GESTRA Steam Systems AK 45. Installation Instructions Condensate Drain Valve AK 45

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1 GESTRA Steam Systems Installation Instructions Condensate Drain Valve

2 Contents Important Notes Page Usage for the intended purpose...4 Safety note...4 Danger...4 Attention...4 PED (Pressure Equipment Directive)...5 ATEX (Atmosphère Explosible)...5 Explanatory Notes Scope of supply...6 System description...6 Function...6 Technical Data Corrosion resistance...7 Sizing...7 Name plate / marking...7 Component Parts...8 Key...9 Installation...10 Flanged design...10 Screwed design...10 Steam trap with socket-weld ends...11 Steam trap with butt-weld ends...11 Attention...11 Heat treatment of welds...11 Draining of steam main...12 Draining of a water pocket...12 Commissioning...12

3 Contents continued Operation Page...13 Maintenance Clean drain valve...13 Tools...13 Replace hand purging knob and valve insert...14 Tools...14 Torques for tightening...14 Spare Parts Spare parts list...15 Decommissioning Danger...15 Disposal...15

4 Important Notes Usage for the intended purpose Use condensate drain valve only for the discharge of condensed water in pipe lines or for air-venting within the admissible pressure/temperature ratings. Check the corrosion resistance and chemical suitability of the drain valve for the application in question. For information on the application in potentially explosive areas see section ATEX Directive 94/9/EC, 1999/92/EC on page 5. Safety note The equipment must only be installed and commissioned by qualified staff. Maintenance and service work must only be performed by adequately trained persons who have a recognized level of competence. Danger The equipment is under pressure during operation. When loosening flanged connections or sealing plugs, hot water and/or steam may escape. This presents the risk of severe scalding. Installation and maintenance work should only be carried out when the system is depressurized (0 bar): isolate the equipment from both upstream and downstream pressure. The equipment becomes hot during operation. This presents the danger of severe burns to hands and arms. Installation and maintenance work should only be carried out when the system is cold. Before carrying out any kind of maintenance work or undoing flanged connections or sealing plugs make sure that all connected lines are depressurized (0 bar) and cooled down to room temperature. Sharp edges on internal parts present a danger of cuts to hands. Always wear industrial gloves when replacing the regulator or the strainer. Attention The name plate indicates the technical specification of the equipment. Do not commission or operate a steam trap without name plate. 4

5 Important Notes continued PED (Pressure Equipment Directive) The equipment fulfils the requirements of the Pressure Equipment Directive 97/23/EC. can be used with fluids of group 2. The equipment is not CE marked according to section 3.3 of the PED. 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. 5

6 Explanatory Notes Scope of supply 1 Condensate drain valve 1 Installation manual System description The automatically discharges condensed water from steam systems during start-up, until the pressure in the system has reached the adjusted valve closing pressure. At shut-down or when the pressure falls below the closing pressure the valve opens and accumulated condensate is automatically discharged. Function When there is no pressure in the system the drain valve is held in the open position by the integrated spring. As soon as the service pressure has reached the closing pressure to which the has been adjusted, the valve closes (by the differential pressure acting on the valve cone against the force of the spring). When the pressure drops below the closing pressure, the opens by spring force. A hand purging knob is provided, so that the can be briefly opened by hand with the system under pressure to clear any deposits from the valve seat area. The is adjusted at our works to close at a differential pressure of 0.8 barg (12 psig). The is provided with a built-in strainer. 6

7 Technical Data Corrosion resistance When used for its intended purpose, the safe functioning of the equipment will not be impaired by corrosion. Sizing The valve body must not be subjected to sharp increases in pressure. The dimensional allowances for corrosion reflect the latest state of technology. Name plate / marking The temperature/pressure limit is indicated on the valve body or on the name plate. For more information see GESTRA technical documents such as data sheets and Technical Information. According to EN 19 the type and design must be specified on the name plate and valve body. Name/logo of the manufacturer Type designation: Pressure rating PN Marking according to ATEX: The equipment is not Ex marked. Material number Max. temperature Max. pressure Flow direction 1 Stamp on name plate, e. g. 05 specifies the manufacturing year and quarter, (in this case the 1 st quarter 2005) MADE BY GESTR A PN40 A K 1/ Marking Fig. 1 PMA21bar/304 psig PMX 22 bar / 319 psig F TMA 400 C/752 7

8 Component Parts A B C D E F G H I J K L Fig. 2 8

9 Component Parts continued Key A Hexagon head screw M 10 x 25, EN 24017, alloy steel 24 CrMo 5 (1.7258) B Hand purging knob C Gasket A 14 x 18 D Name plate E Cover F Valve insert G Bushing (interference fitted, no spare part) H Gasket 40 x 48 x 2 I Body J Strainer K Gasket A 24 x 29 L Sealing plug 9

10 Installation Install the AK so that discharge is to open drain (without back pressure), preferably in a vertical line with downwards flow. The can be installed in any plane with flow in the direction of the arrow. When the valve is installed in a horizontal line, the cover must be on top. If it is necessary to install the in a horizontal line, the pipe on the discharge of the trap should include a 90 downwards bend, Fig. 3, Fig. 4. Flanged design 1. Observe position of installation. 2. Observe flow direction. The flow direction arrow is located on the valve body. 3. Leave at least 40 mm free space around the equipment for subsequent disassembly of the cover E. 4. Remove plastic plugs. They are only used for transit protection. 5. Clean gasket surfaces of the two flanges. 6. Install condensate drain valve. Screwed design 1. Observe position of installation. 2. Observe flow direction. The flow direction arrow is located on the valve body. 3. Leave at least 40 mm free space around the equipment for subsequent disassembly of the cover E. 4. Remove plastic plugs. They are only used for transit protection. 5. Clean internal threads. 6. Install condensate drain valve. 10

11 Installation continued Steam trap with socket-weld ends 1. Observe position of installation. 2. Observe flow direction. The flow direction arrow is located on the valve body. 3. Leave at least 40 mm free space around the equipment for subsequent disassembly of the cover E. 4. Remove plastic plugs. They are only used for transit protection. 5. Remove regulator as described in section Maintenance. 6. Clean socket-weld ends. 7. Apply only electric arc welding process (welding process 111 and 141 in accordance with ISO 4063). Steam trap with butt-weld ends 1. Observe position of installation. 2. Observe flow direction. The flow direction arrow is located on the valve body. 3. Leave at least 40 mm free space around the equipment for subsequent disassembly of the cover E. 4. Remove plastic plugs. They are only used for transit protection. 5. Remove regulator as described in section Maintenance. 6. Clean butt-weld ends. 7. Apply electric arc welding process (welding process 111 and 141 in accordance with ISO 4063) or gas welding (welding process 3 in accordance to ISO 4063). Attention Only qualified welders certified e. g. according to EN may weld the valve into pressurized lines. The valve must not be insulated. Heat treatment of welds A subsequent heat treatment of the welds is not required. 11

12 Installation continued Draining of a steam main Steam Condensate Fig. 3 Draining of a steam main with an elevated condensate line Draining of a water pocket Steam Fig. 4 Draining of a water pocket Commissioning Make sure that the flanged connections of the are tightly bolted together and leakproof. 12

13 Operation The default factory setting of the valve ensures that the closes when the steam pressure reaches 0.8 bar. For other settings/closing pressures please contact GESTRA AG. Maintenance The GESTRA Condensate Drain Valve requires no special maintenance. However, if used in new installations which have not been rinsed it may be necessary to inspect and clean the trap. Clean drain valve 1. Observe the danger note on page 4! 2. Unscrew body screws A and take the cover E off the body I, Fig Remove and clean valve insert F. 4. Unscrew sealing plug L and strainer J. 5. Clean body, internals and all gasket surfaces. 6. Clean seating surfaces of body and cover. 7. Apply heat-resistant lubricant to all threads, seating surfaces of the valve insert and of the cover (e. g. WINIX 2150). 8. Screw in valve insert F, applying a torque of 90 Nm. Replace gasket H only if there are visual signs of damage. 9. Replace gasket K if there are visual signs of damage. 10. Put cover on valve body. Tighten body screws evenly with 25 Nm. 11. Mount sealing plug L together with strainer J and tighten with 120 Nm. Tools n Spanner 16 mm A. F., DIN 3113, Form B n Spanner 22 mm A. F., DIN 3113, Form B n Torque spanner Nm, DIN ISO 6789 WINIX 2150 is a registered trademark of WINIX GmbH, Norderstedt 13

14 Maintenance continued Replace hand purging knob and valve insert 1. Observe the danger note on page 4! 2. Unscrew body screws A and take the cover E off the body I, Fig Unscrew hand purging knob B. 4. Unscrew valve insert F. 5. Unscrew sealing plug L and strainer J. 6. Clean strainer, sealing plug and gasket surfaces. 7. Clean seating surfaces of body and cover. 8. Apply heat-resistant lubricant to all threads, seating surfaces of the valve insert and of the cover (e. g. WINIX 2150). 9. Replace gasket H only if there are visual signs of damage. 10. Replace gasket K if there are visual signs of damage. 11. Mount new hand purging knob F and tighten with a torque of 40 Nm. 12. Mount new valve insert B and tighten with a torque of 90 Nm. 13. Put cover on valve body. Tighten body screws evenly with 25 Nm. 14. Mount sealing plug L together with strainer J and tighten with 120 Nm. Tools Spanner 16 mm A.F., DIN 3113, Form B Spanner 19 mm A.F., DIN 3113, Form B Spanner 22 mm A.F., DIN 3113, Form B Torque spanner Nm, DIN ISO 6789 Torques for tightening Item Designation Torque [Nm] F Valve insert 090 B Hand purging knob 040 A Body screws 025 L Sealing plug 120 All torques refer to a room temperature of 20 C. WINIX 2150 is a registered trademark of WINIX GmbH, Norderstedt 14

15 Spare Parts Spare parts list Item Designation Stock code B Hand purging knob F C Valve insert with gasket J K L Strainer, cpl H Gasket*) 40 x 48 x 2, made of graphite *) Minimum order quantity 50 items. Contact your local dealer for smaller quantities. Decommissioning Disposal Danger Risk of severe burns and scalds to the whole body! Before loosening flanged connections or sealing plugs make sure that all connected lines are depressurized (0 bar) and cooled down to room temperature. Dismantle the valve and separate the waste materials, using the specifications in the table Materials on page 9. For the disposal of the valve observe the pertinent legal regulations concerning waste disposal. 15

16 GESTRA Agencies all over the world: España GESTRA ESPAÑOLA S.A. Luis Cabrera, E Madrid Tel / Fax / ; Polska GESTRA Polonia Spolka z.o.o. Ul. Schuberta 104 PL Gdansk Tel / od 10 Fax / Great Britain Flowserve Flow Control (UK) Ltd. Burrel Road, Haywards Heath West Sussex RH 16 1TL Tel / Fax / Portugal Flowserve Portuguesa, Lda. Av. Dr. Antunes Guimarães, 1159 Porto Tel / Fax / Italia Flowserve S.p.A. Flow Control Division Via Prealpi, 30 l Cormano (MI) Tel / Fax / USA Flowserve GESTRA U.S Ampere Drive Louisville, KY Tel.: / Fax: / GESTRA AG P. O. Box , D Bremen Münchener Str. 77, D Bremen Telephone +49 (0) Fax +49 (0) Internet /806cm 1999 GESTRA AG Bremen Printed in Germany 16

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