GESTRA VK 14 User manual

Vaposcope Sight Glasses
®
VK 14
VK 16
Original Installation Instructions
818577-03

Contents
Foreword............................................................................................................................... 3
Availability.............................................................................................................................................3
Formatting features in the document ......................................................................................................3
Safety................................................................................................................................... 3
Use for the intended purpose .................................................................................................................3
Basic safety notes .................................................................................................................................4
Information on property damage or malfunctions .....................................................................................5
Qualification of personnel.......................................................................................................................5
Protective gear......................................................................................................................................5
Typographic features of warning notes....................................................................................................5
Formatting features for warnings of property damage ..............................................................................5
Description............................................................................................................................ 6
Scope of supply and equipment specification ..........................................................................................6
Task and function..................................................................................................................................8
Storing and transporting the equipment..................................................................................... 9
Storing the equipment ...........................................................................................................................9
Transporting the equipment ...................................................................................................................9
Mounting and connecting the equipment ................................................................................. 10
Preparing installation ...........................................................................................................................10
Connecting the equipment ...................................................................................................................10
Operation ............................................................................................................................ 12
After operation..................................................................................................................... 13
Maintaining the equipment...................................................................................................................13
Removing external dirt deposits............................................................................................................14
Servicing the equipment and installing spare parts ................................................................................14
Troubleshooting ................................................................................................................... 19
Putting the equipment out of operation.................................................................................... 21
Removing harmful substances..............................................................................................................21
Removing the equipment .....................................................................................................................21
Re-using equipment after storage.........................................................................................................22
Returning the equipment......................................................................................................................22
Disposing of the equipment..................................................................................................................23
Technical data ..................................................................................................................... 24
Dimensions and weights ......................................................................................................................24
Pressure & temperature ratings............................................................................................................26
Declaration of Conformity – Standards and Directives ............................................................... 27

3
Foreword
This installation & operating manual will help you
use the following types of equipment safely and
efficiently for their intended purpose.
VK 14, PN 16
VK 16, PN 40
These types will be called equipment in this
document.
This installation & operating manual is intended for
anyone commissioning, using, operating, servicing,
cleaning or disposing of this equipment and, in
particular, for professional after-sales service
technicians, qualified personnel and authorised and
trained staff.
All of these persons must read and understand the
content of this installation & operating manual.
Following the instructions given in this installation &
operating manual helps avoiding danger and
increases the reliability and service life of the
equipment. Please note that in addition to the
instructions given in this installation & operating
manual you must also observe all locally applicable
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 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:
Standard text
Cross-reference
Listing
Sub-items in listings
Steps for action.
Here you will find additional
useful
information and tips serving to assist you
in using the equipment to its fullest
potential.
Safety
Use for the intended purpose
Equipment types VK 14 and VK 16 enable you to
see the flow of fluid in pipes and therefore
recognise any loss of steam or banking-up of
condensate in steam traps.
The equipment must only be used within the
allowable pressure and temperature limits and only
if the chemical and corrosive influences on the
equipment are taken into account.
Correct use includes compliance with the
instructions given in this installation & operating
manual, in particular obedience to all safety
instructions.
Any other use of the equipment is considered to be
improper.
Note that the equipment is also used incorrectly if
the materials of the equipment are not suitable for
the fluid.

4
Basic safety notes
Risk of severe injuries
The equipment is under pressure during
operation and can be hot or very cold,
depending on the fluid used. Only perform work
on the equipment if the following conditions are
satisfied:
The pipes must not be under pressure.
All fluid must be thoroughly removed from
pipes and the equipment.
Before carrying out any work, the higher-
level system must be switched off and
secured so it cannot be switched back on by
unauthorised persons.
Pipes and the equipment must have cooled
to a lukewarm temperature, or around 20 °C.
For equipment used in contaminated areas,
there is a risk of serious or fatal injury from
harmful substances on the equipment. Only
perform work on the equipment after it has been
thoroughly decontaminated. Wear the protective
clothing specified for the contaminated zone
during all work.
The equipment may only be used with fluids that
are not aggressive in contact with material and
seals. Otherwise, leaks may occur and hot, cold
or toxic fluid may escape.
The equipment and its components may only be
installed or removed by specialist personnel.
Specialist personnel must have knowledge and
experience in the following areas:
Producing pipe connections.
Selecting suitable lifting gear for the product
and using it safely.
Working with hazardous (contaminated, hot,
cold or pressurised) fluids.
If the admissible pressure and temperature
ratings are exceeded, the equipment may be
destroyed and hot, cold or pressurised fluid may
escape. Make sure that the equipment is always
used within the admissible pressure and
temperature ratings.
You can find information about the pressure and
temperature ratings on the name plate and in
the “
Technical data ” section.
The equipment is under pressure during
operation and can become hot or cold,
depending on the fluid used. Only bring the
equipment into service if contact with surfaces
is prevented by insulation or other protection.
Always wear protective clothing when working
on the equipment and on pipes carrying fluid.
You will find information on suitable protective
clothing in the safety data sheet for the fluid
used.
If unsuitable lifting gear is used or the gear is
used improperly the equipment or parts of it
could fall down.
Make sure that only qualified personnel lifts
the equipment or parts of it.
Make sure that nobody is standing or
working below the hoisted equipment.
Make sure that the lifting gear is of sufficient
strength for the load to be hoisted and that
the load is properly secured and attached to
it. For more information on the nature and
weight of the components and safe lifting
points please contact the manufacturer.
Make sure that all locally applicable
regulations on safety and the prevention of
accidents are strictly adhered to.
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 equipment is inadequately supported
during installation, there is a risk of getting
crushed if it falls. Use the eyebolt to secure
lifting gear, if available. Secure the equipment
during installation so it cannot fall. Use the
eyebolt to do this, if available. Wear sturdy
safety boots.

5
Information on property damage
or malfunctions
Malfunctions will occur if the equipment is
installed in a wrong position or with the flow
arrow pointing in the opposite direction of the
fluid flow. This may result in damage to the
equipment or the installation. Make sure that
the flow arrow on the equipment body matches
the indicated direction of the fluid flow in the
pipe.
If the material is unsuitable for the fluid,
increased wear may occur and fluid may
escape. Make sure that the material is suitable
for the fluid used in your installation.
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 dea
th 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.

6
Description
Scope of supply and equipment
specification
Scope of supply
Our equipment is delivered packed and ready for
assembly.
Component parts
VK 14, DN 15–25
No.
Designation
1
Body with name plate
2
Gasket
3
MAXOS®sight glass
No.
Designation
4
Spherical washer
5
Union nut
6
Mica shield (optional)

7
VK 14, DN 40–50 and VK 16, DN 15–50
No.
Designation
1
Body with name plate
2
Gasket
3
MAXOS
®
sight glass
No.
Designation
6
Mica shield
7
Flange
8
Hexagon head bolt (4 ×)

8
Optional extras
The mica shield is available as an optional extra for
VK 14, DN 15–25. In the other models, the mica
shield comes as standard.
End connections
The equipment is available with the following end
connections:
VK 14
Flanges
VK 16
Flanges
Screwed sockets
Socket-weld ends
Name plate/identification
The following items are indicated on the body:
Manufacturer
Type designation
Pressure rating
Design pressure
Max. service temperature
Material
Date of manufacturing
Direction of flow
Mark (if required), e. g. CE, UKCA, EAC
Application of European Directives
Fluids
The equipment is designed for the following fluids
(in accordance with the EU Pressure Equipment
Directive or Pressure Equipment (Safety)
Regulations in the UK):
Fluids of group 2
Due consideration must be given to chemical and
corrosive influences.
Potentially explosive atmospheres
The equipment does not have its own potential
source of ignition (as per ATEX Directive). Please
pay attention to the following information:
The high temperature of the fluid can cause the
system to heat up to the point of ignition.
If using in potentially explosive atmospheres, the
plant manufacturer or plant operator is responsible
for preventing temperatures on the surfaces of the
equipment that could lead to ignition.
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.
Task and function
Purpose
Equipment types VK 14 and VK 16 enable you to
see the flow of fluid in pipes and therefore
recognise any loss of steam or banking-up of
condensate in steam traps.
Function
The behaviour of the flow of fluid in the sight glass
provides information about the function of the
steam trap behind the equipment.
If no condensate is visible in the sight glass, it is
banking up.
If only a little condensate is visible, live steam is
flowing through the steam trap regulator. In this
case, the steam trap is probably faulty or cleaning
valves are open.

9
Storing and transporting the
equipment
Attention!
Equipment can be damaged if stored or
transported improperly.

Close all openings with the sealing
plugs or covers supplied with the
equipment or use similar sealing
covers.

Protect the equipment against
moisture and corrosive atmospheres.

Please contact the manufacturer if the
specified transport and/or storage
requirements cannot be met.
Storing the equipment
Please observe the following items when storing
the equipment:
Do not store the equipment for more than 12
months.
Use the supplied sealing plugs or other suitable
seal caps in order to seal off all openings of the
equipment.
Protect the sealing surfaces and contact areas
against mechanical damage.
Protect the equipment and all components
against hard shocks and impacts.
Store the equipment only in closed 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
DANGER
Risk of crushing from falling equipment or
components.

Wear protective clothing during all
work.

Use suitable lifting gear to lift and
move the equipment during all work.

Make sure that the equipment cannot
tip over.

Always lift the equipment by the body
only.

Make sure that there are never any
persons below the suspended
equipment.
Protective clothing must include the following items,
as a minimum:
Safety helmet to EN 397
Safety footwear to EN ISO 20345
Mechanical leather gloves to EN 388.
You will find information on suitable protective
clothing and personal protective equipment (PPE) in
the safety data sheet for the fluid used.
The lifting gear must have sufficient load-bearing
capacity for the equipment.
You can find information on the weight of the
equipment in the supplied documentation.
Meet the requirements for storage also when
transporting the equipment.
Prior to transport seal off connections with
sealing plugs.
If you do not have the sealing plugs
supplied with the equipment use
appropriate seal caps to seal off the
connections.
For short distances (only a few metres) you can
transport the equipment unpacked.
When transporting the equipment over larger
distances use the original packaging.

10
If you do not have the original packaging use a
box that protects the equipment adequately
against corrosion and physical damage.
For a short period of time the equipment
may be transported even if the
temperature is below 0
°C, provided that
the equipment is completely empty and
dry.
Mounting and connecting the
equipment
DANGER
Risk of extremely severe injury or death
due to burns, freezing or intoxication
during work on pipes.

Make sure that there is no hot or cold
fluid in the equipment or pipes.

Make sure that the equipment pipes
are not under pressure.

Make sure that the system is switched
off and secured so it cannot be turned
on by unauthorised persons.

Make sure that the equipment and
pipes are lukewarm.

Wear protective clothing that is
suitable for the fluid, and use suitable
personal protective equipment if
necessary.
Information on suitable protective clothing and PPE
can be found in the safety data sheet of the fluid
used.
Preparing installation
Take the equipment out of the transport
packaging.
Check the equipment for transport damage.
Contact the manufacturer if you detect any kind
of shipping damage.
When supplied by the factory, the connections may
be sealed off with sealing plugs.
Remove sealing plugs before mounting the
equipment.
Keep the sealing plugs and the packing for
further use.
Drain pipes until they are empty.
Make sure that all pipelines upstream and
downstream of the equipment are
depressurised.
Switch the installation off and protect it against
unauthorised or unintended re-activation.
Ensure complete safety when draining the
equipment and surrounding pipes.
Connecting the equipment
DANGER
Incorrectly connected equipment can result
in accidents with extremely severe injuries
or death.

Make sure that only specialist
personnel connect the equipment to
the pipe.

Make sure that the direction of flow in
the pipe matches the flow direction
arrow on the equipment.

Make sure that the connected pipe
does not subject the body to any
stress (forces or torques) during
installation and operation.
Specialist personnel must have knowledge and
experience of the type of pipe connection used.

11
Attention!
Equipment will be damaged if the end
connections are undersized.

Make sure that the connections are
strong and rigid enough to support the
weight of the equipment and to
withstand the forces that occur during
operation.
Maintain the necessary service dimensions from
neighbouring plant parts to ensure sufficient
space when replacing components.
You can find information on the service dimensions
of the various equipment types on page 24 ff.
Make sure that the pipe system of the plant is
clean.
Make sure that the equipment is free from
foreign matter.
Attention!
The incorrect installation po
sition will lead
to malfunctions.

Install the equipment upstream of the
steam trap in the direction of the flow
of fluid, with the tip of the deflector
facing up.
Attention!
Sight glasses can be damaged if welded in
place incorrectly.

Always have sight glasses welded in
place by welders certified to EN 287
or with equivalent qualifications.
Make sure that the equipment is safely mounted
and that all connections are made correctly.

12
Operation
Do not work on the equipment while it is operating.
The plant must be at operating temperature for
adjusting the steam trap.
Adjust the steam trap so that the display in the
sight glass matches the image on the left below.
Normal condensate level (A)
Banked-up condensate (B)
Penetration of live steam due to
leaks or other major disruptions (C)
–
Condensate covers the entire sight
glass. No flow is visible.
The sight glass is nearly opaque.
The downstream steam trap is
working correctly. 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.
Check that the plant part and
equipment are not leaking and are
in perfect condition.
Remedy leaks and damages.
You can find information on what to do in
the
event of problems in section
"
Troubleshooting " on page 19.

13
After operation
DANGER
If fluid escapes personnel may suffer
severe injuries, poisoning or even loss of
life.

After working on the equipment make
sure that all connections and valves
are tight.

Make sure that the gaskets of the
body are leakproof.
DANGER
Risk of extremely severe injury or death
due to burns, freezing or intoxication
during work on pipes.

Make sure that there is no hot or cold
fluid in the equipment or pipes.

Make sure that the equipment pipes
are not under pressure.

Make sure that the system is switched
off and secured so it cannot be turned
on by unauthorised persons.

Make sure that the equipment and
pipes are lukewarm.

Wear protective clothing that is
suitable for the fluid, and use suitable
personal protective equipment if
necessary.
Information on suitable protective clothing and PPE
can be found in the safety data sheet of the fluid
used.
Drain the equipment and pipes via the on-site
drainage system.
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 qualified personnel are allowed to
perform work on contaminated
equipment.

Always wear the protective clothing
prescribed for contaminated areas
when working on the equipment.

Make sure that the equipment is
completely decontaminated before
carrying out any service work.

Follow the pertinent instructions for
handling the hazardous substances in
question.
Atte
ntion!
Frost damage may occur when the
installation is shut down.

Drain the equipment if ambient
temperatures below 0 °C (frost) are to
be expected.
Maintaining the equipment
Combination spanner to DIN 3113, type B
(size 18, 24 or 60, depending on equipment
type)
Torque wrench 25–130 Nm to DIN ISO 6789
Visually inspect the equipment quarterly for
leaks and dirt deposits.
Replace leaking, worn and damaged
components.
Remove dirt deposits.
In normal circumstances, you do not need to clean
the components inside the equipment.
To clean the equipment in its entirety, you will have
to remove the sight glasses.

14
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.
Servicing the equipment and
installing spare parts
You may exchange the following component parts
in case of wear or damage:
Replace components only with genuine spare
parts from the manufacturer.

15
Spare parts for the VK 14
No.
Designation
Stock code
DN 15–25
DN 40–50
2, 3, 6
Sight glass, complete, with gasket and mica
shield
703489
–
2, 3
Sight glass, complete, with gasket
–
703488
4
Spherical washer
703109
–

16
Spare parts for the VK 16
No.
Designation
Stock code
DN 15–25
DN 40–50
2, 3, 6
Sight glass, complete, with gasket and mica
shield
703489
703490

17
Replacing the sight glass
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 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
suitable for the fluid and, if nece
ssary,
wear protective gear.
For more information on suitable protective clothing
and safety gear refer to the safety data sheet of the
fluid in question.
You require the following tools to replace the sight
glass:
Combination spanner to DIN 3113, type B
(size 18, 24 or 60, depending on equipment
type)
Torque wrench 25–130 Nm to DIN ISO 6789
The individual equipment types have
different fastenings.
In equipment types VK 14, DN 15–25, the sight
glass is fastened with a union nut.
In equipment types VK 14, DN 40–50 and
VK 16, the flange is fastened with four hexagon
head bolts.
Otherwise, the same procedure is used for the
different equipment types.
Removing the sight glass of the VK 14, DN 15–
25
Proceed as follows to remove the sight glass of the
VK 14, DN 15–25:
Undo the union nut (5).
Remove the spherical washer (4).
Remove the gasket (2).
Remove the sight glass (3).
Remove the optional mica shield, if present.
Remove the gasket (2).
Remove the second sight glass in the same
way, if applicable.

18
Removing the sight glass of the VK 14, DN 40–
50 and VK 16, DN 15–50
Proceed as follows to remove the sight glass of the
VK 14, DN 40–50 and VK 16:
Undo the four hexagon head bolts (8) in the
flange.
Remove the flange (7).
Remove the gasket (2).
Remove the sight glass (3).
Remove the mica shield (6, optional in the
VK 14).
Remove the gasket (2).
Remove the second sight glass in the same
way, if applicable.
Installing a new sight glass
DANGER
Burns or
intoxication from escaping
medium may cause extremely severe or
even fatal injuries.

Only use new sight glasses and
gaskets that are in perfect condition.

Do not install sight glasses that have
already been in operation.

Clean all components of the
equipment before installation.

Remove foreign matter.

Tighten the fastenings of the
equipment uniformly to the specified
torque.
Check all removed parts for signs of damage.
Replace all worn or damaged parts.
Clean all dirty parts.
Coat the thread and contact surfaces with
temperature-resistant lubricant.
The lubricant must have the same properties as
OKS 217.
Insert the new internal sight glass gasket.
Insert the new mica shield, if applicable.
Insert the new sight glass.
Insert the new external sight glass gasket.
For the VK 14, DN 15–25, insert the spherical
washer.
For the VK 14, DN 40–50 and VK 16, fit the
flange and insert the hexagon head bolts.

19
The torque required for fastening varies depending on the equipment:
VK 14
DN15–25
VK 14
DN40–50
VK 16
DN15–25
VK 16
DN40–50
Union nut (5)
130 Nm
–
–
–
Hexagon head bolt (8)
–
60 Nm
30 Nm
60 Nm
Tighten the union nuts or hexagon head bolts to
the specified torque.
Fit the second sight glass in the same way, if
applicable.
Troubleshooting
Problem
Cause
Remedy
Fluid escapes (equipment is
leaking).
The body has been damaged by
corrosion or erosion.
Replace the equipment with a new one.
Use equipment made of material that is
suitable for the application.
Fluid escapes (equipment is
leaking).
The equipment has been
damaged by frost.
Replace the equipment with a new one.
When shutting down the installation
make sure that all lines and the
equipment are completely drained.
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 connections are not tight.
Provide the connections with leakproof
seals.
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 parts or equipment if
damaged.
The sightglass or water level
gauge does not offer an
unambiguous evaluation of
the operating condition.
The sightglass or water level
gauge is dirty, worn or scratched.
Replace the sightglass or water level
gauge.

20
You can recognise and remedy faults due to
incorrect settings as follows:
Normal condensate level (A)
Banked-up condensate (B)
Penetration of live steam due to
leaks or other major disruptions (C)
–
Condensate covers the entire sight
glass. No flow is visible.
The sight glass is nearly opaque.
The downstream steam trap is
working correctly. 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.
Check that the plant part and
equipment are not leaking and are
in perfect condition.
Remedy leaks and damages.
If faults occur that are not listed above or cannot
be corrected, please contact our Technical
Service or authorized agency in your country.