GESTRA Steam Systems
SMK 22
SMK 22-51
Installation Instructions 810481-02
Steam Trap
SMK 22, SMK 22-51
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
Sizing .....................................................................................................................................................6
Name plate / Marking ............................................................................................................................. 6
Design
Component parts SMK 22 ...................................................................................................................... 7
Component parts SMK 22-51
Key .........................................................................................................................................................9
..................................................................................................................8
Installation
SMK 22, SMK 22-51 .............................................................................................................................10
Design with butt-weld ends .................................................................................................................. 10
Attention ...............................................................................................................................................10
Heat treatment of welds........................................................................................................................10
Commissioning
SMK 22, SMK 22-51 ............................................................................................................................. 11
Attention ............................................................................................................................................... 11
Operation
SMK 22, SMK 22-51 ............................................................................................................................. 12
Thermostatic capsule ...........................................................................................................................12
Contents – continued –
Maintenance
Page
SMK 22, SMK 22-51 .............................................................................................................................
Check steam trap ................................................................................................................................13
Clean / replace membrane regulator ....................................................................................................13
Tools .....................................................................................................................................................13
Torques ................................................................................................................................................ 13
Spare Parts
SMK 22, SMK 22-51 ............................................................................................................................. 14
Spare parts list ....................................................................................................................................14
Decommissioning
Danger ................................................................................................................................................15
Disposal ...............................................................................................................................................15
13
3
4
Important Notes
Usage for the intended purpose
Use steam traps SMK 22, SMK 22-51 only for the discharge of condensed water or for air venting
steam spaces.
Use this equipment only for the discharge of condensate from steam lines within the specified
pressure and temperature ratings and check the corrosion resistance and chemical suitability for the
application in question.
Safety note
The equipment must only be installed and commissioned by qualified staff.
Maintenance and retrofitting must only be performed by adequately trained persons who have a
recognised level of competence.
Danger
The steam trap is under pressure during operation.
When loosening flanged connections, plugs or the regulator, hot water and/or steam may
escape. This presents the risk of severe scalding.
Installation and maintenance work should only be carried out when the system is
depressurized (0 bar): isolate the trap from both upstream and downstream pressure.
The trap becomes hot during operation. This presents the danger of severe burns to
hands and arms. Installation and maintenance work should only be carried out when the
system is cold (20°C).
Sharp edges on internal parts present a danger of cuts to hands. Always wear industrial
gloves when replacing the regulator.
Attention
The name plate indicates the technical specification of the equipment. Do not
commission or operate a steam trap without a name plate.
PED (Pressure Equipment Directive)
The equipment fulfills the requirements of the Pressure Equipment Directive PED 97/23/EC.
For applications with fluids of group 2.
According to section 3.3 the equipment is excluded from the scope of this directive and must therefore
not be CE marked.
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.
Explanatory Notes
Scope of supply
SMK 22
1 Steam trap type SMK 22
1 Wing nut (not fitted)
1 Installation manual
SMK 22-51
1 Steam trap type SMK 22-51
1 Wing nut (not fitted)
1 Installation manual
Description
The thermostatic steam trap features minimum stagnant area and a corrosion-resistant membrane
regulator unaffected by waterhammer. Used for discharging condensate and air-venting steam in
sterile and aseptic applications.
The membrane regulator has a self-centering valve cone that can move freely, thereby ensuring
steam-tight shut-off unaffected by particulate matter.
The membrane regulator features high response sensitivity (evaporation thermostat). Automatic airventing and discharge of condensate without any banking-up within the rated pressure/temperature
range. The opening temperature is approximately 5 K below the boiling point.
All parts in contact with the fluid are made of stainless steel and the body gasket is of EPDM (O-ring),
optional PTFE (SMK 22) and PTFE (SMK 22-51) in accordance with the regulations specified by the
Food and Drug Administration (FDA).
The surface roughness Ra of the wetted surfaces is ≤ 0.8 µm.
Function
The SMK 22... is a steam trap with membrane regulator, the capsule of which is filled with a liquid
having an evaporation temperature that is just a few degrees below the saturation temperature of
water. When condensate is flowing through the trap the liquid filling of the membrane is completely
condensed due to the the low ambient temperature. The pressure in the capsule is lower than the
surrounding pressure (service pressure), which means that the membrane with the valve disc is
pushed in the opening direction. As the temperature rises, the liquid filling starts to evaporate. The
pressure in the capsule increases, the membrane with the valve disc is moved in the closing direction.
The operation of the trap is neither influenced by fluctuations in the upstream pressure nor by back
pressure.
5
6
GESTRA SMK 22
MADE BY GESTRA
PMA 10bar - TMA 150°C - PMX 6bar
DN15 - 1.4435 - QA .... - Charge: ....
GESTRA SMK 22
MADE BY GESTRA
PMA 10bar - TMA 185°C - PMX 6bar
DN15 - 1.4435 - QA .... - Charge: ....
GESTRA SMK22-51
MADE BY GESTRA
PMA 10bar - TMA 185°C - PMX 6bar
DN15 - 1.4404 - QA .... - Charge: ....
Technical Data
Corrosion resistance
If the steam trap is used for the intended purpose, its safety is not impaired by corrosion.
Sizing
The trap body must not be subjected to pulsating loads. The dimensional allowances for corrosion and
anti-corrosive additives reflect the latest state of technology.
Name plate / Marking
The pressure / temperature ratings are indicated on the trap body / the name plate.
For more information see GESTRA data sheets and Technical Information.
According to EN 19 the name plate and the valve body indicate the type and design:
■ Name / logo of the manufacturer
■ Type designation
■ Pressure class PN or Class
■ Material number
■ Max. temperature
■ Max. pressure
■ Flow direction
■ Stamp on trap body, e. g. specifies the quarter and the year of production
(Example: 1
st
quarter 2007).
1
07
Fig. 1
Fig. 2
Fig. 3
Design
Component parts SMK 22
1
9
8
Fig. 4
2
3
4
5
6
0
7
!
Fig. 5
7
8
Design – continued –
Component parts SMK 22-51
"
§
%
&
/
$
(
)
Fig. 6
Design – continued –
Key
SMK 22
1 Joint clamp
2 Upper body part
3 Spring
4 Regulating membrane
5 Body gasket of EPDM (PTFE)
6 Lower body part
7 Wing nut
8 Hexagon nut
9 Hexagon socket screw M 6 x 12
0 Upper body part
! Lower body part
SMK 22-51
" Joint clamp
§ Hexagon nut
$ Wing nut
% Upper body part
& Spring
/ Regulating membrane
( Body gasket of PTFE
) Lower body part
9
10
Installation
SMK 22, SMK 22-51
The trap can be installed in any position. Observe arrow indicating direction of flow. When mounted in
a vertical line with downward flow the trap is self-draining.
Design 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
required for removing the regulating membrane 4 / /.
4. Remove plastic plugs. They are
5. Clean butt-weld ends.
6. Apply arc welding processes 111 and 141 in accordance with ISO 4063 or gas welding process 3
to ISO 4063.
Attention
■ Only qualified welders certified e. g. according to DIN EN 287 may weld the steam trap
into pressurized lines.
Heat treatment of welds
A subsequent heat treatment of the welds is not required.
only used as transit protection.
30 mm is
Commissioning
SMK 22, SMK 22-51
Make sure that the flanged connections of the SMK 22, SMK 22-51 are permanently bolted and tight.
Attention
The steam trap is under pressure at start-up and during the operation.
The steam trap becomes hot during operation. This presents the risk of severe burns to
hands and arms.
Installation and maintenance work may only be carried out when the system is
depressurised (zero bar). Make sure that the lines upstream and downstream of the trap
are not under pressure!
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12
Operation
SMK 22, SMK 22-51
The SMK 22, SMK 22-51 can be serviced (see Maintenance).
Thermostatic capsule
The factory setting of the regulating membrane enables the regulator to be steam-tight when closed
and to open just before the pressure-dependent boiling temperature is reached.
Regulating membrane functioning correctly Regulating membrane defective
≥ 3.2 mm
Fig. 7 Fig. 8
≤ 2.6 mm
Maintenance
SMK 22, SMK 22-51
GESTRA steam trap SMK 22, SMK 22-51 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 / the
regulating capsule.
Check steam trap
You can check the trap for steam loss with GESTRA’s ultrasonic measuring unit VAPOPHONE® or the
test unit TRAPTEST®.
In case of steam loss clean the trap or replace the regulator.
Clean / replace membrane regulator
1. Observe danger note on page 4.
2. Unscrew hexagon nut or wing nut of joint clamp and remove joint clamp from upper and lower
body part. Fig. 4, Fig. 5, Fig. 6
3. Unscrew hexagon socket screws,
4. Remove and clean regulating membrane.
5. Replace regulating membrane in case of signs of wear or damage.
6. Clean body, internals and all gasket surfaces.
7. Press regulating membrane onto lower body part (snaps into place with a click).
8. Insert new body gasket
9. Assemble upper and lower body part.
10. Fit joint clamp and tighten hexagon nut with the torque indicated in the table “Torques” (or mount
wing nut).
11. Screw in hexagon socket screws and tighten with the torque indicated in the table “Torques”.
5 / (.
Fig. 5
Tools
■
Spanner 15 mm A. F. to DIN 3113, form B
■
Key for hexagon socket screws with pilot 6 mm A. F. to DIN 6912
■
Torque spanner 5-22.5 Nm to DIN ISO 6789
Torques
Item
8 / §
7 / $
9
All torques indicated refer to a room temperature of 20 °C.
Designation Torque [Nm]
Hexagon nut 8
Wing nut 8
Hexagon socket screw M 6 x 12 7
13
14
Spare Parts
SMK 22, SMK 22-51
Fig. 9
Spare parts list
SMK 22
Item
4
5
5
/
(
5
4
Fig. 10
Designation Stock code no.
Regulating membrane SMK 22 375862
Body gasket, 39 x 3, made of EPDM acc. to FDA 375673
Body gasket, 29 x 3, made of PTFE acc. to FDA 376777
Regulating membrane SMK 22-51 088524
Body gasket (PTFE), acc. to FDA 377963
SMK 22-51
(
/
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 (zero bar) and cooled down to room temperature (20 °C).
Disposal
Dismantle the equipment and separate the waste materials, using the specifications in the table
“Materials” as a reference.
For the disposal of the equipment observe the pertinent legal regulations concerning waste disposal.
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810481-02/108cm · 2007 GESTRA AG · Bremen · Printed in Germany
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