BK 46 Installation Instructions 810645-00 Steam Trap BK 46 1
Capacity Chart 2 1 Fig. 1 1 2 Max. discharge capacity of hot condensate Max. discharge capacity of cold condensate 2
Design A B C D D E E1 F G H I Fig. 2 J 3
Key A B C D E Hexagon-head screw M10x25, EN 24027 made of 1.7225 Name plate Cover Regulator Bush (interference fit, not a spare part) E1 Protective sleeve against wear (interference fit, not a spare part) F Cover gasket 40 x 48 x 2 G Body H Strainer I Plug gasket A 24 x 29 J Strainer plug 4
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Contents Page Important Notes Use... 7 Important safety note... 7 Danger...7 Explanatory Notes Scope of supply... 8 Description... 8 Function... 8 Technical data... 9 Name plate and ratings...10 Installation BK 46...10 Flanged design...10 Screwed-socket design...10 Socket-weld design...11 Heat treatment of welds...11 Operation Factory setting...11 Maintenance Check steam trap...12 Clean/replace regulator and nozzle insert...12 Clean/replace strainer...12 Torques...13 Spare Parts Spare parts list...13 6
Important Notes Use Use steam trap BK 46 only for the discharge of condensate in steam lines within the admissible pressure/temperature ratings. Check the chemical resistance and suitability of the steam trap for the application in question. Important Safety Note The steam trap may only be installed by qualified staff. Qualified staff are those persons who through adequate training in engineering, the use and application of equipment in accordance with regulations concerning steam systems, and first aid & accident prevention have achieved a recognised level of competence appropriate to the installation and commissioning of this device. Danger The trap is under pressure during operation. When disassembling or opening the trap, loosening the plug or regulator, hot water and steam may escape. This presents the risk of severe burns to the whole body. Installation and maintenance work should only be carried out when the system is depressurized: isolate the trap from both upstream and downstream pressure. The trap becomes hot during operation. This presents the risk of severe burns to hands and arms. Installation and maintenance work should only be carried out when the system is cold. Sharp edges on internal parts present a danger of cuts to hands. Always wear industrial gloves for installation and maintenance work. 7
Explanatory Notes Scope of Supply BK 46 1 Steam trap type BK 46 1 Installation manual Description Thermostatic steam trap with corrosion-resistant thermostatic element (Duo stainless steel bimetallic regulator) unaffected by waterhammer. With Y-type strainer, nonreturn valve and asbestos-free cover gasket (graphite). Installation in any position. The standard version discharges condensate with virtually no banking-up. Function During start-up of the plant the Duo stainless steel plates are flat. The service pressure acts in the opening direction, the valve is completely open. As the condensate temperature rises, the plates deflect, drawing the stage nozzle towards the closed position. As the condensate temperature sinks, the deflection of the Duo stainless steel plates decreases and the steam trap opens at the adjusted opening temperature. The thermostatic and spring characteristics of the stack of plates are balanced such that condensate is always discharged at a given undercooling temperature. The trap provides automatic air-venting at start-up and during operation. BK 46 can also be used for thermal air-venting in steam systems. 8
Technical Data Pressure/temperature ratings BK 46, PN 40 Max. service pressure PMA [barg] 35 32 28 [psig] 508 464 406 Related temperature TMA [ C] 300 335 450 [ F] 572 634 842 Max. differential pressure (inlet pressure minus outlet pressure) PMX 32 barg (464 psig) Materials Body Cover Screws Body gasket Regulator Other internals DIN New designation Old designation 15 Mo 3 (1.5415) 15 Mo 3 (1.5415) 42 CrMo 4 (1.7225) Graphite Stainless steel Stainless steel ASTM A 182 F 1 (DIN equivalent) 1 ) A 182 F 1 (DIN equivalent) 1 ) A 193 B 7 1 ) Physical and chemical properties comply with DIN grade. ASTM nearest equivalent grade is stated for guidance only. 9
Explanatory Notes continued Name Plate / Ratings Reference point for ultrasonic functional test Nominal size Regulator Standard design Ratings acc. to EN ISO 26552 For further specifications according to EN 19 see trap body. Fig. 4 Installation BK 46 The steam trap BK 46 can be installed in any position. In the case of a horizontal installation, make sure that the cover is at the top. Flanged Design 1. Take care of correct position of installation. 2. Take care of flow direction. The flow arrow is on the trap body. 3. Consider space required for opening trap. When the trap is installed a minimum space of 70 mm is required for removing cover C. 4. Remove plastic plugs. They are only used as transit protection. 5. Clean seating surfaces of both flanges. 6. Install steam trap. Screwed-Socket Design 1. Take care of correct position of installation. 2. Take care of flow direction. The flow arrow is on the trap body. 3. Consider space required for opening trap. When the trap is installed a minimum space of 70 mm is required for removing the cover C. 4. Remove plastic plugs. They are only used as transit protection. 5. Clean female thread of screwed sockets. 6. Install steam trap. 10
Installation continued Socket-Weld Design 1. Take care of correct position of installation. 2. Take care of flow direction. The flow arrow is on the trap body. 3. Consider space required for opening trap. When the trap is installed a minimum space of 70 mm is required for removing the cover C. 4. Remove plastic plugs. They are only used as transit protection. 5. Remove regulator as described under Maintenance. 6. Clean socket-weld ends. 7. Arc-weld trap only manually (welding process 111 and 141 in accordance with DIN EN 24053). Attention Only qualified welders certified e. g. according to DIN EN 287 may weld the steam trap into pressurized lines. Do not insulate the steam trap. Heat Treatment of Welds A subsequent heat treatment of the welds is not required. Operation Factory Setting The factory setting ensures that the steam trap works without loss of live steam and with virtually no banking-up of condensate. Any modification of the default setting will displace the opening and closing curve of the trap towards the saturation curve and would result in loss of live steam and/or could lead to a substantial undercooling which would give rise to condensate banking-up. We therefore highly recommend not to change the factory setting. 11
1. Take heed of the note Danger on page 7. 2. Undo body screws A. Remove cover C from the body G. 3. Remove and clean regulator D. 4. Replace regulator D in case of visible signs of wear or damage. 5. Clean body, internals and all gasket surfaces. 6. Apply heat-resistant lubricant to all threads and the seating surface of the nozzle insert and the cover (use for instance WINIX 2150). 7. Screw in regulator and tighten with a torque of 90 Nm. 8. Replace gasket F if there are visual signs of damage. Use the same cover C. Always replace gasket F when using a new cover C or the cover of another steam trap. 9. Put cover onto the body. Tighten body screws A alternately and in several steps to a torque of 25 Nm. 1. Take heed of note Danger on page 7. 2. Unscrew sealing plug J and remove strainer H. 3. Clean strainer, sealing plug and gasket seats. 4. Exchange strainer and sealing plug in case of visible signs of wear or damage. 5. Exchange gasket I if damaged. 6. Apply heat-resistant lubricant to the thread of the sealing plug (use for instance WINIX 2150). 7. Replace gasket I and strainer H and tighten sealing plug J with a torque of 120 Nm. 12 Maintenance The thermostatic steam trap BK 46 does not require any special maintenance. However, if used in new installations which have not been rinsed it may be necessary to check and clean the trap. Check Steam Trap You can check the steam trap BK 46 for steam loss during operation using the ultrasonic measuring unit VAPOPHONE or the test unit TRAPtest. The reference points are at the name plate on the cover. see Fig. 4 Should you detect any loss of live steam clean the trap and/or replace the regulator. Clean/Replace Regulator and Nozzle Insert Tools Spanner A. F. 16 mm to DIN 3113, form B Spanner A. F. 22 mm to DIN 3113, form B Torque spanner 20 120 Nm to DIN ISO 6789 Clean/Replace Strainer Tools Spanner A. F. 30 mm to DIN 3113, form B Torque spanner 20 120 Nm to DIN ISO 6789 WINIX is a registered trademark of WINIX GmbH, Norderstedt
Maintenance continued Torques Item D A Designation Regulator Body screws Torque [Nm] 090 025 J Sealing plug 120 All torques given in the table are based on an ambient temperature of 20 C. Spare Parts Spare Parts List Item Designation Stock code D F Regulator 375 464 H I J Strainer set, complete 375 113 F I Cover gasket*) 40 x48 x 2, graphite Plug gasket*) A24 x 29, stainless steel 375 159 375 162 *) Minimum purchasing quantity 50 pcs. Contact your local dealer for smaller quantities. 13
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