GESTRA Steam Systems
PA 46
PA 47
MPA 46
MPA 47
Installation Instructions 81844700
RapidAction 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
Socketweld design ..............................................................................................................................15
Buttweld 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
3
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
nonmetallic 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 slowopening 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 Hexagonhead 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 programmecontrolled 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 springloaded valve plug out of the valve seat. The large cross
sectional area of the orifice creates a suction effect, giving a shortterm 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
springloaded valve plug out of the valve seat. The large crosssectional area of the orifice creates a
suction effect, giving a shortterm 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.
7
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 X5CrNi1810 (1.4301) X 5 CrNi 18 10 (1.4301)
Seat, hardened X46Cr13 (1.4034) X 46Cr 13 (1.4034)
Valve cone, hardened X39CrMo171 (1.4122) X 35 CrMo 17 (1.4122)
Disk springs 51CrV4 (1.8159) 50 CrV 4 (1.8159)
Compression springs DIN EN 102701SH DIN 17223C
Diaphragm actuator StW 23 (1.0334)
Packing PTFEsilk
Control membrane EPDM
Standard On request
Flanges to Class 150, 300
Buttweld ends for DIN and ASME pipes
Socketweld ends for DIN and ASME pipes
Flanges to Class 400
Buttweld ends for DIN and ASME pipes
Socketweld ends for DIN and ASME pipes
Pressure / Temperature Ratings
Acc. to EN 10921 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 10921 37.3 30.2 25.8 234/29
PN 40 A105 EN 10921
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 10921 58.8 47.6 40.6 257/44
PN 63 A105 EN 10921 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
Technical Data continued
Control pressure chart MPA 46, MPA 47
Fig. 2
Boiler pressure [bar]
Control pressure [bar]
11
12
Design PA 46, PA 47
W
V
U
3
T
S
R
Q
P
O
N
M
L
K
J
1
A
B
C
D
Fig. 3
I
H
E
F
G
Design MPA 46, MPA 47
Y
X
V
4
3
T
Z
W
B
Fig. 4
2
S
R
Q
P
O
N
M
L
K
J
I
H
C
D
E
F
G
13
14
Key
Locking lever
A
Mounting bracket
B
Check hole
C
Valve plug
D
Name plate
E
Gasket D 38 x 44 (DN 2032), D 52 x 60 (DN 4050)
F
Sealing plug
G
Valve seat
H
Valve body
I
Base bushing
J
Packing ring 14 x 28 x 7
K
Wiper ring
L
Pressure ring
M
Disc springs (15 pcs.)
N
Union nut
O
Compression spring
P
Check pin
Q
Pressure pin
R
Split pin 2.5 x 40, ISO 1234
S
Forkhead G 10 x 20, DIN 71752
T
Centering screw
U
Pressure plate
V
Hexagonhead cap screw M10 x 200, ISO 4014
W
Spacer disc
X
GESTRA Diaphragm actuator
Y
Screwed connection (3/8") for control fluid
Z
Hand lever for PA 46, PA 47
1
Hand lever for emergency operation MPA 46, MPA 47
2
Retaining piece for hand lever
3
Hexagonhead cap screw for forkhead M 10 x 25, ISO 4017
4
Installation
Danger
Risk of death, severe injuries, physical damage or destruction caused by explosive
mixtures!
If the equipment is electrically insulated and installed between pipe flanges, electrostatic
charges may build up.
When using the equipment in explosionrisk areas make sure that static electricity will
be discharged (earthing).
PA 46, PA 47, MPA 46, MPA 47
The intermittent valve for removing boiler sludge can be installed in horizontal or vertical pipes.
The hand lever of the PA 46, PA 47 and the hand lever for the emergency operation of MPA 46, MPA 47
must be freely movable.
Attention
■ To avoid waterhammer lay the pipe downstream of the intermittent valve in such a way
that it has a slight fall, or evacuate the pipe before carrying out the boiler blowdown.
■ The length of the pipe between the steam boiler and the intermittent valve for removing
boiler sludge must not exceed two metres!
Flanged design
1. Observe position of installation. The hand lever
(MPA...) must be freely movable.
2. Observe the direction of flow. The arrow indicating the flow direction is specified on the name
plate E.
3. Consider space required for opening the valve. When the intermittent valve for removing boiler
sludge is installed, a minimum space of at least
the actuator!
4. Remove plastic plugs. They are only used as transit protection.
5. Clean seating surfaces of both flange faces.
6. Install intermittent valve for removing boiler sludge.
Socketweld design
1. Observe position of installation. The hand lever
(MPA...) must be freely movable.
2. Observe the direction of flow. The arrow indicating the flow direction is specified on the name
plate E.
3. Consider space required for opening the valve. When the intermittent valve for removing boiler
sludge is installed a minimum space of at least
the actuator!
4. Remove plastic plugs. They are only used as transit protection.
5. Clean socketweld ends.
Arc weld trap only manually (welding processes 111 and 141 in accordance with ISO 4063).
6.
1 or the hand lever for emergency operation 2
150 mm is required for removing or retrofitting
1 or the hand lever for emergency operation 2
150 mm is required for removing or retrofitting
15
16
Installation continued
Buttweld design
1. Observe position of installation. The hand lever 1 or the hand lever for emergency operation 2
(MPA...) must be freely movable.
2. Observe the direction of flow. The arrow indicating the flow direction is specified on the name
plate E.
3. Consider space required for opening the valve. When the intermittent valve for removing boiler
sludge is installed a minimum space of at least
the actuator!
4. Remove plastic plugs. They are only used as transit protection.
5. Arcweld trap only manually (welding processes 111 and 141 in accordance with ISO 4063)
or use gas welding process (welding process 3 in accordance with ISO 4063).
Attention
■ Only qualified welders certified e. g. according to DIN EN 2871 may weld the valve into
pressurized lines.
Heat treatment of welds
A subsequent heat treatment of the welds is not required.
Mounting hand lever PA 46, PA 47
1. Release retaining piece for hand lever 3 and pull it out of the forkhead T.
2. Apply lubricant (e. g. WINIX 5000) to the retaining piece, forkhead and hole for attaching the
hand lever.
3. Push hand lever
1 through mounting bracket B into the forkhead T and fix it in place by
means of the retaining piece 3.
150 mm is required for removing or retrofitting
Commissioning
PA 46, PA 47, MPA 46, MPA 47
The flanged connections of the PA 46, PA 47, MPA 46, MPA 47 must be permanently bolted and
leakproof.
After starting up the steam boiler or pressure vessel, the intermittent valve for removing boiler sludge
should be completely opened and closed once. The valve must close automatically, ensuring tight
shutoff.
The stuffing box must be leakproof! Inspect the check hole C in order to detect any fluid leakage.
If the equipment is mounted in a new and unpurged installation increase the blowdown frequency
a little at the beginning.
®
WINIX
5000 is a registered trademark of WINIX GmbH, Norderstedt
Operation
Duration and frequency of intermittent boiler blowdown
When the GESTRA intermittent valve opens, a localized lowpressure area forms around the blowoff
opening and the boiler sludge rushes out at high velocity, giving the steam boiler a short blow. The
discharge of sludge and precipitated solids (valve fully open) takes approx. 2 seconds. In order to
ascertain the blowdown frequency, the operating data of the installation have to be taken into account:
Use formula of fig. 1 to calculate the amount of boiler water in [kg/h] that must be discharged so that
1.
the admissible conductivity value of the boiler water will not be exceeded. Example: 10 kg/h
Use the capacity chart to determine the discharge capacity in [kg/h] of the existing intermittent
2.
valve or of the intermittent valve that has been selected according to the size of the boiler standpipe.
Example: 2.5 kg/s
3. The results of item 1) and 2) give a blowdown duration of 4 seconds.
For an effective blowdown the valve must only be open for 2 seconds, which means that according to the
above calculation 2 cycles per hour are required.
The time period between blowdowns (valve closed) is therefore 30 minutes.
The GESTRA automatic intermittent blowdown control TA.... features the following settings: Blowdown
duration (valve open) usually 2 seconds. Blowdown frequency (time between blowdowns valve closed)
adjustable, e. g. 30 minutes. It is possible to reduce the intermittent blowdown frequency if continuous
(top) boiler blowdown is performed instead (see installation instructions BA.../ BAE...).
Emergency operation MPA 46, MPA 47
Danger
Risk of severe injuries to the whole body. Make sure that the line for the control fluid of
the diaphragm actuator is depressurized (zero bar) and isolated during the emergency
operation of the MPA 46, MPA 47.
Insert the hand lever for emergency operation only to operate the valve and remove it
immediately after operation.
Fit hand lever for emergency operation
1. Fit hand lever for emergency operation
2. Remove hand lever for emergency operation 2 immediately after operation.
2, operate intermittent valve for removing boiler sludge.
Maintenance
GESTRA intermittent valves for removing boiler sludge PA 46, PA 47, MPA 46 and MPA 47 are usually
free of maintenance.
After starting up the steam boiler or pressure vessel, the intermittent valve for removing boiler sludge
should be completely opened and closed once. The valve must close automatically, ensuring tight
shutoff.
The stuffing box must be leakproof! Inspect the check hole C in order to detect any fluid leakage.
17
18
Maintenance continued
Danger
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
Replacing stuffing box PA 46, PA 47
°C).
1. Undo retaining piece
3 for forkhead T and pull out hand lever 1. Fig. 3
2. Unscrew hexagonhead cap screws W and remove locking lever A.
3. Remove pressure plate
4. Pull out split pin
V and mounting bracket B.
S.
5. Use openend spanner A. F. 28 mm to unscrew the pressure pin R from the valve plug D.
6. Remove compression spring P.
7. Use openend spanner A. F. 32 mm to unscrew the union nut O.
8. Unscrew sealing plug
9. Pull out valve plug
G and remove gasket F.
D.
10. Take out internal parts N M L K L J of stuffing box.
11. Clean stuffing box, valve body and valve plug.
12. Reinsert valve plug D and use abrasive paste type TETRABOR® F400 for polish grinding.
13. Insert new gasket
14. Reinsert internal parts of stuffing box according to order as specified on page 24.
F and screw in sealing plug G. Tighten with a torque of 350 Nm.
Fig. 5, Fig. 6
15. Apply heatresistance lubricant to stuffing box thread (use e.g. WINIX® 2150).
16. Align valve plug D such that the hole for the split pin S is perpendicular to the flow direction of the
intermittent valve.
17. Use openend spanner A. F. 32 mm to screw in union nut O and tighten at room temperature with a
torque of 55 Nm.
18. Apply heatresistant lubricant to both sides of the compression spring P (use e. g. WINIX® 2150)
and place it onto the union nut O.
19. Use openend spanner A. F. 28 mm to screw the pressure pin R onto the valve plug D until the
holes for the split pin S in the valve plug and the pressure pin overlap.
20. Insert split pin S.
21. Reinsert mounting bracket B and pressure plate V. Align check hole C to the right.
22. Insert and screw in hexagonhead cap screws W and locking lever A and tighten them in
diagonally opposite pairs, applying a torque of 20 Nm.
23. Insert hand lever 1 and fix it to the forkhead T by means of retaining piece 3.
24. Operate valve once (open it until it hits the stop).
WINIX® 2150 is a registered trademark of WINIX GmbH, Norderstedt
TETRABOR® is a registered trademark of WackerChemie GmbH, Kempten
Maintenance continued
Replacing stuffing box, valve seat and valve plug PA 46, PA 47
1. Undo retaining piece for forkhead
2. Unscrew hexagonhead cap screws
3. Remove pressure plate
4. Pull out split pin
V and mounting bracket B.
S.
5. Use openend spanner A. F. 28 mm to unscrew the pressure pin
6. Remove compression spring
7. Use openend spanner A. F. 32 mm to unscrew the union nut
8. Unscrew sealing plug
9. Pull out valve plug
10. Take out internal parts
G and remove gasket F.
D.
N M L K L J of stuffing box.
11. Use steel punch to knock the valve seat
T and pull out hand lever 1. Fig. 3
W and remove locking lever A.
R from the valve plug D.
P.
O.
H out of the valve body I. Fig. 7
12. Clean stuffing box and valve body.
13. Insert new valve seat
H such that two opposite holes are in the flow direction of the intermittent
valve.
14. Use punch made of CuZn to fix the valve seat in the valve body.
15. Reinsert valve plug
16. Insert new gasket
D and use abrasive paste type TETRABOR® F400 for polish grinding.
F and screw in sealing plug G. Tighten with a torque of 350 Nm.
Fig. 8
17. Reinsert internal parts of stuffing box according to order as specified on page 24.
®
18. Apply heatresistance lubricant to stuffing box thread (use e.g. WINIX
19. Align valve plug
D such that the hole for the split pin S is perpendicular to the flow direction of the
2150).
intermittent valve.
20. Use openend spanner A. F. 32 mm to screw in union nut
a torque of
55 Nm.
21. Apply heatresistant lubricant to both sides of the compression spring
and place it onto the union nut
O.
22. Use openend spanner A. F. 28 mm to screw the pressure pin
holes for the split pin
23. Insert split pin
24. Put mounting bracket
25. Insert and screw in hexagonhead cap screws
diagonally opposite pairs, applying a torque of
26. Insert hand lever
S in the valve plug and the pressure pin overlap.
S.
B and pressure plate V in place. Align check hole C to the right.
W and locking lever A and tighten them in
20 Nm.
1 and fix it to the forkhead T by means of retaining piece 3.
O and tighten at room temperature with
P (use e. g. WINIX® 2150)
R onto the valve plug D until the
27. Operate valve once (open it until it hits the stop).
Fig. 5, Fig. 6
WINIX® 2150 is a registered trademark of WINIX GmbH, Norderstedt
TETRABOR® is a registered trademark of WackerChemie GmbH, Kempten
19
20
Maintenance continued
Replacing stuffing box MPA 46, MPA 47
1. Detach pressure line for the control fluid of the diaphragm actuator from the screwed socket
2. Remove diaphragm actuator
3. Remove spacer disk
4. Unscrew hexagonhead cap screws
5. Remove pressure plate
6. Pull out split pin
S.
7. Use openend spanner A. F. 28 mm to unscrew the pressure pin
8. Remove compression spring
9. Use openend spanner A. F. 32 mm to unscrew the union nut
10. Unscrew sealing plug
11. Pull out valve plug
D.
12. Take out internal parts
Y. Fig. 4
X and pressure plate V.
W.
V and mounting bracket B.
R from the valve plug D.
P.
O.
G and remove gasket F.
N M L K L J of stuffing box.
13. Clean stuffing box, valve body and valve plug.
14. Reinsert valve plug
15. Insert new gasket
16. Reinsert internal parts of stuffing box according to order as specified on page 24.
17. Apply heatresistance lubricant to stuffing box thread (use e.g. WINIX
18. Align valve plug
D and use abrasive paste type TETRABOR® F400 for polish grinding.
F and screw in sealing plug G. Tighten with a torque of 350 Nm.
Fig. 5, Fig. 6
®
2150).
D such that the hole for the split pin S is perpendicular to the flow direction of the
intermittent valve.
19. Use openend spanner A. F. 32 mm to screw in union nut
O and tighten at room temperature with
a torque of 55 Nm.
20. Apply heatresistant lubricant to both sides of the compression spring
P (use e. g. WINIX® 2150) and
place it onto the union nut O.
21. Use openend spanner A. F. 28 mm to screw the pressure pin
R onto the valve plug D until the
holes for the split pin S in the valve plug and the pressure pin overlap.
22. Insert split pin
23. Reinsert mounting bracket
24. Insert hexagonhead cap screws
S.
B and pressure plate V. Align check hole C to the right.
W and tighten them in diagonally opposite pairs with a torque
of 20 Nm.
25. Put spacer disk
26. Screw on diaphragm actuator
X onto pressure plate V.
Y with a torque of 120 Nm.
27. Attach pressure line for the control fluid of the diaphragm actuator.
28. Operate the valve once.
Z.
WINIX® 2150 is a registered trademark of WINIX GmbH, Norderstedt
TETRABOR® is a registered trademark of WackerChemie GmbH, Kempten
Maintenance continued
Replacing stuffing box, valve seat and valve plug MPA 46, MPA 47
1. Detach pressure line for the control fluid of the diaphragm actuator from the screwed socket
Z.
2. Remove diaphragm actuator Y. Fig. 4
3. Remove spacer disk X and pressure plate V.
4. Unscrew hexagonhead cap screws W.
5. Remove pressure plate V and mounting bracket B.
6. Pull out split pin S.
7. Use openend spanner A. F. 28 mm to unscrew the pressure pin R from the valve plug D.
8. Remove compression spring P.
9. Use openend spanner A. F. 32 mm to unscrew the union nut O.
10. Unscrew sealing plug G and remove gasket F.
11. Pull out valve plug D.
12. Take out internal parts N M L K L J of stuffing box.
13. Use steel punch to knock the valve seat H out of the valve body I. Fig. 7
14. Clean stuffing box, valve body and valve plug.
15. Insert new valve seat H such that two opposite holes are in the flow direction of the intermittent
valve.
16. Use punch made of CuZn to fix the valve seat in the valve body. Fig. 8
17. Insert valve plug D and apply abrasive paste type TETRABOR® F400 for polish grinding.
18. Insert new gasket F and screw in sealing plug G. Tighten with a torque of 350 Nm.
19. Reinsert internal parts of stuffing box according to order as specified on page 24. Fig. 5, Fig. 6
20. Apply heatresistance lubricant to stuffing box thread (use e. g. WINIX® 2150).
21. Align valve plug D such that the hole for the split pin S is perpendicular to the flow direction of the
intermittent valve.
22. Use openend spanner A. F. 32 mm to screw in union nut O and tighten at room temperature with
a torque of 55 Nm.
23. Apply heatresistant lubricant to both sides of the compression spring P (use e.g. WINIX® 2150) and
place it onto the union nut O.
24. Use openend spanner A. F. 28 mm to screw the pressure pin R onto the valve plug D until the
holes for the split pin S in the valve plug and the pressure pin overlap.
25. Insert split pin S.
26. Reinsert mounting bracket B and pressure plate V.
27. Insert hexagonhead cap screws W and tighten them in diagonally opposite pairs with a torque
of 20 Nm.
28. Put spacer disk X onto pressure plate V.
29. Screw on diaphragm actuator Y with a torque of 120 Nm.
30. Attach pressure line for the control fluid of the diaphragm actuator.
31. Operate the valve once.
WINIX® 2150 is a registered trademark of WINIX GmbH, Norderstedt
TETRABOR® is a registered trademark of WackerChemie GmbH, Kempten
21
22
Maintenance continued
Retightening stuffing box
If fluid leaks out of the control hole C, retighten the stuffing box with the union nut O.
Insert pin punch through opening of the mounting bracket B and push it into one of the holes of the
1.
union nut O. Carefully tighten union nut clockwise until the fluid stops leaking out of the control
hole C.
2. Operate valve once the valve must close automatically, ensuring tight shutoff.
Attention
■ If the stuffing box cannot be tightened further by means of the union nut O all internal
parts of the stuffing box must be replaced!
■ If the force of the spring does not close the valve automatically loosen the union nut
O a little. If fluid leaks out of the control hole the internals of the stuffing box must be
replaced.
Replacing control membrane in diaphragm actuator MPA 46, MPA 47
1. Detach pressure line for the control fluid of the diaphragm actuator.
2. Unscrew hexagonhead bolts
3. Remove and clean upper part
4. Take out old control membrane
5. Insert new control membrane
6. Put upper part
6 on top and align its holes with the holes of the control membrane and the
lower part.
7. Insert hexagonhead bolts
opposite pairs to a torque of 5 Nm.
8. Attach pressure line for the control fluid of the diaphragm actuator.
9. Check tightness. If necessary retighten hexagonhead bolts
10. To grease the guide plate pin
diaphragm actuator (use e. g. WINIX 5000).
5 and hexagon nuts. Fig. 9
6 of the diaphragm actuator.
7. Clean lower part 8.
7, aligning its holes with the holes of the lower part.
5 and tighten them with the respective hexagon nuts in diagonally
5 carefully in diagonally opposite pairs.
9 apply lubricant to the grease nipple in the connecting socket of the
Attention
■ The torque for tightening the hexagonhead cap screws 5 must not exceed 5 Nm
because higher torques could damage the control membrane!
WINIX® 5000 is a registered trademark of WINIX GmbH, Norderstedt
Maintenance continued
Torques
Item
G
O
W
U
Y
5
All torques indicated in the table are based at a room temperature of 20 °C.
Intermittent valves for removing boiler sludge Torques [Nm]
PA 46, PA 47, MPA 46, MPA 47 350
PA 46, PA 47, MPA 46, MPA 47 55
PA 46, PA 47, MPA 46, MPA 47 20
PA 46, PA 47 60
MPA 46, MPA 47 120
MPA 46, MPA 47 5
Tools
■ Spanner A. F. 13 mm, DIN 3113, Form B
■ Spanner A. F. 17 mm, DIN 3113, Form B
■ Spanner A. F. 28 mm, DIN 3113, Form B
■ Spanner A. F. 32 mm, DIN 3113, Form B
■ Spanner A. F. 36 mm, DIN 3113, Form B
■ Spanner A. F. 41 mm, DIN 3113, Form B
■ Torque spanner 1 12 Nm, ISO 6789
■ Torque spanner 20 120 Nm, ISO 6789
■ Torque spanner 80 400 Nm, ISO 6789
■ Socket spanner 13 x 250, DIN 3112
■ Punch 20 x 200, made of steel
■ Punch 20 x 200, made of CuZn (brass)
■ Pin punch 8 x 150, DIN 6450 C
■ Grease gun (for valve plug)
23
24
Maintenance continued
Single parts of stuffing box, valve plug, valve seat
N
M
L
K
L
J
H
Fig. 5
Fig. 6
D
Maintenance continued
Mounting/removing valve seat
Fig. 7
Fig. 8
25
26
Maintenance continued
Mounting/removing control membrane
6
7
5
8
9
Fig. 9
Key
Hexagonhead bolt M8 with hexagon nut M8
5
Upper part of the diaphragm actuator
6
Control membrane
7
Lower part of the diaphragm actuator with connector socket
8
Guide pin with plate
9
Retrofitting
GESTRA intermittent valves PA 46 and PA 47 can be retrofitted with a GESTRA diaphragm actuator
(MPA 46, MPA 47).
Danger
Risk of severe burns and scalds to the whole body!
Before carrying out any retrofitting 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
Insert the hand lever for emergency operation 2 only to operate the valve and remove it
immediately after operation.
Mounting diaphragm actuator
°C).
1. Undo centering screw U. Fig. 3
2. Undo retaining piece
Note that the hand lever must not be mounted again!
3. Snap retaining piece
4. Unscrew hexagonhead cap screws
5. Insert hexagonhead cap screws
6. Put spacer disk
7. Apply heatresistant lubricant to the connector socket of the diaphragm actuator
(use e.g. WINIX® 2150).
8. Screw on diaphragm actuator
9. Attach pressure line (
10. Operate the valve once.
3 for forkhead T and pull out hand lever 1.
3 on forkhead T.
W and remove locking lever A.
W and tighten them with a torque of 20 Nm.
X onto pressure plate V.
3
Y with a torque of 120 Nm.
/8") for the control fluid of the diaphragm actuator.
27
28
Retrofitting continued
Mounting the forkhead (hand lever for emergency operation)
1. Align and fit forkhead
the hexagonhead cap screw
2. Fit hand lever for emergency operation
3. Remove hand lever for emergency operation
Tools
■ Spanner A. F. 16 mm, DIN 3113, Form B
■ Spanner A. F. 17 mm, DIN 3113, Form B
■ Spanner A. F. 41 mm, DIN 3113, Form B
■ Torque spanner 20 120 Nm, ISO 6789
Torques
Item
Y
4
W
All torques indicated in the table are based at a room temperature of 20 °C.
T together with hexagonhead cap screw 4 to the pressure plate V. Tighten
2 with a torque of 20 Nm. Fig. 4
2, operate intermittent valve for removing boiler sludge.
Intermittent valves for removing boiler sludge Torques [Nm]
MPA 46, MPA 47 120
MPA 46, MPA 47 20
PA 46, PA 47, MPA 46, MPA 47 20
2 immediately after operation.
Spare Parts
Spare parts list
Item Designation
J K
L M
N F
D H
J K
L M
N F
D H
J K
L M
N F
7
2 3 4 T
9
N F
Internal parts of stuffing box, DN 20 to DN 50:
Base bushing, wiper ring,
Packing ring 14 x 28 x 7, pressure ring,
disk springs (15 pcs.),
Gasket D 38 x 44, D 52 x 60
Valve plug, valve seat and internal parts
of stuffing box, DN 20, DN 25, DN 32:
Base bushing, wiper ring,
Packing ring 14 x 28 x 7, pressure ring,
disk springs (15 pcs.),
Gasket D 38 x 44
Valve plug, valve seat and internal parts
of stuffing box, DN 40, DN 50:
Base bushing, wiper ring,
Packing ring 14 x 28 x 7, pressure ring,
disk springs (15 pcs.),
Gasket D 52 x 60
Control membrane for diaphragm actuator 335 131
Hand lever for emergency operation with forkhead 335 060
Guide pin with plate 335 130
Diaphragm actuator with spacer disk 335 093
Stock code Stock code
PA 46, PA 47 MPA 46, MPA 47
335 064 335 064
335 063 335 063
335 065 335 065
29
30
Parts for retrofitting
List of parts for retrofitting
Item Designation
Y X
2 3 4 T
Diaphragm actuator with spacer disk 335 093
Hand lever for emergency operation with forkhead 335 060
Stock code Stock code
PA 46, PA 47 MPA 46, MPA 47
Decommissioning
Danger
Risk of severe burns and scalds to the whole body!
Before 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
Disposal
Dismantle the valve and separate the waste materials, using the material specifications in the table
„Materials“ on page 8 as a reference.
For the disposal of the valve observe the pertinent legal regulations concerning waste disposal.
°C).
Annex
Declaration of Conformity
We hereby declare that the pressure equipment PA 46, PA 47, MPA 46 and MPA 47 conform to the
following European Directives:
■ Pressure Equipment Directive 97/23/EC of 29 May 1997 for equipment of category 1 according to
the table “Pressure Equipment Directive” on page 5.
■ ATEX Directive 94/9/EC of 23 March 1994.
Applied conformity assessment procedure according to 97/23/EC: Annex III, Module H, verified by the
Notified Body 0525.
Applied conformity assessment procedure according to 94/9/EC: Annex VIII.
This declaration is no longer valid if modifications are made to the equipment without consulation with us.
Bremen, 8th March 2004
GESTRA AG
Dipl.Ing. Uwe Bledschun
(Academically qualified engineer)
Head of the Design Dept.
Dipl.Ing. Lars Bohl
(Academically qualified engineer)
Quality Assurance Manager
31
32
www.gestra.de
81844700/1205cm · © 2004 GESTRA AG · Bremen · Printed in Germany
GESTRA
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