3.341.5275.245
ST Issue 7 - 2013
GKE ball float steam traps
Installation and Maintenance Instructions
The PED Directive 97/23/EC is repealed and replaced by the new
PED Directive 2014/68/EU with effect from 19 July 2016.
1. Safety information
2. General product information
3. Installation
EXPERTISE SOLUTIONS SUSTAINABILITY
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
© Copyright 2009
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ATTENZIONE
Lavorare in sicurezza con apparecchiature
in ghisa e vapore
Working safely with cast iron products on steam
Informazioni di sicurezza supplementari - Additional Informations for safety
Lavorare in sicurezza con prodotti
in ghisa per linee vapore
I prodotti di ghisa sono comunemente presenti
in molti sistemi a vapore.
Se installati correttamente, in accordo alle
migliori pratiche ingegneristiche, sono dispositivi
totalmente sicuri.
Tuttavia la ghisa, a causa delle sue proprietà
meccaniche, è meno malleabile di altri materiali
come la ghisa sferoidale o l’acciaio al carbonio.
Di seguito sono indicate le migliori pratiche
ingegneristiche necessarie per evitare i colpi
d'ariete e garantire condizioni di lavoro sicure
sui sistemi a vapore.
Movimentazione in sicurezza
La ghisa è un materiale fragile: in caso di
caduta accidentale il prodotto in ghisa non è
più utilizzabile. Per informazioni più dettagliate
consultare il manuale d'istruzioni del prodotto.
Rimuovere la targhetta prima di effettuare la
messa in servizio.
Working safely with cast iron
products on steam
Cast iron products are commonly found on steam
and condensate systems.
If installed correctly using good steam
engineering practices, it is perfectly safe.
However, because of its mechanical properties,
it is less forgiving compared to other materials
such as SG iron or carbon steel.
The following are the good engineering practices required to prevent waterhammer and
ensure safe working conditions on a steam
system.
Safe Handling
Cast Iron is a brittle material. If the product is dropped
during installation and there is any risk of damage
the product should not be used unless it is fully
inspected and pressure tested by the manufacturer.
Please remove label before commissioning
Prevenzione dai colpi d’ariete - Prevention of water hammer
Scarico condensa nelle linee vapore - Steam trapping on steam mains:
Vapore
Steam
Intervalli di 30÷50 m. intervals
Pendenza -
Gruppo di sca rico
Trap set
Gradient
1:100
Condensa - Condasate
Pendenza -
Gruppo di sca rico
Trap set
Gradient
Condensa - Condasate
1:100
Gruppo di sca rico
Condensa - Condasate
Trap set
Vapore
Steam
Esempi di esecuzioni corrette ( ) ed errate ( ) sulle linee vapore:
Steam Mains - Do's and Dont's:
Vapore
Steam
Flusso
Flow
Flusso
Flow
Prevenzione delle sollecitazioni di trazione
Prevention of tensile stressing
Evitare il disallineamento delle tubazioni - Pipe misalignment:
Installazione dei prodotti o loro rimontaggio post-manutenzione:
Installing products or re-assembling after maintenance:
Evitare l’eccessivo serraggio.
Utilizzare le coppie di serraggio
raccomandate.
Do not over tighten.
Use correct torque gures.
Per garantire l’uniformità del carico e dell'allineamento,
i bulloni delle ange devono essere serrati in modo
graduale e in sequenza, come indicato in gura.
Flange bolts should be gradually tightened across
diameters to ensure even load and alignment.
Dilatazioni termiche - Thermal expansion:
Gli esempi mostrano l’uso corretto dei compensatori di dilatzione. Si consiglia di richiedere una
consulenza specialistica ai tecnici dell’azienda che produce i compensatori di dilatazione.
Examples showing the use of expansion bellows. It is highly recommended that expert advise is
sought from the bellows manufacturer.
Guide
Guides
Movimento assiale
Axial movement
movimento
movement
Piccolo
movimento
laterale
Small
lateral
movement
Ampio
laterale
Large
lateral
Movimento assiale
Axial movement
Ampio
movimento
laterale
Large
lateral
movement
Distanza breve
Short distance
Guide
Guides
Distanza
media
Medium
distance
Punto di ssaggio
Fixing point
Tiranti limitatori
Limit rods
Punto di ssaggio
Fixing point
Tiranti limitatori
Limit rods
Guide
Guides
Guide
Guides
movimento
movement
Piccolo
laterale
Small
lateral
1. Safety information
Safe operation of these products can only be guaranteed if they are properly installed,
commissioned, used and maintained by qualified personnel (see Section 1.11 on this document)
in compliance with the operating instructions.
General installation and safety instructions for pipeline and plant construction, as well as the
proper use of tools and safety equipment must also be complied with.
1.1 Intended use
Referring to the Installation and Maintenance Instructions, name-plate and Technical Information
Sheet, check that the product is suitable for the intended use/application.
These products comply with the requirements of the European Pressure Equipment Directive
97/23/EC and carry the mark when so required. The products fall within the following
Pressure Equipment Directive categories:
Product
GKE DN1½" - 2" / 40 - 50 - 1 - SEP
I) These products have been specifically designed for use on steam, air or condensate/water,
which is in Group 2 of the above mentioned Pressure Equipment Directive. The products’ use
on other fluids may be possible but, if this is contemplated, Spirax Sarco should be contacted
to confirm the suitability of the product for the application being considered.
II) Check material suitability, pressure and temperature and their maximum and minimum values.
If the maximum operating limits of the product are lower than those of the system in which it
is being fitted, or if malfunction of the product could result in a dangerous overpressure or
overtemperature occurrence, ensure a safety device is included in the system to prevent
such over-limit situations.
III) Determine the correct installation situation and direction of fluid flow.
IV) Spirax Sarco products are not intended to withstand external stresses that may be induced by
any system to which they are fitted. It is the responsibility of the installer to consider these
stresses and take adequate precautions to minimise them.
V) Remove protection covers from all connections before installation.
Group 1 Group 2 Group 1 Group 2
Gases Gases Liquids Liquids
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded) before attempting
to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some previous time.
Consider: flammable materials, substances hazardous to health, extremes of temperature.
1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of
temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.
1.6 The system
Consider the effect on the complete system of the work proposed. Will any proposed action (e.g.
closing isolation valves, electrical isolation) put any other part of the system or any personnel at
risk? Dangers might include isolation of vents or protective devices or the rendering ineffective of
controls or alarms. Ensure isolation valves are turned on and off in a gradual way to avoid system
shocks.
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1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double
isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume
that the system has depressurised even when the pressure gauge indicates zero.
1.8 Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.
1.9 Tools and consumables
Before starting work ensure that you have suitable tools and/or consumables available. Use only
genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and/or others in the vicinity require any protective clothing to protect against
the hazards of, for example, chemicals, high /low temperature, radiation, noise, falling objects,
and dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person. Installation and
operating personnel should be trained in the correct use of the product according to the Installation
and Maintenance Instructions. Where a formal ‘permit to work’ system is in force it must be
complied with. Where there is no such system, it is recommended that a responsible person
should know what work is going on and, where necessary, arrange to have an assistant whose
primary responsibility is safety. Post ‘warning notices’ if necessary.
1.12 Handling
Manual handling of large and/or heavy products may present a risk of injury. Lifting, pushing,
pulling, carrying or supporting a load by bodily force can cause injury particularly to the back. You
are advised to assess the risks taking into account the task, the individual, the load and the
working environment and use the appropriate handling method depending on the circumstances
of the work being done.
1.13 Residual hazards
In normal use the external surface of the product may be very hot. If used at the maximum
permitted operating conditions the surface temperature of some products may reach very high
temperatures (200°C). Many products are not self-draining. Take due care when dismantling or
removing the product from an installation (refer to ‘Maintenance’ instructions).
1.14 Freezing
Provision must be made to protect products which are not self-draining against frost damage in
environments where they may be exposed to temperatures below freezing point.
1.15 Safety information - Product specific
See the specific details relating to the product in the following "Maintenance" section.
1.16 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, this product is recyclable
and no ecological hazard is anticipated with its disposal providing due care is taken.
1.17 Returning products
Customers and stockists are reminded that under EC Health, Safety and Environment Law, when
returning products to Spirax Sarco they must provide information on any hazards and the
precautions to be taken due to contamination residues or mechanical damage which may present
a health, safety or environmental risk. This information must be provided in writing including
Health and Safety data sheets relating to any substances identified as hazardous or potentially
hazardous.
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2. General product information
2.1 General description
The GKE series float steam traps are manufactured with nodular iron body; internal components
are made from stainless steel. They are suitable for use with saturated and superheated steam
on process equipments and on medium / high consumption applications. Working is fully automatic
also regarding air venting (bimetallic thermo element) while the condensate discharge has
modulating characteristics. These traps are ideal for all process drainage applications as condensate is always removed efficiently and quickly over a wide range of fluctuating pressures and load
conditions; they meet all the needs and demands of process automatic control systems. To facilitate the installation on the plant, the mounting connections can be easily positioned in four
different way. For more demanding applications, higher pressure and temperature, see the similar
GHE series manufactured with carbon or stainless steel body.
Standards
This product fully complies with the requirements of the European Pressure Equipment Directive
97/23/EC and carries the mark when so required.
Certification
This product is available with material certification to EN 10204 2.2 or EN 10204 3.1.
Note: all certification/inspection requirements must be stated at the time of order placement.
Sizes and pipe connections
DN 40 and DN 50 flanged EN 1092 PN25/40, standard
DN 40 and DN 50 flanged ANSI B 16.5 Class 150 and 300, on request
1½" and 2" screwed UNI-ISO 7/1 Rp (gas), on request
2.2 Pressure/temperature limits (ISO 6552)
PMA - Maximum allowable pressure 25 bar g @ 300°C
TMA - Maximum allowable temperature 300°C
Minimum allowable temperature -10°C
PMO - Maximum operating pressure 21 bar g @ 300°C
TMO - Maximum operating temperature 300°C
Minimum operating temperature, danger of freezing considered 0°C
ΔPMX - Maximum differential pressure
Designed for a maximum cold hydraulic test pressure of 37.5 bar g
Note: maximum operating pressure can be limited by the rating chosen for the flanges.
GKE 10 10 bar g
GKE 21 21 bar g
2.3 Dimensions/weights (approximate) in mm and kg
DN A A1 B C D E*
1½" - 40 320 324 280 120 300 480 25.0 30.0
2" - 50 320 324 280 120 300 480 25.0 32.0
Connections:
- Black arrow: standard supply configuration (right to left)
- White arrows: optional installation configurations, on request
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Weight
Scrd./SW Flgd.
* Withdrawal distance
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2.4 Materials
N° Part Material
1 Body SG iron GJS400 18 LT UNI 1563
2 Cover SG iron GJS400 18 LT UNI 1563
3 Cover gasket Asbestos-free synthetic fibre
4 Air vent assembly Stainless steel
5 Bracket gasket Asbestos-free synthetic fibre
6 Bracket assembly Stainless steel AISI 304
7 Bracket screws Stainless steel AISI 304
8 Lower valve seat Stainless steel Series 400C
9 Valve plug Stainless steel Series 400C
10 Float arm Stainless steel AISI 304
11 Ball float Stainless steel AISI 304
12 Drain plug Carbon steel ASTM A105
Cover studs Carbon steel ASTM A193 B7
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Cover nuts Carbon steel ASTM A194 8M
2.5 Capacities (kg/h)
The condensate discharge capacities shown below are based on condensate at saturation temperature
Differential
pressure
(bar g)
0.1 1500 3600 1000 1900
0.3 2500 6000 1700 3300
0.5 3200 7700 2150 4100
0.7 3700 8900 2450 4800
1 4300 10600 2900 5700
1.5 5200 12500 3500 6800
2 6000 14100 4000 7800
4 8400 20000 5500 10500
7 11000 26000 7300 13500
10 13000 30500 8500 16300
12 - - 9400 18000
14 - - 10000 19000
18 - - 12000 21500
21 - - 12300 22500
The choice of trap should be based on the following data:
a) Hourly amount of condensate to be discharged,
b) Effective differential pressure,
c) Safety factor: 1.25 to 1.5 for continuous use; 2 to 3 for intermittent use.
GKE 10 GKE 10 GKE 21 GKE 21
DN 40 - 1½" DN 50 - 2" DN 40 - 1½" DN 50 - 2"
Trap type
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3. Installation
Note: Before actioning any installation observe the ‘Safety information’ in Section 1.
Referring to the Installation and Maintenance Instructions, name-plate and Technical Information
Sheet, check that the product is suitable for the intended installation.
3.1 Check materials, pressure and temperature and their maximum values. If the maximum
operating limit of the product is lower than that of the system in which it is being fitted,
ensure that a safety device is included in the system to prevent overpressurisation.
3.2 Determine the correct installation situation and the direction of fluid flow.
3.3 Remove protection covers from all connections before installation.
3.4 Install the trap below and as close as possible to the drainage outlet; make the connections
so that the trap is positioned with the arrow on the body pointed vertically downwards.
3.5 Insert a strainer with an adequate capacity immediately ahead of the trap to prevent damage
to the device’s internal components; in systems with steam recovery, it is recommended to
mount a flow indicator downstream of the trap to check that it is working.
3.6 Avoid long stretches of connecting pipe, especially if arranged horizontally or rising.
3.7 With minimum operating pressures, leave a hydrostatic head of at least one metre between
the drainage outlet and the trap.
3.8 If the device to be drained is fitted with automatic temperature control, apply a vacuum
breaker in addition to the hydrostatic head (see Fig. 1).
3.9 If the condensate has to be raised to a height above the trap, install a check valve
downstream of the trap.
3.10 Avoid raising the condensate in the case of low operating pressure (<1 bar) or automatic
temperature control, but use a steam recovery pump.
3.11 Changing the connection configuration
The device is supplied with the connections arranged in a horizontal line and in the direction
of flow shown in Fig. 2a). To change the arrangement of the connections, use the following
procedure, with reference to Fig. 2 and Fig. 3.
- Open the trap by unscrewing the 8 nuts (13) using a size 24 wrench and remove the
cover (2).
- Disassemble the frame, together with the various mechanisms and ball float, by
unscrewing the 4 screws (7) with a size 13 wrench.
- Change the body position by moving the connections as desired, to one of the possible
solutions given at Fig. 2 (a, b, c, d).
- Fix the frame to the body in such a way that the float is free to move vertically from top
to bottom and viceversa.
- Close the trap again, making sure that the arrow on the cover is pointing vertically downwards.
- When mounting the frame and closing the cover, make sure that the gaskets are in good
condition and correctly positioned.
Note: If the trap is to discharge to atmosphere ensure it is to a safe place, the discharging fluid
may be at a temperature of 100°C (212°F).
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Fig. 1
Fig. 2
By-pass
valve
Sight glass
Check
valve
Vacuum
breaker
Trap
Strainer
System
1 m minimum
Steam supply
Standard installation
Installation for systems with low steam
pressure and possible formation of vacuum
4. Commissioning
After installation or maintenance ensure that the system is fully functioning. Carry out tests on
any alarms or protective devices. Always open isolation valves slowly until normal operating
condition are achieved. Check for leaks and correct operation.
5. Operation
Ball float steam traps quickly remove air, have continuous, modulating condensate discharge,
and can adapt immediately even to large or sudden variations of flow and pressure.
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6. Maintenance
Note: Before actioning any maintenance programme observe the "Safety information" in
Section 1.
Safety note:
These traps are installed in medium pressure steam lines. Personnel doing the adjustment
and maintenance work should wear heavy gloves, long sleeve shirt and other equipment
designed to protect the wearer (goggles, face shield, etc...) in the event of a leak.
6.1 General information
To ensure the device’s long-term, safe operation, an adequate maintenance programme
should be prepared, involving regular inspection and cleaning, for which some important
instructions are given below. All work must be carried out or be supervised by a suitable
competent person.
Before undertaking any maintenance on the trap it must be isolated from both the supply
line and return line and any pressure allowed to safely normalise to atmosphere. The trap
should then be allowed to cool. When reassembling, ensure that all joint faces are clean.
6.2 Routine Maintenance
Check that the ball float is not deformed and does not contain water; in the case of
replacement, do not force the float arm, but remove it by undoing the split pin and dowel
and properly blocking it before unscrewing the nut blocking the float.
- Check that the mechanism’s movement is not hindered and that the valves move freely
to a completely closed position. To replace the main valve assembly, unscrew the four
nuts from the bolts. When mounting the new main valve assembly, check its condition
and the position of the cover gasket, and tighten the nuts uniformly.
- Inspect and clean the air vent assembly, checking that the passages are free and that
the valve plug and discs move without friction. Do not change the valve plug travel.
- Tighten to the recommended tightening torques (see table below).
- After reassembling open isolation valves slowly until normal operating condition are
achieved.
- Check for leaks and correct operation.
Recommended tightening torques
Item Size
Cover nuts
Bracket screws
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1½" - 40 24 A/F M 16 x 70 90
2" - 50 24 A/F M 16 x 70 90
1½" - 40 M 8 x 15 18.2
2" - 50 M 8 x 15 18.2
or
mm
N m
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7. Spare parts
The spare parts are shown in the drawing below and are available in groupings as indicated in the
table. Other parts are not available as spares.
Available spares
Main valve assembly 3, 5, 6, 7, 8, 9, 10
Ball float and cover gasket assembly 3, 11
Air vent assembly (2 off) 4
Gasket set (3+3 off) 3, 5
1 - Body
2 - Cover
3 - Cover gasket
4 - Air vent assembly
5 - Bracket gasket
6 - Bracket assembly
7 - Bracket screws
8 - Lower valve seat
9 - Valve plug
10 - Float arm
11 - Ball float
12 - Drain plug
13 - Studs and nuts
Fig. 3
How to order spares
Always order spare parts by using the description given in the table and state the size and type of
trap, including pressure range and type of the connections.
Example: N° 1 main valve assembly for a ball float steam trap Spirax Sarco GKE 21, DN 1½".
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REPAIRS
Please contact our nearest Branch Office or Agent, or directly Spirax-Sarco S.r.l.
Via per Cinisello, 18 - 20834 Nova Milanese (MB) – ITALY - Tel.: +39 0362 49 17.1 - Fax: +39 0362 49 17 307
LOSS OF GUARANTEE
Total or partial disregard of above instructions involves loss of any right to guarantee.
Spirax-Sarco S.r.l. - Via per Cinisello, 18 - 20834 Nova Milanese (MB) - Tel.: 0362 49 17.1 - Fax: 0362 49 17 307
3.341.5275.245 ST Issue 7 - 2013.04
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