GESTRA BK 15 User manual

1
BK 15
(DN40, DN 50)
Steam Trap
EN
English
Original Installation Instructions
810682-03

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Contents
Important Notes
Usage for the intended purpose ......................................................................... 4
Safety note ....................................................................................................... 4
Danger............................................................................................................. 4
Attention .......................................................................................................... 4
Application of European Directives ..................................................................... 4
Notes on the Declaration of Conformity/Manufacturer's Declaration ..................... 5
Explanatory Notes
Scope of supply ........................................................................................................... 6
Description .................................................................................................................. 6
Design ........................................................................................................................ 6
Technical Data
Rating plate/marking.................................................................................................... 7
Components
Component parts of BK 15 .. ....................................................................................... 8
Key ............................................................................................................................. 9
Installation
BK 15 ....................................................................................................................... 10
Danger...................................................................................................................... 10
Flanged version ........................................................................................................ 10
Socket-weld version................................................................................................... 10
Butt-weld version....................................................................................................... 11
Attention ................................................................................................................... 11
Heat treatment of welds ............................................................................................. 11
Bringing into Service
BK 15 ....................................................................................................................... 12
Danger ..................................................................................................................... 12
Adjusting the regulator (supercooling, controlled steam flowrate)................................... 12
Restoring the factory settings...................................................................................... 12
Tools ......................................................................................................................... 13
Operation
BK 15 ...................................................................................................................... 13
Page

3
Contents continued
Page
Maintenance
BK 15 ....................................................................................................................... 13
Danger...................................................................................................................... 13
Checking the steam trap ............................................................................................ 13
Cleaning/replacing the Thermovit regulator and strainer ............................................... 14
Tools ......................................................................................................................... 14
Torques..................................................................................................................... 14
Spare Parts
Spare parts list .......................................................................................................... 15
Taking out of Service
Danger...................................................................................................................... 15
Attention ................................................................................................................... 15
Disposal .................................................................................................................... 15

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Usage for the intended purpose
Use the BK 15 steam trap only for discharging condensate from steam or for air venting.
Use in pipes for discharging condensate from steam, paying attention to the admissible
pressure and temperature ratings and the impact of chemicals and corrosion on the pres-
sure equipment.
Safety Note
The equipment may only be installed, brought into service, maintained and refitted by
authorised staff who have the required knowledge and have undergone specific training.
Danger
The equipment is under pressure and hot during operation. Risk of injuries and severe
burns to the entire body.
Only perform installation and maintenance work when the equipment is not under pressure
(0 bar) and is cold (20 °C).
Before performing installation or maintenance work, vent the equipment and
isolate it from both upstream and downstream pressure.
Sharp edges on inner parts present a danger of cuts to hands.
Always wear industrial gloves when working on the equipment.
Attention
The rating plate specifies the technical features of the equipment.
Do not bring into service or operate any equipment that does not bear its own specific
rating plate. The pressure and temperature data on the trap's rating plate must conform to
the requirements of the system.
Application of European Directives
Pressure Equipment Directive
The equipment conforms to this directive (see "Manufacturer's Declaration" section) and
can be used for the following fluids: ■Group 2 fluids
ATEX Directive
The equipment does not have a potential ignition source and as such is not subject to this
directive (see "Manufacturer's Declaration" section).
Once installed, static electricity may arise between the equipment and the connected
system. During use in potentially explosive atmospheres, the discharge or prevention of
possible electrostatic charging is the responsibility of the manufacturer or owner of the
system.
If there is a possibility of fluid escaping, e.g. via actuating devices or leaks in screwed
couplings, the manufacturer or owner of the system must take this into consideration when
dividing the area into zones.
Important Notes

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Important Notes continued
Notes on the Declaration of Conformity/
Manufacturer's Declaration
You can find details on the conformity assessment in accordance with European Directives
in our Declaration of Conformity or Manufacturer's Declaration.
You can request the valid Declaration of Conformity or Manufacturer's Declaration from the
address below:
Modifications to the equipment not approved by us will cause this Declaration to lose its
validity.
GESTRA AG
Münchener Strasse 77
28215 Bremen
Germany
Tel. [phone]
Fax [phone]
E-mail [email protected]
Web www.gestra.com

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Design
BK 15:
Version for installation in horizontal and vertical pipes.
Scope of supply
BK 15
1 Steam trap BK 15
1 Installation & Operating Manual
Description
Thermostatic steam trap with corrosion-resistant, water hammer-resistant Thermovit
(Duo stainless steel) regulator. The Thermovit regulator can be adjusted from the outside.
With integral strainer and non-return valve unit. Asbestos-free body gasket (graphite).
Installation in any position.
The steam trap is factory-set to discharge condensate with virtually no banking-up.
Greater supercooling can be set manually from the outside after installation.
The trap vents independently both when the system is started up and during operation.
The BK 15 can also be used as an air vent.
Explanatory Notes

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Rating plate/marking
For pressure and temperature ratings, see the marking on the body or the information on
the rating plate. For further information, see GESTRA publications such as data sheets and
Technical Information booklets.
The type and version are indicated on the rating plate or body:
Manufacturer's name/logo
Type designation
Pressure class PN or Class
Material number
Direction of flow
Stamp on body/rating plate, e.g. indicates the quarter and year of manufacture
(example: 1st quarter of 2010).
1
10
Technical Data
Fig. 1
Thermovit regulator
Standard version
30K supercooling
U
Nominal size
Ratings to
EN ISO 26552

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Component parts of BK 15
Components
Fig. 2
A
B
C
E
F
G
J
H
D
I
K
L
M
N

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Components continued
Key
AUnion nut G¾
BStuffing box ring
CPacking 9 x14 x 7
DCover
EAdjusting fork
FGuide ring
GThermovit regulator
HStrainer
IBush (force-fit, no spare part)
JBody gasket 92,7 x 102 x 1
KBody
LRating plate
MHexagon nut M12
NHexagon bolt M12

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BK 15
Any installation position is possible, as long as the direction of flow arrow is complied with.
If installed in a horizontal pipe, it is best to have the cover facing upwards. We recommend
that you do not insulate the steam trap.
Danger
The equipment is under pressure and hot during operation. Risk of injuries and severe
burns to the entire body.
Only perform installation and maintenance work when the equipment is not under pressure
(0 bar) and is cold (20 °C).
Before performing installation or maintenance work, isolate the equipment from upstream
and downstream pressure, and vent it.
Sharp edges on inner parts present a danger of cuts to hands.
Always wear industrial gloves when working on the equipment.
Flanged version
1. Ensure the correct installation position.
2. Ensure the correct direction of flow. The direction of flow arrow is on the trap body.
3. Leave sufficient space for servicing. When the trap is installed, a minimum space of
90 mm is required for opening cover D.
4. Remove the plastic plugs. They are used only as transit protection.
5. Clean the sealing surfaces of both flanges.
6. Install the trap.
Socket-weld version
1. Ensure the correct installation position.
2. Ensure the correct direction of flow. The direction of flow arrow is on the trap body.
3. Leave sufficient space for servicing. When the trap is installed, a minimum space of
90 mm is required for opening cover D.
4. Remove the plastic plugs. They are used only as transit protection.
5. Remove the Thermovit regulator as described in the Maintenance section.
6. Clean the socket weld end.
7. Install only using arc welding (welding process 111 and 141 to DIN EN 24063), or
equivalent standard.
Installation

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Installation continued
Butt-weld version
1. Ensure the correct installation position.
2. Ensure the correct direction of flow. The direction of flow arrow is on the trap body.
3. Leave sufficient space for servicing. When the trap is installed, a minimum space of
90 mm is required for opening cover D.
4. Remove the plastic plugs. They are used only as transit protection.
5. Clean the butt weld ends
6. Install using arc welding (welding process 111 and 141 to DIN EN 24063) or gas
welding (welding process 3 to DIN EN 24063), or equivalent standard.
Attention
Steam traps may only be welded in pipes by welders with test certification to
DIN EN 287 or equivalent qualifications.
Heat treatment of welds
Subsequent heat treatment of welds is not necessary provided the pipe is made from
similar material to the trap body.
If pipes are of a material that render heat treatment necessary, this must be restricted to
the immediate vicinity of the weld. If this is not possible, remove the Thermovit regulator
before heat treatment.

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Bringing into Service
Make sure that all connections have undergone a suitable pressure test in conformity with
the applicable regulations.
Danger
The equipment is under pressure and hot during operation. Risk of injuries and severe
burns to the entire body.
Only perform installation and maintenance work when the equipment is not under pressure
(0 bar) and is cold (20 °C).
Before performing installation or maintenance work, isolate the equipment from upstream
and downstream pressure, and vent it.
Sharp edges on inner parts present a danger of cuts to hands.
Always wear industrial gloves when working on the equipment.
When union nut Ais slackened to adjust the regulator, hot water or steam escapes.
Adjusting the regulator
(supercooling, controlled steam flowrate)
The Thermovit regulators of the BK 15 are factory-set to ensure they close steam-tight
and remove condensate with virtually no banking-up. If greater supercooling and resulting
banking-up of condensate is required, e.g. for a heating process, this can be set when
bringing into service or during operation:
1. Pay attention to the Danger note! Slacken union nut Aone turn and turn adjustment
screw Eclockwise using a screwdriver. A 1/8turn corresponds to a 4 K change in tem-
perature. Starting from the factory setting, you can turn adjustment screw Eclockwise
a maximum of 1.5 turns.
2. A controlled steam flowrate can also be set if required. To do this, you can turn adjust-
ment screw Eclockwise a maximum of 1.5 turns, starting from the factory setting.
3. Tighten union nut Ato the torque indicated in the table.
Restoring the factory settings
The Thermovit regulators of the BK 15 are factory-set to ensure they close steam-tight and
remove condensate with virtually no banking-up. If necessary, you can restore the factory
settings as follows:
1. Depressurize the steam trap and let it cool to room temperature (20°C).
2. Slacken union nut Aand turn adjustment screw Eclockwise with a screwdriver until
resistance is felt.
3. Turn adjustment screw Ethree turns anti-clockwise. The steam trap will now dis-
charge condensate virtually without banking-up (factory setting).
4. Tighten union nut Ato the torque indicated in the table.

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Bringing into Service continued
Tools
■Screwdriver 5.5/100, DIN 5265, form A
■Combination spanner size 36 mm AF, DIN 3113, form B
■Torque wrench 20–160 Nm, DIN ISO 6789
Operation
BK 15
The BK 15 can be serviced (see Maintenance).
Maintenance
We recommend periodic tests and maintenance to ensure correct functioning of the equip-
ment. For critical applications, we recommend continuous monitoring.
Danger
The equipment is under pressure and hot during operation. Risk of injuries and severe
burns to the entire body.
Only perform installation and maintenance work when the equipment is not under pressure
(0 bar) and is cold (20 °C).
Before performing installation or maintenance work, isolate the equipment from upstream
and downstream pressure, and vent it.
Sharp edges on inner parts present a danger of cuts to hands.
Always wear industrial gloves when working on the equipment.
Checking the steam trap
The BK 15 steam trap can be checked during operation using a GESTRA VAPOPHONE®
ultrasonic measuring unit or TRAPtest®.
If live steam leakage is detected, clean the trap or replace the regulator.

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Maintenance continued
Cleaning/replacing the Thermovit regulator and strainer
1. Pay attention to the Danger note on page 4!
2. Undo hexagon bolt Nand take cover Doff body K.
3. Fully unscrew Thermovit regulator Gand clean it.
4. Remove and clean strainer H.
5. Clean body K, inner parts and all sealing surfaces.
6. Replace Thermovit regulator Gif it shows visible signs of wear or damage.
7. Coat all threads and sealing surfaces with heat-resistant lubricant (e.g. OKS 217).
8. Insert a new body gasket J.
9. Insert strainer H.
10. Screw in Thermovit regulator Gand tighten to the torque specified in the table.
11. Place cover Don body K, and tighten hexagon bolts Nand hexagon nuts Mcross-
wise to the torques specified in the table.
Tools
■Screwdriver 5.5/100, DIN 5265, form A
■Combination spanner size 36 mm AF, DIN 3113, form B
■Torque wrench 20–160 Nm, DIN ISO 6789
Torques
Item Designation Torque [Nm]
GThermovit regulator 140
NM Hexagon bolts/hexagon nuts 45
AUnion nuts 30
All torques are based on room temperature 20°C, threads without lubricant.

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Item Designation Torque [Nm]
GThermovit regulator 140
NM Hexagon bolts/hexagon nuts 45
AUnion nuts 30
All torques are based on room temperature 20°C, threads without lubricant.
*) Min. order quantity 20 items. For smaller quantities, please contact your specialist retailer.
Spare Parts
Spare parts list
Taking out of Service
Danger
The equipment is under pressure and hot during operation. Risk of injuries and severe
burns to the entire body.
Only perform installation and maintenance work when the equipment is not under pressure
(0 bar) and is cold (20 °C).
Before performing installation or maintenance work, isolate the equipment from upstream
and downstream pressure, and vent it.
Sharp edges on inner parts present a danger of cuts to hands.
Always wear industrial gloves when working on the equipment.
Attention
If there is a risk of frost, drain the trap.
Disposal
The equipment must be disposed of in accordance with statutory waste disposal regula-
tions.
Item Designation Stock code
CPacking 9 x 14 x 7 *) 376552
CGJ Thermovit regulator, set of gaskets 098847
HJ Strainer, body gasket 375698
JBody gasket *) 92.7 x 102 x 1, graphite 375699

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810682-03/11-2017cma (808534-04) · GESTRA AG · Bremen · Printed in Germany
GESTRA AG
Münchener Strasse 77
28215 Bremen
Germany
Tel. [phone]
Fax [phone]
E-mail [email protected]
Web www.gestra.com
Agencies all over the world: www.gestra.de