GESTRA Steam Systems
BK 45
BK 45U
BK 46
Installation Instructions 810437-06
Steam Traps BK 45, BK 45U, BK 46
EN
English
1
2
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
Technical Data
Corrosion resistance ............................................................................................................................... 6
Name plate / marking ............................................................................................................................. 6
Component Parts
Component parts BK 45, BK 45U, BK 46 .................................................................................................7
Key .........................................................................................................................................................8
Installation
BK 45, BK 45U, BK 46 .............................................................................................................................9
Danger ...................................................................................................................................................9
Installation instructions ...........................................................................................................................9
Attention .................................................................................................................................................9
Heat treatment of welds........................................................................................................................10
Tools .....................................................................................................................................................10
Commissioning Procedure
Danger .................................................................................................................................................10
Operation
Attention ...............................................................................................................................................10
Contents – continued –
Page
Maintenance
Danger .................................................................................................................................................11
BK 45, BK 45U, BK 46 ...........................................................................................................................11
Checking steam traps ...........................................................................................................................11
Cleaning / exchanging Thermovit regulator and nozzle insert ................................................................ 11
Cleaning / replacing strainer ................................................................................................................. 12
Tools .....................................................................................................................................................13
Tightening torques ................................................................................................................................13
Spare Parts
BK 45, BK 45U, BK 46 ...........................................................................................................................13
Spare parts list .....................................................................................................................................13
Decommissioning
Danger .................................................................................................................................................14
Attention ...............................................................................................................................................14
Disposal................................................................................................................................................14
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4
Important Notes
Usage for the intended purpose
Use steam trap only for discharging condensate or air-venting from steam lines. Use the equipment
only within the allowable pressure and temperature ratings and only if the chemical and corrosive
influences on the equipment are taken into account.
Safety note
Installation, commissioning, retrofitting and maintenance work must only be performed by qualified
staff who – through adequate training – have achieved a recognised level of competence.
Danger
The equipment is under pressure and hot during operation. Risk of severe burns and
injuries to the whole body.
Installation and maintenance work should only be carried out when the system is depressurized (0 bar) and cold (20 °C).
The equipment must be isolated and vented from both upstream and downstream pressure before installation or maintenance work is performed.
Sharp edges on internals present a danger of cuts to hands.
Always wear industrial gloves when servicing the equipment.
Attention
The name plate specifies the technical features of the equipment.
Do not commission or operate any item of equipment that does not bear its specific
name plate. The pressure and temperature ratings on the name plate of the equipment
must meet the requirementes of the installation.
PED (Pressure Equipment Directive)
The equipment fulfills the requirements of the Pressure Equipment Directive PED 97/23/EC.
For use with fluids of group 2.
The equipment is excluded from the scope of the PED according to section 3.3 and must not bear a CE
marking.
ATEX (Atmosphère Explosible)
The equipment does not have ist own potential source of ignition and is therefore not subject to the
ATEX Directive 94/9/EC.
Applicable in Ex zones 0, 1, 2, 20, 21, 22 (1999/92/EC). The equipment is not Ex marked.
Explanatory Notes
Scope of supply
BK 45:
1 Steam trap BK 45
1 Installation manual
Description
Thermostatic/thermodynamic steam trap with corrosion resistant Thermovit® regulator (bimetallic
plates) able to withstand waterhammer. With internal strainer and integral non-return valve action.
Asbestos-free body gasket (graphite/CrNi).
The standard version discharges the condensate with virutally no banking-up, the version “U” with
approx. 30 K undercooling.
Function
During start-up of the plant the steam trap is completely open. Cold condensate and air are discharged. As the temperature rises, the bimetallic plates deflect, drawing the stage nozzle towards the
closed position.
Just before the condensate reaches saturated steam temperature the orifice will be shut off tight.
The thermodynamic effect of the stage nozzle chamber assists in the closing process.
The steam trap provides automatic air-venting at start-up and during operation of the plant and can
also be used for thermal air-venting.
BK 45U:
1 Steam trap BK 45U
1 Installation manual
BK 46:
1 Steam trap BK 46
1 Installation manual
5
6
Technical Data
DN 15 CLASS 150
PMA 1960 bar
PMX 1900 bar
MADE BY GESTRA
TMO 20 °C5
at 1300 bar
TMA 425 °C
BK 4...
Corrosion resistance
If the equipment is used for the intended purpose, its safety is not impaired by corrosion.
Name plate / marking
The temperature/pressure ratings are indicated on the trap body or on the name plate.
For more information see GESTRA technical documents such as data sheets and the Technical
Information.
The name plate or the trap body indicate the type and design:
Name/logo of the manufacturer
Type designation
Pressure class PN or Class
Material number
Max. temperature
Max. pressure
Direction of flow
Stamp on trap body, e. g. specifies the quarter and the year of production
(example: 4th quarter 2009)
Type designation
Max. allowable pressure
Max. allowable temperature
4
09
Nominal size
Type of regulator
U
Pressure rating
Max. operating temperature
at operating pressure ... bar
Max. differential pressure
Fig. 1
Component Parts
Component parts BK 45, BK 45U, BK 46
1
2
3
Fig. 2
Space required for
servicing = 70 mm
4
5
6
4
7
8
9
0
7
8
Componen Parts – continued –
Key
1 Hexagon-head screw M 10 x 25
2 Name plate
3 Cover
4 Thermovit regulator
5 Bushing (interference fitted, no spare part)
6 Gasket 40 x 48 x 2
7 Enclosure
8 Strainer
9 Gasket A 24 x 29
0 Sealing plug
Installation
BK 45, BK 45U, BK 46
When installing the steam trap make sure that the flow arrow on the trap body matches the direction
of flow of the steam. Preferred installation of the steam trap with the strainer insert hanging downwards to facilitate cleaning. Other installation orientations are possible, please consult the factory with
installation details. We recommend not to insulate the steam trap.
Danger
The equipment is under pressure and hot during operation. Risk of severe burns and
injuries to the whole body.
Installation and maintenance work should only be carried out when the system is depressurized (0 bar) and cold (20 °C).
The equipment must be isolated and vented from both upstream and downstream pressure before installation or maintenance work is performed.
Sharp edges on internals present a danger of cuts to hands.
Always wear industrial gloves when servicing the equipment.
Installation instructions
1.
Make sure that the flow arrow on the trap body matches the direction of flow of the steam.
2. Consider space required for servicing the trap. When the trap is installed a minimum withdrawal
space for servicing is required for removing trap parts (see Design, Component Parts BK...).
3. Remove plastic plugs. They are only used as transit protection.
4. Clean end connections.
5.1 Install steam trap with releasable end connections (e. g. flanges).
5.2 For equipment with socket-weld ends or butt-weld ends: Apply arc welding processes 111 and 141
according to ISO 4063 (or equivalent standard).
Attention
Welded trap installation should only be performed by qualified welders (certified ac-
cording to DIN EN 287 or equivalent).
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10
Installation – continued –
Heat treatment of welds
A subsequent heat treatment of the welds is not required.
Tools
Combination spanner A. F. 16 mm, DIN 3113, Form B
Combination spanner A. F. 22 mm, DIN 3113, Form B
Torque spanner (US: torque wrench) 20-120 Nm, ISO 6789
Commissioning Procedure
Make sure that all connections are subjected to a suitable pressure test according to the pertinent
rules and regulations.
Danger
The equipment is under pressure and hot during operation. Risk of severe burns and
injuries to the whole body.
Installation and maintenance work should only be carried out when the system is depressurized (0 bar) and cold (20 °C).
The equipment must be isolated and vented from both upstream and downstream pressure before installation or maintenance work is performed.
Sharp edges on internals present a danger of cuts to hands.
Always wear industrial gloves when servicing the equipment.
Operation
Attention
Drain steam trap if the installation is shut down and ambient temperatures ≤ 0 °C (frost)
are to be expected.
Maintenance
Periodic testing and maintenance of the trap is recommended to ensure proper functioning.
Continuous monitoring is recommended for critical applications.
Danger
The equipment is under pressure and hot during operation. Risk of severe burns and
injuries to the whole body.
Installation and maintenance work should only be carried out when the system is depressurized (0 bar) and cold (20 °C).
The equipment must be isolated and vented from both upstream and downstream pressure before installation or maintenance work is performed.
Sharp edges on internals present a danger of cuts to hands.
Always wear industrial gloves when servicing the equipment.
BK 45, BK 45U, BK 46
GESTRA steam traps BK 45, BK 45U and BK 46 do not require any special maintenance.
However, If used in new installations which have not been rinsed check and clean the Thermovit regulator after the commissioning procedure.
Checking steam traps
You can check the GESTRA steam traps BK 45, BK 45U and BK 46 for correct operation using the
GESTRA ultrasonic measuring unit VAPOPHONE® or TRAPTEST®.
We recommend that you perform the measurement at the lower part of the cover 3.
Should you detect any loss of live steam clean the steam trap or discard and replace the Thermovit
regulator (see table List of Spare Parts).
Cleaning / exchanging Thermovit regulator and nozzle insert
1. Unscrew body screws
2. Unscrew and clean Thermovit regulator
3. Discard and replace Thermovit regulator
of Spare Parts).
4. Clean body and internals. Clean all gasket surfaces.
5. Apply heat-resistant lubricant to all threads, the seating surfaces of the nozzle insert and the cover
(use for instance OKS® 217)
6. Screw in Thermovit regulator and tighten with the torque indicated in the table
tightening.
7. Gasket
6 must be discarded and replaced if there are visible signs of damage. Use the same cover
1 and remove cover 3 from body 7.
4.
4 in case of visible signs of wear or damage (see table List
Torques required for
3. Always discard and replace gasket 6 when using a new cover 3 or the cover of another steam
trap (see table List of Spare Parts).
8. Put cover onto body. Tighten body screws
cated in the table Torques required for tightening.
OKS® 217 is a registered trademark of OKS Schmierstoffe GmbH, München, Germany
1 alternately and in several steps with the torque indi-
11
12
Maintenance
Cleaning / replacing strainer
1. Unscrew sealing plug 0 and strainer 8.
2. Clean strainer, sealing plug and gasket surfaces.
3. Discard and replace strainer and sealing plug in case of visible signs of wear or damage (see table
List of Spare Parts).
4. Discard and replace gasket
5. Apply heat-resistant lubricant to the thread of the sealing plug (e. g.OKS
6. Unscrew sealing plug
with the torque indicated in the table Torques required for tightening.
Tools
Combination spanner A. F. 16 mm, DIN 3113, Form B
Combination spanner A. F. 22 mm, DIN 3113, Form B
Combination spanner A. F. 30 mm, DIN 3113, Form B
Torque spanner (US: torque wrench) 20-120 Nm, ISO 6789
Tightening torques
9 if damaged (see table List of Spare Parts ).
®
217).
0 with gasket 9 and strainer 8. Screw in Thermovit regulator and tighten
Item
4
1
0
All torques indicated in the table are based at a room temperature of 20 °C.
OKS® 217 is a registered trademark of OKS Schmierstoffe GmbH, München, Germany
Designation Torque [Nm]
Thermovit® regulator 90
Body screws 25
Sealing plug 75
Spare Parts
BK 45, BK 45U, BK 46
4
6
8
9
0
Fig. 3
Spare parts list
Item
4
8 9 0
6
9
*) Minimum purchasing quantity 50 items. For smaller quantities please contact your local dealer.
Gasket*) A 24 x 29, stainless steel 375 162 375162 375162
Designation
Thermovit regulator 375 234 375235 375464
Strainer set, cpl. 375 113 375113 375113
Gasket*) 40 x 48 x 2, graphite 375 159 375159 375159
Stock code
BK 45
Stock code
BK 45U
Stock code
BK 46
13
14
Decommissioning
Danger
The equipment is under pressure and hot during operation. Risk of severe burns and
injuries to the whole body.
Installation and maintenance work should only be carried out when the system is depressurized (0 bar) and cold (20 °C).
The equipment must be isolated and vented from both upstream and downstream pressure before installation or maintenance work is performed.
Sharp edges on internals present a danger of cuts to hands.
Always wear industrial gloves when servicing the equipment.
Attention
Drain steam trap if the installation is shut down and ambient temperatures ≤ 0 °C (frost)
are to be expected.
Disposal
For the disposal of the equipment observe the pertinent legal regulations concerning waste disposal.
For your notes.
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Agencies all over the world:
www.gestra.de
GESTRA
España
GESTRA ESPAÑOLA S.A.
Luis Cabrera, 86-88
E-28002 Madrid
Tel. 0034 91 / 5 15 20 32
Fax 0034 91 / 4 13 67 47; 5 15 20 36
E-mail: aromero@flowserve.com
Great Britain
Flowserve GB Limited
Abex Road
Newbury, Berkshire RG14 5EY
Tel. 0044 16 35 / 46 99 90
Fax 0044 16 35 / 3 60 34
E-mail: gestraukinfo@flowserve.com
Italia
Flowserve S.p.A.
Flow Control Division
Via Prealpi, 30
l-20032 Cormano (MI)
Tel. 0039 02 / 66 32 51
Fax 0039 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. 0048 58 / 3 06 10 - 02
0048 58 / 3 06 10 - 10
Fax 0048 58 / 3 06 33 00
E-mail: gestra@gestra.pl
Portugal
Flowserve Portuguesa, Lda.
Av. Dr. Antunes Guimarães, 1159
Porto 4100-082
Tel. 00351 22 / 6 19 87 70
Fax 00351 22 / 6 10 75 75
E-mail: jtavares@flowserve.com
USA
Flowserve GESTRA U.S.
2341 Ampere Drive
Louisville, KY 40299
Tel. 001 502 / 267-2205
FaxL 001 502 / 266-5397
E-mail: FCD-Gestra-USA@flowserve.com
GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen
Münchener Str. 77, D-28215 Bremen
Telephone 0049 (0) 421 / 35 03 -0
Fax 0049 (0) 421 / 35 03 - 393
E-Mail gestra.ag@flowserve.com
Internet www.gestra.de
810437-06/12-2009cm (808837-00) · GESTRA AG · Bremen · Printed in Germany
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