AK 45. Installation Instructions Condensate Drain Valve AK 45. A Siebe Group Product 1

Transcription

1 AK 45 Installation Instructions Condensate Drain Valve AK 45 A Siebe Group Product 1

2 Capacity Chart [lb/h] [kg/h] Capacity [bar] [psi] Differential pressure 1 Max. capacity for cold condensate as a function of the differential pressure (without back pressure) Fig. 1 2

3 psig MADE BY GESTR A F 2 1/ Parts Drawing A B C PMA21bar/304 PMX 32bar/464 psig 4 5 A K 1 5 PN40 D TMA 400 C/752 E F G H I GESTRA J K L Fig. 2 3

4 4

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

6 Contents Important Notes Page Important safety note...7 Danger...7 Explanatory Notes Scope of supply...8 System description... 8 Function...8 Technical data...9 Installation AK Flanged design...10 Screwed design...10 Draining of a steam main...11 Draining of a water pocket...11 Maintenance Clean / replace hand purging knob...12 Clean / replace valve insert...12 Clean / replace strainer...13 Torques...13 Spare Parts Spare part list

7 Important Notes Important Safety Note Use condensate drain valve AK 45 only for venting and draining steam systems. The equipment must only be installed by qualified staff. Qualified staff are those persons who through adequate training in engineering, the use and application of safety equipment in accordance with regulations concerning steam safety systems, and first aid & accident prevention have achieved a recognised level of competence appropriate to the installation and commissioning of this device. Danger The trap is under pressure during operation. When performing maintenance, hot water and steam may escape. This presents the danger of severe burns to the whole body. Installations and maintenance work should only be carried out when the system is depressurized. The lines upstream and downstream of the trap should be isolated. The trap is 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. Sharp edges on internal parts present a danger of cuts to hands. Always wear industrial gloves for installation and maintenance work. 7

8 Explanatory Notes Scope of Supply AK 45 1 Condensate drain valve AK 45 1 Installation instructions System Description The AK 45 automatically drains condensate 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 drained away. Function When there is no pressure the drain valve is held in the open position by the integral spring. As soon as the service pressure has reached the closing pressure to which the AK 45 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 AK 45 opens by spring force. A hand purging knob is provided, so that the AK 45 can be opened by hand with the system under pressure to clear any deposits from the valve seat area. The AK 45 is adjusted at our works to close at a differential pressure of 0.8 barg (12 psig). The AK 45 is provided with an integral strainer. 8

9 Technical Data Pressure / Temperature Ratings Max. service [barg] pressure [psig] Related [ C] temperature [ F] Materials Body Cover Screws Body gasket Other internals DIN reference Forged steel C 22.8 (1.0460) Forged steel C 22.8 (1.0460) Alloy steel 24 CrMo 5 (1.7258) Graphite Stainless steel ASTM equivalent A 105 A 105 A 193 B 7 1 ) 1 ) Physical and chemical properties comply with DIN grade. ASTM nearest equivalent grade is stated for guidance only. 9

10 Installation AK 45 Install the AK so that discharge is to open drain (without back pressure), preferably in a vertical line with downwards flow. Fig. 4, Fig. 5 When the AK 45 is installed horizontally the cover must be on top. If it is necessary to install the AK 45 in a horizontal line, the pipe on the discharge of the trap should include a 90 downwards bend. Flanged Design 1. Observe position of installation. 2. Observe flow direction. The flow direction arrow is located on the trap 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 trap 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 Draining of a Steam Main Steam Condensate AK 45 Fig. 4 Draining of a steam main with an elevated condensate line Draining of a Water Pocket Steam AK 45 Fig. 5 Draining of a water pocket 11

12 Maintenance The GESTRA Condensate Drain Valve AK 45 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 / Replace Hand Purging Knob 1. Observe danger note on page Unscrew, inspect and clean hand purging knob B. Do not disassemble purging knob. 3. Replace hand purging knob B in case of visible signs of wear or damage. 4. Clean sealing surfaces. 5. Replace gasket C if damaged. 6. Apply heat-resistant lubricant to the thread and seating surface of the purging knob (use for instance WINIX 2150). 7. Screw in hand purging knob and tighten with a torque of 40 Nm. Tools Spanner A. F. 19 mm, DIN 3113, form B Torque spanner Nm, DIN ISO 6789 Clean / Replace Valve Insert 1. Observe danger note on page Unscrew body screws A, remove cover E from body. 3. Unscrew, inspect and clean valve insert F. Do not disassemble valve insert. 4. Replace valve insert F in case of visible signs of wear or damage. 5. Clean body and internals. Clean all seating surfaces. 6. Apply heat-resistant lubricant to all threads and seating surfaces of the valve insert and seating surface of the cover (use for instance WINIX 2150). 7. Screw in valve insert F and tighten with a torque of 90 Nm. 8. Replace gasket H if damaged. Use corresponding cover E of the same trap. If a new cover E is used or taken from another trap the gasket H has to be replaced. 9. Put cover back onto the body. Tighten body screws A alternately to a torque of 25 Nm in several steps. Tools Spanner A. F. 16 mm, DIN 3113, form B Spanner A. F. 22 mm, DIN 3113, form B Torque spanner Nm, DIN ISO WINIX is a registered trademark of WINIX GmbH, Norderstedt

13 Clean / Replace Strainer 1. Observe danger note on page Slacken sealing plug L and unscrew together with strainer J. 3. Clean strainer, sealing plug and seating surfaces. 4. Replace strainer and sealing plug in case of visible signs of wear or damage. 5. Replace gasket K if damaged. 6. Apply heat-resistant lubricant to the thread of the sealing plug (use for instance WINIX 2150). 7. Mount sealing plug L with gasket K and strainer J. Tighten sealing plug with 120 Nm. Tools Spanner A. F. 30 mm, DIN 3113, form B Torque spanner Nm, DIN ISO 6789 Torques Item Designation Torque [Nm] B F A Hand purging knob 40 Valve insert 90 Body screws 25 L Sealing plug 120 All torques indicated refer to a room temperature of 20 C. Spare Parts Spare Parts List Item Designation Ref. no. J F C B H K K L Valve insert Gasket*) for purging knob, A 14 x 18, made of stainless steel Hand purging knob Gasket*) for cover, 40 x 48 x 2, made of graphite Strainer with sealing plug and gasket Gasket*) for sealing plug, A 24 x 29, made of stainless steel *) Minimum order quantity 50 items. Contact your local dealer for smaller quantities. 13

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