GESTRA BA 46 Original Installation Instructions Download Page 7

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Qualification of personnel

Specialist personnel must have knowledge and
experience of the following areas:



explosion and fire precautions and occupational
health & safety provisions applicable at the site
of installation



work on pressure equipment



producing pipe connections



working with hot or pressurised fluids



lifting and transporting loads



all information in this installation & operating
manual and other applicable documentation



connecting the power supply of the actuator

Typographic features of warning

notes

DANGER

Notes with the heading DANGER warn
against imminent dangerous situations that
can lead to death or serious injuries.

WARNING

Notes with the heading WARNING warn
against possibly dangerous situations that
could lead to death or serious injuries.

CAUTION

Notes with the heading CAUTION warn
against dangerous situations that could
lead to minor or moderate injuries.

Formatting features for warnings

of property damage

Attention!

This information warns of a situation
leading to property damage.

Description

Scope of supply and equipment

specification

Scope of supply

For equipment types BA 46 and BA 47, delivery
includes the following:



one continuous blowdown valve



one sampling valve



one sealing ring A17 × 23 × 1.5 mm



this installation & operating manual

For equipment types BAE 46 and BAE 47, delivery
includes the following:



one blowdown valve with actuator



one sampling valve



one sealing ring A17 × 23 × 1.5 mm



this installation & operating manual



actuator installation & operating manual



Manufacturer's Declaration for the actuator

The equipment is packaged ready for installation
with sampling valve supplied.

Equipment specification

BA and BAE models have different types of
actuator. Below, the two types of actuator
are shown in separate diagrams. The body
with inner parts is identical in both valves
and is shown separately.

Summary of Contents for BA 46

Page 1: ...Continuous blowdown valve BA 46 BA 47 BAE 46 BAE 47 Original Installation Instructions 818609 04 ...

Page 2: ...ring installation 14 Connecting the equipment 14 Installing the sampling valve 16 Positioning the control lever 16 Starting up the equipment 17 Determining the blowdown rate 17 Determining the flowrate 18 Operating the equipment 25 Normal operation 25 Emergency operation on failure of the actuator in BAE models 25 Flushing the equipment 25 After operation 26 Removing external dirt deposits 26 Requ...

Page 3: ...Dimensions and weights 39 Pressure temperature ratings 43 Manufacturer s Declaration 45 ...

Page 4: ...ble rules and regulations concerning the prevention of accidents as well as approved safety guidelines for good professional practice Availability Keep this installation operating manual together with the plant documentation for future reference Make sure that this installation operating manual is available to the operator The installation operating manual is part of the equipment Please hand over...

Page 5: ...perated or serviced by unqualified personnel The personnel must have the necessary qualification and experience for the required work the equipment is operated using an actuator not approved by the manufacturer the equipment is operated with a control system not approved by the manufacturer Basic safety notes Explosion hazard Explosion risk if equipment is used that is not suitable for the environ...

Page 6: ...ore working on the equipment make sure that the power supply to the actuator is cut off and cannot be switched on accidentally If the stuffing box is leaking there is a risk of severe injuries caused by escaping hot fluid Use the equipment only if it is in proper working condition Replace any leaking stuffing box seal The connections of the electric actuator are live during operation Take care not...

Page 7: ...st dangerous situations that could lead to minor or moderate injuries Formatting features for warnings of property damage Attention This information warns of a situation leading to property damage Description Scope of supply and equipment specification Scope of supply For equipment types BA 46 and BA 47 delivery includes the following one continuous blowdown valve one sampling valve one sealing ri...

Page 8: ...8 Equipment overview BA No Designation 1 Control lever 2 Dial 3 Body 4 Rating plate 5 ATEX label BA only No Designation 6 Sealing plug 7 Sealing ring 8 Stuffing box gland 9 Scale ...

Page 9: ...l pin 14 Thrust ring 15 Spring The following actuators are available as standard EF 10 EF 10 1 EF 0 7 EF 0 7 1 Other actuators are available on request In these models the opening signal can be sent by various controllers The actuator and control system are described in their own separate installation operating manuals ...

Page 10: ... gland 16 Spring bushing 17 Wiper 18 Guide bushing 19 Anti wear bushing 20 Stepped bushings 21 Seat bushing No Designation 22 Sampling valve 23 Locking screw 24 Sealing ring 25 Nozzle needle 26 Packing ring 27 Disc springs 28 Stuffing box screws ...

Page 11: ...al operation BAE 46 PN 40 electric actuator EF 10 BAE 46 1 PN 40 electric actuator EF 10 1 BAE 46 3 PN 40 electric actuator EF 0 7 BAE 46 3 1 PN 40 electric actuator EF 0 7 1 BAE 47 PN 63 electric actuator EF 10 BAE 47 1 PN 63 electric actuator EF 10 1 You can find information on actuator type designations in the manufacturer s installation operating manual Application of European Directives Press...

Page 12: ...with an LRR 1 conductivity controller LRG 1 conductivity electrode or LRGT 1 conductivity transmitter the equipment provides an automatic conductivity regulation system continuous blowdown control Control lever positions Position 0 CLOSED No removal of boiler blowdown Operating position The set quantity of blowdown is continuously removed Position 1 Boiler blowdown is removed at 8 of the maximum f...

Page 13: ...ts are always met when storing the equipment Please contact the manufacturer if you cannot comply with the recommended storage conditions Transporting the equipment DANGER Risk of bruises if the equipment or component parts fall down Use suitable lifting gear when moving or lifting the equipment and or component parts Make sure that the equipment cannot topple over Make sure that nobody is standin...

Page 14: ...d safety gear refer to the safety data sheet of the fluid in question Drain pipes until they are empty Switch the installation off and protect it against unauthorised or unintended re activation To avoid waterhammer make sure that the pipe downstream of the equipment has a down gradient If this is not possible provide other means to ensure draining Connecting the equipment DANGER Incorrectly conne...

Page 15: ...or horizontal provide support for the actuator Please contact the manufacturer if you wish to install the equipment in a different position To allow easy access for routine servicing and exchanging components observe the indicated withdrawal distances and allow for clearances to adjacent installation parts Make sure that the pipe system of the plant is clean Make sure that the equipment is free fr...

Page 16: ...t The lubricant must have the same properties as OKS 217 Screw the sampling valve 22 into the hole in the body with a torque of 130 Nm Positioning the control lever In BA models you can change the position of the control lever by 180 You will find information on the required tools on page 26 Proceed as follows Remove the hex nuts 30 from the control lever Insert the puller 29 beneath the control l...

Page 17: ...arting up the equipment WARNING Risk of burns from hot parts during operation Wear insulated and heat resistant protective gloves to operate the control lever WARNING Risk of being crushed by moving parts BAE type equipment is actuated and controlled remotely It can therefore open or close without warning Never reach into moving parts during operation Actuate the equipment after the steam generati...

Page 18: ...ich the required blowdown rate is achieved at the named differential pressure In the example shown here you would use the flow diagram for DN 15 to DN 32 with a capacity range up to 1 020 kg h Determine the intersection of the curve for the given differential pressure with the required flowrate Drop a perpendicular onto the axis of the control lever position In this example the required control le...

Page 19: ...19 Flow diagram for DN 15 to DN 32 capacity range up to 310 kg h ...

Page 20: ...20 Flow diagram for DN 15 to DN 32 capacity range up to 1 020 kg h ...

Page 21: ...21 Flow diagram for DN 15 to DN 32 capacity range up to 2 120 kg h ...

Page 22: ...22 Flow diagram for DN 40 and DN 50 capacity range up to 1 340 kg h ...

Page 23: ...23 Flow diagram for DN 40 and DN 50 capacity range up to 4 500 kg h ...

Page 24: ...24 Flow diagram for DN 40 and DN 50 capacity range up to 6 300 kg h ...

Page 25: ... the control lever is set to the desired position Emergency operation on failure of the actuator in BAE models If the actuator fails in BAE 46 or BAE 47 models you can adjust the flowrate manually Proceed as follows Disconnect the actuator from the electricity mains and the control system With your hand push the coupling 12 up by roughly one centimetre until the control lever 1 can move freely Adj...

Page 26: ...embling and disassembling the equipment The qualified personnel must observe and follow the instructions given in this operating manual and in the applicable documents Removing external dirt deposits Use fresh water and a cloth to remove dirt and contaminants from the equipment body Required tools for servicing You will need the following tools for equipment servicing or maintenance Size 7 combina...

Page 27: ...omponent parts that get hot during operation can cause burnings Always wear thermally insulated and heat resistant safety gloves when operating the lever If fluid escapes via the stuffing box gland 8 retighten the stuffing box bush Unscrew the nozzle needle 25 by a half turn The torque for the stuffing box screws varies depending on the equipment For models with DN 15 to DN 32 the required torque ...

Page 28: ...28 Servicing the equipment and installing spare parts You may exchange the following component parts in case of wear or damage ...

Page 29: ... 5 335704 335704 7 17 18 19 20 21 24 25 26 Spare parts set DN 15 DN 32 comprising Packing and sealing set Nozzle needle Seat bushing 2 stepped bushings Anti wear bushing Guide bushing 335703 335703 7 17 18 19 20 21 24 25 26 Spare parts set DN 40 DN 50 comprising Packing and sealing set Nozzle needle Seat bushing 2 stepped bushings Anti wear bushing Guide bushing 335705 335705 10 Actuator EF 0 7 fo...

Page 30: ... and shims 32 Remove the grooved pin 33 Lift off the actuator 10 and bracket 11 Fit the actuator as described on page 34 Replacing the stuffing box and inner parts If the stuffing box bush cannot be sealed using the set torque or the control lever can no longer be moved replace the stuffing box with a new one Install the actuator as described on page 30 Remove the hex nuts 30 from the control leve...

Page 31: ...Remove the locking screw 23 and sealing ring 24 Remove the sealing plug 6 and sealing ring 7 Using a brass punch 34 knock the following inner parts out of the body as shown Stuffing box with packing ring 26 and four wipers 17 Guide bushing 18 Anti wear bushing 19 Two stepped bushings 20 Seat bushing 21 ...

Page 32: ...e equipment For models with DN 15 to DN 32 the required torque is 5 Nm For models with DN 40 and DN 50 the required torque is 11 Nm Tighten the locking screw to the specified torque Position the guide bushing 18 so that the retaining groove points towards the locking screw Insert the guide bushing 18 Insert the new stuffing box comprising the packing ring 26 and four wipers 17 as shown Coat the th...

Page 33: ...ith DN 40 and DN 50 the required torque is 11 Nm Tighten the stuffing box screws to the specified torque Turn the nozzle needle to closed position with a torque of 7 Nm Place the control lever 1 on the nozzle needle Align the scale 9 on the dial 2 so that the 0 mark is in the centre of the dial Screw the hex nut 30 onto the nozzle needle holding the control lever firmly Tighten the hex nut to a to...

Page 34: ...ailable if you already have one Designation Contents Stock code Actuator EF 0 7 for BAE 46 3 Actuator Bracket Coupling assembly kit 3 hex bolts 3 shims 336810 Actuator EF 0 7 1 for BAE 46 3 1 336811 Actuator EF 10 for BAE 46 and BAE 47 336812 Actuator EF 10 1 for BAE 46 1 and BAE 47 1 336813 Retrofit kit without actuator Bracket Coupling assembly kit 3 hex bolts 3 shims 335769 ...

Page 35: ...he coupling is lying flat on the control lever Tighten the three hex bolts 31 to a torque of 30 Nm Adjust the actuator 10 as described in the actuator installation operating manual You must set the switch cams for OPEN CLOSED and OPERATING POSITION You will also need to adjust the feedback potentiometer if present Make sure the CLOSED switch cam is adjusted in the actuator in such a way that the c...

Page 36: ... The actuator cuts out automatically The stuffing box is hampering the movement of inner parts Slacken the stuffing box screw a little Replace the stuffing box if damaged Moving inner parts move jerkily or with difficulty or are jammed The drive cuts out automatically The drive or other accessories are defective or damaged Follow the instructions in the installation operating manuals for the drive...

Page 37: ...l down Suitable measures are for instance Equipment that is not too heavy may be supported by a second person For heavy equipment use suitable lifting equipment of sufficient strength Detach the end connections of the equipment from the pipes Put the equipment onto a suitable base Store the equipment as described on page 13 Re using equipment after storage Observe the following instructions if you...

Page 38: ...1 0570 Stuffing box screws1 A2 70 Stuffing box PTFE yarn PTFE yarn Sealing plug1 1 7225 A 193 B7 Sealing ring 1 4301 Seat stepped bushings 1 4104 430F Disc springs 1 8159 Nozzle needle1 1 4021 Locking screw A2 70 A 192 CL 2B BB Welding neck flange butt weld end via transition pieces socket weld end1 1 0460 A 105 1 Pressure bearing components ...

Page 39: ...39 Technical data Dimensions and weights BA BAE ...

Page 40: ...25 425 L mm 150 150 160 180 200 PN 40 CLASS 150 230 CLASS 300 230 S1 mm 20 S2 BA mm 180 S3 BAE 100 Weight BA kg 4 7 5 3 5 8 7 1 10 7 12 5 Weight BAE 8 8 9 4 9 9 11 2 14 8 16 6 BA 47 and BAE 47 flange PN 63 DN mm 25 40 50 in 1 1 2 D BAE only mm 154 H1 mm 126 132 132 H2 BA mm 172 213 213 H3 BAE mm 385 425 425 L mm 190 220 250 S1 mm 20 S2 BA mm 180 S3 BAE 100 Weight BA kg 7 1 10 7 12 5 Weight BAE 11 ...

Page 41: ... 7 1 10 7 12 5 Weight BAE 11 2 14 8 16 6 BA 46 47 and BAE 46 47 butt weld end DN1 mm 15 20 25 32 40 50 in 1 1 1 2 D BAE only mm 154 H1 mm 126 126 126 126 132 132 H2 BA mm 172 172 172 172 213 213 H3 BAE mm 385 385 385 385 425 425 L mm 200 200 200 200 250 250 S1 mm 20 S2 BA mm 180 S3 BAE 100 Weight BA kg 4 1 4 7 4 7 5 4 8 9 10 2 Weight BAE 8 2 8 8 8 8 9 5 13 0 14 3 1 BA 47 and BAE 47 in DN 25 40 50 ...

Page 42: ... only mm 154 H1 mm 126 126 126 126 132 132 H2 BA mm 172 172 172 172 213 213 H3 BAE mm 385 385 385 385 425 425 L mm 200 200 200 200 250 250 S1 mm 20 S2 BA mm 180 S3 BAE 100 Weight BA kg 3 7 3 9 4 2 5 1 8 3 9 5 Weight BAE 7 8 8 0 8 3 9 2 12 4 13 6 1 BA 47 and BAE 47 in DN 25 40 50 only ...

Page 43: ...ar at boiling temperature 237 5 C Type of connection CLASS 150 flange socket weld ends and butt weld ends Pressure1 p bar 19 6 17 7 13 8 10 2 Temperature1 T C 20 100 200 300 1 Operating limits for strength of body cover to ASME B16 5 Type of connection CLASS 300 flange socket weld ends and butt weld ends Pressure1 p bar 51 1 46 6 43 8 39 8 Temperature1 T C 20 100 200 300 1 Operating limits for str...

Page 44: ...Operating limits for strength of body cover to EN 1092 1 Operating data Maximum pressure 46 7 bar at boiling temperature 261 C Type of connection CLASS 600 flange socket weld ends and butt weld ends Pressure1 p bar 102 1 93 2 87 6 79 6 Temperature1 T C 20 100 200 300 1 Operating limits for strength of body cover to ASME B16 5 Operating data Maximum pressure 55 bar at boiling temperature 271 C ...

Page 45: ...turer To download the current Declaration of Conformity or Declaration by Manufacturer go to www gestra com documents or contact GESTRA AG Münchener Straße 77 28215 Bremen Germany Telefon 49 421 3503 0 Telefax 49 421 3503 393 E Mail info de gestra com Web www gestra de This declaration is no longer valid if modifications are made to the equipment without consultation with us ...

Page 46: ...46 ...

Page 47: ...47 ...

Page 48: ...world www gestra de GESTRA AG Münchener Strasse 77 28215 Bremen Germany Phone 49 421 3503 0 Fax 49 421 3503 393 e mail info de gestra com Web www gestra com 818609 04 03 2019_kx_mm 808708 06 GESTRA AG Bremen Printed in Germany ...

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