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GESTRA Steam Systems PA 46 PA 47 MPA 46 MPA 47 Installation Instructions 81844701 RapidAction Intermittent Valve for Removing Boiler Sludge PA 46, PA 47, MPA 46, MPA 47 EN English
44

GESTRA Steam Systems - alnab.se€¦ · Intermittent boiler blowdown ... in accordance with TRD 604. Sludge sediments, which are accumulated precipitates from boiler water

Sep 05, 2018

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  • GESTRA Steam Systems

    PA 46PA 47MPA 46MPA 47Installation Instructions 81844701RapidAction Intermittent Valve for Removing Boiler Sludge PA 46, PA 47, MPA 46, MPA 47

    ENEnglish

  • Contents

    Important Notes

    Usage for the intended purpose ..............................................................................................................4Safety note .............................................................................................................................................4Danger ...................................................................................................................................................4Attention .................................................................................................................................................4PED (Pressure Equipment Directive) ........................................................................................................5ATEX (Atmosphre Explosible) .................................................................................................................5

    Explanatory Notes

    Scope of supply ......................................................................................................................................6Description .............................................................................................................................................7Function .................................................................................................................................................7

    Page

    Installation

    PA 46, PA 47, MPA 46, MPA 47 .............................................................................................................0Attention ...............................................................................................................................................0Flanged design .....................................................................................................................................0Socketweld design ..............................................................................................................................0Buttweld design ..................................................................................................................................Heat treatment of welds........................................................................................................................Mounting hand lever PA 46, PA 47 ........................................................................................................Changing position of hand lever ............................................................................................................Changing the operating side of the intermittent blowdown valve PA 46 / PA 47 .....................................Changing the operating side of the intermittent blowdown valve MPA 46 / MPA 47 ...............................3

    Commissioning

    Danger .................................................................................................................................................4PA 46, PA 47, MPA 46, MPA 47 ............................................................................................................4

    Name plate / marking .............................................................................................................................8Dimensions PA 46, PA 47 ........................................................................................................................9Dimensions MPA 46, MPA 47 ................................................................................................................0End dimensions of flanges (extract) ......................................................................................................Dimensions of buttweld ends (extract) .................................................................................................Dimensions of socketweld ends (extract) .............................................................................................Pressure & temperature ratings / Connections ......................................................................................3Materials ..............................................................................................................................................4Corrosion resistance .............................................................................................................................4Sizing ...................................................................................................................................................4Capacity chart PA 46, PA 47, MPA 46, MPA 47 ......................................................................................5Control pressure chart MPA 46, MPA 47 ................................................................................................6

    Technical Data

    Design

    PA 46, PA 47 .........................................................................................................................................7MPA 46, MPA 47 ...................................................................................................................................8Key .......................................................................................................................................................9

  • 3

    Maintenance

    Retightening stuffing box ......................................................................................................................6Attention ...............................................................................................................................................6Replacing stuffing box PA 46, PA 47 ......................................................................................................7Replacing stuffing box, valve seat and valve plug PA 46, PA 47 .............................................................8Replacing stuffing box MPA 46, MPA 47 ................................................................................................9Replacing stuffing box, valve seat and valve plug MPA 46, MPA 47 .......................................................30Replacing control membrane in diaphragm actuator MPA 46, MPA 47 ...................................................3Attention ...............................................................................................................................................3Torques required for tightening .............................................................................................................3Tools .....................................................................................................................................................3Single parts of stuffing box, valve plug, valve seat .................................................................................33Mounting / removing valve seat ............................................................................................................34Mounting / removing control membrane ...............................................................................................35Key .......................................................................................................................................................36

    Retrofitting

    Danger .................................................................................................................................................36Mounting diaphragm actuator ...............................................................................................................37Mounting an existing MPA 6, MPA 7 diaphragm actuator ...................................................................37Mounting the forkhead (hand lever for emergency operation) ................................................................38Mounting the limit switch (proximity switch) ................................................................................... 3839Tools .....................................................................................................................................................40Torques required for tightening .............................................................................................................40

    Contents continued Page

    Operation

    Danger .................................................................................................................................................5Intermittent boiler blowdown ................................................................................................................5Duration and frequency of intermittent boiler blowdown .......................................................................5

    Emergency operation MPA 46, MPA 47

    Danger .................................................................................................................................................6Fitting hand lever for emergency operation ...........................................................................................6

    Spare Parts

    Spare parts list .....................................................................................................................................4

    Parts for retrofitting

    List of parts for retrofitting ....................................................................................................................4

    Annex

    Declaration of Conformity .....................................................................................................................43

    Decommissioning

    Danger .................................................................................................................................................4Disposal................................................................................................................................................4

  • 4

    Important Notes

    Safety Note

    The equipment must only be installed and commissioned by qualified and competent staff.Retrofitting and maintenance work must only be performed by qualified staff who through adequate training have achieved a recognised level of competence.

    The valve is under pressure during operation. When loosening flanged connections, sealing plugs or stuffing boxes, hot water and steam may escape.The valve becomes hot during operation. This presents the risk of severe burns to hands and arms. Before servicing or retrofitting the valve or loosening flanges, stuffing box connections or sealing plugs make sure that all connected lines are depressurised (0 bar) and cooled down to room temperature (0 C).Sharp edges on internals present a danger of cuts to hands. Always wear industrial gloves when replacing the packing, valve seat or valve plug. During operation moving internals can pinch ones hands or fingers. Do not touch moving parts! The intermittent valves for removing boiler sludge MPA 46, MPA 47 are remote controlled and can open and close very abruptly.

    Danger

    Usage for the intended purpose

    PA 46, PA 47, MPA 46, MPA 47:Use the rapid-action intermittent valves*) only for removing boiler water containing accumulated nonmetallic sediments from steam boilers within the admissible pressure und temperature ratings.Use only compressed air (at room temperature) or pressurized water (at room temperature) as control fluid for the GESTRA diaphragm actuator in accordance with the specified pressure/temperature ratings.*) Please note: In British English an intermittent valve for removing boiler sludge is referred to as (intermittent) bottom blowdown valve. In American English the term (intermittently operating) blowoff valve is used, but only in conjunction with a slowopening valve (ASME code).

    Attention

    The name plate specifies the technical features of the equipment. Note that any piece of equipment without its specific name plate must neither be commissioned nor operated.

  • 5

    PED (Pressure Equipment Directive)

    The equipment meets the requirements of the Pressure Equipment Directive 97/3/EC.Application in fluids of group . With CE marking, except equipment according to section 3.3.

    Important Notes continued

    ATEX (Atmosphre Explosible)

    The valves PA 46, PA 47, MPA 46, MPA 47 can be used in potentially explosive areas, provided that the following notes are observed:The operating fluid must not generate excessively high temperatures. Electrostatic charges that may be generated during operation must be discharged. Make sure that the stuffing box is tight and that the valve spindle can run smoothly. The equipment can be used in Ex zones , , , (999/9/EC)

    II G/D c X.For more information refer to our ATEX Declaration of Conformity.

  • 6

    Explanatory Notes

    Scope of supply

    PA 46 Intermittent valve for removing boiler sludge PA 46 Hand lever Installation manual

    PA 47 Intermittent valve for removing boiler sludge PA 47 Hand lever Installation manual

    MPA 46 Intermittent valve for removing boiler sludge MPA 46 Installation manual

    MPA 47 Intermittent valve for removing boiler sludge MPA 47 Installation manual

    Retrofitting kit for PA 46, PA 47 Diaphragm actuator Spacer disc Installation manual

    Hand lever for emergency operation Hand lever for emergency operation Forkhead G 0 x 0, DIN 775 Hexagonhead cap screw

    Retrofit set for limit switch for MPA 46, MPA 47 Proximity switches with Lplugs Isolation amplifiers Mounting brackets4 Washers Tracing pin Installation manual

  • 7

    Explanatory Notes continued

    Description

    Intermittent valves for manual or automatic and programmecontrolled removing of boiler sludge from land or marine installations, particularly if these installations are operated without constant supervision in accordance with TRD 604. Sludge sediments, which are accumulated precipitates from boiler water that settle at the bottom of the boiler, will be removed from the steam boiler with the the aid of valves PA and MPA. These valves give the boiler a short blow at regular intervals, thereby discharging accumulated sludge and sediments. PA 46 and PA 47 are designed for manual operation (diaphragm actuator can be retrofitted). MPA 46 and MPA 47 feature a diaphragm actuator for compressed air or pressurized water.

    The intermittent valves for removing boiler sludge PA 46 and PA 47 are openend by means of a hand lever. A pressure pin forces the springloaded valve plug out of the valve seat. The large cross sectional area of the orifice creates a suction effect, giving a shortterm high water flow which will discharge the precipitated sludge and sediments and if installed move them to a mixing cooler (= blowdown receiver). The intermittent valve for removing boiler sludge must be completely opened for about seconds with the aid of the hand lever in order to give the boiler a short and highly effective blow.The intermittent valves for removing boiler sludge MPA 46 and MPA 47 are openend by the diaphragm actuator. The guide pin of the diaphragm actuator acts upon the pressure pin, which in turn forces the springloaded valve plug out of the valve seat. The large crosssectional area of the orifice creates a suction effect, giving a shortterm high water flow which will discharge the precipitated sludge and sediments and if installed move them to a mixing cooler (= blowdown receiver). Compressed air (at room temperature) or pressurized water (at room temperature) can be used as control fluid for the diaphragm actuator in accordance with the specified pressure and temperature ratings.The duration of the bottom blowdown, i. e. the time when the valve is open, should be approx. seconds. The time period when the valve remains closed and hence the frequency of the bottom blowdown must be established as a function of the size and capacity of the steam boiler.The duration and frequency of the bottom blowdown must be established individually by the user as a function of the size and capacity of the steam boiler, the boiler water quality and the corresponding load.

    Function

  • 8

    Fig. 1

    MADE BY GESTRA AG

    PA 460525

    TMA 572FB16.34 CL300DN MADE BY GESTRA AG

    PA 470525

    B16.34-CL600

    max. 55bar@271Cmax.800psi@520F

    DN

    MADE BY GESTRA AG

    PA 47

    B16.34-CL600

    max. 55bar@271Cmax.800psi@520F

    DNMADE BY GESTRA AG

    PA 46

    TMA 300CDN 25 PN 40

    Nominal pressure

    Technical Data

    Name plate / marking

    For pressure and temperature ratings see the specification on the valve body or the data given on the name plate. Further details are given in various GESTRA publications, such as datasheets and technical information.In accordance with EN 9, the following type and design data are indicated on the name plate or body:n Manufacturern Type designationn Pressure class PN or Classn Material numbern Maximum temperaturen Maximum pressuren Direction of flown Stamp on valve body, e. g. specificies the manufacturing quarter and year (in this case the 4th quarter of 007)

    407

    Nominal sizeLetter M

    Max. admissible temperature

  • 9

    Fig. 2

    Technical Data continued

    Dimensions PA 46, PA 475

    490

    50

    350

    L

    6808.5

  • 0

    Technical Data continued

    Dimensions MPA 46, MPA 47

    Fig. 3

    536

    0

    35

    G 38

    L6808.5

  • Technical Data continued

    End dimensions of flanges (extract)

    L

    DN EN 09 (00)PN 40EN 09 (00)

    PN 63[inch] [mm] 5 0 5 3 40 50 5 40 50

    D 05 5 40 50 65 40 70 80b 8 8 8 8 0 4 6 6k 75 85 00 0 5 00 5 35g 58 68 78 88 0 68 88 0l 4 4 8 8 8 8 n 4 4 4 4 4 4 4 4L 50 60 80 00 30 90 0 50

    [kg]*) 8.8/3. 9.3/3.7 0.6/5.0 3.8/8. 5.6/0.0 9.3/3.7 3.8/8. 5.6/0.0*) Weight PA 4... / Weight MPA 4...

    L

    DN ASME B6.5 Class 50[inch] [mm] 5 0 5 3 40 50

    D 98.4 07.9 7.5 7.0 5.4b .7 4.3 5.9 7.5 9.0k 69.8 79.4 88.9 98.4 0.6g 4.9 50.8 63.5 73.0 9.l 5.9 5.9 5.9 5.9 9.0n 4 4 4 4 4L 50 60 80 30 30

    [kg]*) 8.8/3. 9.3/3.7 0.6/5.0 3.8/8. 5.6/0.0*) Weight PA 4... / Weight MPA 4...

    L

    DN ASME B6.5 Class 300ASME B6.5Class 600

    [inch] [mm] 5 0 5 3 40 50 5 40 50

    D 7.5 3.8 33.3 55.6 65. 3.8 55.6 65.b 5.9 7.5 9.0 0.6 . 7.5 . 5.4k 8.5 88.9 98.4 4.3 7 88.9 4.3 7g 4.9 50.8 63.5 73.0 9. 50.8 73.0 9.l 9.0 9.0 9.0 . 9.0 9.0 . 9.0n 4 4 4 4 4 4 4 4L 50 60 80 30 30 6 6 50

    [kg]*) 8.8/3. 9.3/3.7 0.6/5.0 3.8/8. 5.6/0.0 9.3/3.7 3.8/8. 5.6/0.0

    *) Weight PA 4... / Weight MPA 4... Other designs, materials and end connections available on request.

    l

    l

    l

  • Technical Data continued

    Dimensions of buttweld ends (extract)

    Dimensions of socketweld ends (extract)

    L

    DN DIN 339, Series DIN 559DIN 339, Series

    DIN 559[inch] [mm] 5 0 5 3 40 50 5 40 50

    d 8 34 43 49 6 34 49 6d 8.5 37 43 54.5 8.5 4.5 54.5

    for pipe 6.9x.3 33.7x.6 4.4x.6 48.3x.6 60.3x.9 33.7x.6 48.3x.9 60.3x.9L 00 00 00 50 50 00 50 50

    [kg]*) 8./.6 8./.6 8.9/3.3 .0/6.4 3.3/7.7 8./.6 .0/6.4 3.3/7.7*) Weight PA 4... / Weight MPA 4...

    L

    DN ASME B6.5, Schedule 40ASME B36.0ASME B6.5, Schedule 80

    ASME B36.0[inch] [mm] 5 0 5 3 40 50 5 40 50

    d 8 34 43 49 6 34 49 6d 0.9 6.6 35. 40.9 5.5 4.3 38. 49.3

    for pipe 6.7x.9 33.4x3.4 4.x3.6 48.3x3.7 60.3x3.9 33.4x4.5 48.3x5. 60.3x5.5L 00 00 00 50 50 00 50 50

    [kg]*) 8./.6 8./.6 8.9/3.3 .0/6.4 3.3/7.7 8./.6 .0/6.4 3.3/7.7

    *) Weight PA 4... / Weight MPA 4... Other designs, materials and end connections available on request.

    DN DIN EN 760, ASME B6.Class 3000[inch] [mm] 5 0 5 3 40 50

    d 40 45 55 6 75d 7.3 34. 4.8 48.8 6.3b 3 3 3 3 6

    for pipe 6.9/6.7 33.7/33.4 4.4/4. 48.3/48.3 60.3/60.3L 00 00 00 50 50

    [kg]*) 7.4/.8 7.7/. 8.6/3.0 .4/5.8 .6/7.0

    *) Weight MPA 46 / Weight MPA 47 Other designs, materials and end connections available on request.

    d d

    bL

  • 3

    Technical Data continued

    Pressure & temperature ratings / Connections

    PA 4..., MPA 4...ASME, Flanged B16.5 Class 150, Buttweld ends B16.25, Socketweld ends B16.11, Class 3000

    pmax (max. pressure) [bar]g 4

    ts (boiling temperature) [C] 98

    pmax (max. pressure) [psi]g 03

    ts (boiling temperature) [F] 388

    Calculated according to ASME B6.34

    PA 4..., MPA 4...ASME, Flanged B16.5 Class 300, Buttweld ends B16.25, Socketweld ends B16.11, Class 3000

    pmax (max. pressure) [bar]g 4

    ts (boiling temperature) [C] 54

    pmax (max. pressure) [psi]g 609

    ts (boiling temperature) [F] 489

    Calculated according to ASME B6.34

    PA 4..., MPA 4...ASME, Flanged B16.5 Class 600, Buttweld ends B16.25, Socketweld ends B16.11, Class 3000

    pmax (max. pressure) [bar]g 55

    ts (boiling temperature) [C] 7

    pmax (max. pressure) [psi]g 800

    ts (boiling temperature) [F] 50

    Calculated according to ASME B6.34

    PA 46, MPA 46, Flanged PN 40, EN 10921 (2001), 1.0460*)

    pmax (max. pressure) [bar]g 9

    ts (boiling temperature) [C] 34Calculated according to DIN EN 56 *) Material in accordance with AD bulletin

    PA 46, MPA 46, Flanged PN 40, EN 10921 (2001), A 105

    pmax (max. pressure) [bar]g 36

    ts (boiling temperature) [C] 46Calculated according to DIN EN 56

    PA 47, MPA 47, Flanged PN 63 / PN 100, EN 10921 (2001), 1.0460*)

    pmax (max. pressure) [bar]g 44

    ts (boiling temperature) [C] 57Calculated according to DIN EN 56 *) Material in accordance with AD bulletin

    PA 47, MPA 47, Flanged PN 63 / PN 100, EN 10921 (2001), A 105

    pmax (max. pressure) [bar]g 55

    ts (boiling temperature) [C] 7Calculated according to DIN EN 56

  • 4

    Technical Data continued

    Materials

    Type PA... / MPA... PA... / MPA... PA... ASME / MPA... ASME

    Designation DIN / EN DIN ASTM

    Body P50GH (.0460) C .8 (.0460) A 05

    Stuffing box union P50GH (.0460) C .8 (.0460) A 05

    Sealing plug 4CrMo4 A 93 B7

    Gasket X5CrNi80 (.430) X 5 CrNi 8 0 (.430)

    Seat, hardened X46Cr3 (.4034) X 46Cr 3 (.4034)

    Valve cone, hardened X39CrMo7 (.4) X 35 CrMo 7 (.4)

    Disk springs 5CrV4 (.859) 50 CrV 4 (.859)

    Compression springs DIN EN 070SH DIN 73C

    Diaphragm actuator StW 3 (.0334)

    Packing PTFEsilk

    Control membrane EPDM

    The valve body is not designed for pulsating loads. The sizing and anticorrosion additives reflect the latest state of technology.

    Sizing

    Corrosion resistance

    When used for its intended purpose, the safe functioning of the equipment will not be impaired by corrosion.

  • 5

    Fig. 4

    Technical Data continued

    Capacity chart PA 46, PA 47, MPA 46, MPA 47

    10 10020 30 601

    2

    2

    3

    3

    4

    6 84 40

    5

    78

    6

    1

    20[kg/s]

    80

    10

    DifferenzdruckDifferential pressure

    Capacityo

    fhotwa

    ter

    Heiw

    asserdurchsatz

    10 10020 30 6040 80 200 300 400 600 800 1000

    2

    3

    4

    5

    78

    6

    20

    [lb/s]

    30

    40

    [bar]

    [psi]

    10 DN 40

    , 50

    DN 0,

    5, 3

    Capa

    city

    of h

    ot w

    ater

    Differential pressure

  • 6

    Fig. 5

    Technical Data continued

    Control pressure chart MPA 46, MPA 47

    DN

    0,

    5, 3

    DN 40

    , 50

    Boile

    r pre

    ssur

    e

    Control pressure

  • 7

    Fig. 6

    Design

    PA 46, PA 47

    n

    m

    l

    1

    2

    3

    k

    j

    i

    h4

    5

    f

    edcba

    6

    09

    78

    o

    g

    t

  • 8

    Fig. 7

    Design continued

    MPA 46, MPA 47

    lk

    s

    q

    po

    3

    4

    jihgfedcba

    5

    6

    78

    09

    n

    t

    r

  • 9

    Design continued

    1 Hand lever for PA 46, PA 47

    2 Locking lever

    3 Distance sleeve

    4 Check hole

    5 Valve plug

    6 Name plate

    7 Gasket D 38 x 44 (DN 03), D 5 x 60 (DN 4050)

    8 Sealing plug

    9 Valve seat

    0 Valve body

    a Base bushing

    b Packing ring 4 x 8 x 7

    c Wiper ring

    d Pressure ring

    e Disc springs (5 pcs.)

    f Union nut

    g Compression spring

    h Check pin

    i Pressure sleeve

    j Split pin .5 x 40, ISO 34

    k Forkhead G 0 x 0, DIN 775

    l Retaining piece

    m Guide sleeve

    n Pressure plate

    o Hexagonhead cap screw M0 x 00, ISO 404

    p Spacer disc

    q GESTRA Diaphragm actuator

    r Screwed socket (3/8") for control fluid

    s Hand lever for emergency operation MPA 46, MPA 47

    t Hexagonhead cap screw for forkhead M 0 x 5, ISO 407

    Key

  • 0

    PA 46, PA 47, MPA 46, MPA 47

    Installation

    The intermittent valve for removing boiler sludge can be installed in horizontal or vertical pipes. The hand lever of the PA 46, PA 47 and the hand lever for the emergency operation of MPA 46, MPA 47 must be freely movable.

    Flanged design

    . Observe position of installation. The hand lever 1 or the hand lever for emergency operation s (MPA...) must be freely movable.

    . Observe the direction of flow. The arrow indicating the flow direction is specified on the name plate 6.

    3. Consider space required for opening the valve. When the intermittent valve for removing boiler sludge is installed, a minimum space of at least 150 mm is required for removing or retrofitting the actuator!

    4. Remove plastic plugs. They are only used as transit protection.5. Clean seating surfaces of both flanges.6. Install intermittent valve for removing boiler sludge.

    Socketweld design

    . Observe position of installation. The hand lever 1 or the hand lever for emergency operation s (MPA...) must be freely movable.

    . Observe the direction of flow. The arrow indicating the flow direction is specified on the name plate 6.

    3. Consider space required for opening the valve. When the intermittent valve for removing boiler sludge is installed a minimum space of at least 150 mm is required for removing or retrofitting the actuator!

    4. Remove plastic plugs. They are only used as transit protection.5. Clean socketweld ends.6. Arc weld trap only manually (welding processes and 4 in accordance with ISO 4063).

    Attention

    If pressurized water is used as control fluid for the diaphragm actuator make sure that the control line to the diaphragm actuator is made from corrosionresistant material.

    To avoid waterhammer lay the pipe downstream of the intermittent valve in such a way that it has a slight fall, or evacuate the pipe before carrying out the boiler blowdown.

    The length of the pipe between the steam boiler and the intermittent valve for removing boiler sludge must not exceed two metres!

  • WINIX is a registered trademark of WINIX GmbH, Norderstedt

    As standard the hand lever is mounted to the right side of the flow direction. If required by the customer we can also deliver the hand lever in other positions. To change the position of the hand lever proceed as follows: . Unscrew GESTRA diaphragm actuator q (if installed).. Undo retaining piece l and pull out of the forkhead k. Pull hand lever 1 (if installed) out of the

    pressure sleeve i.3. Unscrew hexagon head screws o, remove locking lever 2.4. Remove pressure plate n and distance sleeve 3.5. Pull split pin j out of the pressure sleeve i.6. Turn pressure sleeve i to the left by 90, 80 or 70 depending on the desired position of the

    lever.7. Insert new split pin j into the pressure sleeve i and secure it.8. Put pressure sleeve n and distance sleeve 3 in place.9. Mount remaining components in reverse order. Fasten and secure hexagonhead screws o to the

    torque indicated in the table Torques required for tightening.

    Changing position of hand lever

    Heat treatment of welds

    A subsequent heat treatment of the welds is not required.

    . Observe position of installation. The hand lever 1 or the hand lever for emergency operation s (MPA...) must be freely movable.

    . Observe the direction of flow. The arrow indicating the flow direction is specified on the name plate 6.

    3. Consider space required for opening the valve. When the intermittent valve for removing boiler sludge is installed a minimum space of at least 150 mm is required for removing or retrofitting the actuator!

    4. Remove plastic plugs. They are only used as transit protection.5. Clean buttweld ends.6. Arcweld trap only manually (welding processes and 4 in accordance with ISO 4063)

    or use gas welding process (welding process 3 in accordance with ISO 4063).

    Attention

    Only qualified welders certified e. g. according to DIN EN 87 may weld the valve into lines.

    Buttweld design

    Installation continued

    . Release retaining piece for hand lever l and pull it out of the forkhead k.. Apply lubricant (e. g. WINIX 5000) to the retaining piece, forkhead and hole for attaching the hand lever.3. Push hand lever 1 through distance sleeve 3 into the forkhead k and fix it in place by means of

    the retaining piece l.

    Mounting hand lever PA 46, PA 47

  • Changing the operating side of the intermittent blowdown valve PA 46 / PA 47

    Installation continued

    Fig. 8

    90180

    270 0

  • 3

    90180

    270

    Changing the operating side of the intermittent blowdown valve MPA 46 / MPA 47

    Installation continued

    Fig. 9

    0

  • 4

    The flanged connections of the PA 46, PA 47, MPA 46, MPA 47 must be permanently bolted and leakproof.After starting up the steam boiler or pressure vessel, the intermittent valve for removing boiler sludge should be completely opened and closed once. The valve must close automatically, ensuring tight shutoff.The stuffing box must be leakproof! Inspect the check hole 4 in order to detect any fluid leakage.If the equipment is mounted in a new and unpurged installation increase the blowdown frequency a little at the beginning.

    PA 46, PA 47, MPA 46, MPA 47

    Commissioning

    Risk of severe burns! The hand lever of the intermittent blowdown valve PA 46, PA 47 is hot during operation. Touching the hot hand lever can cause severe burns.Use thermally insulated and temperature resistant safety gloves when operating the valve.During operation moving internals can pinch ones hands or fingers, causing severe injuries. Do not touch moving parts.The intermittent blowdown valves MPA 46, MPA 47 are remote controlled and can open and close abruptly.

    Danger

  • 5

    Duration and frequency of intermittent boiler blowdown

    When the GESTRA intermittent valve opens, a localized lowpressure area forms around the blowoff opening and the boiler sludge rushes out at high velocity, giving the steam boiler a short blow. The discharge of sludge and precipitated solids (valve fully open) takes approx. seconds. In order to ascertain the blowdown frequency, the operating data of the installation have to be taken into account.As ancillary equipment for the intermittent blowdown valves MPA... we recommend the GESTRA ProgrammeControlled Blowdown System TA... To control the salt content (TDS) of the boiler water we recommend the GESTRA Continuous Blowdown Valves BA... or BAE...

    Operation

    Intermittent boiler blowdown

    Simple water treatment processes cannot prevent small amounts of alkaline earths from getting into the boiler water, thereby causing residual hardness. As a consequence chemical treatment for removal of hardness in the steam boiler is necessary. The controlled addition of moderate amounts of excess phosphate ions (phosphate treatment) leads to the precipitation of calcium phosphates and magnesium phosphates. Both substances form fine sludge deposits which settle out on heating surfaces and the bottom of the boiler. These sludge deposits can form an adherent insulating coating on heating surfaces, resulting in an effect similar to that of hard scale. These insulating layers formed in zones of high heat transfer retard the flow of heat and cause overheating, which may result in deformation and ultimately failure of the affected boiler parts. It is therefore essential to remove sludge deposits at regular intervals. Although the use of polyacrylates as complexing agents for removing residual hardness has a dispersing effect, the freeflowing boiler sludge must also be removed by blowdown.Hardness salts and other impurities are kept in suspension by polyacrylates but will eventually over time settle down on the boiler bottom in the form of finely divided sludge particles. These sludge deposits impair boiler safety and should be removed by intermittent boiler blowdown.

    Risk of severe burns! The hand lever of the intermittent blowdown valve PA 46, PA 47 is hot during operation. Touching the hot hand lever can cause severe burns.Use thermally insulated and temperature resistant safety gloves when operating the valve.During operation moving internals can pinch ones hands or fingers, causing severe injuries. Do not touch moving parts.The intermittent blowdown valves MPA 46, MPA 47 are remote controlled and can open and close abruptly.

    Danger

  • 6

    Emergency operation MPA 46, MPA 47

    Risk of severe injuries to the whole body. The intermittent blowdown valves MPA 46, MPA 47 are remote controlled and can open and close abruptly. Make sure that the line for the control fluid of the diaphragm actuator is depressurized (zero bar) and isolated during the emergency operation of the MPA 46, MPA 47.Insert the hand lever for emergency operation only to operate the valve and remove it immediately after operation.

    Danger

    Fitting hand lever for emergency operation

    . Fit hand lever for emergency operation s, operate intermittent valve for removing boiler sludge.. Remove hand lever for emergency operation s immediately after operation.

    GESTRA intermittent valves for removing boiler sludge PA 46, PA 47, MPA 46 and MPA 47 are usually free of maintenance. Depending on the quality of the boiler water and the operating mode of the steam generating unit the equipment may have to be serviced after one to two years of operation.

    Maintenance

    If fluid escapes through the check hole 4 the union nut f of the stuffing box must be retightened:. Observe danger note on page 4.. Insert pin punch through the opening in the distance sleeve 3 into one of the holes of the union nut

    f; carefully tighten it clockwise by hand until no more fluid escapes through the check hole 4.3. Open the intermittent blowdown valve completely. The stuffing box must not leak.4. Check control hole 4 for leaks. If fluid escapes, retighten stuffing box. The valve must close auto

    matically without leaking.

    Retightening stuffing box

    Attention

    Replace internals of stuffing box if it can no longer be retightened by tightening the union nut f.

    Loosen the union nut f a little if the force of the spring does not suffice to close the valve automatically. If fluid escapes through the check hole all internals of the stuffing box must be replaced.

  • 7

    Replacing stuffing box PA 46, PA 47

    . Observe danger note on page 4! . Undo retaining piece l for forkhead k and pull out hand lever 1. Fig. 6 3. Unscrew hexagonhead cap screws o and remove locking lever 2. 4. Remove pressure plate n and distance sleeve 3. 5. Pull out split pin j. 6. Use openend spanner A. F. 8 mm to unscrew the pressure sleeve i from the valve plug 5. 7. Remove compression spring g. 8. Use openend spanner A. F. 3 mm to unscrew the union nut f. 9. Unscrew sealing plug 8 and remove gasket 7.0. Pull out valve plug 5.. Take out internal parts e d c b a of stuffing box.. Clean stuffing box, valve body and valve plug.3. Reinsert valve plug 5 and use abrasive paste type TETRABOR F400 for polish grinding.4. Insert new gasket 7 and screw in sealing plug 8. Tighten with the torque indicated in the table

    Torques required for tightening.5. Reinsert internal parts of stuffing box according to order as specified in Fig. 6, Fig. 7, Fig. 106. Apply heatresistance lubricant to stuffing box thread (use e.g. WINIX 50).7. Align valve plug 5 such that the hole for the split pin j is perpendicular to the flow direction of the

    intermittent valve.8. Use openend spanner A. F. 3 mm to screw in union nut f and tighten at room temperature with

    the torque indicated in the table Torques required for tightening.9. Apply heatresistant lubricant to both sides of the compression spring g (use e. g. WINIX 50)

    and place it onto the union nut f.0. Use openend spanner A. F. 8 mm to screw the pressure sleeve i onto the valve plug 5 until the

    holes for the split pin j in the valve plug and the pressure pin overlap.. Insert split pin j.. Reinsert distance sleeve 3 and pressure plate n. Align check hole 4 to the right.3. Insert and screw in hexagonhead cap screws o and locking lever 2 (only with PA 46, PA 47) and

    tighten them in diagonally opposite pairs with the torque indicated in the table Torques required for tightening.

    4. Insert hand lever 1 and fix it to the forkhead k by means of retaining piece l.5. Operate valve once (open it until it hits the stop). The stuffing box must be tight!6. Check control hole 4 for leaks. If fluid escapes, retighten stuffing box. The valve must close auto

    matically without leaking.

    Maintenance continued

    WINIX is a registered trademark of WINIX GmbH, NorderstedtTETRABOR is a registered trademark of WackerChemie GmbH, Kempten

  • 8

    Replacing stuffing box, valve seat and valve plug PA 46, PA 47

    . Observe danger note on page 4! . Undo retaining piece l for forkhead k and pull out hand lever 1. Fig. 6 3. Unscrew hexagonhead cap screws o and remove locking lever 2. 4. Remove pressure plate n and distance sleeve 3. 5. Pull out split pin j. 6. Use openend spanner A. F. 8 mm to unscrew the pressure sleeve i from the valve plug 5. 7. Remove compression spring g. 8. Use openend spanner A. F. 3 mm to unscrew the union nut f. 9. Unscrew sealing plug 8 and remove gasket 7.0. Pull out valve plug 5.. Take out internal parts e d c b a of stuffing box.. Use steel punch to knock the valve seat 9 out of the valve body 0. Fig. 123. Clean stuffing box and valve body.4. Insert new valve seat 9 such that two opposite holes are in the flow direction of the intermittent

    valve.5. Use punch made of CuZn to fix the valve seat in the valve body. Fig. 136. Reinsert valve plug 5 and use abrasive paste type TETRABOR F400 for polish grinding.7. Insert new gasket 7 and screw in sealing plug 8. Tighten with the torque indicated in the table

    Torques required for tightening.8. Reinsert internal parts of stuffing box according to order as specified in Fig. 6, Fig. 7, Fig. 109. Apply heatresistance lubricant to stuffing box thread (use e.g. WINIX 50).0. Align valve plug 5 such that the hole for the split pin j is perpendicular to the flow direction of the

    intermittent valve.. Use openend spanner A. F. 3 mm to screw in union nut f and tighten at room temperature with

    the torque indicated in the table Torques required for tightening.. Apply heatresistant lubricant to both sides of the compression spring g (use e. g. WINIX 50)

    and place it onto the union nut f.3. Use openend spanner A. F. 8 mm to screw the pressure sleeve i onto the valve plug 5 until the

    holes for the split pin j in the valve plug and the pressure pin overlap.4. Insert split pin j.5. Put distance sleeve 3 and pressure plate n in place. Align check hole 4 to the right.6. Insert and screw in hexagonhead cap screws o and locking lever 2 (only with PA 46, PA 47) and

    tighten them in diagonally opposite pairs with the torque indicated in the table Torques required for tightening.

    7. Insert hand lever 1 and fix it to the forkhead k by means of retaining piece l.8. Operate valve once (open it until it hits the stop). The stuffing box must be tight!9. Check control hole 4 for leaks. If fluid escapes, retighten stuffing box. The valve must close auto

    matically without leaking.

    Maintenance continued

    WINIX is a registered trademark of WINIX GmbH, NorderstedtTETRABOR is a registered trademark of WackerChemie GmbH, Kempten

  • 9

    Maintenance continued

    Replacing stuffing box MPA 46, MPA 47

    . Observe danger note on page 4! . Detach pressure line for the control fluid of the diaphragm actuator from the screwed socket r. 3. Remove diaphragm actuator q. Fig. 7 4. Proceed as described under Replacing stuffing box PA 46, PA 47, items to 3.4. Put spacer disk p onto pressure plate n.5. Screw on diaphragm actuator q with the torque indicated in the table Torques required for

    tightening.6. Attach pressure line for the control fluid of the diaphragm actuator.7. Operate valve once (open it until it hits the stop). The stuffing box must be tight!8. Check control hole 4 for leaks. If fluid escapes, retighten stuffing box. The valve must close auto

    matically without leaking.

  • 30

    Maintenance continued

    Replacing stuffing box, valve seat and valve plug MPA 46, MPA 47

    . Observe danger note on page 4! . Detach pressure line for the control fluid of the diaphragm actuator from the screwed socket r. 3. Remove diaphragm actuator q. Fig. 7 4. Proceed as described under Replacing stuffing box, valve seat and valve plug PA 46, PA 47,

    items to 6.7. Put spacer disk p onto pressure plate n.8. Screw on diaphragm actuator q with the torque indicated in the table Torques required for

    tightening.9. Attach pressure line for the control fluid of the diaphragm actuator.30. Operate valve once (open it until it hits the stop). The stuffing box must be tight!3. Check control hole 4 for leaks. If fluid escapes, retighten stuffing box. The valve must close auto

    matically without leaking.

  • 3

    WINIX is a registered trademark of WINIX GmbH, Norderstedt

    Maintenance continued

    Attention

    The torque for tightening the hexagonhead cap screws u must not exceed 5 Nm because higher torques could damage the control membrane!

    . Observe danger note on page 4! . Detach pressure line for the control fluid of the diaphragm actuator. 3. Unscrew hexagonhead bolts u and hexagon nuts. Fig. 14 4. Remove and clean upper part v of the diaphragm actuator. 5. Take out old control membrane w. Clean lower part x. 6. Insert new control membrane w, aligning its holes with the holes of the lower part. 7. Put upper part v on top and align its holes with the holes of the control membrane and the

    lower part. 8. Insert hexagonhead bolts u and tighten them with the respective hexagon nuts in diagonally

    opposite pairs to the torque indicated in the table Torques required for tightening. 9. Attach pressure line for the control fluid of the diaphragm actuator.0. Check tightness. If necessary retighten hexagonhead bolts u carefully in diagonally opposite

    pairs.. To grease the guide plate pin y apply lubricant to the grease nipple in the connecting socket of the

    diaphragm actuator (use e. g. WINIX 5000).

    Replacing control membrane in diaphragm actuator MPA 46, MPA 47

  • 3

    Torques required for tightening

    All torques indicated in the table are based at a room temperature of 0 C.

    Maintenance continued

    Tools

    Combination spanner A. F. 3 mm, DIN 33, Form B Combination spanner A. F. 6 mm, DIN 33, Form B Combination spanner A. F. 7 mm, DIN 33, Form B Combination spanner A. F. 8 mm, DIN 33, Form B Combination spanner A. F. 3 mm, DIN 33, Form B Combination spanner A. F. 36 mm, DIN 33, Form B Combination spanner A. F. 4 mm, DIN 33, Form B Torque spanner Nm, ISO 6789 Torque spanner 0 0 Nm, ISO 6789 Torque spanner 80 400 Nm, ISO 6789 Socket spanner 3 x 50, DIN 3 Punch 0 x 00, made of steel Punch 0 x 00, made of CuZn (brass) Pin punch 8 x 50, DIN 6450 C Grease gun (for valve plug)

    Item Intermittent valves for removing boiler sludge Torques [Nm]

    8 PA 46, PA 47, MPA 46, MPA 47 350

    f PA 46, PA 47, MPA 46, MPA 47 55

    o PA 46, PA 47, MPA 46, MPA 47 0

    q MPA 46, MPA 47 0

    u MPA 46, MPA 47 5

  • 33

    Fig. 10

    Maintenance continued

    Single parts of stuffing box, valve plug, valve seat

    Fig. 11

    e

    d

    c

    b

    c

    a

    9

    5

  • 34

    Fig. 12

    Maintenance continued

    Mounting / removing valve seat

    Fig. 13

  • 35

    Maintenance continued

    Mounting / removing control membrane

    Fig. 14

    v

    w

    x

    u

    y

  • 36

    u Hexagonhead bolt M8 with hexagon nut M8

    v Upper part of the diaphragm actuator

    w Control membrane

    x Lower part of the diaphragm actuator with connector socket

    y Guide pin with plate

    z Mounting bracket

    A Tracing pin

    B Limit switch (proximity switch with L plug)

    C Washer

    D Hexagon nut

    Maintenance continued

    Key

    GESTRA intermittent valves PA 46 and PA 47 can be retrofitted with a GESTRA diaphragm actuator (MPA 46, MPA 47).

    Retrofitting

    Risk of severe burns and scalds to the whole body!Before carrying out any retrofitting work on the valve or loosening flanged connections, stuffing box unions or sealing plugs make sure that all connected lines are depressurized (zero bar) and cooled down to room temperature (0 C).Insert the hand lever for emergency operation s only to operate the valve and remove it immediately after operation.

    Danger

  • 37

    WINIX is a registered trademark of WINIX GmbH, Norderstedt

    Mounting an existing MPA 26, MPA 27 diaphragm actuator

    . Observe danger note on page 4. . Unscrew hexagon head bolts u and hexagon nuts, Fig. 14. 3. Remove upper part v from diaphragm actuator, take out control membrane w. 4. Remove guide pin with plate y. 5. Insert new guide pin with plate y of the retrofit kit. 6. Put upper part v in place and align its holes with the holes of the control membrane plate. 7. Insert hexagon head bolts u, fasten with hexagon nuts and tighten them in diagonally opposite

    pairs with the torque indicated in the table Torques required for tightening. 8. Attach pressure line for the control fluid of the diaphragm actuator. 9. Check tightness. If necessary retighten hexagonhead bolts u carefully in diagonally opposite

    pairs.0. To grease the guide plate y apply lubricant to the grease nipple in the connecting socket of the

    diaphragm actuator (use e. g. WINIX 5000).

    Retrofitting continued

    Mounting diaphragm actuator

    . Observe danger note on page 4! . Undo centering screw m. Fig. 6 3. Undo retaining piece l for forkhead k and pull out hand lever 1. Note that the hand lever must

    not be mounted again! 4. Snap retaining piece l on forkhead k. 5. Unscrew hexagonhead cap screws o and remove locking lever 2. 6. Insert hexagonhead cap screws o and tighten them with the torque indicated in the table

    Torques required for tightening. 7. Put spacer disk p onto pressure plate n. 8. Apply heatresistant lubricant to the connector socket of the diaphragm actuator

    (use e.g. WINIX 50). 9. Screw on diaphragm actuator q with the torque indicated in the table Torques required for

    tightening.0. Attach pressure line (3/8") for the control fluid of the diaphragm actuator.. Operate valve once (open it until it hits the stop). The stuffing box must be tight!. Check control hole 4 for leaks. If fluid escapes, retighten stuffing box. The valve must close auto

    matically without leaking.

  • 38

    Mounting the limit switch (proximity switch)

    . Observe danger note on page 4. . Detach pressure line for the control of the diaphragm actuator from the screwed socket r. 3. Detach diaphragm actuator q, Fig. 7. 4. Remove spacer disk p and pressure plate n. 5. Unscrew and take out hexagonhead screws o. 6. Push mounting bracket z over the hexagonhead screws. 7. Screw in hexagonhead screws o and fasten them in diagonally opposite pairs with the torque

    indicated in the table Torques required for tightening. 8. Put spacer disk p onto pressure plate n. 9. Screw diaphragm actuator q in place and fasten with the torque indicated in the table Torques

    required for tightening.0. Attach pressure line for the control fluid of the diaphragm actuator.. Operate the intermittent blowdown valve once.. Remove check pin h and replace it with tracing pin A. Use screw locking glue (e. g. Loctite 60)

    to fix the tracing pin. 3. Put the proximity switch B into the mounting bracket z, align the proximity switch as shown in

    Fig. 16, Fig. 17 and fix it with washers C and hexagonhead bolts D. Fasten hexagon nuts with the torque indicated in the table Torques required for tightening.

    4. Connect the proximity switch B to the isolation amplifier as specified in the installation instructions of the manufacturer.

    5. Operate the intermittent blowdown valve once (open it until it hits the stop). The stuffing box must be tight!

    6. Check control hole 4 for leaks. If fluid escapes, retighten stuffing box. The valve must close automatically without leaking.

    7. Check performance of the proximity switch.

    Retrofitting continued

    Loctite is a registered trademark of HENKEL KGaA, Dsseldorf

    Mounting the forkhead (hand lever for emergency operation)

    . Observe danger note on page 4.. Align and fit forkhead k together with hexagonhead cap screw t to the pressure plate n.

    Tighten the hexagonhead cap screw t with the torque indicated in the table Torques required for tightening. Fig. 7

    3. Fit hand lever for emergency operation s, operate intermittent valve for removing boiler sludge.4. Remove hand lever for emergency operation s immediately after operation.

  • 39

    Retrofitting continued

    Mounting the limit switch (proximity switch) continued

    Fig. 15

    min. 0,8 / max. 1,6min. 0,032 / max. 0,063

    Fig. 16

    Fig. 17

    B

    Bz

    D

    CBCD

    B

    B

    A

    A

    min. 0.8 / max. .6 min. 0.03" / max. 0.063"

  • 40

    Torques required for tightening

    All torques indicated in the table are based at a room temperature of 0 C.

    Tools

    Combination spanner A. F. 6 mm, DIN 33, Form B Combination spanner A. F. 7 mm, DIN 33, Form B Combination spanner A. F. 4 mm, DIN 33, Form B Torque spanner 0 0 Nm, ISO 6789

    Item Intermittent valves for removing boiler sludge Torques [Nm]

    o PA 46, PA 47, MPA 46, MPA 47 0

    q MPA 46, MPA 47 0

    t MPA 46, MPA 47 0

    D MPA 46, MPA 47

    Retrofitting continued

  • 4

    Spare Parts

    Spare parts list

    Item DesignationStock code Stock code

    PA 46, PA 47 MPA 46, MPA 47

    a bc de 7

    Internal parts of stuffing box, DN 0 to DN 50:

    Base bushing, wiper ring, Packing ring 4 x 8 x 7, pressure ring, Disk springs (5 pcs.), Gasket D 38 x 44, D 5 x 60

    335 064 335 064

    5 9a bc de 7

    Valve plug, valve seat and internal parts of stuffing box, DN 0, DN 5, DN 3:

    Base bushing, wiper ring, Packing ring 4 x 8 x 7, pressure ring, Disk springs (5 pcs.),Gasket D 38 x 44

    335 063 335 063

    5 9a bc de 7

    Valve plug, valve seat and internal parts of stuffing box, DN 40, DN 50:

    Base bushing, wiper ring, Packing ring 4 x 8 x 7, pressure ring, Disk springs (5 pcs.),Gasket D 5 x 60

    335 065 335 065

    w Control membrane for diaphragm actuator 335 3

    s l t k Hand lever for emergency operation with forkhead 335 060

    y p Guide pin with plate, spacer disk 335 30

    q p Diaphragm actuator with spacer disk 335 093

  • 4

    Decommissioning

    Danger

    Risk of severe burns and scalds to the whole body!Before loosening flanged connections, stuffing box unions or sealing plugs make sure that all connected lines are depressurized (zero bar) and cooled down to room temperature (0 C).

    Dismantle the valve and separate the waste materials, using the material specifications in the table Technical Data as reference.For the disposal of the valve observe the pertinent legal regulations concerning waste disposal.

    Disposal

    Parts for retrofitting

    List of parts for retrofitting

    Item DesignationStock code Stock code

    PA 46, PA 47 MPA 46, MPA 47

    q p Diaphragm actuator with spacer disk 335 093

    y pGuide sleeve with plate, spacer disk (for retrofitting MPA 6, MPA 7 to MPA 46, MPA 47)

    335 30

    s l t k Hand lever for emergency operation with forkhead 335 060

    z A B C D

    Proximity switch, including isolation amplifier and Lplug

    33540

  • 43

    We hereby declare that the pressure equipment PA 46, PA 47, MPA 46 and MPA 47 conform to the following European Directives: Pressure Equipment Directive 97/3/EC of 9 May 997 for equipment of category according to the table Pressure Equipment Directive on page 5. ATEX Directive 94/9/EC of 3 March 994.

    Applied conformity assessment procedure according to 97/3/EC: Annex III, Module H, verified by the Notified Body 055.

    Applied conformity assessment procedure according to 94/9/EC: Annex VIII.

    This declaration is no longer valid if modifications are made to the equipment without consulation with us.

    Declaration of Conformity

    Bremen, 30th November 004GESTRA AG

    Annex

    Dipl.Ing. Lars Bohl (Academically qualified engineer)

    Quality Assurance Manager

    Dipl.Ing. Uwe Bledschun (Academically qualified engineer)

    Head of the Design Dept.

  • 44884470/808cm 004 GESTRA AG Bremen Printed in Germany

    Agencies all over the world:

    www.gestra.de

    GESTRA AGP. O. Box 0 54 60, D8054 Bremen Mnchener Str. 77, D85 BremenTelephone 0049 (0) 4 35 03 0 Fax 0049 (0) 4 35 03 393EMail gestra.ag@flowserve.com Internet www.gestra.de

    GESTRA

    Singapore

    Flowserve Pte. Ltd. Tuas Avenue 0Singapore 6388Tel. 0065 / 68 79 89 00Fax 0065 / 68 6 49 40EMail fcd_gestra_singapore@flowserve.comWeb www.gestra.com

    Flowserve GB LimitedAbex RoadNewbury, Berkshire RG4 5EYTel. 0044 6 35 / 46 99 90Fax 0044 6 35 / 3 60 34Email gestraukinfo@flowserve.comWeb www.flowserve.com

    Great Britain

    USA

    Flowserve GESTRA U.S.34 Ampere DriveLouisville, KY 4099Tel. 00 50 / 67 05Fax 00 50 / 6653 97Email fcdgestrausa@flowserve.com

    South Africa

    Flowserve SA (Pty) Ltd.Unit No. Director RoadSpartan Extension Kempton Park 63Tel. 007 / 9 3 73 00Fax 007 / 9 74 64 0EMail tvniekerk@flowserve.comWeb www.flowserve.com

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