GESTRA BK 15 Original Installation Instructions - User Manual

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BK 15

(DN40, DN 50)

Steam Trap

E N

E n g l i s h

Original Installation Instructions

810682-03

Contents

Important Notes

Usage for the intended purpose ......................................................................... 4

Safety note ....................................................................................................... 4

Danger ............................................................................................................. 4

Attention .......................................................................................................... 4

Application of European Directives ..................................................................... 4

Notes on the Declaration of Conformity/Manufacturer's Declaration ..................... 5

Explanatory Notes

Scope of supply ........................................................................................................... 6
Description .................................................................................................................. 6
Design ........................................................................................................................ 6

Technical Data

Rating plate/marking .................................................................................................... 7

Components

Component parts of BK 15 ..

....................................................................................... 8

Key ............................................................................................................................. 9

Installation

BK 15 ....................................................................................................................... 10
Danger

......................................................................................................................

Flanged version ........................................................................................................ 10
Socket-weld version ................................................................................................... 10
Butt-weld version ....................................................................................................... 11
Attention ................................................................................................................... 11
Heat treatment of welds ............................................................................................. 11

Bringing into Service

BK 15 ....................................................................................................................... 12
Danger ..................................................................................................................... 12
Adjusting the regulator (supercooling, controlled steam flowrate)................................... 12
Restoring the factory settings...................................................................................... 12
Tools ......................................................................................................................... 13

Operation

BK 15 ...................................................................................................................... 13

Page

Contents

continued

Page

Maintenance

BK 15 ....................................................................................................................... 13
Danger ...................................................................................................................... 13
Checking the steam trap ............................................................................................ 13
Cleaning/replacing the Thermovit regulator and strainer ............................................... 14
Tools ......................................................................................................................... 14
Torques ..................................................................................................................... 14

Spare Parts

Spare parts list .......................................................................................................... 15

Taking out of Service

Danger ...................................................................................................................... 15
Attention ................................................................................................................... 15
Disposal .................................................................................................................... 15

Usage for the intended purpose

Use the BK 15 steam trap only for discharging condensate from steam or for air venting.

Use in pipes for discharging condensate from steam, paying attention to the admissible

pressure and temperature ratings and the impact of chemicals and corrosion on the pres-

sure equipment.

Safety Note

The equipment may only be installed, brought into service, maintained and refitted by

authorised staff who have the required knowledge and have undergone specific training.

Danger

The equipment is under pressure and hot during operation. Risk of injuries and severe

burns to the entire body.

Only perform installation and maintenance work when the equipment is not under pressure

(0 bar) and is cold (20 °C).

Before performing installation or maintenance work, vent the equipment and

isolate it from both upstream and downstream pressure.

Sharp edges on inner parts present a danger of cuts to hands.

Always wear industrial gloves when working on the equipment.

Attention

The rating plate specifies the technical features of the equipment.

Do not bring into service or operate any equipment that does not bear its own specific

rating plate. The pressure and temperature data on the trap's rating plate must conform to

the requirements of the system.

Application of European Directives

Pressure Equipment Directive

The equipment conforms to this directive (see "Manufacturer's Declaration" section) and

can be used for the following fluids:

■

Group 2 fluids

ATEX Directive

The equipment does not have a potential ignition source and as such is not subject to this

directive (see "Manufacturer's Declaration" section).
Once installed, static electricity may arise between the equipment and the connected

system. During use in potentially explosive atmospheres, the discharge or prevention of

possible electrostatic charging is the responsibility of the manufacturer or owner of the

system.
If there is a possibility of fluid escaping, e.g. via actuating devices or leaks in screwed

couplings, the manufacturer or owner of the system must take this into consideration when

dividing the area into zones.

Important Notes

continued

Notes on the Declaration of Conformity/
Manufacturer's Declaration

You can find details on the conformity assessment in accordance with European Directives

in our Declaration of Conformity or Manufacturer's Declaration.
You can request the valid Declaration of Conformity or Manufacturer's Declaration from the

address below:

Modifications to the equipment not approved by us will cause this Declaration to lose its

validity.

GESTRA AG

Münchener Strasse 77
28215 Bremen
Germany
Tel.

+49 421 3503-0

Fax

+49 421 3503-393

E-mail info@de.gestra.com
Web www.gestra.com

Design

BK 15:

Version for installation in horizontal and vertical pipes.

Scope of supply

BK 15

1 Steam trap BK 15

1 Installation & Operating Manual

Description

Thermostatic steam trap with corrosion-resistant, water hammer-resistant Thermovit

(Duo stainless steel) regulator. The Thermovit regulator can be adjusted from the outside.

With integral strainer and non-return valve unit. Asbestos-free body gasket (graphite).

Installation in any position.

The steam trap is factory-set to discharge condensate with virtually no banking-up.

Greater supercooling can be set manually from the outside after installation.

The trap vents independently both when the system is started up and during operation.

The BK 15 can also be used as an air vent.

Explanatory Notes

Rating plate/marking

For pressure and temperature ratings, see the marking on the body or the information on

the rating plate. For further information, see GESTRA publications such as data sheets and

Technical Information booklets.
The type and version are indicated on the rating plate or body:



Manufacturer's name/logo



Type designation



Pressure class PN or Class



Material number



Direction of flow



Stamp on body/rating plate, e.g. indicates the quarter and year of manufacture

(example: 1st quarter of 2010).

Technical Data

Fig. 1

Thermovit regulator
Standard version
30K supercooling

Nominal size

Ratings to

EN ISO 26552

Component parts of BK 15

Components

Fig. 2

Components

continued

Key

Union nut G¾

Stuffing box ring

Packing 9 x14 x 7

Cover

Adjusting fork

Guide ring

Thermovit regulator

Strainer

Bush (force-fit, no spare part)

Body gasket 92,7 x 102 x 1

Body

Rating plate

Hexagon nut M12

Hexagon bolt M12

BK 15

Any installation position is possible, as long as the direction of flow arrow is complied with.

If installed in a horizontal pipe, it is best to have the cover facing upwards. We recommend

that you do not insulate the steam trap.

Danger

The equipment is under pressure and hot during operation. Risk of injuries and severe

burns to the entire body.
Only perform installation and maintenance work when the equipment is not under pressure

(0 bar) and is cold (20 °C).
Before performing installation or maintenance work, isolate the equipment from upstream

and downstream pressure, and vent it.
Sharp edges on inner parts present a danger of cuts to hands.

Always wear industrial gloves when working on the equipment.

Flanged version

1.  Ensure the correct installation position.
2.  Ensure the correct direction of flow. The direction of flow arrow is on the trap body.
3.  Leave sufficient space for servicing. When the trap is installed, a minimum space of

90 mm

is required for opening cover

4. Remove the plastic plugs. They are used

only

as transit protection.

5. Clean the sealing surfaces of both flanges.
6. Install the trap.

Socket-weld version

90 mm

is required for opening cover

4. Remove the plastic plugs. They are used

only

as transit protection.

5. Remove the Thermovit regulator as described in the

Maintenance

section.

6. Clean the socket weld end.
7. Install

only

using arc welding (welding process 111 and 141 to DIN EN 24063), or

equivalent standard.

Installation

continued

Butt-weld version

90 mm

is required for opening cover

4. Remove the plastic plugs. They are used

only

as transit protection.

5. Clean the butt weld ends
6. Install using arc welding (welding process 111 and 141 to DIN EN 24063) or gas

welding (welding process 3 to DIN EN 24063), or equivalent standard.

Attention



Steam traps may only be welded in pipes by welders with test certification to

DIN EN 287 or equivalent qualifications.

Heat treatment of welds

Subsequent heat treatment of welds is not necessary provided the pipe is made from

similar material to the trap body.
If pipes are of a material that render heat treatment necessary, this must be restricted to

the immediate vicinity of the weld. If this is not possible, remove the Thermovit regulator

before heat treatment.

Bringing into Service

Make sure that all connections have undergone a suitable pressure test in conformity with

the applicable regulations.

Danger

The equipment is under pressure and hot during operation. Risk of injuries and severe

burns to the entire body.
Only perform installation and maintenance work when the equipment is not under pressure

(0 bar) and is cold (20 °C).
Before performing installation or maintenance work, isolate the equipment from upstream

and downstream pressure, and vent it.
Sharp edges on inner parts present a danger of cuts to hands.

Always wear industrial gloves when working on the equipment.
When union nut

is slackened to adjust the regulator, hot water or steam escapes.

Adjusting the regulator

(supercooling, controlled steam flowrate)

The Thermovit regulators of the BK 15 are factory-set to ensure they close steam-tight

and remove condensate with virtually no banking-up. If greater supercooling and resulting

banking-up of condensate is required, e.g. for a heating process, this can be set when

bringing into service or during operation:
1. Pay attention to the Danger note! Slacken union nut

one

turn and turn adjustment

screw

clockwise using a screwdriver. A

turn corresponds to a 4 K change in tem-

perature. Starting from the factory setting, you can turn adjustment screw

clockwise

a maximum of 1.5 turns.

2. A controlled steam flowrate can also be set if required. To do this, you can turn adjust-

ment screw

clockwise a maximum of 1.5 turns, starting from the factory setting.

3. Tighten union nut

to the torque indicated in the table.

Restoring the factory settings

The Thermovit regulators of the BK 15 are factory-set to ensure they close steam-tight and

remove condensate with virtually no banking-up. If necessary, you can restore the factory

settings as follows:
1. Depressurize the steam trap and let it cool to room temperature (20°C).
2. Slacken union nut

and turn adjustment screw

clockwise with a screwdriver until

resistance is felt.

3. Turn adjustment screw

three turns anti-clockwise. The steam trap will now dis-

charge condensate virtually without banking-up (factory setting).

4. Tighten union nut

to the torque indicated in the table.

Bringing into Service

continued

Tools

■

Screwdriver 5.5/100, DIN 5265, form A

■

Combination spanner size 36 mm AF, DIN 3113, form B

■

Torque wrench 20–160 Nm, DIN ISO 6789

Operation

BK 15

The BK 15 can be serviced (see

Maintenance

We recommend periodic tests and maintenance to ensure correct functioning of the equip-

ment. For critical applications, we recommend continuous monitoring.

Danger

The equipment is under pressure and hot during operation. Risk of injuries and severe

burns to the entire body.
Only perform installation and maintenance work when the equipment is not under pressure

(0 bar) and is cold (20 °C).
Before performing installation or maintenance work, isolate the equipment from upstream

and downstream pressure, and vent it.
Sharp edges on inner parts present a danger of cuts to hands.

Always wear industrial gloves when working on the equipment.

Checking the steam trap

The BK 15 steam trap can be checked during operation using a GESTRA VAPOPHONE

ultrasonic measuring unit or TRAP

test

If live steam leakage is detected, clean the trap or replace the regulator.

Maintenance

continued

Cleaning/replacing the Thermovit regulator and strainer

1. Pay attention to the Danger note on page 4!
2. Undo hexagon bolt

and take cover

off body

3. Fully unscrew Thermovit regulator

and clean it.

4. Remove and clean strainer

5. Clean body

, inner parts and all sealing surfaces.

6. Replace Thermovit regulator

if it shows visible signs of wear or damage.

7. Coat all threads and sealing surfaces with heat-resistant lubricant (e.g. OKS 217).
8. Insert a new body gasket

9. Insert strainer

10. Screw in Thermovit regulator

and tighten to the torque specified in the table.

11. Place cover

on body

, and tighten hexagon bolts

and hexagon nuts

cross-

wise to the torques specified in the table.

Tools

■

Screwdriver 5.5/100, DIN 5265, form A

■

Combination spanner size 36 mm AF, DIN 3113, form B

■

Torque wrench 20–160 Nm, DIN ISO 6789

Torques

Item

Designation

Torque [Nm]

Thermovit regulator

140

Hexagon bolts/hexagon nuts

Union nuts

All torques are based on room temperature 20°C, threads without lubricant.

Item

Designation

Torque [Nm]

Thermovit regulator

140

Hexagon bolts/hexagon nuts

Union nuts

All torques are based on room temperature 20°C, threads without lubricant.

*) Min. order quantity 20 items. For smaller quantities, please contact your specialist retailer.

Spare Parts

Spare parts list

Taking out of Service

Danger

The equipment is under pressure and hot during operation. Risk of injuries and severe

burns to the entire body.
Only perform installation and maintenance work when the equipment is not under pressure

(0 bar) and is cold (20 °C).
Before performing installation or maintenance work, isolate the equipment from upstream

and downstream pressure, and vent it.
Sharp edges on inner parts present a danger of cuts to hands.
Always wear industrial gloves when working on the equipment.

Attention



If there is a risk of frost, drain the trap.

Disposal

The equipment must be disposed of in accordance with statutory waste disposal regula-

tions.

Item

Designation

Stock code

Packing 9 x 14 x 7 *)

376552

CGJ

Thermovit regulator, set of gaskets

098847

Strainer, body gasket

375698

Body gasket *) 92.7 x 102 x 1, graphite

375699

810682-03/11-2017cma (808534-04) · GESTRA AG · Bremen · Printed in Germany

GESTRA AG

Münchener Strasse 77
28215 Bremen
Germany
Tel.

+49 421 3503-0

Fax

+49 421 3503-393

E-mail info@de.gestra.com
Web www.gestra.com

Agencies all over the world:

www.gestra.de

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