Flowserve BA46 User Manual
GESTRA
GESTRA Steam Systems
BA 46
BA 47
BAE 46
BAE 47
Installation Instructions 818609-00
Continuous Blowdown Valve
BA 46, BA 47, BAE 46, BAE 47
1
2
Contents
Page
Important Notes
Usage for the intended purpose .............................................................................................................5
Safety notes ...........................................................................................................................................5
Danger ...................................................................................................................................................5
Attention .................................................................................................................................................6
PED (Pressure Equipment Directive) ........................................................................................................6
ATEX (Atmosphère Explosible) .................................................................................................................6
Explanatory Notes
Scope of supply ...................................................................................................................................... 6
System description .................................................................................................................................7
Function .................................................................................................................................................7
Design .................................................................................................................................................... 8
Technical Data
Pressure ratings .....................................................................................................................................8
Materials ................................................................................................................................................8
Pressure/Temperature ratings .................................................................................................................8
Dimensions of end connections ..............................................................................................................9
Overall lengths ........................................................................................................................................9
Corrosion resistance ............................................................................................................................... 9
Sizing .....................................................................................................................................................9
Name plate / marking ...........................................................................................................................10
Dimensions BA 46, BA 47 ..................................................................................................................... 11
Dimensions BAE 46, BAE 47 ................................................................................................................. 12
Capacity chart for DN 15 to 32, capacity ranges at a glance
Capacity chart for DN 15 to 32, capacity range up to 310 kg/h ..............................................................14
Capacity chart for DN 15 to 32, capacity range up to 1020 kg/h ............................................................15
Capacity chart for DN 15 to 32, capacity range up to 2120 kg/h ............................................................16
Capacity chart for DN 40 and 50, capacity ranges at a glance ...............................................................17
Capacity chart for DN 40 and 50, capacity range up to 1340 kg/h .........................................................18
Capacity chart for DN 40 and 50, capacity range up to 4500 kg/h .........................................................19
Capacity chart for DN 40 and 50, capacity range up to 6300 kg/h .........................................................20
..................................................................13
Design
BA 46, BA 47 ........................................................................................................................................ 21
BAE 46, BAE 47 ....................................................................................................................................22
Key ....................................................................................................................................................... 23
Contents – continued –
Page
Installation
BA 46, BA 47, BAE 46, BAE 47 ..............................................................................................................24
Attention ...............................................................................................................................................24
Valve with flanged ends ........................................................................................................................ 24
Valve with socket-weld ends .................................................................................................................24
Valve with butt-weld ends ....................................................................................................................24
Attention ...............................................................................................................................................25
Heat treatment of welds........................................................................................................................25
Reposition control lever by 180 ° (if position of installation is unfavourable) .......................................... 25
Install sample valve ..............................................................................................................................25
Wiring
Danger ...............................................................................................................................................26
Continuous blowdown valves BAE 46, BAE 47 with actuator .................................................................26
Factory settings of BAE 46, BAE 47 .......................................................................................................26
Commissioning
Danger ...............................................................................................................................................26
BA 46, BA 47, BAE 46, BAE 47 ..............................................................................................................26
Attention ...............................................................................................................................................27
Continuous blowdown valves BA 46, BA 47 without actuator ................................................................27
Continuous blowdown valves BAE 46, BAE 47 with actuator .................................................................27
Operation
Danger ...............................................................................................................................................27
BA 46, BA 47, BAE 46, BAE 47 ..............................................................................................................27
Attention ...............................................................................................................................................27
Calculating the amount of boiler blowdown ...........................................................................................28
Emergency Operation
BAE 46, BAE 47 ....................................................................................................................................28
Maintenance
Changing packing and internals of BA 46, BA 47 ........................................................................... 28 - 29
Changing packing and internals of BAE 46, BAE 47 ....................................................................... 29 - 30
Torques ................................................................................................................................................30
Tools .....................................................................................................................................................30
Removing internals ............................................................................................................................... 31
3
4
Contents – continued –
Page
Retrofitting
Danger ...............................................................................................................................................32
Mounting the actuator ........................................................................................................................... 32
Toques ..................................................................................................................................................32
Tools .....................................................................................................................................................32
Spare Parts
Spare parts list ....................................................................................................................................33
Retrofitting Parts
Retrofitting parts list ............................................................................................................................34
Decommissioning
Danger .................................................................................................................................................34
Disposal................................................................................................................................................34
Annex
Declaration of Conformity ....................................................................................................................35
Important Notes
Usage for the intended purpose
BA 46, BA 47:
Use the continuous blowdown valves BA 46, BA 47 only for discharging water from steam boilers to
ensure the correct water conditions in the boiler. Application in pipes within the admissible pressure/
temperature ratings, taking the chemical and corrosive effects on the pressure equipment into account.
BAE 46, BAE 47:
Use the continuous blowdown valves BAE 46, BAE 47 only in conjunction with the control equipment
KS 90, LRR 1-40 or LRR 1-5, LRR 1-6 for discharging water from steam boilers to ensure the correct
water conditions in the boiler. Application in pipes within the admissible pressure/temperature ratings,
taking the chemical and corrosive effects on the pressure equipment into account.
To ensure the safe operation of the BAE 46, BAE 47 mount only actuators that are explicitly specified by
GESTRA onto the control valve. Specified and approved actuators are:
ARIS EF 0.5, ARIS EF 1, ARIS EF 1-1 and ARIS EF 1-40.
Safety note
The equipment must only be installed and commissioned by qualified and competent staff.
Retrofitting and maintenance work must only be performed by qualified staff who – through adequate
training – have achieved a recognised level of competence.
Danger
The valve is under pressure during operation.
When loosening flanged connections, sealing plugs or stuffing boxes, hot water and
steam may escape.
The valve becomes hot during operation.
This presents the risk of severe burns to hands and arms.
Before servicing the valve or loosening flanges, stuffing box connections or sealing plugs
make sure that all connected lines are depressurised (0 bar) and cooled down to room
temperature (20 °C).
During operation moving internals can pinch one‘s hands or fingers. Do not touch
moving parts! The continuous blowdown valves BAE 46, BAE 47 are remote controlled
and can open and close very abruptly.
The terminal strips of the actuator EF ... are live during operation.
This presents the danger of electric shock.
Cut off power supply before fixing or removing the equipment.
Sharp edges on internals present a danger of cuts to hands. Always wear industrial
gloves when replacing the packing, valve seat or valve plug.
5
6
Important Notes – continued –
Attention
The name plate specifies the technical features of the equipment. Note that any piece of
equipment without its specific name plate must neither be commissioned nor operated.
PED (Pressure Equipment Directive)
The equipment meets the requirements of the Pressure Equipment Directive 97/23/EC.
Application in fluids of group 2. With CE marking, except equipment according to section 3.3.
ATEX ( Atmosphère Explosible)
The valves BA 46, BA 47 can be used in potentially explosive areas, provided that the following notes
are observed:
The operating fluid must not generate excessively high temperatures. Electrostatic charges that may
be generated during operation must be discharged. Make sure that the stuffing box is tight and that
the valve spindle can run smoothly. The equipment can be used in Ex zones 1, 2, 21, 22 (1999/92/EC)
II 2 G/D c X.
According to the European Directive 94/9/EC the valves BAE 46, BAE 47 must not be used in
potentially explosive areas. For more information refer to our ATEX Declaration of Conformity.
Explanatory Notes
Scope of supply
BA 46
1 Continuous blowdown valve BA 46
1 Sample valve (not mounted)
1 Gasket A17 x 23 x 1.5
1 Installation manual
BA 47
1 Continuous blowdown valve BA 47
1 Sample valve (not mounted)
1 Gasket A17 x 23 x 1.5
1 Installation manual
Retrofitting kit for BA 46, BA 47
1 Electric actuator
EF 0.5, EF 1, EF 1-1 or EF 1-40
1 Mounting kit for coupling / mounting bracket
1 Installation manual for ARIS actuator EF...
Spare parts
1 Kit according to spare parts list, page 33
BAE 46
1 Continuous blowdown valve BAE 46
1 Sample valve (not mounted)
1 Gasket A17 x 23 x 1.5
1 Installation manual
1 Installation manual of the ARIS actuator EF...
1 Declaration of manufacturer
BAE 47
1 Continuous blowdown valve BAE 47
1 Sample valve (not mounted)
1 Gasket A17 x 23 x 1.5
1 Installation manual
1 Installation manual for ARIS actuator EF...
1 Declaration of manufacturer
Explanatory Notes – continued –
System description
Due to the continuous evaporation process in the steam boiler the density and hence the TDS
(= Total Dissolved Solids) concentration of the boiler water is increased. The TDS level must remain
within the limits specified by the boiler manufacturer and applicable guidelines. For this purpose a
certain amount of boiler water (= boiler blowdown) is discharged continuously or periodically. The
continuous blowdown valves BA... and BAE... feature specially designed and wear resistant nozzle stems
that enter concentrically into a system of expansion chambers which are arranged one after the other,
making the valve well suited for the continuous discharge of boiler blowdown at very high differential
pressures. The continuous blowdown valves BA... and BAE ... are suitable for operation in steam boiler
plants according to TRD 604, EN 12952 and EN 12953
n BA 46 PN 40, manually operated
n BA 47 PN 63, manually operated
n BAE 46 PN 40, operated by the electric actuator EF...*)
n BAE 47 PN 63, operated by the electric actuator EF...*)
*) Explosion-proof actuators or actuators powered by d. c. or three-phase current are available
on request.
Function
The continuous blowdown valve BA 46/BA 47 is moved to its control position by means of the control
lever. Use the scale on the control lever to adjust the required amount of boiler blowdown.The required
amount of boiler blowdown is calculated with the aid of a formula or read off on a nomogram. The
continuous blowdown valve BAE 46/BAE 47 is motored to its control position by means of the actuator EF... The actuator is activated by the GESTRA conductivity controller KS 90 working in conjunction
with the GESTRA conductivity electrode LRGT 1...-1 or the conductivity controller LRR 1-5, LRR 1-6 in
combination with the GESTRA conductivity electrode LRG 16... or the conductivity controller LRR 1-40 in
conjunction with the conductivity electrode LRG 1..-40.
The actuator opens or closes the continuous blowdown valve as a function of the required amount of
boiler blowdown and the desired operating position, at which – independent of the actual electrical
conductivity of the boiler water – a freely selectable fundamental amount can be discharged by the BAE
46/BAE 47. The valve positions “OPEN” and “CLOSED” are limited by the cam-operated switch located in
the actuator, the “OPERATING POSITION” is variably adjustable by means of an operating cam. The power
flow towards the closing direction is transmitted via a rigid coupling with integrated torsion spring. The
coupling permits the actuator to travel a little bit further when the nozzle stem is pressed into the valve
seat.
The conductivity of the boiler water is monitored by the equipment combination consisting of a
conductivity electrode and a conductivity controller. The continuous evaporation process in the steam
boiler increases the boiler water density and, consequently, the TDS level, causing the conductivity of
the boiler water to rise. Once the set limit value is reached, the actuator receives an opening pulse from
the conductivity controller according to the deviation from the conductivity setpoint. When the adjusted
conductivity setpoint is attained, the actuator closes the continuous blowdown valve or returns to the
adjusted operating position. The valve positions “CLOSED” and “OPEN” are limited by the cam-operated
switch in the actuator, the “OPERATING POSITION” is variably adjustable by means of an operating cam
or a feedback potentiometer.
.
7
8
Explanatory Notes – continued –
Design
Type Standard Special version
BA(E) 46
BA(E) 47
Flanged to
EN 1092-1, PN 40
Flanged to
EN 1092-1, PN 63
Flanged to ASME, Class 150, 300
Butt-weld ends for pipes to DIN or ASME
Socket-weld ends for pipes to DIN or ASME
Flanged to ASME, Class 400
Butt-weld ends for pipes to DIN or ASME
Socket-weld ends for pipes to DIN or ASME
Technical Data
Pressure ratings
Type EN ASME
BA(E) 46 PN 40 Class 150, 300
BA(E) 47 PN 63 Class 400
Materials
Designation EN DIN ASTM
Valve body
BA..., BAE...
Nozzle stem X20Cr13 (1.4021) X20Cr13 (1.4021)
Seat and stage sleeves X14CrMoS17 (1.4104) X14CrMoS17 (1.4104)
Locking screw A2-70 A2-70 A193 CL 2B-B8
Sealing plug 42CrMo4 (1.7225) A193 B7
P250GH (1.0460) C 22.8 (1.0460) A 105
Pressure/Temperature ratings
Type Ratings according to
EN 1092-1 1.0460*)
BA(E) 46
BA(E) 47
*) Material according to AD 2000
EN 1092-1 A105
ASME B16-34 A105 Class 150 17.7 13.8 10.2 198 / 14
ASME B16-34 A105
EN 1092-1 1.0460*)
EN 1092-1 A105
ASME B16-34 A105
PN 40 37.3 30.2 25.8 234 / 29
PN 40 40 37.9 33.5 246 / 36
Class 300 46.6 43.8 39.8 254 / 42
PN 63 58.8 47.6 40.6 257 / 44
PN 63 63 59.6 52.7 271 / 55
Class 400 62.1 58.4 53.1 270 / 55
max. pressure [bar] at
100 °C 200 °C 300 °C ts / p
max
Technical Data – continued –
Dimensions of end connections
Outside diameter of pipe x wall thickness
Butt-weld ends for pipe*) [DN] 15 20 25 32 40 50
EN PN 40 21.3 x 2 26.9 x 2.3 33.7 x 3.4 42.4 x 2.6 48.3 x 2.6 60.3 x 2.9
EN PN 63 21.3 x 2 26.9 x 2.6 33.7 x 2.6 42.4 x 2.9 48.3 x 2.9 60.3 x 2.9
ASME Schedule 40 CL150/300 21.3 x 2.8 26.7 x 2.9
ASME Schedule 80 CL400/300 21.3 x 3.7 26.7 x 3.9 33.4 x 4.5 42.2 x 4.8 48.3 x 5.1 60.3 x 5.5
Inside diameter x depth
Socket-weld ends EN/ASME**) [DN] 15 20 25 32 40 50
EN/ASME 21.8 x 10 27.3 x 13 34.1 x 13 42.8 x 13 48.8 x 13 61.3 x 16
*) The dimensions (outside diameter of pipe x wall thickness) refer to the connecting pipe, not to the dimensions
of the butt-weld end!
**) The dimensions (inside diamter x depth) refer to the socket-weld ends.
Overall lengths
End connection [mm]
[inch]
Flange Class 150 L 150 150 160 180 230 230
Flange Class 300 L 150 150 160 180 230 230
Flange Class 400 L 216 216 250
Butt-weld ends L 200 200 200 200 250 250
Socket-weld ends L 200 200 200 200 250 250
Flange PN 40 L 150 150 160 180 200 230
Flange PN 63 L 190 220 250
Weight BA 4... [kg] 4.7 5.3 5.8 7.1 10.7 12.5
Weight BAE 4... [kg] 8.8 9.4 9.9 11.2 14.8 16.6
15
½
33.4 x 3.4 42.2 x 3.6 48.3 x 3.7 60.3 x 3.9
20
¾
25
1
32
1¼
40
1½
50
2
Corrosion resistance
When used for its intended purpose, the safe functioning of the equipment will not be impaired by
corrosion.
Sizing
The valve body must not be subjected to sharp increases in pressure. The sizing and dimensional
allowances for corrosion reflect the latest state of technology.
9
10
Technical Data – continued –
MADE BY GESTRA AG
BA 47
0525
TMA 300°C
PN 63
DN
MADE BY GESTRA AG
BA 46
0525
TMA 572°F
B16.34 CL300
DN
MADE BY GESTRA AG
BA 47
0525
TMA 572°F
B16.34 CL400
DN
MADE BY GESTRA AG
BA 46
TMA 300°C
DN 25 PN 40
Name plate / marking
For pressure and temperature ratings see the designation on the valve body or the data given on the
name plate. Further details are given in various GESTRA publications, such as datasheets and technical
information.
In accordance with EN 19, the following type and design data are indicated on the name plate or body:
n Manufacturer
n Type designation
n Pressure class PN or Class
n Material number
n Maximum temperature
n Maximum pressure
n Direction of flow
n Stamp on valve body, e. g. specificies the manufacturing quarter and year
(in this case the 4
th
Nominal size
4
05
quarter of 2005)
max. admissible temperature
Nominal pressure
Letter “E”
Fig. 1
Technical Data – continued –
Dimensions BA 46, BA 47
180
DN 15-32: 172
DN 40, 50: 213DN 40, 50: 132
Fig. 2
DN 15-32: 126
20
L
11
Loading...