Flowserve PA46 User Manual

GESTRA Steam Systems

PA 46
PA 47
MPA 46
MPA 47

Installation Instructions 81844700

RapidAction Intermittent Valve for Removing Boiler Sludge
PA 46, PA 47, MPA 46, MPA 47

1

2

Contents

Page

Important Notes

Usage for the intended purpose ..............................................................................................................4

Safety note .............................................................................................................................................4

Danger ...................................................................................................................................................4

Classification pursuant to Article 9 of the Pressure Equipment Directive (PED) 97/23/EC .........................

Classification pursuant to Annex 1 of ATEX Directive 94/9/EC ..................................................................5

Explanatory Notes

Scope of supply ......................................................................................................................................6

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

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

Technical Data

End connection .......................................................................................................................................8

Pressure ratings .....................................................................................................................................8

Materials ................................................................................................................................................8

Pressure & temperature ratings ..............................................................................................................8

Corrosion resistance ...............................................................................................................................9

Sizing .....................................................................................................................................................9

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

Capacity chart PA 46, PA 47, MPA 46, MPA 47 ......................................................................................10

Control pressure chart MPA 46, MPA 47 ................................................................................................11

5

Design

PA 46, PA 47 .........................................................................................................................................12

MPA 46, MPA 47 ...................................................................................................................................13

Key .......................................................................................................................................................14

Installation

PA 46, PA 47, MPA 46, MPA 47 .............................................................................................................15

Flanged design .....................................................................................................................................15

Socketweld design ..............................................................................................................................15

Buttweld design .................................................................................................................................16

Heat treatment of welds .......................................................................................................................16

Mounting of hand lever ........................................................................................................................16

Commissioning

PA 46, PA 47, MPA 46, MPA 47 ............................................................................................................16

Operation

Duration and frequency of intermittent boiler blowdown .......................................................................17

Contents  continued 

Page

Emergency operation MPA 46, MPA 47

Danger .................................................................................................................................................17

Fit hand lever for emergency operation .................................................................................................17

Maintenance

Danger .................................................................................................................................................17

Replacing stuffing box PA 46, PA 47 ......................................................................................................18

Replacing stuffing box, valve seat and valve plug PA 46, PA 47 .............................................................19

Replacing stuffing box MPA 46, MPA 47 ................................................................................................20

Replacing stuffing box, valve seat and valve plug MPA 46, MPA 47 .......................................................21

Retightening stuffing box ......................................................................................................................22

Replacing control membrane in diaphragm actuator MPA 46, MPA 47 ...................................................22

Torques ................................................................................................................................................23

Tools .....................................................................................................................................................23

Single parts of stuffing box, valve plug, valve seat .................................................................................24

Mounting/removing valve seat ..............................................................................................................25

Mounting/removing control membrane .................................................................................................26

Key .......................................................................................................................................................27

Retrofitting

Danger .................................................................................................................................................27

Mounting diaphragm actuator ...............................................................................................................27

Mounting forkhead................................................................................................................................28

Tools .....................................................................................................................................................28

Torques ................................................................................................................................................28

Spare Parts

Spare parts list .....................................................................................................................................29

Parts for retrofitting

List of parts for retrofitting ....................................................................................................................30

Decommissioning

Danger .................................................................................................................................................30

Disposal................................................................................................................................................30

Annex

Declaration of Conformity .....................................................................................................................31

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4

Important Notes

Usage for the intended purpose

PA 46, PA 47, MPA 46, MPA 47:

Use the rapid-action intermittent valves*) only for removing boiler water containing accumulated
nonmetallic sediments from steam boilers within the admissible pressure und temperature ratings.

Use only compressed air (at room temperature) or pressurized water (at room temperature) as control
fluid for the GESTRA diaphragm actuator in accordance with the specified pressure/temperature
ratings.

Application in potentially explosive atmospheres as classified according to Annex I of ATEX Directive
94/9/EC.

*) Please note:
In British English an intermittent valve for removing boiler sludge is referred to as “(intermittent)
bottom blowdown valve”.

In American English the term “(intermittently operating) blowoff valve” is used, but only in
conjunction with a slowopening valve (ASME code).

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.

Before carrying out installation and maintenance work make sure the system is
depressurized.
Isolate the valve from both upstream and downstream pressure.
Depressurize control lines!

The valve becomes hot during operation.
This presents the risk of severe burns to hands and arms.
Before carrying out installation and maintenance work make sure that the valve is cold.

Risk of severe burns and scalds to the whole body!
Before carrying out any maintenance work on the valve or loosening flanged
connections, stuffing box unions or sealing plugs make sure that all connected lines
are depressurized (zero bar) and cooled down to room temperature (20 °C).

During operation moving internals can pinch one’s hands or fingers, causing severe
injuries. Do not touch the valve during operation! The intermittent valves for removing
boiler sludge MPA 46, MPA 47 are time controlled and can open and close abruptly.

Sharp edges on internals present a danger of cuts to hands. Always wear industrial
gloves when replacing the packing, valve seat or valve plug!

Important Notes  continued 

Classification pursuant to Article 9 of the Pressure Equipment Directive (PED) 97/23/EC

Type

Fluid Gas, steam Liquid Gas, steam Liquid

Fluid group 1 2 1 2 1 2 1 2

Application no yes no yes no yes no yes

Type

MPA 46 CL 150 20, 25, 32, 40, 50

MPA 46 CL 300 20, 25, 32 40, 50

MPA 46 PN 40 20, 25, 32 40, 50

MPA 47 CL 400 25 40, 50

MPA 47 PN 63 25 40, 50

PA 46 CL 150 20, 25, 32, 40, 50

PA 46 CL 300 20, 25, 32 40, 50

PA 46 PN 40 20, 25, 32 40, 50

PA 47 CL 400 25 40, 50

PA 47 PN 63 25 40, 50

PN CLASS

CE Marking no

PA 46, PA 47 MPA 46, MPA 47

Nominal size DN

Exception pursuant to article 3.3 Category I

0525

Classification pursuant to Annex 1 of ATEX Directive 94/9/EC

Type

Equipment group II II

Equipment category 2 2

Potentially explosive atmosphere (1999/92/EC) 1, 2, 21, 22 1, 2, 21, 22

CE Marking / EX Marking

Marking “X”

PA 46, PA 47 MPA 46, MPA 47

II 2 G/D c X

The equipment itself does not generate inadmissibly high
surface temperatures. The user must make sure that the
operating fluid does not generate inadmissibly high surface
temperatures.

II 2 G/D c X

5

6

Explanatory Notes

Scope of supply

PA 46

1 Intermittent valve for removing boiler sludge PA 46
1 Hand lever
1 Installation manual

PA 47

1 Intermittent valve for removing boiler sludge PA 47
1 Hand lever
1 Installation manual

MPA 46

1 Intermittent valve for removing boiler sludge MPA 46
1 Installation manual

MPA 47

1 Intermittent valve for removing boiler sludge MPA 47
1 Installation manual

Retrofitting kit for PA 46, PA 47

1 Diaphragm actuator
1 Spacer disc
1 Installation manual

Hand lever for emergency operation

1 Hand lever for emergency operation
1 Forkhead G 10 x 20, DIN 71752
1 Hexagonhead cap screw

Spare Parts

1 Kit according to spare parts list (see page 29)

Explanatory Notes  continued 

Description

Intermittent valves for manual or automatic and programmecontrolled removing of boiler sludge from
land or marine installations, particularly if these installations are operated without constant supervision
in accordance with TRD 604. Sludge sediments, which are accumulated precipitates from boiler water
that settle at the bottom of the boiler, will be removed from the steam boiler with the the aid of valves
PA and MPA. These valves give the boiler a short blow at regular intervals, thereby discharging
accumulated sludge and sediments.

■ PA 46 and PA 47 are designed for manual operation (diaphragm actuator can be retrofitted).

■ MPA 46 and MPA 47 feature a diaphragm actuator for compressed air or pressurized water.

Function

The intermittent valves for removing boiler sludge PA 46 and PA 47 are openend by means of a hand
lever. A pressure pin forces the springloaded valve plug out of the valve seat. The large cross
sectional area of the orifice creates a suction effect, giving a shortterm high water flow which will
discharge the precipitated sludge and sediments and  if installed  move them to a mixing cooler
(= blowdown receiver). The intermittent valve for removing boiler sludge must be completely opened
for about 2 seconds with the aid of the hand lever in order to give the boiler a short and highly
effective blow.

The intermittent valves for removing boiler sludge MPA 46 and MPA 47 are openend by the diaphragm
actuator. The guide pin of the diaphragm actuator acts upon the pressure pin, which in turn forces the
springloaded valve plug out of the valve seat. The large crosssectional area of the orifice creates a
suction effect, giving a shortterm high water flow which will discharge the precipitated sludge and
sediments and  if installed  move them to a mixing cooler (= blowdown receiver). Compressed air
(at room temperature) or pressurized water (at room temperature) can be used as control fluid for the
diaphragm actuator in accordance with the specified pressure and temperature ratings (see diagram
on page 11).

The duration of the bottom blowdown, i. e. the time when the valve is open, should be approx.
2 seconds. The time period when the valve remains closed and hence the frequency of the bottom
blowdown must be established as a function of the size and capacity of the steam boiler. We
recommend that approx. 10 per cent of the total amount of boiler water to be removed is discharged
via the intermittent valve for removing boiler sludge.

The duration and frequency of the bottom blowdown must be established individually by the user
as a function of the size and capacity of the steam boiler, the boiler water quality and the
corresponding load.

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8

Technical Data

Connections

Type

(M)PA 46 Flanges to DIN, PN 40

(M)PA 47 Flanges to DIN, PN 63

Pressure Ratings

(M)PA 46 EN – PN 40 Class 150, 300
(M)PA 47 EN – PN 63 Class 400

Materials

Designation DIN EN DIN ASTM

Body *) PA..., MPA... P250GH (1.0460) C 22.8 (1.0460) A 105

Stuffing box union *) P250GH (1.0460) C 22.8 (1.0460) A 105

Sealing plug *) 42CrMo4 (1.7225) A193 B7

Gasket X5CrNi1810 (1.4301) X 5 CrNi 18 10 (1.4301)

Seat, hardened X46Cr13 (1.4034) X 46Cr 13 (1.4034)

Valve cone, hardened X39CrMo171 (1.4122) X 35 CrMo 17 (1.4122)

Disk springs 51CrV4 (1.8159) 50 CrV 4 (1.8159)

Compression springs DIN EN 102701SH DIN 17223C

Diaphragm actuator StW 23 (1.0334)

Packing PTFEsilk

Control membrane EPDM

Standard On request

Flanges to Class 150, 300

Buttweld ends for DIN and ASME pipes

Socketweld ends for DIN and ASME pipes

Flanges to Class 400

Buttweld ends for DIN and ASME pipes

Socketweld ends for DIN and ASME pipes

Pressure / Temperature Ratings

Acc. to EN 10921 for 1.0460 acc. to PED and AD 2000 or A 105 acc. to PED

max. pressure [bar] at t = Control Control

100 °C 200 °C 300 °C ts/p max fluid pressure

40 37.9 33.5 246/36

(M)PA 46

(M)PA 47

Ratings according to

PN 40 1.0460 EN 10921 37.3 30.2 25.8 234/29

PN 40 A105 EN 10921

Class 150 A105 ASME B16.34 17.7 14.0 10.2 198/14

Class 300 A105 ASME B16.34 46.4 43.9 38.9 254/41

PN 63 1.0460 EN 10921 58.8 47.6 40.6 257/44

PN 63 A105 EN 10921 63 59.6 52.7 271/55

Class 400 A105 ASME B16.34 61.8 58.4 51.7 270/54

Water

or

com

pressed

air

Max.
8 bar

Technical Data  continued 

Corrosion resistance

If the unit is used for the intended purpose, its safety is not impaired by corrosion.

Sizing

The housing must not be subjected to sharp increases in pressure. The dimensional allowances for
corrosion reflect the latest state of technology.

Name plate / Marking

According to EN 19 the name plate and the housing indicate the valve type and design:

■ Type designation PA 46, PA 47: Design with hand lever

MPA 46, MPA 47: Design with diaphragm actuator

■ Marking according to ATEX: Marking: II 2G/D c X

■ Stamp on valve body, e. g. indicates term and year of production

(Example: 4th quarter 2004)

4

04

Code letter “M” for
diaphragm actuator

Direction of flow

Nominal size

PN /CL

CE marking if required

Type of
equipment

9

10

Technical Data  continued 

Capacity chart PA 46, PA 47, MPA 46, MPA 47

Calculation of the amount of boiler water to be discharged
according to the following formula:

Q · S

A =
K – S

Conductivity of
feedwater: S [µS/cm]
Admissible conductivity
of boiler water: K [µS/cm]
Boiler capacity: Q [kg/h]
Amount of boiler water
to be discharged: A [kg/h]

Fig. 1

Example

Conductivity of
feedwater: S = 20 µS/cm
Admissible conductivity
of boiler water: K = 4000 µS/cm
Boiler capacity: Q = 2000 kg/h
Amount of boiler water
to be discharged: A ≈ 10 kg/h

How to read chart fig. 1

Boiler pressure: 25 bar
Nominal size of intermittent valve for removing boiler
sludge DN 32
Capacity: 2.5 kg/s