GESTRA UNA 38 Original Installation Instructions Download Page 5 | Manualshive

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5

Qualification of personnel

A qualified person must be acquainted with and
experienced in the following:



the pertinent on-site rules and regulations for
preventing fire and explosions as well as
industrial safety regulations



working on pressure equipment



making pipe connections



working with dangerous (hot or pressurized)
fluids



lifting and transporting loads



observing all notes and instructions in this
installation & operating manual and the
applicable documents

Protective gear

The operator must ensure that anyone working on
the equipment must wear the required protective
clothing and safety gear stipulated for the site of
installation. The protective clothing must be suitable
for the used media and must protect the wearer
against safety and health hazards associated with a
particular job to be carried out at the site of
installation. Protective clothing & equipment must
provide protection from potential hazards, in
particular from injuries to:



Head



Eyes



Body



Hand



Feet



Hearing

Note that this list is not exhaustive. The operator
must establish personal protective equipment
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
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.

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Summary of Contents for UNA 38

Page 1: ...Ball float steam trap UNA 38 UNA 39 Original Installation Instructions 818603 03 ...

Page 2: ... equipment 12 Storing the equipment 12 Transporting the equipment 12 Mounting and connecting the equipment 13 Preparing installation 13 Orientation of the equipment 13 Connecting the equipment 14 Operation 16 After operation 17 Removing external dirt deposits 18 Maintaining the equipment 18 Servicing the equipment and installing spare parts 26 Troubleshooting 31 Putting the equipment out of operat...

Page 3: ...s installation 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 elem...

Page 4: ... dangerous contaminated hot or pressurized fluids If the admissible temperature and pressure limits are exceeded the equipment may be destroyed and hot or pressurized fluid may escape Make sure that the equipment is only operated within the admissible service range and limits For more information on limits and pressure temperature ratings see name plate and the section Technical Data Risk of minor...

Page 5: ...h a particular job to be carried out at the site of installation Protective clothing equipment must provide protection from potential hazards in particular from injuries to Head Eyes Body Hand Feet Hearing Note that this list is not exhaustive The operator must establish personal protective equipment guidelines and specify any additional protective gear that is required if the worker is exposed to...

Page 6: ...embly Equipment specification UNA 38 No Designation 1 Hex nuts 2 Sleeves 3 Body 4 Body gasket 5 Set screws 6 Bimetallic vent 7 SIMPLEX control unit 8 DUPLEX control unit No Designation 9 Cover 10 Rating plate 11 Drain with screw plug 12 SIMPLEX AO 80 MAX control unit 13 DUPLEX AO 80 MAX control unit 14 Direction of flow arrow ...

Page 7: ...Direction of flow arrow 15 Body 16 Set screws 17 Body gasket 18 SIMPLEX control unit 19 Cover No Designation 20 Manual vent valve 21 Rating plate 22 Sleeves 23 Hex nuts 24 Drain with screw plug 25 SIMPLEX AO 140 MAX control unit ...

Page 8: ...owing items are available as optional extra Optional equipment for UNA 38 No Designation 26 Manual vent valve with socket wrench 27 Sealing ring for manual vent valve 28 Manual lifting lever with socket wrench 29 Sealing ring for manual lifting lever In equipment with control unit SIMPLEX the hand vent valve is included as standard Optional equipment for UNA 39 No Designation 30 Lever for manual l...

Page 9: ...ld ends Butt weld ends Butt weld ends via transition pieces Name plate The following items are indicated on the name plate Manufacturer Type designation Design Nominal size Pressure rating Design temperature Design pressure Max admissible differential pressure CE marking Date of manufacturing The following items are indicated on the equipment body Material Batch code Direction of flow The followin...

Page 10: ...ect to this directive see Manufacturer s Declaration section When installed static electricity may arise between the equipment and the connected system When used in potentially explosive atmospheres the plant manufacturer or plant operator is responsible for discharging or preventing possible static charge If it is possible for medium to escape e g through actuating mechanisms or leaks in threaded...

Page 11: ...nual lifting lever The optional manual vent valve allows you to vent the pipe manually The diagram below shows a UNA 38 with DUPLEX control unit The DUPLEX control unit is only supplied for the UNA 38 A special MAX control unit is available for high condensate flowrates If the float 33 is raised while the fill level is rising first of all the nozzle needle 34 is pulled out of the pilot valve This ...

Page 12: ...osed rooms that meet the following environmental conditions Air humidity below 50 not condensing Indoor air clean salt free and non corrosive Temperature 5 40 C Make sure that all these requirements are always met when storing the equipment Please contact the manufacturer if you cannot comply with the recommended storage conditions Transporting the equipment CAUTION Do not drop the equipment If it...

Page 13: ... loss of life Make sure that no hot or hazardous fluid is in the equipment or the pipes Make sure that the pipes upstream and 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 suitab...

Page 14: ...4 Connecting the equipment DANGER Incorrectly connected equipment can cause fatal accidents or severe injuries Make sure that only qualified skilled personnel connect the equipment to pipes Make sure that the flow arrow on the equipment body matches the direction of flow in the pipe Specialist personnel must be highly qualified and fully experienced in making pipe connections for the respective ty...

Page 15: ...of the equipment In this case connect the air balance pipe to the bore on top of the cover Make sure that the pipe system of the plant is clean Make sure that the equipment is free from foreign matter Mount the equipment in the desired installation position Make sure that pipes satisfy the following conditions Pipes must be routed such as to avoid water pockets Pipes must always be on a downward i...

Page 16: ...vent the equipment turn the hand vent valve viewed from top anticlockwise To close the hand vent valve after air venting turn it clockwise Fasten the hand vent valve hand tight The optional float lifting lever allows the float to be manually lifted irrespective of the liquid level It can be used to purge any dirt away from the seat area and out of the equipment by opening the orifice and draining ...

Page 17: ...n 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 DANGER If the equipment is used in contaminated areas there is a risk of severe injuries or death caused by harmful substances in or on the equipment Only qua...

Page 18: ... of the UNA 38 tighten it to a torque of 70 Nm Removing external dirt deposits To remove dirt deposits rinse the equipment with fresh water and wipe it with a clean lint free cloth To remove any persistent residues use a cleaning agent that is suitable for the material and carefully wipe the equipment with a clean lint free cloth Maintaining the equipment You require the following tools for workin...

Page 19: ...with different types of condensate The following condensates in particular cause problems 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 v...

Page 20: ...emove the cover 9 from the body 3 Take the body gasket out of the body Dispose of the gasket in accordance with regulations at the location of use To remove the cover of the UNA 39 proceed as follows Remove the twelve hex nuts 23 Remove the twelve sleeves 22 from the set screws 16 Remove the cover 19 from the body 15 Take the body gasket out of the body Dispose of the gasket in accordance with reg...

Page 21: ...ocation of use Cleaning the equipment Check the equipment at regular intervals for contamination The intervals depend on the amount of dirt in the system The operator must determine the maintenance intervals Remove any parts that are dirty and cannot be cleaned properly To clean the inside of the equipment proceed as follows Detach the cover from the body as described on page 20 Remove the control...

Page 22: ...place all gaskets with new ones of the same type The jobs described in this section differ depending on the type of equipment To install the control unit of the UNA 38 proceed as follows Attention Malfunctions may occur if the control unit is installed incorrectly When installing the equipment make sure that the name plate points upwards and the float arm is free to move up and down Make sure that...

Page 23: ... gasket 43 to the control unit Position the control unit 18 on the body 15 Screw in the two Allen screws 44 Tighten the Allen screws to a torque of 40 Nm The set screws in the body are not shown in the diagram for reasons of clarity Attach the cover to the body as described on page 24 ...

Page 24: ...lows Make sure that the control unit is correctly fitted The float 33 must be able to move upwards Lubricate the threads and contact surfaces of the set screws with temperature resistant lubricant The lubricant must have the same properties as OKS 217 Insert a new body gasket 4 in the body 3 Place the cover 9 on the body The rating plate 10 must face upwards The four set screws 5 must be inserted ...

Page 25: ... must have the same properties as OKS 217 Insert a new body gasket 17 in the body 15 Make sure that the twelve set screws 16 are securely screwed in the holes in the body Position the cover 19 on the twelve set screws 16 The set screws must fit through the holes in the cover The drainage screw plug 24 must face downwards Place the twelve sleeves 22 on the set screws Screw the twelve hex nuts 23 on...

Page 26: ...26 Servicing the equipment and installing spare parts You may exchange the following component parts in case of wear or damage Spare parts for UNA 38 ...

Page 27: ...plete with body gasket 80 MAX 560553 4 7 SIMPLEX control unit complete with body gasket 50 560554 64 560555 80 560556 4 12 SIMPLEX AO 80 MAX control unit complete with body gasket 80 MAX 560557 26 27 Manual vent valve complete with sealing ring All 560559 28 29 Manual lifting lever complete with sealing ring All 560560 6 45 Bimetallic vent complete with sealing ring All 560558 ...

Page 28: ... 17 18 Control unit complete with body gasket 80 560172 110 560171 140 560170 17 25 Control unit complete with body gasket 140 MAX 560179 20 46 Manual vent valve complete with sealing ring All 560178 17 43 Seal set1 All 560539 1 Contains Body gasket 17 Regulator gasket 43 Seat gasket ...

Page 29: ... a new sealing ring of the same type in the hole in the control unit 8 Screw the new bimetallic vent into the hole in the control unit Tighten the bimetallic vent to a torque of 90 Nm Attention Equipment may leak if the gasket is damaged Replace all gaskets that you loosen during your work Use only new gaskets of the same type For the disposal of the gaskets observe the pertinent on site regulatio...

Page 30: ...ry remove the socket wrench Slacken the hex bolt on the manual lifting lever 29 Remove the manual lifting lever from the body Remove the sealing ring 28 For the disposal of the gaskets observe the pertinent on site regulations concerning waste disposal Attention Equipment may leak if the gasket is damaged Replace all gaskets that you loosen during your work Use only new gaskets of the same type At...

Page 31: ...d Fully open the shut off valves The discharge capacity is too low The equipment is cold or only warm to the touch Insufficient thermal output of the user The inlet outlet or the equipment is dirty If fitted operate the float lifting lever Clean the pipes Clean all internals If necessary replace internals or the whole equipment The discharge capacity is too low Insufficient thermal output of the u...

Page 32: ...the application Fluid escapes equipment is leaking The equipment or the body is damaged Replace the equipment with a new one Fluid escapes equipment is leaking A gasket is damaged Replace the gasket with a new one Clean gasket seating surfaces Fluid escapes equipment is leaking The stuffing box packing has not been tightened enough Tighten the stuffing box packing hand tight Make sure that the stu...

Page 33: ...mental damage may be caused by poisonous fluid residues Before disposing of the equipment make sure that it is clean and free of fluid residues For the disposal of all materials observe the pertinent legal regulations concerning waste disposal Remove all residues from the equipment For the disposal of all residues observe the pertinent legal regulations concerning waste disposal Removing the equip...

Page 34: ...ent from the pipes Put the equipment onto a suitable base Store the equipment as described on page 12 Re using equipment after storage Observe the following instructions if you want to remove the equipment and use it again somewhere else Make sure that the equipment is free of any fluid residues Make sure that all connections are in good condition and leak free If necessary re work welded connecti...

Page 35: ...dy 1 5415 A182 F1 Flange butt weld end socket weld end 1 5415 A182 F1 Pipe weld end flange optional 1 7335 A182 F12 Cover 1 7357 A217 WC6 Body gasket Graphite CrNi Set screws sleeves and hex nuts 1 7709 Other components Stainless steel 1 ASTM material is comparable to EN material Note the differences in chemical and physical properties Materials for UNA 39 Component EN ASTM Body 1 7335 A182 F12 Fl...

Page 36: ...36 Technical data Dimensions and weights Dimensions and weights for UNA 38 Remember to add an additional 30 mm 1 2 in and 100 mm 3 9 in as service dimensions when a manual vent valve is fitted ...

Page 37: ...7 16 8 Socket weld end 300 11 8 300 11 8 300 11 8 420 16 5 420 16 5 Butt weld end 300 11 8 300 11 8 300 11 8 300 11 8 300 11 8 Pipe weld end 300 11 8 300 11 8 300 11 8 420 16 5 420 16 5 Service dimension S mm in All 310 12 2 310 12 2 310 12 2 310 12 2 310 12 2 Weight kg lb Flange 38 83 8 38 83 8 38 83 8 40 88 2 42 92 6 Socket weld end butt weld end pipe weld end 35 77 2 35 77 2 35 77 2 35 77 2 35 ...

Page 38: ...38 Dimensions and weights for UNA 39 ...

Page 39: ...70 6 7 170 6 7 235 9 3 245 9 6 L2 mm in Flange PN160 285 11 2 300 11 8 305 12 0 315 12 4 ASME class 900 1500 flanges 310 12 2 320 12 6 330 13 0 350 13 8 Butt weld end 240 9 4 240 9 4 240 9 4 240 9 4 Socket weld end 240 9 4 240 9 4 305 12 0 315 12 4 Service dimension S mm in All 150 5 9 150 5 9 150 5 9 150 5 9 Weight kg lb Flange 67 147 7 70 154 3 70 154 3 78 191 8 Socket weld end butt weld end 65 ...

Page 40: ...00 450 510 520 530 Maximum admissible differential pressure PMX2 bar 50 64 80 psi 725 928 1160 Pressure1 p psig 1450 1243 1001 510 406 323 Temperature1 T F 14 392 572 842 950 968 986 1 Limit values for body cover to EN 1092 1 2 See table at end of section Pressure and temperature ratings for UNA 38 with ASME class 600 flange Pressure1 p barg 100 100 69 9 61 7 59 7 42 5 Temperature1 T C 10 20 100 3...

Page 41: ...32 986 1 Limit values for body cover to EN 1092 1 and strength limit 2 See table at end of section Pressure and temperature ratings for UNA 38 high temperature with ASME class 600 flange Pressure1 p barg 100 100 78 2 67 6 51 2 32 4 Temperature1 T C 10 20 100 350 450 500 530 Maximum admissible differential pressure PMX2 bar 50 64 80 psi 725 928 1160 Pressure1 p psig 1450 1450 1134 980 742 470 Tempe...

Page 42: ...12 662 842 932 986 1 Limit values for body cover in accordance with strength limit 2 See table at end of section Pressure and temperature ratings for UNA 39 with PN 160 ASME class 1500 flange Pressure1 p barg 160 134 8 104 3 71 6 46 4 37 3 Temperature1 T C 10 300 450 500 520 540 550 Maximum admissible differential pressure PMX2 bar 80 110 140 psi 1160 1595 2030 Pressure1 p psig 2320 1955 1512 1038...

Page 43: ...212 662 932 968 1004 1022 1 Limit values for body cover to EN 1759 1 2 See table at end of section Pressure and temperature ratings for UNA 39 with weld end socket weld end Pressure1 p barg 160 134 8 104 3 71 6 46 4 37 3 Temperature1 T C 10 300 450 500 520 540 550 Maximum admissible differential pressure PMX2 bar 80 110 140 psi 1160 1595 2030 Pressure1 p psig 2320 1955 1512 1038 673 541 Temperatur...

Page 44: ...44 Orifice and differential pressure Orifice AO Hole diameter mm Differential pressure PMX bar UNA 38 UNA 39 50 2 8 50 64 2 3 64 80 2 1 9 80 80 MAX 6 5 80 110 1 6 110 140 1 4 140 140 MAX 6 5 140 ...

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: ...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 818603 03 07 2017 kx_mm 808710 02 GESTRA AG Bremen Printed in Germany ...

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