GESTRA GK 11 Installation Instructions Manual Download Page 18 | Manualshive

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18

Servicing the equipment and

installing spare parts

You may exchange the following component parts
in case of wear or damage:

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Summary of Contents for GK 11

Page 1: ...Steam Traps GK 11 GK 21 with stage nozzle for large quantities of condensate Original Installation Instructions 813078 02 ...

Page 2: ...g the equipment 9 Mounting and connecting the equipment 10 Preparing installation 10 Connecting the equipment 10 Orientation of the equipment 11 Operation 12 Adapting settings 13 After operation 15 Removing external dirt deposits 16 Maintaining the equipment 17 Servicing the equipment and installing spare parts 18 Troubleshooting 27 Adjusting the gland seal 30 Putting the equipment out of operatio...

Page 3: ...llation operating manual is available to the operator The installation operating manual is part of the equipment Please hand over this installation operating manual when selling the equipment or passing it on Formatting features in the document Certain text elements of this installation operating manual feature a specific typographic design You can easily distinguish the following text elements St...

Page 4: ... the system Risk of minor injuries Sharp edges on internals present the danger of cuts to hands Always wear industrial gloves when servicing the equipment If the support of the equipment during installation is insufficient the equipment might fall down thereby causing bruises or injuries Make sure the equipment is safely held in place during installation and cannot fall down Wear protective safety...

Page 5: ...ipment guidelines and specify any additional protective gear that is required if the worker is exposed to a specific risk at the site of installation 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 co...

Page 6: ...struction No Designation 1 Direction of flow arrow 2 Rating plate 3 Sealing plug both sides 4 Body 5 Stage plunger 6 Lid 7 Screw spindle with handwheel No Designation 8 Counter nut for fixing threaded spindle in place 9 Scale with pointer and Operation sign 10 Sight glass lid 11 Sight glass 12 VAPOSOSCOPE insert ...

Page 7: ...n GK 11 Vertical installation with direction of flow from bottom to top Vertical installation with direction of flow from top to bottom You can change the installation position of the equipment The steam trap must always be installed in the pipe with the screw spindle horizontal To change the installation position you must realign the VAPOSCOPE insert To do this proceed as described in the section...

Page 8: ...in the Ex label signifies that operation at an excessive surface temperature caused by the medium must be avoided The equipment itself does not generate additional surface temperatures 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 respon...

Page 9: ...er if you cannot comply with the recommended storage conditions Transporting the equipment CAUTION Do not drop the equipment If it falls down it may cause bruises and injuries To transport and mount the equipment safely use suitable lifting gear Connect the noose strap of the lifting gear to the body Provide sufficient support for the equipment during transport and installation Wear protective saf...

Page 10: ...d downstream of the equipment are depressurised Make sure that the installation is switched off and protected against unauthorised or unintended activation Make sure that the equipment and the pipes have cooled down to room temperatures Wear protective clothing that is suitable for the fluid and if necessary wear protective gear For more information on suitable protective clothing and safety gear ...

Page 11: ...tion Make sure that the equipment is safely mounted and that all connections are made correctly Orientation of the equipment Attention The VAPOSCOPE may show incorrect displays if in the wrong installation position Only install the VAPOSCOPE in one of the installation positions described here The deflector tip of the VAPOSCOPE insert must always point downwards To position the VAPOSCOPE insert you...

Page 12: ...properties as OKS 217 Insert one sight glass seal Insert the mica disc Insert the sight glass Insert the second sight glass seal In type GK 21 insert the spherical washer in the upper sight glass Insert the sight glass lid The necessary torque for tightening the hex nuts varies depending on type Please refer to the following table for the correct torque GK 21 DN50 GK 11 DN65 DN80 GK 11 DN100 GK 11...

Page 13: ...nd information on suitable protective clothing and personal protective equipment in the safety data sheet of the medium used The system must be at operating temperature for setting the equipment Set the equipment such that the display in the sight glass conforms to the diagram on the left below Normal condensate level Banking up of condensate Penetration of live steam if medium throughput is exces...

Page 14: ...n the handwheel clockwise The pointer on the scale moves towards the C CLOSED mark Set the equipment such that a normal condensate level is visible in the sight glass Hand tighten the counter nuts The equipment can now only be opened as far as this position It can still be fully closed however You can affix the supplied Operation sign to mark this setting Affix the Operation sign so that it is opp...

Page 15: ...d against unauthorised or unintended activation Make sure that the equipment and the pipes have cooled down to room temperatures Wear protective clothing that is suitable for the fluid and if necessary wear protective gear For more information on suitable protective clothing and safety gear refer to the safety data sheet of the fluid in question Attention Frost damage may occur when the installati...

Page 16: ...istant lubricant The lubricant must have the same properties as OKS 217 The necessary torque for tightening the sealing plug varies depending on type Please refer to the following table for the correct torque GK 21 DN50 GK 11 DN65 DN80 GK 11 DN100 GK 11 DN150 100 Nm 190 Nm 190 Nm 190 Nm Tighten the sealing plug to the specified torque Removing external dirt deposits To remove dirt deposits rinse t...

Page 17: ...ems very oily condensates condensates that resinify or become gummy condensates that recrystallize condensates that contain solid matter In these cases check the equipment at regular intervals for contamination and if necessary remove dirt deposits To reduce contamination we recommend installing a sedimentation vessel or a dirt pocket arrangement upstream of the equipment In normal cases the compo...

Page 18: ...18 Servicing the equipment and installing spare parts You may exchange the following component parts in case of wear or damage ...

Page 19: ... 1 stage plunger 20 1 sealing ring for collar screw 21 1 nozzle insert seal 22 1 x nozzle insert 23 1 threaded pin for stage plunger 3 for DN150 24 1 x body gasket Seal set comprising 369719 369720 369721 369718 24 1 x body gasket 21 1 nozzle insert seal 19 4 sealing ring for sealing plug 20 1 sealing ring for collar screw 23 1 x threaded pin 25 Stuffing box1 26 1 sealing ring for shoulder screw 1...

Page 20: ...que wrench to DIN ISO 6789 Temperature resistant lubricant is required for lubricating the system The lubricant must have the same properties as OKS 217 The types of equipment differ in the number of hexagon head bolts and whether they are equipped with an additional spherical washer In GK 11 steam traps the lid of the sight glass is fastened with six hexagon head bolts In GK 21 steam traps the li...

Page 21: ...e for the correct torque GK 21 DN50 GK 11 DN65 DN80 GK 11 DN100 GK 11 DN150 25 Nm 30 Nm 90 Nm 90 Nm Tighten the hex nuts to the specified torque Secure the second sight glass in the same way Removing the lid DANGER Personnel working on pipes are exposed to safety risks and may suffer severe injuries poisoning or even loss of life Make sure that no hot or hazardous fluid is in the equipment or the ...

Page 22: ...ed Make sure that the component parts are not damaged by physical shocks The required bearing capacity of the lifting gear depends on the equipment type Contact the manufacturer for more information on the weights of the individual parts You can remove the lid together with the spindle and stage plunger The lid is secured to the body with hex nuts 27 The number of hex nuts varies depending on type...

Page 23: ...types have one threaded pin Remove the threaded pins 23 from the stage plunger 5 Completely unscrew the stage plunger from the spindle 28 Position the new stage plunger on the spindle such that the two holes for the threaded pins are one above the other By hand screw the threaded pins into the holes Remove the collar screw 29 Remove the sealing ring 20 of the collar screw Lift the nozzle insert 22...

Page 24: ...lace the stuffing box Remove the two hex nuts 31 and the stuffing box gland 32 You do not need to remove the stuffing box bush 33 in order to replace the stuffing box Remove the packing rings 25 from the lid Replace the packing rings with the same number of new ones Check all removed parts for signs of damage Replace all worn or damaged parts Clean all dirty parts The gaskets of the equipment must...

Page 25: ...must have the same properties as OKS 217 Attention Equipment may not work properly or get damaged if parts are tilted or skewed when installed Use suitable lifting gear to mount the component parts Do not tilt or skew the component parts during installation During installation make sure that the component parts are not damaged by physical shocks The required bearing capacity of the lifting gear de...

Page 26: ...e necessary torque for tightening the nuts on the lid varies depending on type Please refer to the following table for the correct torque GK 21 DN50 GK 11 DN65 DN80 GK 11 DN100 GK 11 DN150 55 Nm 60 Nm 120 Nm 250 Nm Tighten the nuts to the specified torque If necessary adjust the stuffing box seal as described on page 30 Set the medium flow as described on page 13 ...

Page 27: ...only warm to the touch The shut off valves for fluid flow are closed Fully open the shut off valves The handwheel can only be moved by exerting a lot of force It has reached its end position for this direction of rotation Turn the handwheel in the other direction The stroke limiter is locked Slacken the counter nut of the stroke limiter and reset the stroke limiter The handwheel can only be moved ...

Page 28: ...too tightly Slacken the stuffing box screw a little Replace the stuffing box if damaged The equipment does not close fully Inner parts are damaged or worn Replace the inner parts or the equipment The flowrate is too low The equipment is cold or only lukewarm Insufficient heat output of consumers Contamination in the inflow outflow or equipment Clean the pipe Clean all inner parts Replace inner par...

Page 29: ...clearly visible flow The sight glass is nearly opaque Do not change the settings Open the equipment until a normal condensate level is displayed Close the equipment until a normal condensate level is displayed Close the equipment until a normal condensate level is displayed Check that the part of the system and the equipment are not leaking and are in perfect condition Fix leaks and damages Settin...

Page 30: ...uestion The torque for tightening the hex nuts on the stuffing box varies depending on type The necessary torque for tightening the hex nuts depends on the condition of the stuffing box Tighten the hex nuts sufficiently firmly to ensure the following conditions are satisfied No medium may escape from the gland seal The gland seal must not hinder the movement of the stage plunger If these condition...

Page 31: ...ear For more information on suitable protective clothing and safety gear refer to the safety data sheet of the fluid in question CAUTION Do not drop the equipment If it falls down it may cause bruises and injuries To transport and mount the equipment safely use suitable lifting gear Connect the noose strap of the lifting gear to the body Provide sufficient support for the equipment during transpor...

Page 32: ...s nuts 1 7709 A193 B7 A194 size 4 Nozzle insert 1 0460 A105 1 0619 A216 WCB Stage plunger 1 0460 A105 1 0619 A216 WCB Spindle 1 4104 AISI 430 F Handwheel 5 1300 5 3106 A536 60 40 18 Gasket Graphite CrNi Packing rings Graphite Sight glass Borosilicate glass Mica disc Mica ASTM material is comparable to EN material Note the differences in chemical and physical properties ...

Page 33: ...100 150 Length L mm 320 420 620 900 Width B1 mm 220 275 485 670 B2 mm 100 120 200 285 Diameter of handwheel D1 mm 140 200 315 Height H mm 165 195 326 495 Service dimension1 S mm 90 110 230 300 Weight kg 25 50 52 145 310 1 From upper edge of spindle equipment fully open ...

Page 34: ... 7 7 9 11 2 Diameter of handwheel D1 in 5 5 7 9 12 4 Height H in 6 5 7 7 12 8 19 5 Service dimension1 S in 3 5 4 3 9 1 11 8 Weight lb 55 1 110 2 114 6 319 7 683 4 1 From upper edge of spindle equipment fully open Pressure temperature ratings You can find the values for your equipment on the rating plate ...

Page 35: ...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 36: ...rld www gestra de 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 813078 02 07 2017 kx_mm 801123 02 GESTRA AG Bremen Printed in Germany ...

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