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GESTRA Steam Systems
BK 27N
Installation Instructions 818627-00
Steam Trap
BK 27N, DN 40- 50
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Page 2
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Contents
Page
Important Notes
Usage for the intended purpose ..............................................................................................................4
Safety note ............................................................................................................................................. 4
Danger ...................................................................................................................................................4
Attention .................................................................................................................................................4
PED (Pressure Equipment Directive) ........................................................................................................4
ATEX (Atmosphère Explosible) .................................................................................................................4
Explanatory Notes
Scope of supply ...................................................................................................................................... 5
Description ............................................................................................................................................. 5
Function .................................................................................................................................................5
Design ....................................................................................................................................................5
Technical Data
Pressure / temperature ratings ...............................................................................................................6
Corrosion resistance ............................................................................................................................... 6
Sizing .....................................................................................................................................................6
Name plate / marking .............................................................................................................................. 6
Design
Component parts BK 27N ........................................................................................................................7
Key .........................................................................................................................................................8
Installation
BK 27N ...................................................................................................................................................9
Flanged design ....................................................................................................................................... 9
Socket-weld design ................................................................................................................................ 9
Butt-weld design ..................................................................................................................................10
Attention ...............................................................................................................................................10
Heat treatment of welds .......................................................................................................................10
Commissioning
BK 27N ................................................................................................................................................11
Attention ..............................................................................................................................................11
Setting the regulator (undercooling, controlled steam flow) .................................................................. 11
Restoring factory settings ....................................................................................................................11
Operation
BK 27N .................................................................................................................................................12
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Contents continued
Page
Maintenance
Check steam trap .................................................................................................................................12
Clean / replace bimetallic regulator and strainer .................................................................................... 12
Tools .....................................................................................................................................................12
Torques ................................................................................................................................................ 13
Spare Parts
Spare parts list ....................................................................................................................................13
Annex
Declaration of Conformity ............................................................................................................... 14
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Important Notes
Usage for the intended purpose
Use steam trap BK 27N only for the discharge of condensed water in pipe lines or for air-venting within
the admissible pressure/temperature ratings.
Check the corrosion resistance and chemical suitability of the steam trap for the application in question.
Safety note
The equipment must only be installed and commissioned by qualified staff.
Maintenance and service work must only be performed by adequately trained persons who have
a recognised level of competence.
Danger
The steam trap is under pressure during operation.
When loosening flanged connections, plugs or the regulator, hot water and/or steam may
escape. This presents the risk of severe scalding.
Installation and maintenance work should only be carried out when the system is
depressurized (0 bar): isolate the trap from both upstream and downstream pressure.
The trap becomes hot during operation. This presents the danger of severe burns to
hands and arms. Installation and maintenance work should only be carried out when
the system is cold (20 °C).
Sharp edges on internal parts present a danger of cuts to hands. Always wear industrial
gloves when replacing the regulator or the strainer.
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 fulfills the requirements of the PED 97/23/EC. The equipment can be used with fluids
of group 2. With CE marking (except equipment according to section 3.3 of the PED).
ATEX (Atmosphère Explosible)
The equipment does not have its own potential source of ignition and is therefore not subject to the
ATEX Directive 94/9/EC.
The equipment can be used in potentially explosive areas 0, 1, 2, 20, 21, 22 (1999/92/EC).
The equipment is not Ex market.
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Explanatory Notes
Scope of supply
BK 27N:
1 Steam trap BK 27N
1 Installation manual
Description
Thermostatic steam trap with corrosion-resistant thermostatic element (Duo stainless steel bimetallic
regulator, externally adjustable) unaffected by waterhammer. With internal Y-type strainer, integrated
non-return valve and asbestos-free cover gasket (graphite). Installation in any position.
The default factory setting allows the steam trap to discharge condensate with virtually no banking-up. For
more undercooling the settings of the installed, depressurized steam trap can be modified externally.
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. BK 27N can also be used for
thermal air-venting in steam systems.
Design
BK 27N:
For installation in horizontal and vertical pipes.
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Technical Data
Pressure / temperature ratings
BK 27N:
For the pressure and temperature ratings, see the designation on the body or the data given on the name
plate: Pressure PN/Class, material number, max. temperature, max. pressure, max. differential pressure.
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 sharp increases in pressure. The sizing and dimensional
allowances for corrosion reflect the latest state of technology.
Name plate / marking
For the pressure and temperature ratings, see the designation on the trap 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 the body / name plate, e. g. specificies the manufacturing quarter and year
(in this case the 3
rd
quarter of 2005).
3
05
Fig. 1
Nominal size
Page 7
Design
Component parts BK 27N
I
J
A
B
C
D
E
Fig. 2
F
G
H
I
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Design continued
Key
A Sealing plug ¼" A
B Gasket A 14 x 18, 1.4301, DIN 7603
C Cover
D Bimetallic regulator
E Strainer
F Gasket 92.7 x 102 x 1
G Body
H Bush (interference fit, not a spare part!)
I Hexagon-head screw M 16, DIN 2510-5
J Bolt with waisted shank, form L, DIN 2510, M 16 x 80, A.F. 10
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Installation
BK 27N
The steam trap BK 27N can be installed in horizontal or vertical position, but the flow direction arrow
must be taken into account. In the case of a horizontal installation, the cover should be 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
is required for removing cover C.
4. Remove plastic plugs. They are only used as transit protection.
5. Clean seating surfaces of both flanges.
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
is required for removing the cover C.
4. Remove plastic plugs. They are only used as transit protection.
5. Remove regulator as described under
6. Clean socket-weld ends.
7. Arc-weld trap only manually (welding process 111 and 141 in accordance with DIN EN 24063).
Maintenance.
100 mm
100 mm
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Installation continued
Butt-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
is required for removing the cover C.
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
n Only qualified welders certified e. g. according to DIN EN 287 may weld the steam trap
into pressurized lines.
n Do not insulate the steam trap.
Heat treatment of welds
A subsequent heat treatment of the welds is not required provided that the pipe is made from a
material similar to that used for the steam trap.
If, however, heat treatment is necessary, make sure that the treatment is limited to the area
immediately around the weld. Should this not be possible remove the bimetallic regulator before
carrying out the heat treatment.
100 mm
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Commissioning
BK 27N
Make sure that the flanged connections of the BK 27N are permanently bolted and tight.
Attention
The equipment is under pressure during commissioning and operation. When loosening
the sealing plug A in order to chance the settings of the regulator, hot water or steam
will escape. The force of the flowing steam will throw the sealing plug out.
This presents the risk of severe burns and scalds to the whole body. The equipment is hot
during operation. This presents the risk of severe burns to hands and arms.
Always wear industrial gloves when changing the regulator settings. Installation and
maintenance work should only be carried out when the system is depressurised (zero
bar). Isolate the equipment from both upstream and downstream pressure.
Setting the regulator (undercooling, controlled steam flow)
The default factory of the bimetallic regulator of the BK 27N ensures steam-tight shut-off and the
discharge of condensate with virtually no banking up.
Settings for a larger amount of undercooling (banking-up of condensate):
1. Depressurise the steam trap and wait until it has cooled down to room temperature (20 °C).
2. Unscrew sealing plug
3. Use a screwdriver to turn the nozzle stem of the bimetallic regulator
¼ turn corresponds to approx. 8K change in temperature. Max. 1½ turns to the right starting from
factory setting are possible.
4. Tighten sealing plug
Settings for controlled steam flow
1. Depressurise the steam trap and wait until it has cooled down to room temperature (20 °C).
2. Unscrew sealing plug
3. Use a screwdriver to turn the nozzle stem of the bimetallic regulator
¼ turn corresponds to approx. 8K change in temperature. Max. 1½ turns to the left starting from
factory setting are possible.
4. Tighten sealing plug
A.
D to the right.
A with a torque of 40 Nm.
A.
D to the left.
A with a torque of 40 Nm.
Restoring factory settings
1. Depressurise the steam trap and wait until it has cooled down to room temperature (20 °C).
2. Unscrew sealing plug
3. Use a screwdriver to turn the nozzle stem of the bimetallic regulator
the stop. Then turn it 3 ¼ to the left.
4. Tighten sealing plug
A.
D to the right until it hits
A with a torque of 40 Nm.
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Operation
BK 27N
Certain operating conditions make servicing of the BK 27N necessary (see section Maintenance).
Maintenance
GESTRA steam traps type BK 27N 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 27N for steam loss during operation using the ultrasonic measuring
unit VAPOPHONE® or the test unit TRAPtest®.
Should you detect any loss of live steam clean the trap and/or replace the regulator.
Clean / replace bimetallic regulator and strainer
1. Take heed of the note “Danger” on page 4.
2. Undo bolts
3. Remove and clean regulator
4. Remove and clean strainer
5. Clean body
6. Replace regulator
7. Apply heat-resistant lubricant to all threads and seating surfaces (use for instance WINIX
8. Insert new gasket
9. Insert strainer
10. Screw in regulator
11. Put cover
to a torque of 90 Nm.
J. Remove cover C from the body G.
D.
E.
G, internals and all seating surfaces.
D in case of visible signs of wear or damage.
®
2150).
F.
E.
D and tighten with a torque of 350 Nm.
C onto the body G. Tighten bolts J and nuts I alternately and in several steps
Tools
n Combination spanner 32 A.F., DIN 3113, form B
n Combination spanner 18 A.F., DIN 3113, form B
n Combination spanner 19 A.F., DIN 3113, form B
n Open-end spanner 10 A.F., DIN 3110, ISO 3318
n Torque spanner 20 – 120 Nm, DIN ISO 6789
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Maintenance continued
Torques
Item
D
J I
A
Designation Torques [Nm]
Regulator 350
Bolts, nuts 90
Sealing plug 40
All torques given in the table are based at an ambient temperature of 20 °C.
WINIX® 2150 is a registered trademark of WINIX GmbH, Norderstedt
Spare Parts
Spare parts list
Item
D
Regulator BK 27N3), compl., incl. gasket F
A
B
Gasket for sealing plug (A 14 x 8) 000992
F
E
3
) Note: The regulator of the BK 27N does not fit into the body of the BK 27!
4
) 20 pcs. Contact your local dealer for smaller quantities.
Designation Stock code
Sealing plug ¼“ A 096178
Gasket4) 92.7 x 102 x 1 376677
Strainer 097018
376607
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Annex
Declaration of Conformity
We hereby declare that the equipment BK 27N conforms to the following European Directives:
n EC Pressure Equipment Directive (PED) 97/23/EC dated 29 May 1997, apart from the equipment
according to section 3.3
n Applied conformity assessment procedure according to: Annex III, Module H, verified by the
Notified Body
0525.
This declaration is no longer valid if modifications are made to the equipment without consultation
with us.
.
Dipl.-Ing. Uwe Bledschun
Head of Design Dept.
Bremen, den 30th November 2004
GESTRA AG
Dipl.-Ing. Lars Bohl
Quality Assurance Representative
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For your notes
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Agencies all over the world:
www.gestra.de
España
GESTRA ESPAÑOLA S.A.
Luis Cabrera, 86-88
E-28002 Madrid
Tel. 00 34 91 / 5 15 20 32
Fax 00 34 91 / 4 13 67 47; 5 15 20 36
E-mail: aromero@flowserve.com
Great Britain
Flowserve Flow Control (UK) Ltd.
Burrel Road, Haywards Heath
West Sussex RH 16 1TL
Tel. 00 44 14 44 / 31 44 00
Fax 00 44 14 44 / 31 45 57
E-mail: gestraukinfo@flowserve.com
Italia
Flowserve S.p.A.
Flow Control Division
Via Prealpi, 30
l-20032 Cormano (MI)
Tel. 00 39 02 / 66 32 51
Fax 00 39 02 / 66 32 55 60
E-mail: infoitaly@flowserve.com
Polska
GESTRA POLONIA Spolka z.o.o.
Ul. Schuberta 104
PL - 80-172 Gdansk
Tel. 00 48 58 / 3 06 10 -02 od 10
Fax 00 48 58 / 3 06 33 00
E-mail: gestra@gestra.pl
Portugal
Flowserve Portuguesa, Lda.
Av. Dr. Antunes Guimarães, 1159
Porto 4100-082
Tel. 0 03 51 22 / 6 19 87 70
Fax 0 03 51 22 / 6 10 75 75
E-mail: jtavares@flowserve.com
USA
Flowserve GESTRA U.S.
2341 Ampere Drive
Louisville, KY 40299
Tel.: 00 15 02 / 4 95 01 54, 4 95 17 88
Fax: 00 15 02 / 4 95 16 08
E-mail: dgoodwin@flowserve.com
GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen
Münchener Str. 77, D-28215 Bremen
Telephone +49 (0) 421 35 03 - 0
Fax +49 (0) 421 35 03 -393
E-Mail gestra.ag@flowserve.com
Internet www.gestra.de
818627-00/306cm · © 2001 GESTRA AG · Bremen · Printed in Germany
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