Flowserve BK 15 User Manual

BK 15

Installation Instructions 810682-01

Steam Trap BK 15, DN 40-50 mm



1

Contents

Page

Important Notes

Usage for the intended purpose......................................................................................6

Safety note ......................................................................................................................6

Warning...........................................................................................................................6

Ratings pursuant to article 9 of the PED .........................................................................6

Explanatory Notes

Scope of supply ..............................................................................................................7

Description ......................................................................................................................7

Function ..........................................................................................................................7

Technical data ...........................................................................................................7 – 8

Corrosion resistance .......................................................................................................8

Sizing ..............................................................................................................................8

Name plate / marking ......................................................................................................9

Installation

BK 15 ..............................................................................................................................9

Flanged design ...............................................................................................................9

Screwed-socket design .................................................................................................10

Socket-weld design .......................................................................................................10

Butt-weld design............................................................................................................10

Heat treatment of welds ................................................................................................10

Commissioning

BK 15 ............................................................................................................................11

Adjust regulator (undercooling, controlled steam flowrate) ...........................................11

Restore factory setting ..................................................................................................11

Operation

BK 15 ............................................................................................................................11

Maintenance

Check steam trap ..........................................................................................................12

Clean/replace regulator and nozzle insert ....................................................................12

Clean/replace strainer ...................................................................................................13

Torques .........................................................................................................................13

Spare Parts

Spare parts list ..............................................................................................................14

Annex

Declaration of Conformity..............................................................................................15

2

Capacity Chart

[lb/h]

50000
40000

30000
20000

10000

8000
6000

5000
4000

3000

2000

1000

Capacity [kg/h]

20000

10000

800
600
500
400

300

200

[kg/h]

8000
6000

5000
4000

3000
2000

1000

800
600

500
400

300

200

100

0.1 0.2 0.3 0.4 0.6 0.8 1 2 3 4 6 8 10 22 bar

3

2

1

Fig. 1

1.5 2 3 4 5 6 8 10 20 30 40 50 60 80 100 200 320 psi

Differential pressure (assuming discharge to atmospheric pressure)

Condensate discharge at boiling point

1

without banking-up

2

Condensate flowrate at 30 K below
saturation temperature

3

Max. discharge capacity of
cold condensate

3

Parts Drawing

A
B
C

N

D

E

F

G

Fig. 2

4

H

I

J

K

L

M

Key

A

Union nut ¾" BSP

B

Gland ring

C

Packing
Cover

D

Adjusting screw

E

Guide ring

F
G

Regulator

H

Strainer
Bush (force-fit, no spare part)

I

Cover gasket 92.7 x 102 x 1

J

Body

K

Name plate

L

Hexagon nut M 12

M

Hexagon bolt M 12

N

5

Important Notes

Usage for the intended purpose

Use steam trap BK 15 only for the discharge of condensate in steam lines or for air
venting. Use this equipment only within the specified pressure and temperature
ratings and check corrosion resistance and chemical suitability for the application in
question.

Safety Note

The valve must only be installed by qualified staff.
Qualified staff are those persons who – through adequate training in engineering, the

use and application of safety equipment in accordance with regulations concerning
safety systems, and first aid & accident prevention – have achieved a recognised level
of competence appropriate to the installation and commissioning of this device.

Danger

The steam trap is under pressure during operation.
When loosening flanged connections, sealing plugs or the regulator hot
water or steam may escape. This presents the danger of severe burns and
scalds to the whole body.
Installation and maintenance work should only be carried out when the
system is depressurized: isolate the trap from both upstream and
downstream pressure.

The steam trap becomes hot during operation. This presents the risk of
severe burns to hands and arms. Installation and maintenance work should
only be carried out at room temperatures.

Sharp edges on internals present a danger of cuts to hands. Always wear
industrial gloves for installation and maintenance work.

Ratings pursuant to article 9 of the PED1)

Fluid

Use no yes no yes

Category I
Nominal size DN 40–50 mm 40 –50 mm

CE marking no yes
Type

1

) PED = Pressure Equipment Directive

gas liquid

1212

Exception pursuant

to article 3.3

BK 15

CL 150

BK 15

PN 40 CL 300

6

Explanatory Notes

Scope of Supply
BK 15

1 Steam trap type BK 15
1 Installation manual

Description

Thermostatic/thermodynamic steam trap with corrosion-resistant regulator unaffected
by waterhammer. The Duo stainless steel regulator is externally adjustable. With
integral strainer and non-return valve action. Asbestos-free cover gasket (graphite).
Installation in any position.

The steam trap is adjusted at our factory to discharge condensate with virtually no
banking-up. More undercooling (banking-up of condensate) can be manually adjusted
during operation from the outside.

Function

During start-up of the plant the Duo stainless steel plates are flat. The service
pressure acts in the opening direction, the valve is completely open. As the
condensate temperature rises, the plates deflect, drawing the stage nozzle towards
the closed position. As the condensate temperature sinks, the deflection of the Duo
stainless steel plates decreases and the steam trap opens at the adjusted opening
temperature.

The thermostatic and spring characteristics of the stack of plates are balanced such
that condensate is always discharged at a given undercooling temperature.
The trap provides automatic air-venting at start-up and during operation. The correct
functioning of the BK 15 is neither affected by upstream pressure variations nor by
back pressure. The BK 15 can also be used for thermal air-venting in steam systems.

Technical Data

Pressure/Temperature Ratings PN 40

Body material Forged steel 1.0460 (P250GH / C22.8) / ASTM A105
Nominal sizes (DN) 40, 50
Connections Flanged to DIN PN 40
Service pressure PMA [barg] 40 35 28 21 14.5

[psig] 580 508 406 305 210

Related temperature TMA [°C] 20 200 300 400 450

[°F] 68 392 572 752 842

7

Explanatory Notes – continued –

Technical Data – continued –

Pressure/Temperature Ratings Class 300

Body material Forged steel 1.0460 (P250GH / C22.8) / ASTM A105
Nominal sizes (DN) 40, 50
Connections Flanged to ASME Class 300
Service pressure PMA [barg] 51 43.9 38.9 34.6 20.2

Related temperature TMA [°C] 20 200 300 400 450

Pressure/Temperature Ratings Class 150

Body material Forged steel 1.0460 (P250GH / C22.8) / ASTM A105
Nominal sizes (DN) 40, 50
Connections Flanged to ASME Class 150
Service pressure PMA [barg] 19.7 14 10.2 6.5 4.6

Related temperature TMA [°C] 20 200 300 400 450

Admissible differential pressure1)2)

Differential pressure ∆PMX 22 barg (319 psig)

1

) Note pressure/temperature ratings 2) Inlet pressure minus outlet pressure

[psig] 740 637 565 500 293

[°F] 68 392 572 752 842

[psig] 287 203 149 94.3 66.7

[°F] 68 392 572 752 842

Materials EN DIN ASTM equivalent

Body P250GH (1.0460) C22.8 (1.0460) A105
Cover P250GH (1.0460) C22.8 (1.0460) A105
Bolts 42CrMo4 (1.7225) A193 B7
Body gasket graphite
Regulator stainless steel
Other internals stainless steel

Corrosion Resistance

When used for its intended purpose the safe functioning of the steam trap will not be
impaired by corrosion.

Sizing

The valve body must not be subjected to pulsating loads. The dimensional allowances
for corrosion reflect the latest state of technology.

8

Explanatory Notes – continued –

Name Plate/Marking

Nominal size

Ratings acc. to
EN ISO 26552

For further specifications according to EN 19 see trap body.

Fig. 4

Installation

Regulator
Standard design

U

30 K undercooling

BK 15

The steam trap BK 15 can be installed in any position. In the case of a horizontal
installation, make sure that the cover is at the top.

Flanged Design

1. Take care of correct position of installation.

2. Take care of flow direction. The flow arrow is on the trap body.

3. Consider space required for opening trap. When the trap is installed a minimum
space of 90 mm is required for removing cover .

4. Remove plastic plugs. They are only used as transit protection.

5. Clean seating surfaces of both flanges.

6. Install steam trap.

D

9

Installation – continued –

Screwed-Socket Design

1. Take care of correct position of installation.

2. Take care of flow direction. The flow arrow is on the trap body.

3. Consider space required for opening trap. When the trap is installed a minimum
space of 90 mm is required for removing the cover .

4. Remove plastic plugs. They are only used as transit protection.

5. Clean female threads of the screwed sockets.

6. Install steam trap.

Socket-Weld Design

1. Take care of correct position of installation.

2. Take care of flow direction. The flow arrow is on the trap body.

3. Consider space required for opening trap. When the trap is installed a minimum
space of 90 mm is required for removing the cover .

4. Remove plastic plugs. They are only used as transit protection.

5. Remove regulator as described under Maintenance.

6. Clean socket-weld ends.

7. Arc-weld trap only manually (welding process 111 and 141 in accordance with
DIN EN 24063).

Butt-Weld Design

D

D

1. Take care of correct position of installation.

2. Take care of flow direction. The flow arrow is on the trap body.

3. Consider space required for opening trap. When the trap is installed a minimum
space of 90 mm is required for removing the cover .

D

4. Remove plastic plugs. They are only used as transit protection.

5. Clean butt-weld ends.

6. Arc-weld trap only manually (welding process 111 and 141 in accordance with
DIN EN 24063) or use gas-welding process (welding process 3 in accordance with
DIN EN 24063).

Attention

■

Only qualified welders certified e. g. according to DIN EN 287 may weld
the steam trap into pressurized lines.

■

Do not insulate the steam trap.

Heat T reatment of Welds

A subsequent heat treatment of the welds is not required.

10

Commissioning

BK 15

Make sure that all flange bolts are firmly fastened, ensuring tight shut-off.

Danger

The steam trap is under pressure at start-up and during operation.
When loosening the union nut hot water or steam may escape. This

A

presents the danger of severe burns and scalds to the whole body.
The steam trap becomes hot during operation. This presents the risk of
severe burns to hands and arms. Installation and maintenance work should
only be carried out at room temperatures.
Always wear industrial gloves when adjusting the regulator.

Adjust Regulator (Undercooling, Controlled Steam Flowrate)

The regulator of the BK 15 is adjusted at our factory to close steam-tight and open as
soon as condensate is formed. If a certain undercooling and, consequently, banking-up
of condensate is required for e. g. a heating process, the trap setting can be modified at
start-up and during operation:

1. Take notice of the danger note. Slacken union nut (one turn) and turn adjustment

E

screw clockwise with a screwdriver. 1/8 turn corresponds to approx. 4 K (degC)

A

change in discharge temperature. Starting from factory setting you can turn the
adjustment screw up to 1.5 turns to the right.

E

2. If required you can also adjust a controlled steam flowrate. Starting from factory
setting turn the adjustment screw for this purpose 1.5 turns to the left.

3. Tighten union nut with a max. torque of 30 Nm.

A

E

Restore Factory Setting

The regulator of the BK 15 is adjusted at our factory to close steam-tight and open as
soon as condensate is formed. If necessary, the factory setting can be restored as
follows:

1. To depressurize the steam trap cut off steam and – in the case of back pressure –
condensate line(s). Let the trap cool down to room temperature.

2. Undo union nut and turn adjustment screw with a screwdriver clockwise until a

A

E

resistance is felt.

3. Turn adjustment screw 3 turns anticlockwise. The steam trap will now discharge

E

condensate with virtually no banking-up (factory setting).

4. Tighten union nut with a max. torque of 30 Nm.

A

Tools

■

Screwdriver 5.5/100 mm to DIN 5265, form A

■

Spanner A.F. 36 mm to DIN 3113, form B

■

Torque spanner 20 – 160 Nm to DIN ISO 6789

11

Operation

BK 15

The BK 15 requires maintenance for certain operating modes (see Maintenance).
The control unit of the BK 15 can be adjusted during operation (see Commissioning).

Maintenance

GESTRA steam traps type BK 15 do not require any special maintenance. However, if
used in new installations which have not been rinsed it may be necessary to check and
clean the trap.

Check Steam Trap

You can check the steam trap BK 15 for steam loss during operation using the
ultrasonic measuring unit VAPOPHONE

®

or the test unit TRAP

test

®

.

Should you detect any loss of live steam clean the trap and/or replace the regulator.

Clean/Replace Regulator

1. Take notice of the note “Danger” on page 6.

2. Undo hexagon bolts . Remove cover from the body .

3. Remove and clean regulator .

4. Replace regulator in case of visible signs of wear or damage.

N

G

G

D K

5. Clean body, internals and all gasket surfaces.

6. Apply heat-resistant lubricant to all threads and the seating surface of the nozzle
insert and the cover (use for instance WINIX

®

2150).

7. Screw in regulator and tighten with a torque of 140 Nm.

8. Insert new gasket .

9. Place cover onto the body. Tighten hexagon bolts alternately and in several steps

J

N

to a torque of 45 Nm.

Tools

■

Spanner A. F. 32 mm to DIN 3113, form B

■

Spanner A. F. 18 mm to DIN 3113, form B

■

Torque spanner 20 – 160 Nm to DIN ISO 6789

WINIX® 2150 is a registered trademark of WINIX GmbH, Norderstedt

12

Maintenance – continued –

Clean/Replace Strainer

1. Take notice of note “Danger” on page 6.

2. Undo hexagon bolts . Remove cover from the body .

3. Remov e regulator .

4. Remov e and clean strainer .

5. Clean body, internals and all gasket surfaces.

6. Apply heat-resistant lubricant to all threads and the seating surface of the nozzle
insert and the cover (use for instance WINIX

7. Insert strainer .

8. Screw in regulator and tighten with a torque of 140 Nm.

9. Insert new gasket .

10. Place cover onto the body. Tighten hexagon bolts alternately and in several
steps to a torque of 45 Nm.

Tools

■

Spanner A. F. 18 mm to DIN 3113, form B

■

Torque spanner 20 – 160 Nm to DIN ISO 6789

Torques

Item Designation Torque [Nm]

G
N
A

All torques given in the table are based at a room temperature of 20°C. Threads without lubricant.

N D K

G

H

H

G

J

Regulator 140

Hexagon bolts 45

Union nuts 30

®

2150).

N

WINIX® 2150 is a registered trademark of WINIX GmbH, Norderstedt

13

Spare Parts

Spare Parts List

Item

GCJC
H
J

*) Minimum purchasing quantity 20 pcs. For smaller quantities please contact your local dealer.

Gasket*) 92.7 x 102 x 1, graphite 375699 375699

Designation

Packing*) 9 x 14 x 7 376552 376552

Regulator 098847 098847

Strainer, complete 375698 375698

Stock code Stock code

DN 40 DN 50

14

Annex

Declaration of Conformity

We hereby declare that the pressure equipment BK 15, DN 40 - 50 mm conforms to
the following European Directive:

■

EC Pressure Equipment Directive (PED) No. 97/23 of 29 May 1997
Steam traps are pressure equipment as defined in article 1, section 2.1.4 of the PED.
Applied conformity assessment procedure: Module A as described in Annex III.

This declaration is no longer valid if modifications are made to the equipment without
consultation with us.

Bremen, 28th September 2001

GESTRA GmbH

Head of the Design Dept.

Uwe Bledschun

Academically qualified engineer

Quality Assurance Representative

Lars Bohl

Academically qualified engineer

15

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®

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A Unit of Flowserve Corporation

810682-01/702c · ©2001 GESTRA GmbH · Bremen · Printed in Germany

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