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Kaysafe Engineering Limited

2nd Floor, 12 Linkfield Corner, Redhill, Surrey, RH1 1BB Vat Reg No. GB: 443 1567 59

Telephone No. 01737 772210 First Point Assessment Supplier No. 10042295

Fax No. 01737 771200 Email address: quality@kaysafe.co.uk

Page 1

150 2500# ANSI RATED - Y-TYPE STRAINERSFLANGED ASME B16.5

INSTALLATION, OPERATING & MAINTENANCE INSTRUCTIONSAll information and recommendations contained in these instructions are to the best of ourknowledge correct. Since the conditions of use are beyond our control, users must satisfythemselves that the equipment/ products installed in the process lines are comparable with thedesign parameters for which the equipment/products was intended.

IMPORTANTBefore installing the equipment, please fully read these instructions and ensure relevant safetyprecautions are adhered to. Particular attention must be paid to ensuring that the operatingconditions of the strainer fall within the pressure/temperature tables shown herein.

PRODUCT WARRANTYShould any after-delivery problems arise, please contact Kaysafe Engineerings QualityDepartment during normal business hours on the above number or e-mail:quality@kaysafe.co.uk

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Kaysafe Engineering Limited

2nd Floor, 12 Linkfield Corner, Redhill, Surrey, RH1 1BB Vat Reg No. GB: 443 1567 59

Telephone No. 01737 772210 First Point Assessment Supplier No. 10042295

Fax No. 01737 771200 Email address: quality@kaysafe.co.uk

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1.1 - UNPACKINGAll Kaysafe Engineering Limited products are tested and inspected during manufacture andprior to shipment. However, the user should carry out an inspection at the time of unpacking todetect and possible damage that may have been caused during shipment.

1.1a STORAGE & PRESERVATIONAll Kaysafe Engineering products must, if not installed immediately, and to ensure their integrity,be stored dry and well ventilated areas to prevent and corrosion and/or contamination from theatmosphere (sudden changes in temperature must be avoided and prevention of this will stopcondensation and damage), this must be in a secure and covered area, accessed only by

authorised personnel. They must be checked prior to installation.

1.2 - INSTALLATIONY-Type Strainers are delivered completely assembled for fitting into the pipeline. The followingnotes & checklist should be observed prior to installation:-Y-Type Strainers are designed to be self-supporting for installation both horizontally andvertically. Y-Type Strainers must be fitted into the pipeline in the correct orientation. Thedirection of flow is clearly marked on the Strainer body. Always check adjoining pipe-work forcleanliness When bolting up the pipeline flanges, ensure that the correct bolting and gaskets areused in accordance with size, type and rating of the flange specification. The Y-Type Strainer,

should wherever possible should be mounted into adjoining pipe-work in such a way as to avoidexcessive stress. The fitting of a differential pressure gauge is recommended to indicate whenthe screen should be cleaned. The fitting of a blow-down valve on the drain connection shouldalso be considered as this can assist and reduce maintenance.

IMPORTANT NOTESEnsure that the Strainer is in the correct orientation.Gradually tighten the flange bolting in a diagonal sequence up to the torque specified - seeoverleaf.Ensure that there is adequate clearance for the drain connection & screen removal with noobstructions.

Ensure adequate protective clothing is worn I.e. safety shoes gloves etc. during installation.

2.1 - COMMISSIONINGEnsure that the Strainer has been installed in accordance with the Installation instructionsabove.Check that the flange bolting has been adequately tightened to the correct torque.Seal off any drains connections and return the process flow (utilising vents for dispelling air asappropriate).Ensure that the gaskets fitted, refer to Purchase Order, are compatible with the *service andtemperature, see overleaf:-

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Kaysafe Engineering Limited

2nd Floor, 12 Linkfield Corner, Redhill, Surrey, RH1 1BB Vat Reg No. GB: 443 1567 59

Telephone No. 01737 772210 First Point Assessment Supplier No. 10042295

Fax No. 01737 771200 Email address: quality@kaysafe.co.uk

Page 3

MATERIAL TEMPERATURE

C.N.A.F -29C to 399C (-20F to 750F) **

GRAPHITE -29C to 399C (-20F to 750F)

P.T.F.E. -20C to 260C (-20F to 500F)

RTJ Soft Iron -60C to 500C (-76C to 932F)

RTJ S/S 316 -110C to 550C (-166F to 1022F)

* For service compatibility, please refer to suitable compatibility chart.** The gasket material may withstand higher temperatures than shown, this figure has beenused as it is the threshold of the Strainer material

2.2 - SPECIAL TOOLSThere are no special tools required for this equipment.

2.3 - IMPORTANTKaysafe Engineerings Cast Y-Type Strainers are designed to operate at full pressure @ 0C toASME B16.5for group 1.1 & 29C for group 2.2 materials. Therefore as long as the operating conditions i.e.Pressure & temperature f all within the parameters of the relevant tables below, then the unitcomplies with the requirements of ASME B16.5 depending upon the rating of the inlet/outletflange & material of construction being used.

PRESSURE RATINGSCARBON STEEL (Group 1.1)

TEMPERATURE SAFE WORKING PRESSURECARBON STEEL

CARBON STEEL BAR

F C 150LB 300LB 600LB 900LB 1500LB 2500LB32 to 0 to 38 19.6 51.2 102.0 153.06 255.45 425.41

200 93.3 17.9 46.54 93.08 139.62 232.70 387.83

300 148.8 15.8 45.16 90.67 135.83 226.15 377.14

400 204.4 13.7 43.78 87.56 131.00 218.56 364.04

500 260.0 11.7 41.36 82.74 123.76 206.5 344.05

600 315.5 9.6 37.92 75.50 113.07 188.57 314.40

650 343.3 8.6 36.88 74.12 111.01 185.12 308.54

700 371.1 7.5 36.88 73.43 110.32 183.75 306.13

750 398.9 6.5 34.82 69.64 104.11 173.75 289.58

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Kaysafe Engineering Limited

2nd Floor, 12 Linkfield Corner, Redhill, Surrey, RH1 1BB Vat Reg No. GB: 443 1567 59

Telephone No. 01737 772210 First Point Assessment Supplier No. 10042295

Fax No. 01737 771200 Email address: quality@kaysafe.co.uk

Page 4

PRESSURE/TEMPERATURE RATINGSSTAINLESS STEEL (Group 2.2)

TEMPERATURE SAFE WORKING PRESSURESTAINLESS STEEL

STAINLESS BAR

F C 150LB 300LB 600LB 900LB 1500LB 2500LB

-20 to 100 -29 to 38 18.96 49.64 99.28 148.9 248.21 413.69

200 93.3 16.55 42.75 85.50 128.2 213.39 355.77

300 148.8 14.82 38.61 77.22 115.8 192.71 321.30

400 204.4 13.44 35.51 71.02 106.2 177.20 295.10

500 260.0 11.72 33.10 65.85 98.94 164.78 274.41600 315...5 9.65 31.03 62.40 93.42 155.48 259.23

650 343.3 8.32 30.68 61.36 91.70 153.06 255.11

700 371.1 7.58 29.65 59.64 89.29 148.93 248.21

750 398.9 6.55 29.30 58.26 87.56 145.48 242.70

The Strainer should be pressurised gradually up to approx. 50% of the normal workingpressurecheck for leaks, any detected leaks should be rectified accordingly. Check anyinstrumentation where fitted in accordance with manufacturers instructions. Upon satisfactory

completion of all necessary checks, pressurise the Strainer up to full working pressure and flow-rate, re-check for leaks and rectify accordingly.

3.1OPERATIONKaysafe Engineerings Y-Type Strainers are mechanical devices for removing solids & othercontaminants from the process fluid by means of a perforated plate/mesh screen. Since Y-TypeStrainers have no moving parts, they do not require any operating procedure.

3.2SAFETYKaysafe Engineering Limited assumes that when the unit is to be installed or maintenance workis carried out, particularly in hazardous service, that all operators / maintenance personnel will

be adequately protected in accordance with the relevant legislation & codes of practice.

3.3TRAININGNo special training is required for this type of equipment, however, we recommend that allinstallation and maintenance work be carried out by a skilled/qualified competent fitter & withinCOSHH regulations.

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Kaysafe Engineering Limited

2nd Floor, 12 Linkfield Corner, Redhill, Surrey, RH1 1BB Vat Reg No. GB: 443 1567 59

Telephone No. 01737 772210 First Point Assessment Supplier No. 10042295

Fax No. 01737 771200 Email address: quality@kaysafe.co.uk

Page 5

4.1MAINTENANCEThe only maintenance for this type of equipment is to periodically remove and clean the screen,which will depend largely upon the amount of contaminants in the process fluid. The cleaninginterval can best be determined from the installation of a differential pressure gauge or byoperational experience with subsequent maintenance periods. When removing the screen, thefollowing should be observed:-

A) Before attempting any maintenance whatsoever, it is essential that the process line is de-pressurised by either a by-pass system or by closing the inlet/outlet valves (if fitted) or bywhatever means necessary to ENSURE THAT THE PRESSURE & FLOW HAVE BEEN SHUT-OFF & THAT THE PIPELINE IS DEPRESSURISED.

CAUTION !

OPENING A CLOSURE CAN BE A HAZARDOUS ACTIVITY.ALL INSTRUCTIONS SHOULD BE READ CAREFULLY BY ALL PERSONNEL ENGAGED INTHE OPERATION/MAINTENANCE OF THIS EQUIPMENT.

B) Vent off the Strainer within strict safety precautions, to reduce hazardous conditionsdeveloping i.e. blow-out, flashing etc, and drain unit.

C) Slacken the bolting on the cover gradually using a suitable wrench whilst supporting theStrainer body.

D) Remove the nuts/washers & retain for re-assembly. Then remove the cover, utilising liftinghandles/eyebolts (where fitted) & withdraw the screen for cleaning / replacement. (Coverhandles/eyebolts are for lifting the cover only and should not be used for lifting the completeunit.

E) The screen of the Y-Type should then be cleaned in a suitable medium compatible with the

process fluidcare should be taken not to damage the screen during handling, DO NOT bangor hammer the screen. Where air is available, the contaminant may be blown off the perforatedplate / mesh by applying air to the outside of the screen for In to Out process flow & insidefor Out to In.

WHEN USING COMPRESSED AIR ALWAYS WEAR THE APPROPRIATE SAFETYGLASSES/CLOTHING

F) Coarse retention Y-type Strainers can be cleaned using a stainless steel wire brush. (Forrecommended cleaning techniquessee overleaf).

G)Always inspect the screen for any damage or wear & replace as necessary.

H) Re-fit the new or cleaned screen making sure that it is properly located in the machinedrecesses within the Strainer body & cover. Always renew the cover gasket, the use of a jointingcompound is not recommended.

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Kaysafe Engineering Limited

2nd Floor, 12 Linkfield Corner, Redhill, Surrey, RH1 1BB Vat Reg No. GB: 443 1567 59

Telephone No. 01737 772210 First Point Assessment Supplier No. 10042295

Fax No. 01737 771200 Email address: quality@kaysafe.co.uk

Page 6

I) Clean the cover and inspect the cover bolting, replace as necessary, coat the threads withapproved lubricant. NEVER USE OIL OR GREASE ON STRAINERS HANDLING OXYGEN.

J) Carefully fit the gasket in position & reposition the cover. Install the bolting and hand tightenin turn.

K) For bolts greater than 25mm diameter, it is recommended that hydraulic/Pneumatic torquetensioning equipment is used. For smaller bolting it is recommended that a calibrated torquewrench is used. Proceed to tighten the bolting in a diagonal sequence up to 30% of the finaltorque valuesee opposite.

L) Check that the mating faces are bearing uniformly, then continue to tighten in a diagonalsequence gradually until the final torque value is achieved.

M) Seal off any drain and vent connections and return process flow Check for any leaks andrectify accordingly

GENERAL NOTESi) All gasket and seals should be inspected during installation and at regular schedule

maintenance intervals. If there are any signs of damage or deterioration then they should bereplaced.ii) All flange bolting should be checked periodically for tightness and re-tightened as necessaryto the correct torque value. Bolting should also be kept lubricated to aid maintenance.iii) Periodic inspection should be made to monitor corrosion and damage to the paint-work.Corrective action should be carried out in accordance with approved procedures.

RECOMMENDED SPARES FOR Y TYPE STRAINERSCOMMISSIONING1 cover gasket per strainer2 YEARS OPERATING2 cover gaskets per strainer5 YEARS 1 spares kit per strainer. (Each kit consists of 1 screen and 2 cover gaskets).

RECOMMENDED TORQUE VALUESThe values shown below are intended to assist the user of this manual in determining thecorrect value to torque standard flange bolting. Due to the many standard flange specificationsand bolting diameters, the responsibility for assessing torque values which are not shown on thetable below rest with the user.

TEMPERATURE SAFE WORKING PRESSURECARBON

STEEL

CARBONSTEEL

BAR

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Kaysafe Engineering Limited

2nd Floor, 12 Linkfield Corner, Redhill, Surrey, RH1 1BB Vat Reg No. GB: 443 1567 59

Telephone No. 01737 772210 First Point Assessment Supplier No. 10042295

Fax No. 01737 771200 Email address: quality@kaysafe.co.uk

Page 7

F C 150LB 300LB 600LB 900LB 1500LB 2500LB

32 to100

0 to 38 19.6 51.2 102.0 153.06 255.45 425.41

200 93.3 17.9 46.54 93.08 139.62 232.70 387.83

300 148.8 15.8 45.16 90.67 135.83 226.15 377.14

400 204.4 13.7 43.78 87.56 131.00 218.56 364.04

500 260.0 11.7 41.36 82.74 123.76 206.5 344.05

600 315.5 9.6 37.92 75.50 113.07 188.57 314.40

650 343.3 8.6 36.88 74.12 111.01 185.12 308.54

700 371.1 7.5 36.88 73.43 110.32 183.75 306.13

750 398.9 6.5 34.82 69.64 104.11 173.75 289.58

FAULT POSSIBLE CAUSE CORRECTIVE ACTION

Leakage through flange joints Closure bolting loose Re-tighten bolting

Closure gasket worn Replace gasket

Closure gasket joint fouled with debrisor foreign matter

Clean joint

Flange face damaged Re-machine faces

Flanges not uniformly tighteningsequence Clogged screen bearing dueto incorrect bolt Clean/

Slacken bolting and re-tighten incorrect diagonal sequence tospecified torque

High pressure loss across Mono-in-line strainer Decreased flow-rate

Process change i.e. increase in flowrate, dirt levels etc. Process fault

Check process and adjustaccordingly to design data replacescreen

Clogged screenClean/replace screen Checkprocess

Pipeline blockage Check pipeline

Major leak Rectify leaks

High dirt carryover Damaged screen Replace screen

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Kaysafe Engineering Limited

2nd Floor, 12 Linkfield Corner, Redhill, Surrey, RH1 1BB Vat Reg No. GB: 443 1567 59

Telephone No. 01737 772210 First Point Assessment Supplier No. 10042295

Fax No. 01737 771200 Email address: quality@kaysafe.co.uk

Page 8

5.1SPARE PARTSSpare parts list for Y-Type Strainers are available upon request, alternatively a price & deliverycan be obtained direct over the telephone. In either case, please contact our Sales Departmenton:- Tel: (01737) 772210 E-mail: sales@kaysafe.co.uk

All damaged or worn parts should be replaced and obtained direct from KaysafeEngineering Limited or approved distributor.

It is highly recommended that as a minimum at least two cover gaskets & one screen iskept in stock as insurance spares.