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GESTRA Steam Systems
DK 45
Installation Instructions 818676-00
Steam Trap
DK 45
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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) ........................................................................................................5
ATEX (Atmosphère Explosible) .................................................................................................................5
Explanatory Notes
Scope of supply ......................................................................................................................................6
Description ........................................................................................................................................... 6
Function ................................................................................................................................................6
Technical Data
Corrosion resistance ...............................................................................................................................7
Sizing .....................................................................................................................................................7
Name plate / marking .............................................................................................................................7
Design
DK 45 ....................................................................................................................................................8
Key ......................................................................................................................................................... 9
Installation
Danger .................................................................................................................................................10
DK 45 ...................................................................................................................................................10
Steam trap with flanges ....................................................................................................................... 10
Steam trap with screwed sockets ......................................................................................................... 10
Steam trap with socket-weld ends .......................................................................................................11
Steam trap with butt-weld ends ............................................................................................................ 11
Attention ............................................................................................................................................... 11
Heat treatment of welds........................................................................................................................11
Commissioning
DK 45 ...................................................................................................................................................11
Operation
DK 45 ...................................................................................................................................................11
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Contents – continued –
Page
Maintenance
Checking steam trap .............................................................................................................................12
Cleaning / replacing the regulator und the nozzle insert ........................................................................12
Cleaning / replacing the strainer ...........................................................................................................13
Tools .....................................................................................................................................................13
Torques ................................................................................................................................................13
Spare Parts
Spare parts list ....................................................................................................................................14
Decommissioning
Danger .................................................................................................................................................14
Disposal................................................................................................................................................14
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Important Notes
Usage for the intended purpose
Use steam trap 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.
For information on the application in potentially explosive areas see section “ATEX Directive 94/9/EC,
1999/92/EC” on page 5.
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
recognized level of competence.
Danger
The equipment is under pressure during operation.
When loosening flanged connections or sealing plugs, 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 equipment from both upstream and downstream
pressure.
The equipment 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.
Before carrying out any kind of maintenance work or undoing flanged connections or
sealing plugs make sure that all connected lines are depressurized (0 bar) and cooled
down to room temperature.
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 indicates the technical specification of the equipment.
Do not commission or operate a steam trap without name plate.
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Important Notes – continued –
PED (Pressure Equipment Directive)
The equipment fulfils the requirements of the Pressure Equipment Directive 97/23/EC.
DK 45 can be used with fluids of group 1 and 2.
With CE marking (apart from equipment according to section 3.3).
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 marked.
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Explanatory Notes
Scope of supply
DK 45
1 Steam trap
1 Installation manual
Description
Thermodynamic steam trap for discharging condensate with virtually not banking-up. With integrated
non-return valve and Y-type strainer. Asbestos-free body gasket (graphite).
Installation in any position.
Function
The thermodynamic steam trap features a movable valve disk that rests on a double seat. The
condensate enters the steam trap from below, thereby lifting the disk off its seat. It is then deflected
by 180° and flows through the small seat orifice into the discharge line. As the temperature of the
condensate increases, upstream pressure builds up in the space above the valve disk. When the
condensate evaporates into steam, a low-pressure area is formed under the disk due to the increased
flow velocity, forcing the disk downwards against its bearing surface and stopping all flow. Since the
pressure above the valve disk is acting on a larger surface area, the closing force is much higher
than the pressure pushing against the disk from the inlet side. As the steam loses heat, some of it
condenses, reducing the pressure above the valve disk and hence the closing force. As soon as the
pressure on top of the disk has dropped to a value that equals the opening pressure produced by the
upstream pressure, the disk is lift off its seat, and the cycle repeats itself. External factors such as
heat, wind, precipitation etc. can effect the functioning and performance of the thermodynamic steam
trap considerably. However, the DK 45 is not influenced by these environmental factors because the
regulator is protected by the permanently mounted cap.
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Technical Data
DK 45
MADE BY GESTRA
PN 40
TMA 400 °C
at 23,1 bar
DN
Corrosion resistance
When used for its intended purpose, the safe functioning of the equipment will not be impaired by
corrosion.
Sizing
The trap body must not be subjected to sharp increases in pressure.
The dimensional allowances and additives for corrosion reflect the latest state of technology.
Name plate / marking
The temperature/pressure limit is indicated on the trap body. For more information see GESTRA
technical documents such as data sheets and Technical Information.
According to EN 19 the type and design must be specified on the name plate and trap body.
■ Name/logo of the manufacturer
■ Type designation: DK 45
■ Pressure rating PN
■ Marking according to ATEX: The equipment is not Ex marked.
■ Material number
■ Max. temperature
■ Max. pressure
■ Flow direction
■ Stamp on name plate, e. g. specifies the manufacturing year and quarter,
(in this case the 1
st
quarter 2005)
1
05
Fig. 1
Nominal size
Marking
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Design
DK 45
A
B
C
D
E
F
8
G
H
I
J
Fig. 2
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Design – continued –
Key
A Hexagon-socket screw M 10 x 25
B Name plate
C Cover
D Regulator
E Bushing (interference-fitted, cannot be replaced)
F Gasket 40 x 48 x 2
G Body
H Strainer
I Gasket A 24 x 29
J Sealing plug
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Installation
Danger
Danger of severe injuries, death and destruction caused by the explosion of explosive
mixtures.
An electrically insulated installation of the equipment between pipe flanges can generate
static electricity. If the equipment is to be installed in explosive-risk areas, appropriate
measures have to be taken in order to discharge static electricity (earthing)!
DK 45
The DK 45 can be installed in horizontal and vertical lines.
In the case of a horizontal installation, make sure that the cover it at the top.
Steam trap with flanges
1. Observe correct position of installation.
2. Observe direction of flow. The flow arrow is on the trap body.
3. Consider space required for opening trap. When the trap is installed a minimum space of at least
70 mm is required for removing the cover C.
4. Remove plastic plug. They are only used as transit protection.
5. Clean seating surfaces of both flanges.
6. Install steam trap.
Steam trap with screwed sockets
1. Observe correct position of installation.
2. Observe direction of flow. The flow arrow is on the trap body.
3. Consider space required for opening trap. When the trap is installed a minimum space of at least
70 mm is required for removing the cover C.
4. Remove plastic plug. They are only used as transit protection.
5. Clean threads of screwed sockets.
6. Install steam trap.
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Installation – continued –
Steam trap with socket-weld ends
1. Observe correct position of installation.
2. Observe direction of flow. The flow arrow is on the trap body.
3. Consider space required for opening trap. When the trap is installed a minimum space of at
least 70 mm is required for removing the cover C.
4. Remove plastic plug. They are only used as transit protection.
5. Remove regulator as described in section
6. Clean socket-weld ends.
7. Apply
Steam trap with butt-weld ends
1. Observe correct position of installation.
2. Observe direction of flow. The flow arrow is on the trap body.
3. Consider space required for opening trap. When the trap is installed a minimum space of at
4. Remove plastic plug. They are only used as transit protection.
5. Remove regulator as described in section
6. Clean butt-weld ends.
7. Apply electric arc welding process (welding process 111 and 141 in accordance with
only electric arc welding process (welding process 111 and 141 in accordance with
ISO 4063).
least 70 mm is required for removing the cover C.
ISO 4063) or gas welding (welding process 3 in accordance to ISO 4063).
Maintenance.
Maintenance.
Attention
■ Only qualified welders certified e. g. according to EN 287-1 may weld the steam
trap into pressurized lines.
■ The steam trap must not be insulated.
Heat treatment of welds
A subsequent heat treatment of the welds is not required.
Commissioning
Make sure that the flanged connections of the DK 45 are tightly bolted together and leakproof.
Operation
Certain operating modes of the DK 45 may require servicing. For more information see section
Maintenance.
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Maintenance
The GESTRA steam trap DK 45 does 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.
Checking steam trap
You can check the steam trap DK 45 for loss of live steam during operation using the ultrasonic
measuring unit VAPOPHONE® or the test unit TRAPtest®.
The points of reference for the sensor are located on the name plate, Fig. 2
Should you detect any loss of live steam clean the trap and/or replace the regulator.
Cleaning / replacing the regulator und the nozzle insert
1. Observe the danger note on page 4!
2. Undo the body screws
3. Unscrew the regulator
4. Clean body, internals and all gasket surfaces.
5. Apply heat-resistant lubricant to all threads and seating surfaces of the nozzle insert and the cover
(e. g. WINIX® 2150).
6. Screw in regulator and tighten with a torque of
7. Replace gasket
gasket F when using a new cover C or the cover or another steam trap.
8. Put cover onto the trap body. Tighten body screws
of 25 Nm.
A and take the cover C off the body G.
D and insert a new regulator.
90 Nm.
F if there are visual signs of damage. Use the same cover C. Always replace
A alternately and in several steps to a torque
WINIX® 2150 is a registered trademark of WINIX GmbH, Norderstedt
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Maintenance – continued –
Cleaning / replacing the strainer
1. Observe danger note on page 4!
2. Unscrew sealing plug
3. Clean strainer, sealing plug and gasket seats.
4. Replace strainer and sealing plug in case of visible signs of wear or damage.
5. Replace gasket
6. Apply heat-resistant lubricant to the thread of the sealing plug (use for instance WINIX
7. Install sealing plug
of 120 Nm.
Tools
■ Spanner A. F. 16 mm to DIN 3113, form B
■ Spanner A. F. 22 mm to DIN 3113, form B
■ Spanner A. F. 30 mm to DIN 3113, form B
■ Torque spanner 20 – 120 Nm, ISO 6789
Torques
J and remove strainer H.
I if damaged.
J with gasket I and strainer H. Tighten sealing plug with a torque
®
2150).
Item
D
A
J
All torques are based at 20 °C room temperature.
WINIX® 2150 is a registered trademark of WINIX GmbH, Norderstedt
Designation Torque [Nm]
Regulator 090
Body screws 025
Sealing plug 120
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Spare Parts
Spare parts list
Item
D
H I J
F
I
*) Minimum order quantity: 50 pcs. Contact your local dealer for smaller quantities.
Gasket*) A24 x 29, stainless steel 375162
Designation Stock code no.
Regulator 377735
Strainer, cpl. 375113
Gasket*) 40 x 48 x 2, graphite 375159
Decommissioning
Danger
Risk of severe burns and scalds to the whole body!
Before loosening flanged connections or sealing plugs make sure that all connected lines
are depressurized (0 bar) and cooled down to room temperature.
Disposal
Dismantle the valve and separate the waste materials, using the specifications in the table “Materials”
on page 7.
For the disposal of the valve observe the pertinent legal regulations concerning waste disposal.
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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. 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 / 502 267 2205
Fax: 00 15 02 / 502 266 5397
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
818676-00/706cma · 2006 GESTRA AG · Bremen · Printed in Germany
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