responsibility is safety.
Post 'warning notices' if necessary.

4 IM-P404-10 EMM Issue 5

1.11 Handling
Manual handling of large and/or heavy products may present a risk of injury. Lifting,
pushing, pulling, carrying or supporting a load by bodily force can cause injury
particularly to the back. You are advised to assess the risks taking into account
the task, the individual, the load and the working environment and use the appropriate
handling method depending on the circumstances of the work being done.

1.12 Residual hazards

In normal use the external surface of the product may be very hot. If used at the
maximum permitted operating conditions the surface temperature of flash vessels
may reach a temperature approaching 198 °C (390 °F).
Many products are not self-draining. Take due care when dismantling or removing
the product from an installation (refer to Section 7 - 'Maintenance instructions').

1.13 Freezing
Provision must be made to protect products which are not self-draining against
frost damage if they are inoperative in environments where they may be exposed
to temperatures below freezing point during shutdown. The vessel should be
thoroughly defrosted prior to use. Trace heating should be considered under servere
environmental conditions, in order to prevent the operating temperature of the
vessel dropping below -10 °C (14 °F) during service.

1.14 Disposal
This product is recyclable and no ecological hazard is anticipated with its disposal
providing due care is taken.

1.15 Returning products

Customers and stockists are reminded that under EC 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 resides 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 as hazardous or potentially hazardous.

IM-P404-10 EMM Issue 5 5

2. Specific product safety information
The following information is specific to FV type flash vessels and should be read in
conjunction with the 'Safety information', Section 1

2.1 Overpressure protection

Flash vessels must be protected against overpressure situations and provision is
made for fitting a safety valve. However, it should not be assumed that the safety
valve will be the same size as the connection. Safety valve sizing must be in accordance
with National Standards. A connection is also provided for a pressure gauge. Safety
valves and pressure gauges are both available from Spirax Sarco.

Warning
If this product is not used in the manner specified by this IMI, then the
protection provided may be impaired.

6 IM-P404-10 EMM Issue 5

3. Product information
3.1 General information
Spirax Sarco products are designed, manufactured and tested to exacting standards to
meet modern system requirements. Where applicable, they satisfy current safety and design
codes and users can expect long service life when products are selected, installed and
maintained in accordance with Spirax Sarco recommendations.
The FV type flash vessels are designed and constructed to comply with the Pressure
Equipment Directive (PED), these vessels are particularly suited to boiler heat recovery
systems where efficient separation of flash steam from blowdown is essential to prevent
contamination of the boiler feedtank and/or heat transfer surfaces. Spirax Sarco flash
vessels are equally suited to condensate steam flash applications.
This Installation and Maintenance Instruction document provides comprehensive information
on operation, installation and maintenance and should be read prior to commencing work
on the product.

Flash steam outlet

Pressure gauge connection

Safety valve connection

Inspection cover

Inlet

Installation supports

Inspection cover

Condensate/residual blowdown outlet

Fig. 1 Typical features of the FV type flash vessel (model FV15/FV18 shown)

IM-P404-10 EMM Issue 5 7

3.2 Technical data
Designed for use with saturated steam.
Material of construction: Carbon steel

Paint finish Temperature resistant silver paint

Maximum design pressure 14 bar g (203 psi g)

Maximum design temperature 198 °C (390 °F)

Minimum design (operating) -10 °C (14 °F)

temperature

Designed for a maximum cold In accordance with the Pressure Equipment

hydraulic test pressure Directive (PED).

Note : Maximum design Pressure and temperature can be further limited, lower than that
stated on the nameplate depending on the chosen flange rating of the system.

PN16 13.3 bar g @ 198 °C (192.9 psi g @ 390 °F)

Class A150 13.8 bar g @ 198 °C (200.1 psi g @ 390 °F)

Note: These vessels will withstand full vacuum conditions.

Conforms to Ped 2014/68/EU Category

Fig. 2 Typical FV type flash vessel name-plate details

8 IM-P404-10 EMM Issue 5

4. Installation
Note:
Before actioning any installation observe the 'Safety information' in Sections 1 and 2.

FV type flash vessels are supplied with integral support brackets.

Brackets should be fastened firmly to secure mounting points. It is important that external
stresses are not introduced into the vessel and shims should be used beneath the support
brackets if necessary to obtain accurate pipeline alignment during installation.
Ensure that the blanking plugs supplied with the vessel are fitted securely, both at ambient
and operating temperatures.
The vessel must be mounted with the flash steam outlet uppermost, (see Figure 1). Each
vessel incorporates a " BSP screwed boss for a pressure gauge, U-syphon gauge and cock.
A separate connection is provided to accommodate a safety valve* and it is recommended
that a float trap is fitted beneath the condensate/residual blowdown outlet. Fitment of a
vacuum breaker may be required to counteract the creation of vacuum conditions by steam
condensation.

* It must not be assumed that the safety valve will be the same size as the connection - refer
to 'Overpressure protection', Section 2.1.

5. Commissioning
Before putting the unit into service, ensure that:

- Blanking plugs are tight; check for tightness also when vessel has reached operating
temperature. Caution:- Maximum operating temperature is 198 °C (390 °F).

- All connections to adjoining pipework/plant are sound and secured so that no external
stresses are introduced into the unit

- No extraneous objects / material are present within the vessel.

- Any associated safety accessory (e.g. safety valve) has been correctly sized, adequately
tested and is in working order.

- Check allowable pressure/temperature rating of flanges used and ensure operation and
safety accessories are set within this limit.

IM-P404-10 EMM Issue 5 9

6. Operation
Operation of flash vessels is inherently simple and no special operating instructions are
required. The vessel allows for the safe expansion of saturated water from high to lower
pressures with the accompanying production of flash steam.
On a precautionary note, vessels are designed to operate at high temperatures and care
should be taken to avoid personal injury if vessels are unlagged.

Operating conditions
Spirax Sarco flash vessels are designed to operate under saturated steam conditions up to
14 bar g @ 198 °C (203 psi g @ 390 °F). They have a minimum design operating temperature
of -10 °C (14 °F).

Note : Maximum design Pressure & Temperature can be further limited, lower than that stated
on the nameplate depending on the chosen flange rating of the system.

PN16 13.3 bar g @ 198 °C (192.9 psi g @ 390 °F)

Class A150 13.8 bar g @ 198 °C (200.1 psi g @ 390 °F)

7. Maintenance
Flash vessels require no routine maintenance; however, blanking plugs should be checked
periodically for tightness and, where used, insulation for security.
Vessels should be included in a written scheme of examination including regular internal
visual inspection for signs of excessive corrosion, by a suitably qualified competent person
who is responsible for determining the frequency of examination.

8. Spare parts
No spare parts are required or available for flash vessels. Repairs to pressure vessels are not
recommended as specialist design procedures and welding operations are required, together
with reinspection by a qualified competent person.

10 IM-P404-10 EMM Issue 5

IM-P404-10 EMM Issue 5 11
12 IM-P404-10 EMM Issue 5