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GESTRA

Technical Information
Steam Traps and Valves for Energy Industries Electronic Controls Automation Special Equipment and Vessels for Heat Recovery

2012

Contents

Steam Traps and Valves

Steam Traps and Trap Testing Equipment Condensate Header and Steam Manifold

Gravity Circulation Checks Screwed Non-Return Valves DISCO Non-Return Valves

DISCOCHECK Dual-Plate Check Valves DISCO Swing Check Valves

Return Temperature Control Valves Self-Acting Pressure and Temperature Controllers Control Valves

Safety Valves Strainers Stop Valves

Industrial Electronics System solutions

General

Level

Basics, type code Schematic layout of steam boiler Old/new equipment at a glance Type approvals at a glance Bus system, compact, conventional

Temperature, conductivity, Continuous and intermittent boiler blowdown Oil and turbidity monitoring, steam flow metering

Bus, compact Conventional Conventional

Special Equipment and Vessels for Heat Recovery

Condensate Recovery and Vessels for Heat Recovery Desuperheating Plants Feedwater Deaerating Plants Mixing Cooler (Blowdown Receiver)

Condensate Dampening Pots Steam Driers and Purifiers Plate-Type Heat Exchangers Vessels

GESTRA Academy Tools for Design Engineers Users & Operators General Information

Training Seminars Programs & sizing software, 2D and 3D CAD drawings Information on ATEXDirective 94/9/EC Information on Pressure Equipment Directive

Technical Literature Technical Documentation Material Reference Chart, Steam Tables Design of GESTRA Valves Index by Product Name and Code at Back of Technical Information

GESTRA Steam Traps and Steam Trap Monitoring Equipment


A1
Page Steam Trap Selection.......................................................................................................................... 5 Thermostatic Steam Trap BKwith Duo S.S. (Bimetallic) Regulator................................................6 7 Thermostatic Steam Trap MK with Membrane Regulator..............................................................8 9 Ball Float Trap UNA, UNA Special............................................................................................10 15 Stainless Steel Traps MK, UNA....................................................................................... see MK, UNA Thermodynamic Steam Trap DK................................................................................................16 17 Steam Traps for Sterile and Aseptic (SIP) Applications SMK. .....................................................18 19 Steam Traps for Special Applications Condensate Drain Valves AK............................................................................................. 20 21 Steam Trap with Adjustable Discharge Temperature UBK.................................................. 20 21 Steam Trap for Low-Pressure Steam Heating Plants MK. ................................................. 20 21 Steam Traps for Large Condensate Flowrates TK, GK....................................................... 20 21 Steam Traps for Air-Venting BK, MK .................................................................................. see BK, MK Steam Trap Units for UNIVERSAL (Swivel) Connectors . .................................................................... 22 UNIVERSAL (Swivel) Connector Units.........................................................................................23 24 Compressed-Air Draining Condensate Ball-Float Traps for Draining Condensate from Compressed-Air and Other Gas Lines UNA.......................................................................................................... 25 Pump Steam Trap, Compact Condensate Lifter UNA.......................................................................... 26 Why Testing Steam Traps.................................................................................................................. 27 Steam Trap Monitoring Equipment VK, VKE, VKP.................................................................... 28 29 Condensate Collector V 21.9/K, Steam Manifold V 21.9................................................................... 30 Condensate Collector V 20.8/K, Steam Manifold V 20.8................................................................... 31 Drain Module QuickEM, QuickEM Control. ..................................................................................32 33

GESTRA Steam Traps

GESTRA Steam Trap Series UNA 25-PK: The UNA 25-PK is the first pump steam trap with standard overall length acc. to ISO 6554 and EN 558 for handling large flowrates of hot condensate. Its straight-through body is designed for installation in horizontal lines and can be easily integrated in any steam and condensate system. Replacing conventional float traps used in installations with strongly fluctuating operating parameters with pump steam traps makes good economic sense and is easy to do thanks to the trap's standarized overall length. The pump steam trap is available with flanged or screwed end connections and offers trapping capacity of more than 3000 kg/h and pumping capacity of more than 600 kg/h.

For steam and energy management, we are right on target


Steam Trap Selection Not all steam trap types are equally suitable for a given appli cation. Depending on the operating conditions and service in question, one or more systems will be particularly well suited.
Ratings: 1 2 3

The following table contains 15 criteria for steam trap selection based on the operation of the plant and the specific requirements on the part of the plant owner.
Steam trap types

Criteria 1. Operation with Condensate from steam 1 1 1 1 1 1 different Condensate from compressed air 1 1 condensates Condensate, distillate from chemical products 1 3*) 2. Different modes of operation Continuous operation: Constant formation of condensate; 2 1 1 1 1 flowrate and pressure vary Discontinuous operation: Intermittent formation of condensate; 2 1 2 1 3*) flowrate and pressure vary strongly Any operation: Heat exchanger may be controlled on the 3**) 2 2*) 1 3*) steam side 1

Up to approx. 30 % of upstream pressure 1 1 1 1 1 1 3. Operation with back pressure From 30 % to 60 % of upstream pressure 3*) 1 1 1 1 1 > 60 % of upstream pressure 3*) 1 3 1 1 1 > 100 % of upstream pressure 1 4. Sensitivity to dirt Kondensat sehr stark verschmutzt 1 1 1 1 1 1 5. Air-venting Automatic 1 1 2 1 3*) 3 6. Condensate Condensate temperature nearly discharge at boiling temperature 2*) 2**) 1 1 1 1 definite temperatures Condensate undercooling 1*) 1**) approx. 30 K (required) Condensate undercooling 2*) adjustable

7. Frost resistance 8. Condensate Intermittent condensate formation Reduced condensate formation (< 10 kg/h) discharge without loss of live steam Continuous condensate formation (> 10 kg/h) 9. Resistance to waterhammer 10. Non-return valve action 11. Application in vacuum 12. Installation in any position 13. Ease of maintenance 14. Service life of control unit 15. Application with superheated steam

Tra p ty bim pe BK eta llic with reg Tra ula p ty tor me pe MK mb w ran e re ith The gul ato rm r typ ody e D nam K ic Bal l flo wit at tra hD upl p type ex c U Bal ont NA l flo rol a wit t tra hS imp p type lex U Pu con NA mp trol s typ tea eU m NA trap 25PK

= = = =

Excellent Good Fair or conditional Not recommended, unsuitable

Please note: For cold condensates or condensates with a saturation curve deviating from that of water only float traps featuring Simplex control (without thermal venting) can be used.

1 1

*) e. g. air venting difficulties *) Air venting difficulties, **) With partial load (reduced differential pressure) flowrate possibly not sufficient *) Possibly readjustment required *) Possibly readjustment required

*) Manual air-venting This may apply to small heat exchangers (e. g. laboratory equipment) *) Possibly readjustment required **) Might require special membrane regulator *) with U-type regulator or by readjustment **) with U-type capsule *) By a corresponding readjustment reduction in flowrate; if possible use steam trap with adjustable discharge temperature UBK *) Only ensured with V-type design

1 1 1 1 1 1 3 1 1 1 1

1 1 1 1 1*) 1*) 2 1 1 2 3

1 2 2 1 1 2 1 1 2 2

1*) 1 1 1 3*) *) 1 *) 1 1 3*)

3*) 1 1 1 3*) *) 1 *) 1 1 1

3 1 1 1 1 1 1 1 1 1

*) Built-in non-return valve = 1 *) Built-in non-return valve = 1 *) UNA 1... can be converted

*) UNA 1.. like MK, UNA2.. not recommended

A1

Thermostatic Steam Traps BK with Duo Stainless Steel (Bimetallic) Regulator PN 40 PN630
Features of the BKseries
Robust regulator for roughest operating conditions (unaffected by waterhammer and frost) Suitable for superheated steam applications Automatic air-venting (steam trap can be used for thermal air-venting in steam systems) Installation in any position (horizontal and vertical lines) Stage nozzle acts as non-return valve Stainless steel internals Repairable in-line Base bushing ensures positive metal-to-metal sealing between body and regulator. Up to p 275 bar g Optional extra: Integrated steam trap monitoring for BK 45 (temperature or steam loss)

Application
L

BK 45, BK 46 DN 15, 20, 25

For open-loop controlled heating processes. Draining of saturated steam lines superheated steam lines steam tracers Can also be used for thermal air-venting

Air-venting
Steam trap for thermostatic air-venting with bimetallic regulator The thermostatic steam traps with corrosion-resistant Duo S.S. (bimetallic) regulator of the BK series can also be used for air-venting. Application Thermostatic steam trap for automatic air-venting and discharge of non-condensable gases and steam/air mixtures from steam lines and heat exchangers. Special adjustment might be required.

Pressure/Temperature Ratings
Type PN / Class PMX [bar] 22 22 22 22 22 32 32 45 45 85 110 275 275 275 275 275 45 85 110 275 Material EN ASTM 1.0460 1.0460 1.0460 1.0460 A105 A105 SA350 LF2 A105 A105 Max. Pressure /Temp. Rating1) PMA TMA p/T [bar] [C] [bar/C] 40.0 450 27.6 / 300 13.1 / 450 51.1 51.1 40.0 51.1 40.0 51.7 100.0 63.0 181.04) 201.04) 425 425 450 425 450 450 5304) 500 5304) 5404) 5404) 5804) 580 625 650 5004) 5004) 5404) 5934) 39.8 / 300 51.1 / 464) 27.6 / 300 39.8 / 300 39.0 / 250 41.1 / 250 47.6 / 300 100.0 / 131.5 / 4504) 4504) 28.8 / 425 28.8 / 4254) 13.1 / 450 28.8 / 425 27.6 / 450 29.8 / 450 25.8 / 500 30.9 / 5304) 44.5 / 5404)

BK 45, BK 45U3) BK 45, BK 45U3) BK 45-LT BK15 DN40, 50 BK15 DN40, 50 BK 46 BK 46 BK 37 BK 27N DN40, 50 BK 28 BK 29 BK212 BK 212-F91 BK 212-S BK 212-F91-S BK 212-1.4901 BK 37-ASME BK 28-ASME BK 29-ASME BK212-ASME

PN 40 Class 300 Class 300 PN 40 Class 300 PN 40 Class 300 PN 63/100 PN 63 PN 100 PN 160 PN 630 PN 630 Class 400/600 Class 600 Class 900 Class 2500

BK 15, DN 40, 50

1.5415 A182-F12) 1.5415 A182-F12) 1.5415 A182-F12) 1.5415 A182-F12) 1.5415 A182-F12) 1.7335 A182-F12

100.0 / 4504) 30.9 / 5304)

1.7383 A182-F22 630.04) 1.4903 A182-F91 775.04) 1.7383 A182-F 22 1.4903 A182-F91 1.4901 A182-F12 630 775 800 103.44)

447.0 / 5004) 261.0 / 5404) 607.0 / 5004) 205.0 / 5804) 289.0 / 5404) 163.0 / 5804) 473.0 / 5754) 255.0 / 6254) 418.0 / 6004) 207.0 / 6504) 85.7 / 3004) 85.7 / 3004) 42.8 / 5004) 50.6 / 5004)

A182-F12 103.44) A182-F12 155.04) A182-F22 430.94)

101.4 / 4504) 43.6 / 5404) 235.0 / 5004) 63.0 / 5934)

1) Limits for body/cover. Functional requirements may restrict the use to below the limits quoted. For full details on limiting conditions depending on end connection and type of regulator see data sheet. 2) Material complies with EN and ASTM requirements. 3) Opening undercooling approx. 30 K. 4) Only applicable for traps with butt-weld (BW) or socket-weld (SW) ends DN 25. Note that limits will be lower for traps with other dimensions or flanged end connections.

Thermostatic Steam Traps BK with Duo Stainless Steel (Bimetallic) Regulator PN 40 PN630
Available End Connections and Overall Lengths in mm
Type BK 45 DN15 25 BK 15 DN 40, 50 BK 46 Connection Flanged EN PN 40 Flanged ASME1501) Flanged ASME 3001) Screwed sockets Socket-weld (SW) Butt-weld (BW) Flanged EN PN 40 Flanged ASME 300 Screwed sockets
L

DN 15 [1/2"] 150 150 150 95 95 200 150 150 95 95 210 160 160 210 160 200 330 330 230 160 160 230 160 160 230 200 200

DN 20 [3/4"] 150 150 150 95 95 200 150 150 95 95 230 160 160 230 160 200 330 330 230 160 160 230 160 160 230 200 200

DN 25 [1"] 160 160 160 95 95 200 160 160 95 95 230 160 160 230 160 200 330 330 230 160 160 230 160 160 254 200 200

DN 40 [11/2"] 230 230 230 130 130 250 230 260 241 180 180

DN 50 [2"] 230 230 230 230 250 230 300 292 180 180

Socket-weld (SW) BK 27N DN40,50 Flanged EN PN 40 Flanged EN PN 63 Flanged ASME 400/600 Socket-weld (SW) Butt-weld (BW) BK 37 BK 28 BK 29 Flanged EN PN 63/100 Socket-weld (SW) Butt-weld (BW) Flanged EN PN 160 Socket-weld (SW) Butt-weld (BW)

BK 27N, DN 40, 50

BK 37, BK 28, BK 29, DN 15, 20, 25

BK 212... Series

Butt-weld (BW) Socket-weld (SW) Socket-weld (SW) Butt-weld (BW)

BK 37-ASME Flanged ASME 400/600

BK 28-ASME Flanged ASME 400/600 Socket-weld (SW) Butt-weld (BW) BK 29-ASME Flanged ASME 900/1500
L

Socket-weld (SW) Butt-weld (BW)


1)

BK 212, DN 15, 20, 25

BK 45 with ASME flanges: overall length 172 mm available on request.

Capacity Charts
The charts show the maximum hot condensate capacities. BK 45 DN 15-25 PMX 22 bar BK 46 DN 15-25 PMX 32 bar BK 15 DN 40 and 50 PMX 22 bar (Curve 1) (Curve 1) (Curve 2) BK 27N DN 40 and 50 PMX 45 bar BK 37 DN 15-25 PMX 45 bar BK 28/BK 28 ASME PMX 85 bar BK 29/BK 29 ASME PMX 110 bar BK 212/BK 212 ASME PMX 250 bar (Curve 1) (Curve 3) (Curve 2) (Curve 2) (Curve 4)

A1

230

Thermostatic Steam Traps MK with Membrane Regulator PN25 PN 40


Features of the MK series
Very sensitive response characteristic Function is not impaired by high back pressure Automatic air-venting (trap can be used for thermal air-venting in steam systems) Installation in any position (horizontal and vertical lines) High hot-water capacities even with low differential pressures With tandem seat (double sealing) for low condensate flowrates Built-in non-return valve Stainless steel internals (corrugated membrane of Hastelloy) Design U with undercooling capsule: utilization of a certain amount of sensible heat by banking-up of condensate, decreasing the amount of flash steam Optional extra: Integrated condensate monitoring for MK45 (temperature or steam loss)

Application
Type MK 45-1 MK 35/31 1) MK 45-2 MK 35/32 1) MK 25/2 1) MK 25/2 S 1) MK 35/2 S 1) MK 35/2 S3 1) MK 36/51 1) MK 36/52 1) With tandem seat (double sealing) For low condensate flowrates, steam-tracing, steam-line drainage, air-venting With single seat For medium condensate flowrates, steam-tracing, drainage of heatexchangers, air-venting With single seat For large condensate flowrates, drainage of heat exchangers With tandem seat (double sealing) with flat gasket For small/large condensate flowrates, steam tracing, steam-line drainage, venting and vacuum-breaking. Also suitable for food, biological and pharmaceutical applications. For small and large condensate flowrates; steam-tracing, steam-line drainage, air-venting

MK 45-1 DN 15, 20, 25

Inless Sta steel Inless Sta steel

MK 45 A-1 MK 45 A-2
1) Can

MK 35/31, DN 10, 15

also be used for vacuum breaking (aerating).

Air Venting
Steam Trap for Thermostatic Air-Venting with Membrane Regulator The thermostatic steam traps with membrane regulators of the MK series can also be used for air-venting. Application Thermostatic steam trap for automatic air-venting and discharge of non-condensable gases and steam/air mixtures from steam lines and heat exchangers. A special type of membrane might be required.

Pressure/Temperature Ratings
Type
L

PN / Class PMX EN [bar] 21 32 32 32 32 32 32 32

Material ASTM A105 A105 A105 A105 A105/ A216-WCB

MK 35/2 S, DN 25

MK 35/31, MK 35/32 MK 45-1, MK45-2 MK 45-1, MK45-2 MK 35/2 S, DN 25 MK 35/2 S3, DN25 MK 25/2, MK 25/2 S, DN40, 50 MK36/51, MK 36/52 MK45 A-1, MK 45 A-2 MK45 A-1, MK 45 A-2
Sta Sta Inless steel I nless steel

PN 25 PN 40 Class 300 PN 40 PN 40 PN 40 Class 300

1.0460 1.0460 1.0460 1.0460 1.0460/ 1.0619

PMA [bar] 25.0 40.0 51.1 40.0 40.0 49.0 40.0 41.4

Max. Pressure/Temp. Rating1) TMA p/T [C] [bar/C] 400 18.6 / 225 14.4 / 400 450 425 450 450 400 400 450 27.6 / 300 39.8 / 300 27.6 / 300 27.6 / 300 32.0 / 250 29.9 / 250 26.1 / 300 13.1 / 450 28.8 / 425 13.1 / 450 13.1 / 450 28.0 / 400 25.7 / 400 23.4 / 450

1.43012) A479-F304 1.4404 A182-F316L 1.4404 A182-F316L

MK 35/2 S 3, DN 25

1) Limits for body/cover. Functional requirements may restrict the use to below the limits quoted. For full details on limiting conditions depending on end connection and type of regulator see data sheet. 2) EN material comparable to ASTM material.

Thermostatic Steam Traps MK with Membrane Regulator PN25 PN 40


Available End Connections and Overall Length
Overall length (L) in mm Type MK 45-1 MK 45-2 MK 45 A-1
L

Connection Flanged DIN PN 40 Flanged ASME 1501) Flanged ASME 3001) Socket-weld (SW) Butt-weld (BW) 2) Screwed sockets Socket-weld (SW) Flanged DIN PN 40 Flanged ASME 150 Flanged ASME300 Screwed sockets Socket-weld (SW)

DN8 DN10 DN 15 DN 20 DN 25 DN 40 DN 50 1/4" 3/8" 1/2" 3/4" 1" 11/2" 2" 65 70 65 65 150 150 150 95 95 200 70 95 65 150 65 150 150 150 95 95 200 65 65 160 160 160 95 95 200 65
1) MK

230 230 230 130 130

230 230 230 230 230

StaInless Screwed sockets MK 45 A-2 steel


MK 35/2 S3 only DN25 MK 35/2 S only DN25 MK 35/31 MK 35/32 MK 25/2 DN 40 50 MK 25/2 S DN40 50
MK 25/2 , DN 40, 50

MK 36/51 MK 36/52
L

MK 25/2 S, DN 40, 50

Inless Sta steel

Screwed sockets Union butt-weld nipples 3) Hinged clamp

45 with ASME flanges: overall length 172 mm available on request. MK 45

2) Only

of carbon steel or stainless steel

3) Made

MK 36/51, DN 8, 10, 15, 20 mm Connection: screwed socket

MK 36/51, DN 15 mm Design with union butt-weld nipples

MK 36/51, DN 8, 10, 15, 20 mm Connection: hinged clamp

Capacity Charts
The charts show the maximum hot condensate capacities. MK 45-1/MK 45A-1 MK 45-2/MK 45A-2 MK 36/51 (Curve 1) (Curve 4) (Curve 3) MK 35/31 MK 35/32 MK 36/52 (Curve 1) (Curve 2) (Curve 2) MK 25/2 S, DN 40, 50 MK 25/2, DN 40, 50 (Curve 1) (Curve 2) MK 35/2 S3, DN 25 (Curve 3) MK 35/2S, DN 25 (Curve 4)

9000

1 2 3

2 3 4 1

Capacity

Capacity

0,6 0,8 1 8 10 20

8 10 200

22

32 465

0,6 0,8 1 8 10 20

8 10 200

22 320

32 465

Differential pressure

30 40

60 80 100

Differential pressure

30 40 50 60 80 100

A1

Ball-Float Traps UNA PN 16 PN 160


Features of the UNA series
Unaffected by back pressure and condensate temperature No loss of live steam due to continuous water seal at the seat No banking-up of condensate even with extreme load and pressure fluctuations Particularly well suited for heat exchangers controlled from the steam side
UNA 14/16 v DN15 25

Repairable in-line Thanks to the rolling ball valve only reduced operating forces and small control units are required (compact, lightweight design for large flowrates) Internals made from corrosion-resistant stainless steels UNA 14, 16, 38: body convertible for horizontal / vertical flow and left to right / right to left.

Unaffected by dirt Automatic thermostatic air-venting (Duplex design) Ideal for discharging cold condensates, distillates and condensates derived from chemical products (Simplex design)

Application
Condensate discharge without banking-up, even at varying operating con ditions and back pressure. Automatic air-vent ing (Duplex design). Also for the discharge of cold condensates and distillates, and for draining gas and compressed air systems (Simplex design).
UNA 23/25/26 h DN15 50

Pressure/Temperature Ratings and Designs


Type PN / Class PMX [bar]
L

EN

Material ASTM

PMA [bar] 25.0 16.0 40.0 40.0 40.0 40.0 63.0 100.0 100.0 160.0 16.0 25.0 25.0 63.0 40.0 40.0 40.0

Druck-/Temperaturgrenzen1) TMA p/T [C] [bar/C] 350 300 400 350 400 400 450 530 530 550 300 400 400 450 300 300 300 19.4 / 200 11.2 / 250 25.8 / 300 31.6 / 250 28.0 / 300 25.8 / 300 54.0 / 300 69.0 / 450 74.9 / 450 15.0 / 350 9.6 / 300 23.1 / 400 25.0 / 350 21.0 / 400 21.0 / 400 43.5 / 450 22.3 / 530 29.0 / 530

UNA 14 UNA 23 UNA 16 UNA 25 UNA 26, DN 15, 20, 25 UNA 26, DN 40, 50 UNA 27h3) UNA 38 UNA 38 High-temperature UNA 39 UNA-Spezial Typ 62 UNA-Spezial
UNA27 h DN 25 50
L1

PN 25 PN 16 PN 40 PN 40 PN 40 PN 40 PN 63 PN 100 PN 100 PN 160 PN 16 PN 25 PN 25 PN 63

13 13 22 32 32 32 45 80 80 140 16 22 22 45 22 32 32

EN-JS 1049

UNA 23/25/26 v DN40, 50 with MAX regulator


L

EN-JL 1040 A126-CI.B2) 1.0460 / A105 / 1.0619 A216-WCB EN-JS 1049 1.0460 / A105 / 1.0619 A216-WCB 1.0619 1.5419 1.5415/ 1.7357 1.7335/ 1.7357 1.7335 EN-JL 1040 1.0619 1.0619 1.5419 1.4404 / 1.4408 1.4404 / 1.4408 1.4404 / 1.4408 A216-WCB A217-WC12) A182-F1 / A217-WC62) A182-F12 / A217-WC62) A182-F12 A126-CI.B A216-WCB A216-WCB A217-WC12) A182-316L / A351-CF8M A182-316L / A351-CF8M A182-316L / A351-CF8M

118.0 / 500 35.0 / 550 11.2 / 250 22.0 / 200 22.0 / 200 54.0 / 300 29.3 / 200 27.2 / 250 32.0 / 250 9.6 / 300 13.0 / 400 13.0 / 400 43.5 / 450 25.8 / 300 25.8 / 300 28.0 / 300

UNA UNA-Spezial UNA 16A UNA 26h, 3) DN 15, 20, 25 UNA 26h, DN 40, 50
1)

StaInless steel

PN 40 PN 40 PN 40

L2

Limits for body/cover. Functional requirements may restrict the use to below the limits quoted. For full details on limiting conditions depending on end connection and type of regulator see data sheet. 2) ASTM nearest equivalent is stated for guidance. Physical and chemical properties comply with EN. 3) These types/materials are only available for design h for installation in horizontal lines.
UNA 39 DN15, 25, 50

10

Ball-Float Traps UNA PN 16 PN 160


Available End Connections and Overall Length
Overall length (L) in mm Type Connection DN 15 DN 20 DN 25 DN 40 1 3/4" /2" 1" 11/2" UNA 14h, 14v Flanged ENPN25 150 150 160 Screwed sockets 95 95 95 UNA 16h, 16v, Flanged ENPN40 150 150 160 UNA 16Ah, 16Av Flanged ASME 150 RF 150 150 160 Screwed sockets 95 95 95 S S E L IN TA S Socket-weld (SW) 95 95 95 STEEL Butt-weld (BW) 200 200 200 UNA 23h, 23v Flanged ENPN16 150 150 160 230 UNA 25h, 25v Flanged ENPN40 150 150 160 230 UNA 26h, 26v Flanged ENPN40 150 150 160 230 UNA 26h Flanged ENPN40 210 210 230 320 DN 50 2" 230 230 230 320

L1

L2

UNA-Special Typ 62, PN16 UNA-Special, PN25 UNA-Special, PN63

L1

UNA PN 25

UNA26h Flanged ASME 150 + 300 RF 210 210 230 320 320 Screwed sockets 200 200 200 255 255 Socket-weld (SW) 200 200 200 230 230 Butt-weld (BW) 200 200 200 230 230 Flanged ENPN63/PN 100 300 300 420 416 UNA 27h1) and Flanged ASME 600 RF 300 300 421 427 Socket-weld / SW via transition pieces 300 300 420 2) 420 2) UNA 38 420 2) Butt-weld / BW via transition pieces 300 300 420 2) L1/L2 L1/L2 UNA 39 L1/L2 Flanged EN PN160 215/285 230/300 245/315 Flanged ASME 900 RF 250/320 260/330 280/350 Butt-weld (BW) 170/240 170/240 170/240 1) not available as DN15 2) UNA 38 socket-weld (SW) ends and butt-weld (BW) ends DN 40 + DN 50: 300 mm, SW and BW via transition pieces: 420 mm Type Connection UNA-Special Flanged EN PN 16 L 1 Typ 62, PN 16 L2 L 1 UNA-Special Flanged ENPN 25 PN 25 L2 L 1 UNA PN25 Flanged ENPN 25 L2 L 1 UNA-Special Flanged EN PN 63 PN 63 L2 Length L1/L2 in mm DN 50 DN65 DN80 2 1/2" 3" 2" 470 490 395 420 445 470 345 395 140 335 565 690 400 435 DN 100 4" 700 595 140 400 700 450

STAINLESS STEEL

UNA 38h

L2

Available Designs
Type UNA 14 UNA 16, 16A UNA 23 UNA 25/26 End connection options horizontal vertical angle pattern x1) x1) x1) x1) x x x x

Simplex: Float control (without thermostatic bellows) Duplex: Flow control + automatic air-venting Simplex-R: Float control + inner vent pipe Orifice (AO) for max. differential pressure AO 4, 13 AO 4, 13, 22 AO 2, 4, 8, 13, 4 max.*), 8 max.*), 13 max.*) AO 2, 4, 8, 13, 22, 32, 4 max.*), 8 max.*), 13 max.*) 22 max.*), 32 max.*) AO 16, 28, 45 AO 50, (64), 80, 80 max. AO 80, 110, 140, 140 max. AO 23), 3.54), 5, 10, 16 AO 25), 3.54), 5, 10, 16, 22 AO 2, 3.5, 5, 8, 12, 16, 22 AO 16, 22, 32, 40, 45
5) 6)

Simplex x x x x x x x x6) x6) x 6) x6 )

Control unit Duplex Simplex-R x x x x x x x x x x2)7) x7) x

UNA 27h x x1) UNA 38 x1) UNA 39 UNA-Special Typ 62, PN 16 UNA-Special PN25 UNA PN25 UNA-Special PN 63 1) A conversion of h to v or vice versa is possible 2) This design is not available for DN100 mm 3) This design is not available for DN80 mm 4) This design is not available for DN65 mm

x x x x x

This design is not available for DN50 mm Simplex:Flow control + hand vent valve + float lifting lever 7) Duplex: Flow control + automatic air-venting *) DN 40, DN 50 Type UNA 23 UNA23, 25, 26 (UNA 27 h and 38 on request) UNA 23, 25, 26, 27 h, 38

Optional Items for Ball-Float Traps


Item Sightglass cover Float lifting lever with gasket Vent valve with gasket (for Duplex design)

11

A1

Ball-Float Traps UNA PN 16 PN 160


Capacity Charts
The charts show the maximum hot condensate capacities for the range of float-controlled orifices (AO) and sizes available.

UNA 14, UNA 16

UNA 23, UNA 25, UNA 26

DN

15

-2

5,

AO

22

(on

ly

r fo

UN

16

Capacity Durchuss

Differenzdruck Differential pressure

Capacity

Differential pressure

UNA 27 h

UNA 23, 25, 26 max. (DN 40, 50)

Capacity

Differential pressure

12

Capacity

Ball-Float Traps UNA PN 16 PN 160


Capacity Charts
The charts show the maximum hot condensate capacities for the range of float-controlled orifices (AO) and sizes available.

UNA 38, Orifice 50, 64, 80

UNA 38, Orifice 80 max

DN

-0 N5 5 D0

AX* AX* 800MM O O8 A -A

Capacity

Capacity

Differential pressure

Differential pressure

UNA 39, DN 15, 25 and 50


0 N5 - AO
140 X* MA
* Traps with small end connection sizes do not reach the flowrates indicated in this chart.

AO 80 0 AO 11 0 AO 14

Capacity

Differential pressure

13

A1

* Traps with small end connection sizes do not reach the flowrates indicated in this chart.

Ball-Float Traps UNA PN 16 PN 63


Capacity Charts
The charts show the maximum hot condensate capacities for the range of orifices (AO) and sizes available.

UNA-Special Type 62, PN16


10

Capacity

Available orifices (AO) 1 DN 65 2 DN 65 DN 80 3 DN 80 4 DN 100 5 DN 65 6 DN 80 7 DN 65 DN 80 DN 100 8 DN 100 9 DN 100 10 DN 100

AO 16 AO 10 AO 16 AO 10 AO 16 AO 5 AO 5 AO 2 AO 3.5 AO 10 AO 5 AO 3.5 AO 2

Differential pressure

UNA PN25, DN80 and 100


Available orifices (AO) 1 DN 80 2 DN 80 DN 100 3 DN 80 4 DN 100 5 DN 80 DN 100 6 DN 80 DN 100 7 DN 80 8 DN 100 9 DN 80 DN 100 10 DN 100
Differential pressure

AO 22 AO 16 AO 22 AO 12 AO 16 AO 8 AO 12 AO 5 AO 8 AO 3.5 AO 5 AO 2 AO 3.5 AO 2

14

Capacity

Ball-Float Traps UNA and UNA-Special PN 16 PN 63


Capacity Charts
The charts show the maximum hot condensate capacities for the range of orifices (AO) and sizes available.

UNA-Special PN25, DN50 and 65


A1
Available orifices (AO) 1 DN 50 2 DN 50 DN 65 3 DN 50 DN 65 4 DN 65 5 DN 50 6 DN 50 DN 65 7 DN 65 AO 22 AO 16 AO 22 AO 10 AO 16 AO 10 AO 5 AO 3.5 AO 5 AO 2
Capacity Differential pressure

UNA-Special PN63 (PN40)

Capacity

Available orifices (AO) 1 DN 65 2 DN 65 3 DN 80 4 DN 65 DN 80 5 DN 100 6 DN 65 DN 100 7 DN 80 8 DN 65 9 DN 100 10 DN 80 11 DN 80 DN 100 12 DN 100

AO 45 AO 40 AO 45 AO 32 AO 40 AO 45 AO 22 AO 40 AO 32 AO 16 AO 32 AO 22 AO 16 AO 22 AO 16

Differential pressure

15

Thermodynamic Steam Traps DK PN 40, PN 63/Class 600


Features of the DKseries
Discharge with virtually no banking-up Robust, insensitive regulator Installation in any position Max. admissible back pressure 80 % of the upstream pressure

Application
Type DK 45
L

Rhombusline body with enclosed, weather-resistant regulator for discharging steam lines and tracing systems without banking-up of condensate Compact steam trap for small condensate flowrates for discharging steam lines and tracing systems without banking-up of condensate Compact steam trap for large condensate flowrates for discharging steam lines and tracing systems without banking-up of condensate

DK 47-L DK 57-L DK 47-H DK 57-H

DK 45

Pressure/Temperature Ratings
Type PN / Class PMX [bar] 32 42 42 Material EN ASTM 1.0460 1.40212) A105 AISI420 PMA [bar] 40.0 63.0 63.0 Pressure/Temp. Rating1) TMA p/T [C] [bar/C] 450 27.6 / 300 13.1 / 450 400 400 50.0 / 300 50.0 / 300 42.0 / 400 42.0 / 400

DK 45 DK 47 DK 57

PN 40 PN 63 / Class 600 PN 63 / Class 600

1.40272) A743-CA40

1) Limits for body/cover. Functional requirements may restrict the use to below the limits quoted. For full details on limiting conditions depending on end connection and type of regulator see data sheet. 2) ASTM nearest equivalent is stated for guidance. Physical and chemical properties comply with EN.

Available End Connections and Overall Length


L

Type DK 45

Connections Flanged EN PN 40 Flanged ASME 1501) Flanged ASME 3001) Screwed sockets Socket-weld (SW) Butt-weld (BW)

DK 47

DN10 3/8" 78 55

Overall length (L) in mm DN 15 DN 20 1/2" 3/4" 150 150 150 95 95 200 78 78 65 70 150 150 150 95 95 200 90 90 80 80

DN 25 1" 160 160 160 95 95 200 95 95 90

DK 47-L DK 47-H DK 57-L DK 57-H


1)

Screwed sockets Screwed sockets Screwed sockets Screwed sockets

DK 45 with flanged ASME: Overall length 172 mm on request.

DK 57

16

Thermodynamic Steam Traps DK PN 40, PN 63/Class 600


Capacity Charts
The charts show the maximum hot condensate capacities.

DK 45
2000 1000 800 600 500 400 300 200

1000 800 600 500 400 300 200 150

100 80 1
20

Capacity Capacity

Durchsatz

8 10
200

20

32 [bar]

30 40 50 60 80 100

300 420 [psi]

Differential PMX pressure

DK 47

DK 57

1" H " H
" H

1" "
"

H H
H
, " " L

- 1" /8"

", /8

Capacity

Differential pressure

Capacity

Differential pressure

17

A1

[lb/h]

[kg/h]

GESTRA Steam Traps for Sterile and Aseptic (SIP) Applications

Application
Typ SMK 22 Virtually pocket-free For small and medium condensate flowrates. Internal surface roughness Ra 0.8 m machine faced, optionally up to Ra 0.4 m electropolished. Virtually pocket-free For small and medium condensate flowrates. Internal surface roughness Ra 0.8 m machine faced, optionally Ra 0.6 m machine faced. Virtually pocket-free For small and medium condensate flowrates. Functional unit easy to exchange. Internal surface roughness Ra 0.8 m machine faced, optionally Ra 0.6 m machine faced. Virtually pocket-free For medium and large condensate flowrates. Functional unit easy to exchange. Internal surface roughness Ra 0.8 m machine faced, optionally Ra 0.6 m machine faced. Virtually pocket-free For small and medium condensate flowrates. Internal surface roughness Ra 0.8 m machine faced, optionally Ra 0.6 m machine faced. Connection via socket for mounting between clamps DIN 32676-DN 40. Virtually pocket-free For medium and large condensate flowrates. Internal surface roughness Ra 0.8 m machine faced, optionally Ra 0.6 m machine faced. Connection via socket for mounting between clamps DIN 32676-DN 40.

SMK 22-51

SMK 22-81

SMK22, DN 15

SMK 22-82

Funktionseinheit SMK 22-81 L

Funktionseinheit SMK 22-82

SMK22-51

Pressure/Temperature Ratings
Type PN / Class PMX EN SMK 22 SMK 22-51 SMK 22-81 SMK 22-82 Functional unit SMK 22-81 SMK 22-82 PN 10 PN 10 PN 10 PN 10 [bar] 6 6 6 6 Material ASTM A276 316L2) A182 316L2) A182-316L2) A182-316L2) PMA [bar] 10.0 10.0 10.0 10.0 Pressure/Temp. Rating1) TMA p/T [C] [bar/C] 1853) 10.0 / 20 6.0 / 1853) 1853) 1853) 1853) 10.0 / 20 10.0 / 20 10.0 / 20 6.0 / 1853) 6.0 / 1853) 6.0 / 1853)

1.4435 1.4404 1.4404 1.4404

SMK22-81, SMK 22-82

1) Limits for body/cover. Functional requirements may restrict the use to below the limits quoted. For full details on limiting conditions depending on end connection and type of regulator see data sheet. 2) ASTM nearest equivalent is stated for guidance. Physical and chemical properties comply with EN. 3) 185 C with PTFE gasket, 150 C with EPDM gasket.

L1

Available End Connections and Overall Length


Overall length (L) in mm
Functional unit SMK22-81, SMK 22-82

Type

Connections

DN 10 3/8" 83 65 90 65 96

DN 15 1/2" 83 65 90 65 96

DN 20 3/4" 83 65 90 65 96

DN 25 1" 83 65 90 65 96 65

DN 50 2"

DN 65 21/2"

DN 80 3"

DN 100 4"

DN 150 6"

SMK 22 SMK 22-51 SMK 22-81 SMK 22-82


SMK 22-82

Butt-weld ends Clamp Butt-weld ends Clamp Butt-weld ends Clamp 50.5 Socket for mounting between clamps DIN 32676-DN 40 L1 standard L1 long L1 very long

L1

Functional unit SMK 22-81 SMK 22-82

35 45 65

18

GESTRA Steam Traps for Sterile and Aseptic (SIP) Applications

Capacity Charts SMK22, SMK 22-51


[Lb/h] 2000 [kg/h] 1000 900 800 1500 700

The chart shows the maximum capacities for hot and cold condensate. Curve 1 SMK 22, SMK 22-51, SMK 22-81 This curve indicates the max. capacity of hot condensate that the steam trap with regulating membrane Steriline can discharge with virtually no banking-up. Curve 2 SMK 22, SMK 22-51, SMK 22-81, SMK 22-82 This curve shows the max. capacity of cold condensate that the steam trap can discharge (20 C at start-up). Curve 3 SMK 22-82 This curve indicates the max. capacity of hot condensate that the steam trap with regulating membrane Steriline can discharge with virtually no banking-up.

2
600

1000 900 800 700 600 500 400

500 400

300

1
250 200

300

150

Capacity

100

0,1

0,2

0,3 0,4

0,6 0,8 1

4 5 6 [bar]

1,45 2 3 4 5 6 7 8 10 Differential pressure

20

30 40

60 80 [psi]

Other steam traps and non-return valves for sterile and aseptic applications: MK 45A-1 and MK 45A-2 MK 36/51 and MK 36/52 UNA 16A UNA 26A VKE stainless steel RK 86A RK 16A RK 26A see pages 8 9 see pages 8 9 see pages 10 12 see pages 10 12 see pages 28 29 see pages 42 43 see pages 44 45 see pages 44 45

19

A1

Steam Traps for Special Applications


Application
Type AK 45 Condensate drain valve for discharging condensate from steam systems during start-up and draining residual condensate at shut-down, with integral Y-type strainer and hand purging knob. Factory-set closing pressure 0.8 bar. Steam trap with adjustable condensate discharge temperature, thereby suppressing the formation of flash steam. With Y-type strainer. Steam trap for low-pressure steam-heating installations. Steam trap with thermostatic pilot control using thermostatic capsules for the discharge of very large condensate flowrates with relatively continuous condensate formation. Thermodynamic steam trap with stage nozzle for the discharge of very large condensate flowrates. With integral Vaposcope (sightglass) for optimum trap adjustment.

UBK 46

MK 20
L

AK 45, DN 15, 20, 25

TK23, TK 24 GK 111)
1)

DN 50 mm: GK 21

Pressure/Temperature Ratings
Type PN / Class PMX EN AK 45
L

Material ASTM A105 A105 A126 CI.B2) A216 WCB A126 CI.B2)

PN 40 PN 40 PN 6 PN 16 PN 25 PN 16

[bar] 32 4,5 5 / 14 6

1.0460 1.0460 EN-JM 1030 1.0619 EN-JL 1040

Max. Pressure/Temperature Rating1) PMA TMA p/T [bar] [C] [bar/C] 40,0 450 27.6 / 300 13.1 / 450 40,0 6,0 16,0 25,0 16,03) 450 300 300 400 300 27.6 / 300 4.5 / 250 16.0 / 120 25.0 / 120 13.1 / 425 3.6 / 300 10.0 / 300 13.0 / 400

UBK 46 MK 20 TK 23 TK 24 GK 11, GK 21

UBK 46, DN 15, 20, 25

5 / 10 EN-JL 1040

16.0 / 1203) 13.0 / 3003)

1) Limits for body/cover. Functional requirements may restrict the use to below the limits quoted. For full details on limiting conditions depending on end connection and type of regulator see data sheet. 2) ASTM nearest equivalent is stated for guidance. Physical and chemical properties comply with EN. 3) GK 11, DN 150, PN 10, max. 10 bar

Available End Connections and Overall Lengths


Overall length (L) in mm Type Connection DN 10 3/8" DN 15 1/2" 150 150 150 95 150 150 150 95 95 120 DN 20 3/4" 150 150 150 95 150 150 150 95 95 125 DN 25 1" 160 160 160 95 160 160 160 95 95 DN 50 2" 230 230 320 DN 65 21/2" 290 290 420 DN 80 3" 310 310 420 DN 100 4" 350 350 620 DN 150 6" 900

MK 20, DN 15, 20

AK 45

Flanged EN PN 40 Flanged ASME150 Flanged ASME 300 Screwed sockets

UBK 46

Flanged EN PN 40 Flanged ASME 150 Flanged ASME300 Screwed sockets Socket-weld (SW)

L TK, DN 50, 65, 80, 100

MK 201) TK23 TK24 GK112)


1) 2)

Male/female thread Flanged EN PN 16 Flanged EN PN 25 Flanged EN PN 16

Straight-through or angle design (see representation) DN50 mm: GK21

L GK11, DN 65, 80, 100, 150 GK 21, DN 50

20

Steam Traps for Special Applications

Capacity Charts
The charts show the maximum hot condensate capacities. (Exception: AK45 cold water capacity.)

AK 45

Cold water capacity

Capacity

Capacity

Differential pressure

Differential pressure

Capacities, opening temperatures UBK 46


Service pressure Factory-set opening temperature Capacity at t 10 K below opening temperature Cold water capacity at 20 C (start-up capacity)

[barg] [C] [kg/h]

1 60 30

2 64 60 320

4 72 90 480

8 84 120

12 93 130

16 102 140

20 110 150

26 118 160

32 128 170

[kg/h] 250

760 1020 1280 1500 1780 2040

TK 23, TK 24
For differential pressures < 1 bar use capsule OH2 (max. service pressure 5 bar).

GK 11, GK 21

Capacity

Capacity

Differential pressure Differential pressure

21

A1

MK 20

Steam Trap Units for UNIVERSAL (Swivel) Connectors


Features
Maintenance-free, ultra-compact steam traps made from stainless steel, suitable for all UNIVERSAL (Swivel) connectors Installation in any position Integrated spiral wound gasket for connector Only two screws make for a quick and easy installation All steam trap units are optionally available with a UNIVERSAL connector (not fitted), e.g. UC 36, UCY 36 or TS 36.

Application
Type BK 36A/7
BK 36A/7

"Thermostatic/thermodynamic bimetallic" trap unit with corrosion-resistant Duo S.S. regulator unaffected by waterhammer, for condensate with virtually no banking-up and automatic air-venting of steam lines and tracing systems. "Thermostatic capsule" trap unit with corrosion-resistant membrane regulator 5N1 unaffected by waterhammer, for condensate discharge with virtually no banking-up and automatic air-venting of steam lines and tracing systems.

MK 36A/71 MK 36A/72

DK 36A/7 "Thermodynamic" trap unit for condensate discharge with virtually no banking-up.

Specification
MK 36A/71

Type

PN / Class PMX EN [bar] 32 32 32

Material ASTM

BK 36A/7 DK 36A/7
1)

Class 300 Class 300

1.4408 A351-CF8M 1.4408 A351-CF8M 1.4408 A351-CF8M

PMA [bar] 49.6 49.6 49.6

Pressure /Temperature1) TMA p/T [C] [bar/C] 400 31.6 / 300 29.4 / 400 400 400 31.6 / 300 29.4 / 400 31.6 / 300 29.4 / 400

MK 36A/71, MK 36A/72 Class 300 L

Limits for body/cover. Functional requirements may restrict the use to below the limits quoted. For full details on limiting conditions depending on end connection and type of regulator see data sheet.

Available Connections and Lengths


DK 36A/7

Type BK 36A/7; MK 36A/71; MK 36/A72; DK 36A/7

Connection Universal connector

Length L
1/2" 3/4"

1" 65

65

65

[lbs/h] 6000 5000 4000 3000 2000

[kg/h] 2500 2000

1000 800 600 500 400 300 200

1000 800 600 500 400 300

MK 36A/72 DK 36A/72 MK 36A/71 BK 36A/7

Condensate Capacities Capacity

Kondensat-Durchsatz

200

100 80 60 50 40 30 1 14,5 20
2

100 80 60

The chart shows the discharge capacity of hot condensate


3 40 4 60 6 80 100 8 10 200 20 300 32 [bar] 465 [psig]

30

Differenzdruck PMX Differential pressure

Differential pressure PMX

22

UNIVERSAL Connector Unit TS 36


The compact-type Trap Station TS 36 features additional test and shut-off functions and is a more convenient alternative to the simpler connector units UC 36 and UCY 36. When installed with a suitable steam trap with UNIVERSAL (Swivel) connector (sold separately) the equiptmen can discharge condensate from steam systems. The two in-built isolating valves are designed to completely shut off the condensate inlet and outlet independently from each other. The integral blowdown valve provides a means for cleaning the strainer and the test valve enables the steam trap operation to be checked. The steam traps can be easily attached to and removed from the TS 36 by means of only two screws.
TS 36-1

The following GESTRA connector steam traps can be used:


Bimetallic steam trap BK 36A/7 Steam trap with membrane capsule MK 36A/71 Steam trap with membrane capsule MK 36A/72 Thermodynamic steam trap DK 36A/7 Non-GESTRA swivel connector steam traps can also be fitted to the TS 36.

TS 36-2

23

A1

UNIVERSAL Connector Unit UC 36, UCY 36, TS 36


Features
Body / internals made from corrosion-resistant stainless steels UNIVERSAL (Swivel) connector for steam trap Connector unit can remain in pipeline during maintenance work Steam trap unit is easy to install and remove by means of only two screws
L

Application
Type UC 36 UCY 36 TS 36-1
UCY 36

Universal connector Universal connector with integrated strainer Compact-type connector unit with 2 isolating valves, test valve and strainer with blowdown valve. Coloured handwheels indicate inlet and outlet and assist in the correct installation. Flow direction from left to right. Compact-type connector unit with 2 isolating valves, test valve and strainer with blowdown valve. Coloured handwheels indicate inlet and outlet and assist in the correct installation. Flow direction from right to left.

TS 36-2

Pressure/Temperature Ratings
L

Type UC 36, UCY 36, TS 36 p (pressure)


UC 36

ASME B 16.5 Class 300 (PN 50) Material Group 2.2) [bar] [C] 49.6 38 42.2 100 35.7 200 33.7 bar at 242 C 31.6 300 29.4 400

T (temperature) PMO (max. service pressure)

Based on ASME B 16.5, ASME B 16.34

Available Connections and Lengths


Type UC 36, UCY 36 TS 36-1, TS 36-2 Connection Screwed sockets NPT Screwed sockets G Socket-weld ends Length L
1/2" 3/4"

1" 75 on request

75 120

75 120

TS 36-1

Schematic diagram

TS 36-2

TS 36-1 Flow direction from left to right

TS36-2 Flow direction from right to left

24

Ball-Float Traps for Draining Condensate from Compressed-Air and Other Gas Lines UNA
Features
Body convertible for horizontal / vertical Liquid drainer for compressed air and gases flow and left to right / right to left. with ball float and rolling ball valve The trap is suitable for draining gas and compressed air systems Purging device and connection for air-balance pipe included as standard Internals made from corrosion-resistant stainless steels Closing unit for temperatures up to 40 C with rolling ball made from Perbunan, up to 120 C with rolling ball made from stainless steel

UNA 14 Pv

Specification
Type PN / Class PMX EN UNA 14Ph, UNA 14Pv with S.S. valve ball UNA 14Ph, UNA 14Pv with Perbunan valve ball
1)

Material ASTM PMA [bar] 25.0 25.0

PN 25 PN 25

[bar] 16 16

EN-JL 1049 EN-JL 1049

Pressure /Temperature1) TMA p/T [C] [bar/C] 120 25.0 / 20 25.0 / 120 40 25.0 / 20 25.0 / 40

Limits for body/cover. Functional requirements may restrict the use to below the limits quoted. For full details on limiting conditions depending on end connection and type of regulator see data sheet.

Available End Connections and Overall Length


Overall length L in mm Type Connection DN 15 DN 20 DN 25 1 3/4" /2" 1" Screwed sockets3) 95 95 95 Una 14 Ph FlangedEN PN25 150 150 160 95 95 95 Una 14 Pv Screwed sockets3) FlangedEN PN25 150 150 160 3) Screwed sockets BSP to EN ISO 228-1 or screwed sockets NPT

Capacity Chart UNA 14P

Hints on Installation
The condensate/distillate must be free to fall towards the trap. Isolating valves in horizontal lines lead to the formation of water pockets. In this case an air-balance pipe is required (see drawing).

Product line Balance pipe Collecting pocket

Liquid drainer for horizontal installation

With or without valve; valve spindle horizontal

25

A1

Pump Steam Trap UNA 25-PK Compact-Design Condensate Lifter UNA 25-PS
Description
UNA 25-PK: Ball-float operated steam trap with pumping function. The equipment works primarily as a steam trap. The integral automatic pump function ensures efficient condensate discharge even if the steam pressure is low or the back pressure high. UNA 25-PS: Float-operated condensate lifter, designed for effective return of condensate. Steam is used as motive power to displace condendate out of the body.

Features
Integrated inlet and outlet check valves. Rolling ball valve (UNA 25-PK) for tight shut-off even with low condensate flowrates. Float-controlled compact changeover unit for controlling the motive steam inlet and the vent outlet.

UNA 25-PK Flanged DN 40

Specification
Type PN / Class Material EN ASTM EN-JS 1049 EN-JS 1049 40.0 PMA [bar] 40.0 Pressure/Temperature1) TMA PMO PMOB p/T [C] [bar] [bar] [bar/C] 350 6.0/13.0 3.0 31.6 / 250 25.0 / 350 350 350 350 6.0/13.0 13.0 13.0 3.0 5.0 5.0 / 250 / 250 / 350 / 350 31.6 / 250 25.0 / 350

UNA 25-PK UNA 25-PK UNA 25-PS UNA 25-PS


1)

PN 40 PN 40

Class 150 EN-JS 1049 Class 150 EN-JS 1049

Limits for body/cover. Functional requirements may restrict the use to below the limits quoted. For full details on limiting conditions depending on end connection and type of regulator see data sheet.

Available Connections and Lengths


Type
UNA 25-PS Flanged DN 40

Connection Flanged EN PN 40 Flanged ASME 150 Screwed G or NPT

Length L in mm DN 40 [1"] 230 227 227

UNA 25-PK UNA 25-PS

26

Testing Steam Traps

Like any other industrial valve steam traps are subject to wear and their correct functioning can be impaired by precipitated solids and dirt deposits. To assess the performance of a steam trap the following questions have to be answered: Does the steam trap work properly? If not, does the faulty trap cause loss of steam (leakage) or banking-up of condensate (obstructed discharge passage)? Faulty steam traps are a major source of waste in a steam distribution system. A trap that is blowing live steam is the worst offender, but traps that are plugged or stuck closed can also be costly. The decreased plant efficiency due to loss of energy and additional make-up water results in lost production. Furthermore, an increase of pressure is liable to arise in condensate systems which will lead to difficulties at all locations where condensate is discharged. The magnitude of such a steam loss depends on the cross-sectional area of the leak and, at the same time, the amount of discharged condensate. Locations where only small amounts of condensate are formed and discharged, e. g. drainage points in steam lines and tracing systems, are particularly problematical. On the other hand, locations where relatively large amounts of condensate are discharged will not give rise to considerable loss of live steam because of the presence of a large volume of liquid. Steam traps which are obstructed or stuck closed do not cause loss of energy and/or water but reduce to a greater or lesser extent the efficiency of heat-transfer equipment and steam users. And water hammer caused by condensate banking-up leads to considerable physical damage in steam and condensate systems. Experience shows that installations where no regular trap testing and servicing takes place have a failure rate of defective steam traps in the order of 15 25 %. Regular maintenance and trap testing, which should be carried out at least once a year, can strongly reduce the failure rate to 5 %.

Level meters use conductivity readings to monitor steam trap performance. A test chamber with an integral level electrode is installed upstream of the trap to detect any defective steam trap. The corresponding output signal is displayed by the Remote Test Unit NRA 1-3x (remote monitoring). The system VKE can monitor all types and makes of steam traps to detect loss of live steam. The correct operation of RHOMBUSline steam traps type BK 45/46, MK 45, UBK 46 can be verified by using the compact-type level probes NRG 16-19, NRG 16-27 and NRG 16-28. The test station NRA 1-3x will evalute the data coming from the system VKE. Another way to test traps is to use an ultrasonic listening device which detects the sound produced by steam flowing through the traps. Depending on the test system used the sound sensed by the device is either graphically represented in the form of a curve (VKP 40) or indicated by the deflection on the scale of a meter (VKP 10). When using the VKP 10, the field data specialist has to assess the indicator deflection and, consequently, the operation of the steam trap. The VKP 40, however, can directly track leaks associated with faulty steam traps and provides comprehen sive reporting and a complete trap survey history.

Annual costs caused by steam loss / potential savings


Number of steam traps installed Annual failure rate (Empirical value with first check approx. 15 25 %)
A Number of defective steam traps B Steam loss per steam trap (kg/h) C Annual operating hours D Annual steam loss (kg) E Cost of steam per ton F Annual loss in EURO G CO2 saved per year (kg) D / 1000 x E D x 0,16*) = = A x B xC =

Test Systems
Steam traps can be tested during operation by using sightglasses, ultrasonic listening devices or level meters. Sightglasses (Vaposcopes Type VK 14, VK 16) provide an effective means of observing the flow of liquids in pipework. They are installed upstream of the traps, and allow the assessment of the traps by making their operation visible.

*) Results may vary as a function of the fuel used for generating steam and condensate return.

Example
A Number of defective steam traps B Steam loss per steam trap C Annual operating hours D Annual steam loss E Cost of steam per ton 20 3 kg/h 8000 h 480,000 kg 30.00 Euro/t

F Annual loss 14,400. Euro G CO2 saved per year 76,800 kg


By the way: A new steam trap costs depending on the end connection only approx. e 150 to e 200.

27

A1

Steam Trap Monitoring Equipment

Application

L VK14

Type Vaposkope VK 14, VK 16 VKE 16-1, VKE 16A Vapophone VKP 10 TRAPtest VKP40/VKP 40Ex NRG 16-19 NRG 16-27 NRG 16-28

Sightglass with borosilicate glass for checking heat exchangers and steam traps (installation upstream of traps). Visual supervision of flow conditions in condensate lines. Test chamber for level electrode for monitoring steam traps (installed upstream of the steam trap) to detect steam loss or banking-up of condensate (VKE 26). For installation in horizontal lines or mounting at steam traps (VKE 26). Ultasonic detector for detecting steam leakage in steam systems; for monitoring steam traps and stop valves. Computer-based monitoring, recording and evaluation system for steam traps of all types and makes to detect loss of steam and condensate banking up. Level electrodes for installation in the test chamber VKE or in the body of Rhombusline steam traps. Designed for detecting loss of live steam/banking-up of condensate (used in conjunction with test unit NRA 1-3 or teststation NRA 1-3 CANbus). Response sensitivity 1.0 S/cm.

The Vaposcope can be installed in horizontal and vertical lines (without conversion). Installation in flow direction upstream of steam trap. The application of the VK 14 is limited to fluids with pH 9. The VK 16 is fitted with mica disks as standard for applications up to pH 10.

Vaposcope VK

Test Set VKE


L VK16 L

Consisting of: test chamber VKE16-1 / VKE 16 A or VKE 26 with integrated level electrode NRG 16-19 or NRG 16-27 for all condensate discharge systems and types. Test station NRA 1-3 or teststation NRA 1-3 CANbus for remote monitoring. Simultaneous and continuous monitoring of up to 16 steam traps to detect steam loss or banking-up of condensate. VKE 26: use in conjunction with float ball steam traps.

Pressure/Temperature Ratings
Type PN / Class EN VK 14 VK 16 VKE 16-1 PN 16 PN 40 PN 40 EN-JL 1040 1.0619 1.0619 1.4571 1.0460 1.4571 Material ASTM A126 CI.B2) A 216 WCB A216 WCB TP 316 Ti2) A1052) AISI 316 Ti PMA [bar] 16.0 40.0 40.0 40.0 40.0 40.0 Pressure/Temperature1) TMA PO/TO [C] [bar/C] 280 12.8 / 200 9.6 / 280 300 400 250 400 238 30.4 / 250 27.6 / 300 28.4 / 250 23.1 / 400 31.6 / 250 25.0 / 350 28.4 / 250 23.1 / 400 40.0 / 20 32.0 / 238

INLE VKE 16A STA L STEE

SS

PN 40 PN 40 PN 40

Test chamber VKE16-1

Electrode connection either on the left or on the right side.

VKE 26 NRG 16-19, NRG 16-27, NRG 16-28

1) Limits for body/cover. Functional requirements may restrict the use to below the limits quoted. For full details on limiting conditions depending on end connection and type of regulator see data sheet. 2) ASTM nearest equivalent is stated for guidance. Physical and chemical properties comply with EN.

Available Connections and Overall Lengths


Type VK14 VK 16
VKE 26 with NRG 16-19

Connection Flanged EN PN 16 Flanged EN PN 40 Flanged ASME150 Flanged ASME 300 Screwed sockets Socket-weld Flanged EN PN 40 Flanged ASME150 Flanged ASME 300 Screwed sockets Socket-weld Flanged EN PN 40 External/internal thread 3/8" BSP External thread 3/8" BSP

VKE 16-1

VKE 16 A VKE 26 NRG 16-19 NRG 16-27


NRG 16-19 NRG 16-27 NRG 16-28

DN 15 1/2" 130 150 150 150 95 95 150 150 150 95 95 160

Overall length L in mm DN 20 DN 25 DN 40 3/4" 1" 11/2" 150 160 200 150 160 230 150 160 230 150 160 230 95 95 130 95 95 130 150 160 150 160 150 160 95 95 95 95 160 160 200

DN 50 2" 230 230 230 230 210 210 230

NRG 16-28

Nominal length = 31 mm with integrated Pt 1000 thermocouple External thread M 24 x 1.5 for installation in the bodies of Rhombusline steam traps with integrated Pt 1000 thermocouple

28

Steam Trap Monitoring Equipment

System VKE Remote monitoring Rhombusline*


TE
Screened cable max. 100 m long Screened cable max. 100 m long max. 16 steam traps type Rhombusline, e.g. MK 45-1 and BK 45 Alarm or CANBus Electrode NRG 16-28 * Combination possible Electrode NRG 16-19 or NRG 16-27 Test station NRA 1-3 Test station NRA 1-3 max. 16 test chamber VKE 16-1/16A

Remote monitoring with Universal Test Chamber*


TE A1
Battery charger 230 V/ 50 Hz

Alarm or CANBus

Vapophone VKP 10
The VKP 10 is used to detect sound in the ultrasonic range as caused by steam flowing through a steam trap. The ultrasonic vibrations are detected by a probe and converted into electric signals which are indicated on the meter of a measuring instrument. Protection: IP 41
Probe Measuring instrument Name plate

Measuring

Charging

Connecting cable Sensitivity adjustor

4 3 2 1 TEST 0

5 6 7 8 10 9

1 2 3 4 5 6

Connecting cable Meter

TRAPtest VKP 40 /VKP 40Ex


Monitoring, Recording and Evaluation System for steam traps of all types and makes With the aid of the VKP 40Ex (explosion proof) intrinsically safe version for hazardous locations or the VKP 40, steam traps can be checked for loss of live steam and banking-up of condensate, thus evaluating their performance. The PC software enables: Recording and organising steam trap data Storage and evaluation of all test results Simple and easy steam loss calculation for failed steam traps Printing out repair job lists Features: Hand-held terminal with user-friendly interface for ease of operation (only 5 keys) Illuminated display for showing the recorded sound emissions as curves (visual indication of steam losses) Data exchange between PC and hand-held terminal at the click of the mouse PC software works with windows versions from other countries Protection: IP 65 VKP 40Ex approval BVS 03 ATEX E 149 CE 0158 Ex II 2G Eex ib II C T4

Testing and diagnostic system

29

Condensate Collector and Steam Manifold PN 40, DN 40, 50 V 21.9/K, V 21.9


Description
L1 L2

Function V 21.9/K
The condensate discharged by the steam trap flows downwards between immersion tube and external collecting tube, thereby creating a water pocket into which the immersion tube enters. The space between immersion tube and collecting tube above the water pocket acts as a dampening cushion consisting of flash steam and air bubbles. This steam cushion effectively prevents water hammer like a dampening pot. The condensate flowing into the unit will be forced into the higher condensate collecting line as a function of its service pressure (differential pressure).

D1

Compact-type condensate collector ( vertical design) with internal immersion tube and integrated bellowssealed stop valves (V 21.9/K). Without immersion tube as steam manifold V 21.9 with integrated bellows-sealed stop valves. Lateral connections in DN15, 20 or 25 available. Collecting tube in DN40 or 50.
H1 H DN1

Connections
Flanged EN, PN 40 Flanged ASME Class 150 RF Flanged ASME Class 300 RF Butt-weld ends

H3 L M

H2

Dimensions and Weights


Number of lateral connections 4
BC

All connections butt-weld ends A 60 60 60 B 160 160 160 C 280 600 920 L 150 150 150

(without steam traps)

Weight

All connections flanges A 107 107 107 B 160 160 160 C 374 694 1014 L 230 230 230

(without steam traps)

Weight

approx. kg 20 41 62

approx. kg 31 57 83

8 12

A DN2

Butt-weld ends /flanges


Connections 4 8 12 DN1 15-25 15-25 15-25 DN2 40/50 40/50 40/50 D1 125 125 125 H 305 305 305 H1 310 310 310 H2 76 76 76 H3 54 54 54 L1 365 365 365 L2 375 375 375 M 16 16 16

Pressure/Temperature Ratings
Service pressure PMA Inlet temperature TMA [bar] [C] PN 40 Material P250GH (A105) 40.0 40.0 20 100 35.0 200 28.0 300 21.0 400

Materials
EN V 21.9/K, V 21.9 Stop valves Body Yoke Seat Plug and plug seat Bellows seal Body gasket Hand wheel P250GH / 1.0460 P240GH / 1.0619 1.4370 1.4021 1.4571 Graphite / CrNi EN-JL 1030 / EN GJL-200 C 22.8 / 1.0460 GS-C 25 / 1.0619 1.4370 1.4021 1.4571 Graphite / CrNi GG 20 P250GH / 1.0460 DIN C 22.8 / 1.0460

30

Condensate Collector and Steam Manifold PN 40, DN 40 V 20.8/K, V 20.8


Section A-A 230
80

Description
Compact-type condensate collector ( vertical design) with internal immersion tube and integrated stuffing box stop valves (V 20.8/K). Without immersion tube as steam manifold V 20.8 with integrated stuffing box stop valves. Lateral connections in DN15, 20 or 25 available. Collecting tube in DN40.
DN 15 DN 20 DN 25
215

Function V 20.8/K
The condensate discharged by the steam trap flows downwards between immersion tube and external collecting tube, thereby creating a water pocket into which the immersion tube enters. The space between immersion tube and collecting tube above the water pocket acts as a dampening cushion consisting of flash steam and air bubbles. This steam cushion effectively prevents water hammer like a dampening pot. The condensate flowing into the unit will be forced into the higher condensate collecting line as a function of its service pressure (differential pressure).

Connections
Butt-weld ends Socket-weld ends Flanged EN, PN 40 Flanged ASME Class 150 RF Flanged ASME Class 300 RF

DN 15 DN 20 DN 25

60

L D

50

73

Dimensions and Weights


Number of lateral connections 2 4 6 8 10
A

Section B-D
DN 40

All connections butt-weld ends A 45 45 45 45 45 B 160 160 160 160 160 C 90 250 410 570 730 L 152 152 152 152 152

Weight (without steam traps) approx. kg 4 8 12 16 20 A 92 92 92 92 92

All connections flanges PN 401) B 160 160 160 160 160 160 C 184 344 504 664 824 984 L2) 236 236 236 236 236 236

Weight (without steam traps) approx. kg 9 17 25 34 43 51

top

M16

12 45 160 890 152 24 92 1) Dimensions, weights, ASME flange connections see data sheet 2) DN 15 L = 232 mm

C B A

Pressure/Temperature Ratings
Flanges PN 40 EN 1092-1 / Butt-weld ends DIN 3239-1 / 1.0460 (P250GH / C 22.8)
bottom

Service pressure Inlet temperature

PMA TMA

[bar] [C]

40.0 20

34.7 150

28.4 250

24.0 350

23.1 400

Flanges B16.5 Class 300, Butt-weld ends B16.25 Sched. 40 / 1.0460 (P250GH / A105)
Service pressure Inlet temperature

PMA TMA

[bar] [C]

51.0 20

45.0 150

41.0 250

37.0 350

34.0 400

Materials
V20.8 V20.8/K Body Immersion tube (V20.8/K) Handwheel Pressure piece for packing Gasket Stem Plug Plug seat Top piece Wiper ring Packing EN P250GH (1.0460) 1.0305 Sheet steel 1.0401 1.0330 1.4104 1.4034 1.4104 1.0501 Novapress Graphite ASTM A105 A106* Sheet steel A 576-1015* A109* AISI 430 F* Chromium steel (13 %) AISI 430 F* A 576-1035* Novapress Graphite A 576-1035*

Locknut 1.0501 *) ASTMnearest equivalent grade is stated for guidance only. Physical and chemical properties comply with ENgrade.

31

A1

Drain Module QuickEM PN 16, PN 40, DN 15, 20, 25 QuickEM Control PN 16, PN 40, DN 15, 20, 25
Description
GESTRA Drain Modules QuickEM are completely interconnected units for horizontal or vertical installation with or without bypass. They come with valves and steam traps, non-return valves, sightglass and shut-off valves as well as all necessary pipes, fittings, flanges, gaskets and screws. Note that counterflanges, bolts and seals are not part of the supply. GESTRA Drain Modules QuickEM Control are used for monitoring steam traps and an electrode is directly fitted into the steam trap or a test chamber.

Pressure & Temperature Limits / End Connections


QuickEM with and without bypass, anges PN 16, EN 1092-1 PS (max. admissible pressure) TS (max. admissible temperature) pH value PMX / P (admissible differential pressure) [bar] QuickEM with and without bypass, anges PN 40, EN 1092-1 PS (max. admissible pressure) TS (max. admissible temperature) pH value PMX / P (admissible differential pressure) [bar] [bar] [C] 40.0 20 37.3 100 30.2 200 10 see data sheets for steam traps 28.4 250 25.8 300 [bar] [C] 16.0 20 14.4 100 12.8 200 9 see data sheets for steam traps 11.2 250 9.6 280

QuickEM Control with and without bypass, anges PN 16, EN 1092-1 PS (max. admissible pressure) QuickEM with bypass TS (max. admissible temperature) [bar] [C] 16.0 20 14.4 100 12.8 200 11.2 238 9.6 238

PMX / P (admissible differential pressure) [bar]

see data sheets for steam traps

QuickEM Control with and without bypass, anges PN 40, EN 1092-1 PS (max. admissible pressure) TS (max. admissible temperature) QuickEM without bypass [bar] [C] 40.0 20 37.3 100 30.2 200 28.4 238 25.8 238

PMX / P (admissible differential pressure) [bar]

see data sheets for steam traps DN 20 Dimensions Weight [kg] [mm] A B PN 16 PN 40 908 200 27 31 908 200 27 31 908 200 33 908 200 34 DN 20 Dimensions Weight [kg] [mm] A B PN 16 PN 40 858 250 27 27 858 250 27 27 858 200 33 858 200 33 DN 20 Dimensions Weight [kg] [mm] A B PN 16 PN 40 623 14 17 623 14 17 623 20 623 21 DN 20 Dimensions Weight [kg] [mm] A B PN 16 PN 40 472 14 14 472 14 14 623 20 623 20 DN 25 Dimensions Weight [kg] [mm] A B PN 16 PN 40 988 200 45 49 988 200 45 49 988 200 51 988 200 53 DN 25 Dimensions Weight [kg] [mm] A B PN 16 PN 40 828 300 45 45 828 300 45 45 988 200 51 988 200 51 DN 25 Dimensions Weight [kg] [mm] A B PN 16 PN 40 666 16 20 666 16 20 666 23 666 23 DN 25 Dimensions Weight [kg] [mm] A B PN 16 PN 40 505 16 16 505 16 16 666 22 666 22

Dimensions and Weights


QuickEM with bypass QuickEM BK QuickEM MK QuickEM UNA 14 QuickEM UNA 16 QuickEM Control with bypass QuickEM Control without bypass QuickEM Control BK QuickEM Control MK QuickEM Control UNA 14 QuickEM Control UNA 16 QuickEM without bypass QuickEM-BK QuickEM-MK QuickEM-UNA 14 QuickEM-UNA 16 QuickEM-Control without bypass QuickEM Control BK QuickEM Control MK QuickEM Control UNA 14 QuickEM Control UNA 16 *) PN 16 / PN 40 DN 15 Dimensions Weight [kg] [mm] A*) B PN 16 PN 40 821/841 200 21 25 821/841 200 21 25 821/841 200 26 821/841 200 27 DN 15 Dimensions Weight [kg] [mm] A B PN 16 PN 40 671 250 21 21 671 250 21 21 821 200 27 821 200 27 DN 15 Dimensions Weight [kg] [mm] A*) B PN 16 PN 40 564/584 11 14 564/584 11 14 564/584 16 564/584 17 DN 15 Dimensions Weight [kg] [mm] A B PN 16 PN 40 429 11 11 429 11 11 580 17 580 17

QuickEM Control with bypass

32

Drain Module QuickEM PN 16, PN 40, DN 15, 20, 25 QuickEM Control PN 16, PN 40, DN 15, 20, 25
Capacity Chart
The charts show the maximum hot condensate capacities.

QuickEM, QuickEM Control


UNA 14 DN 15-25 Orifice 4 UNA 14 / UNA 16 DN 15-25 Orifice 13 UNA 16 DN 15-25 Orifice 22 BK 45 MK 45-1 3 4 5 2 1 (Curve 3) (Curve 4) (Curve 5) (Curve 1) (Curve 2)

Kondensat-Durchsatz Capacity Condensate Capacities

Differential pressure Differenzdruck Differential pressure

33

33

A1

GESTRA Steam Traps for SIP Applications

GESTRA Steam Trap SMK 22-81 for SIP applications GESTRA has added a low-cost variant type SMK 22-81 to its product range of steam traps for SIP applications. Like the field-proven types SMK 22 and SMK 22-51, the new SMK 22-81, too, features the highquality GESTRA capsule with regulating membrane. This regulating capsule ensures rapid warming up and immediate condensate discharge without any banking-up, thereby guaranteeing absolutely safe and reliable sterilization processes. Like all other traps of the SMK series, the new SMK 22-81 is also made from stainless steel type 1.4404. Thanks to the design of the trap fewer welded connections are necessary and, if required, the functional unit can be exchanged without having to bend the line.

34

GESTRA Gravity Circulation Checks, DISCO Non-Return Valves and DISCO Swing Check Valves

DISCO Non-Return Valves Gravity Circulation Checks and DISCO Non-Return Valves for sanitation applications and hvac systems.

Page

Type SBO 11, Type SBO 21, Type SBO 31. ................................................................................... 37 Type RK 70, Type RK 71........................................................................................................... 38 39 Type MB 14.............................................................................................................................. 38 39 DISCO Non-Return Valves for industrial applications and hvac systems. Type RK 41, Type RK 44, Type RK 44 S . .................................................................................. 40 41 Type RK 76 . ............................................................................................................................ 40 41 Type RK 86 . ............................................................................................................................ 42 43 Type RK 86 A . ......................................................................................................................... 42 43 DISCO Non-Return Valves for special applications. Type RK 16 A, Type RK 16 C..................................................................................................... 44 45 Type RK 26 A . ..........................................................................................................................44 45 Type RK 49 . .............................................................................................................................46 47 Type RK 29 A . ......................................................................................................................... 48 49 DISCO Check Valves DISCOCHEck Dual-Plate Check Valves BB, DINdesign1) Wafer-type valves DN 50 1200 mm (2 48"), PN 6 160.................................................... 50 53 DISCO Swing Check Valves CB Wafer-type valves DN 50 300 mm (2 12"), PN 6 40........................................................ 54 55 Swing Check Valves WB Wafer-type valves DN 50 300 mm (2 12"), PN 10/16......................................................... 56 57 NAF-Check Valves ................................................ 58 59 Wafer-type valves DN 40 1000 mm (11/2 40"), PN 10 40.
1) DISCOCHecK

Dual-Plate Check Valves BB also available in ASME design.

35

A2

GESTRA DISCO Non-Return Valves

GESTRA DISCO Non-Return Valves Type RK 86 and 86A: These non-return valves feature a patented universal centering body. Standard valves fit between flanges PN 6-40, Class 150/300 as well as between BS10 flanges. Body material: stainless steel or austenitic steel.

36

Gravity Circulation Checks SBO, PN 6

Outlet: Screwed female Inlet: Union nut

Application
Downstream of circulating pumps in heating and hot water installations to prevent gravity circulation.

Pressure/Temperature Ratings / Material



1)

Max. service pressure [bar] 6

Max. service temperature [C] 1301)

Materials Body Brass (CW614N) Valve cone PPO

Max. service temperature at atmospheric pressure

SBO 11

Dimensions
Type Size DN L [mm] 1" 66 G 11/2 G 1 SBO 11 11/4" 82 G 2 G 11/4 1" 57 G 11/2 R 1 SBO 21 11/4" 70 G 2 R 11/4
3/4"

1" 40 G 11/2

11/4" 45 G2

39 G 11/4

Connections Inlet 2) (BSP thread) Outlet


2)

SBO 11 and SBO 21: Thread of union nut

Opening Pressures
Differential pressures at zero volume flow.
SBO21

Outlet: Screwed male Inlet: Screwed female

Type DN Opening pressure [mbar] Direction of flow with out with spring spring X X V Y 1" SBO 11 1 7 6 6 11/4" 1" SBO 21 1 7 6 5 11/4" 3 /4" SBO 31 1" 2 9 7 5 11/4"

Pressure Drop Charts


SBO 11, SBO 21
Partial opening / instable range Full opening / stable range

SBO 31
Partial opening / instable range Full opening / stable range

w Volume flow V

w Volume flow V

Pressure drop p [bar] Curve 1: SBO 21 DN 1" Curve 2: SBO 11 DN 1" Curve 3: SBO 21 DN 11/4" Curve 4: SBO 11 DN 11/4"

Pressure drop p [bar] Curve 1: SBO 31 DN 3/4" Curve 2: SBO 31 DN 1" Curve 3: SBO 31 DN 11/4"

37

A2

Outlet: Screwed male Inlet: Union nut

SBO 31

DISCO Non-Return Valves RK, PN6 to PN 16 Screwed Non-Return Valves MB, PN16
Application
Type PN For liquids, especially suited for heating and hot-water installations. Application as gravity circulation check and check valve. For liquids, gases, vapours. Application as gravity circulation check, vacuum breaker, breather, foot valve, pressure-relief valve or pressure-maintaining valve RK 70 6 RK 71 16 MB 14 16

Body Material
Type RK 70
L

Nominal sizes DN 15 100 mm 125 200 mm 15 100 mm 15 50 mm

EN reference Brass (CW617N) Plastic PPE Grey cast iron (EN-JL 1040) Plastic Polyamid 6 Brass (CW617N) 1.4571 Brass (CW614N) 1.4571

ASTM equivalent 1) Brass A126 Class A Brass AISI 316Ti Brass AISI 316Ti

Body Body Plug Body Body

RK 71 MB 14

Valve disk

RK 70 (lower part) / RK 71 (upper part) DN 15 100 mm

Valve disk Valve disk

1) ASTM material similar to EN material. Observe different physical and chemical properties!

Dimensions
RK 70 RK 71 MB 14 DN L D D L D A.F. [mm] [in] [mm] [mm] [mm] [mm] [mm] [mm] 15
1/2

20
3/4

25 1 22 56 56 61 62 46

32 11/4 72 72 61 62 46

40 11/2 82 82 72 83 65

50 2 95 95 72 83 65

65 21/2 46

80 3

100 125 150 200 4 5 6 8

16 40 40 49 42 30

19 47 47 49 42 30

28 31.5 40

50 60 90 106 140

115 132 152 184 209 264 115 132 152

RK 70 DN 125 200 mm

Pressure/Temperature Ratings
Type PN Nominal sizes DN 125 200 6 / -10 16 / -60 16 / -60 G 1/2 G 2 PMA / TMA / [bar] / [C] 1.5 / 100 1.5 / 100 14 / 200 14 / 200 0.5 / 130 0.5 / 130 13 / 250 13 /250 RK 70 6 15 100 6 / -30 6 RK 71 MB 14 16 16 15 100

RK Designs
L

Type

Seat
without spring

Spring
special spring Nimonic spring

MB 14

metal-to EPDM FPM PTFE metal

Earthing connection
Use RK 86

RK 70 RK 71 MB 14

(Plastic) X X

Use RK

Use 41 RK 86

Use RK41

X : standard : not available

38

DISCO Non-Return Valves RK, PN6 to PN 16 Screwed Non-Return Valves MB, PN16
Opening Pressures
Differential pressures at zero volume flow.

Pressure Drop Charts


The curves given in the chart are valid for water at 20 C. To read the pressure drop for other fluids the equivalent water volume flowrate must be calculated and used in the graph. The values indicated in the chart are applicable to spring-loaded valves with horizontal flow. With vertical flow insignificant deviations occur only within the range of partial opening.
VW = V 1000 VW = Equivalent water volume flow in [l/s] or [m3/h]

RK 71*)
DN Opening pressures [mbar] Direction of flow without with spring spring 15 20 25 32 40 50 65 80 100

X
2.5 2.5 2.5 3.5 4.0 4.5 5.0 5.5 6.5

X
10 10 10 12 13 14 15 16 18

V
7.5 7.5 7.5 8.5 9 9.5 10 10.5 11.5

Y
5 5 5 5 5 5 5 5 5

= Density of fluid (operating condition) in [kg/m3] V = Volume of fluid (operating condition) in [l/s] or [m3/h]

RK 70, RK71

When selecting valve please consider:


Partial opening/ instable range  Full opening/ stable range

RK 70*)
DN Opening pressures [mbar] Direction of flow without with spring spring 15 20 25 32 40 50 65 80 100 125 150 200

X
0.4 0.4 0.4 0.5 0.5 0.6 0.7 0.8 0.9 2.5 2.5

X
7.8 7.8 7.8 9 9.5 9.7 10.4 11.6 12.3

V
7.4 7.4 7.4 8.5 9 9.1 9.7 10.8 11.4

Y
7 7 7 8 8.5 8.5 9 10 10.5

MB 14

When selecting valve please consider:


Partial opening/ instable range  Full opening/ stable range

2.0 9.0 7.0 5.0 10.0 7.5 5.0 10.0 7.5 5.0

*) RK 70, 71 are not available with special spring or without spring

[bar]

39

A2

DISCO Non-Return Valves RK, PN 6 to PN 40

Application
Type RK41 RK44 RK44S RK76 PN 16 16 16 40
For liquids, gases, vapours. Application as gravity circulation check, vacuum breaker, breather, foot valve, pressure-maintaining valve, check valve. RK 41 especially suited for heating installations, RK 44 and RK 44S for sea water and drinking water, RK76 for industrial applications

Body Material
Type RK 41
L

Nominal sizes (DN) 15 100 mm 125 200 mm 15 100 mm 125 200 mm 15 100 mm 125 200 mm 15 100 mm

EN reference Special brass (CW710R) 1.4571 Grey cast iron (EN-JL 1040) 1.4006 Bronze (CC480 K-GS) 1.4571 Grey cast iron (EN-JL 1040) Bronze (CC480 K-GS) Bronze (CC480 K-GS) Bronze (CC483 K-GS) Bronze (CC483 K-GC) Bronze (CC480 K-GS) 1.4107 1.4571

ASTM equivalent 1) Special Brass AISI 316 Ti A126 Class B A182 F6 B584 C90500 AISI 316 Ti A126 Class B B584 C90500 B584 C90500 B505 C90700 B505 C90700 B584 C90500 A217-CA15 AISI 316 Ti

Body Body Plug Body Body Plug Body Body Plug Body

Valve disk

RK 44 RK 44S
D

RK 41/ RK 44 / RK 44S DN 15 100 mm

Valve disk

Valve disk

RK 76
1)

Valve disk

ASTM material similar to EN material. Observe different physical and chemical properties!

Dimensions
L

RK 41 RK 44 RK 44S RK 76

DN L D D D D

[mm] [in] [mm] [mm] [mm] [mm] [mm]

15
1/2

20
3/4

25 1 22 56 58 58 65

32 11/4 72 74 74 75

40 11/2 82 84 84 85

50 2 95 97 97 98

65 21/2 46

80 3

100 125 150 200 4 5 6 8

RK 41 / RK 44 / RK 44S DN 125 200 mm

16 40 42 42 45

19 47 49 49 55

28 31,5 40

50 60 90 106 140

115 132 152 184 209 264 117 132 152 184 209 264 117 132 152 184 209 264 118 134 154

Pressure/Temperature Ratings with metal-to-metal seat


Type
D

PN 16 16

Nominal sizes DN 16 / -60 16 / -10 16 / -200 16 / -10 16 / -200 49.6 / -10 125 200 125 200

p / T / [bar] / [C] 14 / 200 13 / 200 14 / 200 14 / 200 16 / 90 35.8 / 200 13 / 250 13 / 300 13 / 250 13 / 250 16 / 90 31.6 /300

RK 41

16 15 100 16 15 100 16 15 200 40 / Cl 300 15 100

RK 44

RK 44S RK 76
L

RK 76 DN15 100 mm

Designs
Type
metal-to- metal

Seat
EPDM (40 up to 150C)2) FPM (25 up to 200C)2) PTFE (190 up to 250C)2) without spring

Springs
special spring Nimonic spring

Earthing connection

RK 41 RK 44 RK 44S RK 76
2)

X X X X

O O O O

O O O O

O O O O

O O O

O Use RK 86

Observe pressure/temp. ratings of the equipment X : standard O : optional : not available

40

DISCO Non-Return Valves RK, PN 6 to PN 40


Short overall length according to DIN EN 558-1, table 11, series 49 ^ DIN 3202, part 3, series K4) (=

Pressure Drop Charts


The curves given in the chart are valid for water at 20 C. To read the pressure drop for other fluids the equivalent water volume flowrate must be calculated and used in the graph. The values indicated in the chart are applicable to spring-loaded valves with horizontal flow. With vertical flow insignificant deviations occur only within the range of partial opening.
VW = V 1000 VW = Equivalent water volume flow in [l/s] or [m3/h]

Opening Pressures
Differential pressures at zero volume flow.

RK 41, RK 44, RK761)


DN Opening pressures [mbar] Direction of flow without with spring spring

RK44S
DN Opening pressures [mbar] Direction of flow without with spring spring

X 15 2.5
20 2.5 25 2.5 32 3.5 40 4.0 50 4.5 65 5.0 80 5.5
1)

X
10 10 10 12 13 14 15 16 18 35 38 37

V
7.5 7.5 7.5 8.5 9 9.5 10 10.5 11.5 22.5 24.0 23.5

Y
5 5 5 5 5 5 5 5 5 10 10 10

X 15 2.5
20 2.5 25 2.5 32 3.5 40 4.0 50 4.5 65 5.0 80 5.5 100 6.5 125 150 200 12.5 14.0 13.5

X
25 25 25 27 28 29 30 31 33 35 38 37

V
22.5 22.5 22.5 23.5 24.0 24.5 25.0 25.5 26.5 22.5 24.0 23.5

Y
20 20 20 20 20 20 20 20 20 10 10 10

= Density of fluid (operating condition) in [kg/m3] V = Volume of fluid (operating condition) in [l/s] or [m3/h]

100 6.5 125 150 200 12.5 14.0 13.5

only DN 15-100

RK41, RK44, RK 44S


When selecting valve please consider:
Partial opening/ instable range  Full opening/ stable range
RK 41, RK 44 DN 125-200 RK 44S DN 15-200

RK76
When selecting valve please consider:
Partial opening/ instable range  Full opening/ stable range

41

A2

DISCO Non-Return Valves RK, PN 6 to PN 40


Short overall length according to DIN EN 558-1, table 11, series 49 ^ DIN 3202, part 3, series K4) (=

RK86 and RK 86 A Our Robust All-Rounder Application


Type PN For liquids, gases, vapours. Application as gravity circulations check, vacuum breaker, breather, foot valve, pressure-maintaining valve, check valve. RK 86 A especially suited for low temperatures, aggressive fluids, boiler feedwater lines, and other industrial applications. RK 86 40/class 300 RK 86 A 40/class 300

D max.

D min.

Body Material
Type RK 86
L

Nominal sizes DN 15 100 mm 125 200 mm 15 100 mm 125 200 mm

EN reference Chromium steel, 1.4317 1.4571 GP240GH (1.0619) 1.4006 1.4408 1.4571 1.4408 1.4404

ASTM equivalent 1) A 743-CA6-NM AISI 316Ti A 216 WCB A182 F6 A A351 CF 8M AISI 316 Ti A351 CF 8M A182 F316 L

Body Body Body Body

Valve disk Plug


Valve disk

RK 86A
1)

RK 86 / RK 86 A DN 15 100 mm

Plug

ASTM material similar to EN material. Observe different physical and chemical properties!
Dm in.

Dimensions
Nominal sizes [mm] [Inch] L 15
1/2

20
3/4

25 1 22 64 82

32 11/4 28 73 93 0.8

40 11/2 31,5 83 104

50 2 40 96 118

65 21/2 46 110 136

80 3 50 128 158

100 4 60 151 186

125 5 90 194 194 194 194 216 11

150 6 106 220 226 226 220 251 14

200 8 140 275 286 293 275 308 25

Overall dimensions D min [mm] D max PN 10/16 PN 25 D


D max.

16 44 67

19 53 76

PN 40 Class 125/150 Class 300

RK 86 / RK 86 A DN 15 100 mm

Weight

[kg]

0.27 0.38 0.52

1.12 1.78 2.43 3.37 5.34

Pressure/Temperature Ratings with metal-to-metal seat


Typ RK 86 RK 86 A
D

PN 40/class 300 40/class 300 40/class 300

DN 15 100 125 200 15 200 51 / -10 51 / -10 49.6 / -200

p / T / [bar] / [C] 43.9 / 200 43.9 / 200 35.8 / 200 36.9 / 350 34.5 / 400 24 / 550

Designs
Type
metal-to- metal

Seat
EPDM ( 40 up to 150C)2) FPM PTFE 3) ( 25 up to 200C)2) without spring

Springs
special spring Nimonic spring 4) Earthing connection

RK 86 RK 86A
L
2) 3)

X X

O O

O O

O O

O O

O O

O O

X X

RK 86 / RK 86 A DN 125 200 mm

Observe pressure/temp. ratings of the equipment DN 15-100 190 C up to 250 C; DN 125-200 60 up to 200 C 4) Required for temperatures above 300 C

X : standard O : optional

42

DISCO Non-Return Valves RK, PN 6 to PN40

Pressure Drop Charts


The curves given in the chart are valid for water at 20 C. To read the pressure drop for other fluids the equivalent water volume flowrate must be calculated and used in the graph. The values indicated in the chart are applicable to spring-loaded valves with horizontal flow. With vertical flow insignificant deviations occur only within the range of partial opening.
VW = V 1000 VW = Equivalent water volume flow in [l/s] or [m3/h]

Opening Pressures
Differential pressures at zero volume flow.

RK 86, RK86 A
DN Opening pressures [mbar] Direction of flow without with spring spring X X V 10 10 10 12 13 14 15 16 18 35 38 37 7.5 7.5 7.5 8.5 9 9.5 10 10.5 11.5 22.5 24.0 23.5

15 2.5 20 2.5

Y
5 5 5 5 5 5 5 5 5 10 10 10

25 2.5 32 3.5 40 4.0 50 4.5 65 5.0 80 5.5 100 6.5 125 150 200 12.5 14.0 13.5

= Density of fluid (operating condition) in [kg/m3] V = Volume of fluid (operating condition) in [l/s] or [m3/h]

RK86, 86A
When selecting valve please consider:
Partial opening/ instable range  Full opening/ stable range

Volume ow Vw

Pressure drop

43

A2

DISCO Non-Return Valves RK, PN 40


Short overall length according to DIN EN 558-2, table 11, series 52 (^ = DIN 3202, part 3, series K5)

Application
Type RK 16 A RK 16 C RK 26 A PN 40/class 300 40/class 300 40/class 300 For liquids, gases, vapours. Application as check valve, breather, foot valve, pressure-relief valve or pressure-maintaining valve. RK 26 A and RK16 C for aggressive fluids and low temperatures.

Body Material
Type RK 16A RK 16C RK 26A
1)

Nominal sizes DN Body Valve disk Body Valve disk Body Valve disk 15 100 mm 15 100 mm 15 100 mm

EN reference 1.4571 1.4571 2.4610 2.4610 1.4408 1.4571

ASTM equivalent 1) AISI 316Ti AISI 316Ti Hastelloy C Hastelloy C A351 CF8M AISI 316 Ti

L RK 16 A, RK 16 C DN 15-100

ASTM material similar to EN material. Observe different physical and chemical properties!

Dimensions
DN L
D

[mm] [in] [mm] [mm] [mm] [mm]

15
1/2

20
3/4

25 1

32 11/4 40 81 81 81

40 11/2 45 93 93 93

50 2 56 108 108 108

65 21/2 63 128 128 128

80 3 71 143 143 143

100 4 80 1632) 1693) 1632) 1693) 1632) 1693)

125 5 110

150 6 125

200 8 160

25 52 52 52

31.5 35.5 63 63 63 72 72 72

RK 16 A RK 16 C RK 26 A
2)

D D D
3)

PN 10/16

PN 25/40

RK 26 A DN 15-100

Pressure/Temperature Ratings with metal-to-metal seat


Type RK 16 A RK 16 C RK 26 A PN 40/Class 300 40/Class 300 40/Class 300 Nominal sizes DN 15 100 mm 15 100 mm 15 100 mm 49.6 / -200 49.6 / -200 49.6 / -200 p / T / [bar] / [C] 35.8 / 200 35.8 / 200 35.7 / 200 24 / 550 29.3 / 400 25 / 550

Designs
Seat Type
RK 16 A RK 16 C RK 26 A
4) Observe

Spring
PTFE (190 up to 250 C)4) without spring special spring Nimonic spring 5)

meta-tometal

EPDM ( 40 up to 150 C)4)

FPM ( 25 up to 200 C)4)

Earthing connection

X X X

O O

O O

O O

O O O

O O

O O

O O O

pressure/temp. ratings of the equipment 5) Required for temperatures above 300 C.

X : standard O : optional : not available

44

DISCO Non-Return Valves RK, PN 40


Short overall length according to DIN EN 558-2, table 11, series 52 (^ = DIN 3202, part 3, series K5)

Pressure Drop Charts


The curves given in the chart are valid for water at 20 C. To read the pressure drop for other fluids the equivalent water volume flowrate must be calculated and used in the graph. The values indicated in the chart are applicable to spring-loaded valves with horizontal flow. With vertical flow insignificant deviations occur only within the range of partial opening.

VW = V 1000 VW = Equivalent water volume flow in [l/s] or [m3/h]

= Density of fluid (operating condition) in [kg/m3] V = Volume of fluid (operating condition) in [l/s] or [m3/h]

Opening Pressures
Differential pressures at zero volume flow.

Opening Pressures
Differential pressures at zero volume flow.

RK 16 A, RK 26 A
DN Opening pressures [mbar] Direction of flow without with spring spring X X V 10 10 10 12 13 14 15 16 18 7.5 7.5 7.5 8.5 9 9.5 10 10.5 11.5

RK16 C
DN 15 20 25 32 40 50 65 80 100 Opening pressures [mbar] Direction of flow without with spring spring X X V 2.5 2.5 2.5 3.5 4.0 4.5 5.0 5.5 6.5 25 25 25 27 28 29 30 31 33 22.5 22.5 22.5 23.5 24.0 24.5 25.0 25.5 26.5

15 2.5

Y
5 5 5 5 5 5 5 5 5

Y
20 20 20 20 20 20 20 20 20

20 2.5 25 2.5 32 3.5 40 4.0 50 4.5 65 5.0 80 5.5 100 6.5

RK16 A, RK16 C (dashed lines apply to RK 16 A)


When selecting valve please consider:
Partial opening/ instable range  (RK 16C) Full opening/ stable range

RK26 A
When selecting valve please consider:
Partial opening/ instable range  Full opening/ stable range

45

A2

DISCO Non-Return Valves RK, PN 63 to PN 160


Short overall length according to DIN EN 558-2, table 11, series 52 (^ = DIN 3202, part 3, series K5)

Application
Type RK 49 PN 160 For liquids, gases, vapours and aggressive fluids. Used as non-return valve (for unidirectional flow), vacuum breaker or priming foot valve. RK 49 for high pressures and temperatures

Body Material
Type RK 49 Body Valve disk Body Plug
1)

Nominal sizes DN 15 65 mm 80 200 mm

EN reference 1.4581 1.4986 1.7357 1.4922

ASTM equivalent 1) A351 CF8 A217 WC6

ASTM material similar to EN material. Observe different physical and chemical properties!

RK 49, DN15 65 mm

Dimensions
DN L RK 49 D [mm] [in] [mm] [mm] 15
1/2

20
3/4

25 1 74

32 11/4 40 84

40 11/2 45 95

50 2 56 110

65 21/2 63 130

80 3 71 147

100 4 80 173

125 5 110 209

150 6 125 245

200 8 160 301

25 54

31.5 35.5 63

Pressure/Temperature Ratings with metal-to-metal seat


Type RK 49 PN 160 Nominal sizes DN 15 65 80 200 160 / -10 160 / -10 p / T / [bar] / [C] 133.3 / 300 160.0 / 300 119.6 / 550 37.5 / 550

Designs
Seat Type
L
metal-tometal EPDM FPM PTFE without spring

Springs
special spring Nimonic spring 2)

Earthing connection

RK49, DN80 200 mm

RK 49
2) Required

for temperatures above 300 C.

X : standard O : optional : not available

46

DISCO Non-Return Valves RK, PN 63 to PN 160


Short overall length according to DIN EN 558-2, table 11, series 52 (^ = DIN 3202, part 3, series K5)

Pressure Drop Charts


The curves given in the chart are valid for water at 20 C. To read the pressure drop for other fluids the equivalent water volume flowrate must be calculated and used in the graph. The values indicated in the chart are applicable to spring-loaded valves with horizontal flow. With vertical flow insignificant deviations occur only within the range of partial opening.

VW = V 1000 VW = Equivalent water volume flow in [l/s] or [m3/h]

= Density of fluid (operating condition) in [kg/m3] V = Volume of fluid (operating condition) in [l/s] or [m3/h]

Opening Pressures
Differential pressures at zero volume flow.

RK 49

When selecting valve please consider:


Partial opening/ instable range  Full opening/ stable range

RK 49
DN Opening pressures [mbar] Direction of flow without with spring spring X X V 16.5 17.5 18.0 18.0 19.5 22.0 23.0 17.5 20.0 23.0 24.0 29.0 73 74 76 76 79 84 87 75 80 86 88 98 56.5 57.0 58.0 58.0 59.5 62.0 63.0 57.5 60.0 63.0 64.0 69.0 15 20 25 32 40 50 65 80 100 125 150 200

Y
40 40 40 40 40 40 40 40 40 40 40 40

47

A2

DISCO Non-Return Valves RK, PN 63 to PN 400

Application
Type RK 29 A PN 63 400 Cl 400 2500 For large pressure ratings and special tasks.

Materials
D

Type RK 29A
1)

Nominal sizes DN 15 200 mm

EN reference 1.4571 1.4571

ASTM equivalent 1) AISI 316Ti AISI 316Ti

Body

Plug

ASTM material similar to EN material. Observe different physical and chemical properties!

Dimensions RK 29A
L

RK 29 A, DN 15-40 mm PN63/100/160/250/320/400 ASME Class 400/600/900/1500/2500 RK 29A, DN 50-100 mm PN 250/320/400 ASME Class 1500/2500

PN 63 PN 100 PN 160 class 400 class 600 class 900 DN L D L D L D L D L D L D 15 35 63 35 63 35 63 35 54 35 54 35 63 25 40 84 40 84 40 84 40 73 40 73 40 79 40 56 105 56 105 56 105 56 95 56 95 56 98 50 56 115 56 121 56 121 56 111 56 111 56 142.5 80 71 149 71 156 71 156 71 149 71 149 71 168 100 80 176 80 183 80 183 80 176 80 193.5 80 205 150 125 250 125 260 125 260 125 247.5 125 266.5 125 288.5 200 160 312 160 327 160 327 160 304.5 160 320.5 160 358.5 PN 250 400 see data sheet. Cl 1500 and 2500 see data sheet.

Pressure/Temp. Ratings acc. EN1092-1, material group 15E0


Type RK 29A Max. service pressure [bar] at temperature [C] Pressure rating 200 200 500 PN 63 63 53.8 44.2 PN 100 100 85.3 70.2 PN 160 160 136.5 112.4

Pressure/Temp. Ratings acc. ASME B 16.5, material group 2.4


Type RK 29A Pressure rating Max. service pressure [bar] at temperature [C] 218 200 500 37.6 56.6 84.7

class 400 66.2 51.1 class 600 99.3 76.6 class 900 148.9 114.9 Tightness of seat in accordance with DIN 3230, part 3, leakage rate BN 2, BO 3. Sealing surfaces machined according to EN 1092-1, form B2, ASME B 16.5 RF smooth finish (63-125 in). Other designs available on request.

RK 29A, DN 50-200 mm PN 63/100/160 ASME Class 400/600/900

Designs
Type
metal-to- metal

Seat
EPDM (40 up to 150C)2) FPM (25 up to 200C)2) PTFE (190 up to 250C)2)

Springs
without spring special spring Nimonic spring 3)

Earthing connection

RK 29A
2) Observe

pressure/temp. ratings of the equipment 3) Required for temperatures above 300 C.

X : standard O : optional : not available

48

DISCO Non-Return Valves RK, PN 63 to PN 400

Pressure Drop Charts


The curves given in the chart are valid for water at 20 C. To read the pressure drop for other fluids the equivalent water volume flowrate must be calculated and used in the graph. The values indicated in the chart are applicable to spring-loaded valves with horizontal flow. With vertical flow insignificant deviations occur only within the range of partial opening.
VW = V 1000 VW = Equivalent water volume flow in [l/s] or [m3/h]

Opening Pressures
Differential pressures at zero volume flow.

RK 29 A
DN without spring Opening pressures [mbar] Direction of flow with spring with spring with spring

X
PN 160 Cl 900 15 25 40 50 80 100 150 200
1)

X
PN 400 Cl 2500 6 8 10 10 13 24 PN 160 Cl 900 22 26 30 30 32 34 46 52 PN 400 Cl 2500 22 26 30 30 36 58 PN 160 Cl 900 16 18 20 20 21 22 28 31

V
PN 400 Cl 2500 16 18 20 20 23 34

Y
PN 400 Cl 2500 10 10 10 10 10 101) 101) 10

6 8 10 10 11 12 18 21

= Density of fluid (operating condition) in [kg/m3] V = Volume of fluid (operating condition) in [l/s] or [m3/h]

RK29A
When selecting valve please consider:
Partial opening/ instable range

only for PN 63-400

Full opening / stable range

Volume flow V w

[bar] Pressure drop

49

A2

DISCOCHECK Dual-Plate Check Valves BB


Short overall length according to DIN EN 558-1, table 11, series 16 (^ = DIN 3202, part 3, series K 3)

Application
For liquids, gases, vapours. In heating, air-conditioning, water-supply and cooling installations, steam and condensate systems, oil pipelines and natural gas lines. For use with sea water, in sewage works, downstream of fans and compressors. For drinking water: with lining, and for sea water with rubber lining. With adjustable dampers for installations with waterhammer problems. Metal-to-metal or soft seat (EPDM, FPM).

80

Materials
Design Part designation Grey cast iron (BB ... G) Body Dual plate Body Body Dual plate Body Body Dual plate Dual plate Nominal size DN EN reference ASTM equivalent 1) A 126 Class A A 536 60-40-18 A 105 A 216 WCB A 216 WCB A 182 F 316 L A 351 CF8 M A 182 F 316 L A 351 CF 8 M

150 1000 EN-JL 1040 150 1000 EN-JS 1030 100 + 125 150 500 100 500 50 125 150 500 50 80 100 500 1.0460 1.0619 1.0619 1.4404 1.4408 1.4404 1.4408

DN 50 125 mm

Carbon steel (BB ... C) Stainless steel


A
1)

Physical and chemical properties comply with EN grade.

Pressure/Temperature Ratings with metal-to-metal seat


Design Type PN
80

Max. service pressure [bar] at temperature [C] 2) 20 100 150 200 250 300 350 400 450 500 550 6 10 16 10 16 25 40 6 10 10 16 25 40 5.4 4.8 4.2 3.6 9.0 8.0 7.0 6.0 10 7 6.9

BB 11 G / 21 G Grey cast iron down to 10 C 12 G/ 22 G at nominal pressure 14 G / 24 G Carbon steel BB 12 C /22 C down to 10 C 14 C /24 C at nominal pressure 15 C/25 C 16 C/ 26 C 17 C 18 C 6 10 16 10 16 25 40 63 10 16 25 40 63

16 14.4 12.8 11.2 9.6

9.6 8.9 7.6 7.1 6.7 6.4

DN 150 500 mm DN 600 1000 only in grey cast iron

16 15.3 14.2 12.1 11.4 10.7 10.3 25 23.9 22.2 18.9 17.8 16.7 16.1 40 38.2 35.6 30.2 28.4 26.7 25.8

63 58.5 54.6 47.6 44.8 40.6 37.8 36.4 10 9.8 9.1 8.5 8.1 7.8 7.5 7.3 7.2

100 100 93.3 86.7 75.6 71.1 64.4 60 57.8

Stainless steel BB 12 A /22 A down to 14 A /24 A 200 C at nominal 15 A / 25 A pressure 16 A / 26 A


2)

16 15.6 14.6 13.7 13 12.4 12 11.7 11.4 11.2 11.1 25 24.4 22.8 21.3 20.3 19.4 18.8 18.2 17.9 17.6 17.3 40 39.1 36.4 34.1 32.5 31.1 30 29.2 28.6 28.1 27.7 63 61.6 57.4 53.8 51.2 49 47.3 45.9 45.1 44.2 43.7

17 A 18 A

100 100 93.3 86.7 82.2 77.8 74.2 71.6 69.3 67.6 66.2 63.1

For temperatures above + 300 C special springs of Inconel X 750 are required.

BB 12A-18A DN 50 125 applicable up to max. 500 C.

If PN > 40 ask for corresponding data sheets. If DN > 500 and made from grey cast iron ask for corresponding data sheets.

50

DISCOCHECK Dual-Plate Check Valves BB


DIN design DN50 1000 mm, PN 6 100 1)

BB Designs
Type
metal-to- metal EPDM (40 up to 150C) 1)

Opening Pressures
Seat
FPM (25 up to 200C) 1) NBR (30 up to 110C) 1)

Lining
Rubber 5)

Differential pressures at zero volume flow.


DN Opening pressures [mbar] with upward flow without with spring spring 7 WA 7 WAI 2 WA 5 VO 50 65 80 100 125 150 200 250
5 VO 12)

PTFE 2) VESTOSINT 4) (25 up to 200C) 1)

BB.....G BB.....C BB.....A


1) 2) 3) 4)

O X X

X O O

O O O

O O O

O 3)

O 6) O 6)

O 6) O 6)
: not available

O 3)

6 6 7 7 10 11 (15) 12 (18) 14 (18) 15 (25) 17 (25) 19 (25) 22 23 (28)

13 13 14 14 17 18 (22) 19 (25) 21 (25) 22 (32) 24 (32) 26 (32) 29 30 (35)

8 8 9 9 12 13 (17) 14 (20) 16 (20) 17 (27) 19 (27) 21 (27) 24 25 (30)

17 17 19 19 25 27 (35) 33 (41) 35 (55) 39 (55) 43 (55) 49 51 (61)


5)


6)

Type
BB.....G BB.....C BB.....A
7)

Damper 7)
O O O

Earthing connection
O O

Drain plug
O O 9) O 9)

without spring

Springs
Inconel spring8) 2 WA 10) 7 WA 11)

300 350 400 450 500

O O O

O O

O O O

X X X

O O O
: not available


8) 9) 10) 11) 12)

X : standard O : optional From DN200 up to DN500. Max. temperature rating 110 C, see table Pressure/Temperature Ratings BB with Dampers Inconel X 750 (Required for temperatures above 300 C). Opening pressure 7 mbar (spring 7 WAI). From DN150 Spring for 2 mbar opening pressure with horizontal installation. Spring for 7 mbar opening pressure (standard) with horizontal installation. Spring for 5 mbar opening pressure with vertical installation and downward flow.

Values indicated in brackets apply for BB 17/18/19.

Pressure Drop Chart


The chart is valid for water at 20 C; for other fluids, the equivalent water volume flowrate must be calculated and used in the chart. The values indicated in the chart are applicable to valves with 7 mbar springs with horizontal flow. With vertical flow deviations occur only within the range of partial opening. The dashed lines in the chart are valid for valves with 2 mbar springs with horizontal flow. The chart and the flow characteristics apply to values up to PN 40. For valves with higher pressure ratings (PN) the loss coefficients (zeta values) and the pressure drops are increased by approx. 20 %. The kvs values are correspondingly reduced.
VW = V 1000 VW = Equivalent water volume flow in [l/s] or [m3/h]

Volume flow V w

= Density of fluid (operating condition) in [kg/m3] V = Volume of fluid (operating condition) in [l/s] or [m3/h]

Pressure drop p

1) If

PN > 40 and DN > 500 mm ask for corresponding data sheets.

51

A2

X : standard O : optional Observe pressure / temp. ratings of equipment Cover FPM ring with PTFE From DN 150. Not possible for smaller sizes. Inside and outside of body lined with VESTOSINT , seat made of EPDM. Internals either of bronze or of stainless steel. Temp. range 10 C up to 80 C. Inside of body lined with rubber, seat made of EPDM. Internals either of bronze or of stainless steel. Temp. range 10 C up to 90 C. From DN150. For smaller sizes use BB...A

29 (41)

DISCOCHECK Dual-Plate Check Valves BB


DIN design DN50 1000 mm, PN 6 100 1)

Dimensions and Weights


DN PN Dimensions [mm] D L A 50 3) 65 3) 80 3) 100 125 150 200
1) If

Type Code
Weight 2) [kg] DN PN Dimensions [mm] D L A 6 250 300 350 400 450 500 10 16 25 40 10 16 25 40 10 16 25 40 10 16 25 40 10 16 40 6 10 16 25 40 319 330 330 114 87 343 355 375 380 386 114 110 403 420 425 440 446 127 120 460 477 475 491 498 140 142 517 549 Weight 2) [kg] 33 35 35 38 41 44 45 47 51 55 ,562.5 67 69 73 79 ,580.5 86 88 95 1075 FPM 150 C 4 2 BB Valve Type Series 1 DN50 125 mm and from DN450 mm as well as from PN 63 2 DN150 400 mm up to PN40 Pressure rating 1 2 4 5 6 PN6 (only grey cast iron) PN 10 PN 16 PN 25 PN40

10 16 25 40 10 16 25 40 10 16 25 40 10 16 25 40 10 16 25 40 10 16 25 40 6 10 16 25 40

109 2.5 109 2.5 43 8 109 2.5 109 2.5 129 4 129 129 4 46 11 4

129 4 144 6 144 6 64 12 144 6 144 6 164 7 164 7 64 19 171 ,5 7.5 171 194 194 70 28 196 196 209 220 220 76 40 226 226 264 275 275 89 64 286 293 ,5 7.5 12 12 12 12 12 ,513.5 ,513.5 14 14 ,518.5 20 20 22 23

Body material G Grey cast iron C Steel A Austenitic steel Nominal size DN 50 500 Seat HD metal-to-metal EPDM FPM PTFE Springs/Opening pressures 7 WA Spring for 7 mbar with horizontal installation 7 WAI Inconel spring for 7 mbar with horizontal installation 2 WA Spring for 2 mbar with horizontal installation 5 VO Spring for 5 mbar with downward flow BB 24 C 150 FPM 7 WA Dual-plate check valve BB 24, PN16, made of cast steel type GS-C 25, DN150 mm with FPM gasket and spring (7 mbar) for horizontal installation.

530 12555 541 13055 152 163 558 13855 574 14355 580 14455 596 15255 620 152 181 16455 627 16855 631 17055

7 WA

PN > 40 and DN > 500 mm ask for corresponding data sheets. 2) Weights rated for cast steel grade GP 240 GH (GS-C 25). 3) DN50, 65 and 80 only available as BB ... A (stainless steel).

Typical example: Explanatory note:

52

DISCOCHECK Dual-Plate Check Valves BB


DIN design DN150 1000 mm, PN 6 100 1)

BBwith Lining
BB with lining from DN 150

Application
Design with plastic lining: for drinking water and sea water. Design with rubber lining: for sea water. Design with dampers: to solve waterhammer problems. Metal-to-metal or elastic seat (EPDM, FPM)
1) For

pressure ratings > PN40 and sizes > DN 500 please ask for corresponding data sheets.

Temperature Limits
Hard-rubber lining Plastic lining

Rubber lining 10C up to 90C

Dual plates, hinge pins and springs are not lined. Dual plates standard with O-rings of EPDM or on request with metal seating surface.

BB with Dampers Application


To solve waterhammer problems in pipelines carrying liquids.To evaluate possible waterhammer problems please ask for our questionnaire.

Pressure/Temperature Ratings
Size DN
Max. service pressure Max. service temperature Max. admissible pressure at line leading to the valve (pump switched off) [mm] [inch] [bar] [C] [bar] 200 8 16 250 10 16 300 12 13 110 0.5 350 14 9 400 16 13 500 20 9

BB with patented adjustable dampers, DN 200 800.

53

A2

Plastic lining 10C up to 80C

DISCO Swing Check Valves CB DN50 300 mm, PN6 40


Application
Type CB 14 CB 24 S CB 26 CB 26 A
D

PN 16 16 40 40

For liquids, gases, vapours: CB 14 for water and compressed air CB 24 S for sea water, drinking water, swimming-pool water For low temperatures CB 26 A for aggressive fluids, drinking water, or swimming-pool water

Materials
Type Part designation Nominal sizes EN reference DN 1.0038 galvanized NBR Bronze (CC 483K-GS) Bronze (CC 332G) Bronze (CC 332G) 1.0460 1.0038 1.4581 GGG-40.3(EN-JS 1049) 1.4571 1.4581 1.4581 ASTM 1) equivalent A 284 B galvanized NBR B 505 C 90 700 B 148 Alloy 952 B 148 Alloy 952 A 105 A 284 B A 351 CF 8 MC AISI 316 TI A 351 CF8 MC A 351 CF 8 MC

70
L a

Body 50 300 mm CB 14 CB 24 S CB 26 CB 26 A Flap 50 300 mm Body 50 100 mm 125 300 mm Flap 50 300 mm Body 50 200 mm 250 300 mm 50 80 mm 100 300 mm Flap

CB 14, DN 50 200 mm

Body 50 200 mm

250 300 mm Flap 50 300 mm


D
1)

Physical and chemical properties comply with ENgrade.

Pressure/Temperature Ratings
Type CB 14 CB 24 S CB 26
L

Nominal sizes DN 50 300 50 300 50 200 250 300

PN 16 16 40 40 16 / -10 16 / -200 40 / -10 40 /-10

p / T / [bar] / [C] 6.0 / 60 16.0 / 90 33.3 / 200 33.3 / 200 37.3 / 200 4.0 / 80 15.6 / 2502) 25.7 / 3502) 27.6 / 300 30.6 / 4502)

CB 14, DN 250 300 mm

CB 26 A 50 300 40 40 / -10 2) Max. pressure/temperature rating for CB without springs.

CB Designs
Type
metal-to- metal NBR (30 up to 110C) 3)

Seat
EPDM (40 up to 150C) 3) FPM (25 up to 200C) 3) PTFE 4) (25 up to 200C) 3)

Springs
without spring special spring

CB 14 CB 24S O CB 26 O CB 26A O
3) 5)

X 5) X

O X X

O O O

O O

X O O O


X : standard O : optional : not available

4) Cover FPM ring with PTFE Observe pressure / temp. ratings of the equipment Flap made from NBR (Perbunan) Temp. range: 10 C up to 80 C

Weights and Dimensions


D

60

CB 24 S, CB 26, CB 26 A DN50 300 mm

Nominal size Dimensions [mm] Weight [kg] DN CB 14 CB 24 S, CB 26, CB 26 A CB 26 CB14 CB 24 S CB 26 A D L a d 6) [mm] [in] D L a d 6) 50 2 98 14 45 47 98 17 40 50 0.7 0.9 0.9 14 60 64 118 20 50 64 1.0 1.4 1.4 65 21/2 118 80 3 132 14 70 75 132 24 58 75 1.4 2.0 2.0 100 4 154 14 90 98 154 27 72 99 1.5 3.1 3.1 125 5 184 16 115 124 184 32 88 125 2.5 5.2 5.3 150 6 209 16 145 148 209 32 112 144 3.3 6.7 6.9 200 8 264 18 185 196 264 42 150 198 5.5 13.7 14.1 250 10 319 35 220 242 319 47 182 244 11.2 22.9 23.6 300 12 375 43 270 288 375 52 216 292 14.0 32.8 33.8
6)

Minimum flange bore and inside pipe diameter.

54

DISCO Swing Check Valves CB DN50 300 mm, PN6 40


Pressure Drop Charts
The curves given in the chart are valid for water at 20 C. To read the pressure drop for other fluids the equivalent water volume flowrate must be calculated and used in the graph. The values indicated in the chart are applicable to valves with horizontal flow. With vertical flow insignificant deviations occur only within the range of partial openings.
VW = V 1000 VW = Equivalent water volume flow in [l/s] or [m3/h]

CB 14

= Density of fluid (operating condition) in [kg/m3] V = Volume of fluid (operating condition) in [l/s] or [m3/h]

Opening Pressures
Differential pressures at zero volume flow. Type DN Opening pressures [mm] [mbar] Direction of flow X V Y CB 14 50 150 8 0 1) 200 300 15 0

Opening pressures [mbar] Direction of flow without with spring spring X X V Y CB 24 S 50 150 5 12 7 CB 26/
1) Valves

Type DN [mm]

CB24 S, CB26, CB 26 A

200 300 8 50 80 5 11 18 200 300

15 12 18 25

7 7 7 7
1)

CB 26 A 100 150

should not be used for downward flow applications, since the spring will not close the valve flap.

55

A2

Swing Check Valves WB without spring, DN 50 300 mm, PN 10/16


Application
WB 26 WB 26 A
a

for liquids, gases and vapours for aggressive fluids for sea water

WB 24 S

Installation in horizontal or vertical lines with upward flow.

Materials
Type WB 26 WB 26 A
do D

ASTM reference AISI 420 galvanized AISI 316 AISI 316L AISI 316L Aluminium bronze NBR as standard

EN 1) equivalent 1.4034 galvanized 1.4401 1.4404 1.4404 Aluminium bronze

Body and flap Flap DN 50 100 Body Flap Body and flap

WB 24 S
1)

O-rings Physical and chemical properties comply with ASTM grade.

Pressure/Temperature Ratings
Nominal pressure
L

PN [bar] [C] [C]

16 NBR 16 110 10

Design with O-rings 2) Max. service pressure Related temperature Min. temperature 3)
2)

WB 26, WB 26A, WB 24 S DN 50 300 mm

O-rings in flap and valve faces made of NBR as standard. 3) Minimum temperature for nominal pressure rating.

WB Design
Type
metal-to- metal NBR ( 30 up to 110C) 4)

Seat
EPDM ( 40 up to 150C) 4) FPM (25 up to 200C) 4) PTFE (25 up to 200 C) 4)

Springs
without spring special spring

WB 24S WB 26 WB26A
4) Observe

O O O

X X X

Use CB 26 Use CB 26 Use CB 26A

O O O

Use CB 26 Use CB 26A

X X X

pressure/temp. ratings X : standard O : optional : not available

Weights and Dimensions


Nominal size DN [mm] [in] L 14 14 14 18 18 20 22 26 32 21/2 Dimensions [mm] D a do Weight 5) [kg]

50 2 65
5)

109 35 32 0.95 129 48 40 1.2 144 60 54 1.6 164 78 70 2.5 195 98 92 3.5 220 116.5 275 330 380 160 200 235 112 4.7 154 7.6 200 240 13.2 20.5

80 3 100 4 125 5 150 6 200 8 250 300 10 12

The weight ratings apply for WB 26 and WB 26 A. WB24 S reduced by approx. 5 %.

56

Swing Check Valves WB without spring, DN 50 300 mm, PN10/16


Pressure Drop Chart
The curves given in the chart are valid for water at 20 C. To read the pressure drop for other fluids the equivalent water volume flowrate must be calculated and used in the graph. The values indicated in the chart are applicable to valves with horizontal flow. With vertical flow insignificant deviations occur only within the range of partial openings.
VW = V 1000 VW = Equivalent water volume flow in [l/s] or [m3/h]

Opening Pressures
Opening pressure zero when valve is installed in horizontal line.

57

A2

= Density of fluid (operating condition) in [kg/m3] V = Volume of fluid (operating condition) in [l/s] or [m3/h]

NAF-Check Valves DN40 1000 mm, PN10 40


Application
for liquids, gases, vapours, aggressive fluids and low temperatures.
L

Weight and Dimensions


Type PN DN [mm] 40 D 84 92 108 128 158 180 203 263 315 370 432 480 530 592 692 804 911 1124 Dimensions [mm] L 33 43 46 64 64 70 76 89 114 114 127 140 152 152 178 229 241 300 A 15 5 12 16 26 36 51 71 90 125 146 175 188 228 282 301 374 458 Weight [kg] 1.2 1.7 1.7 3 5 7 9 16 28 41 48 65 94 115 192 270 402 782

50 65 526 620 1) 526 630 2) 528 620 1) 528 630 2)


D

80 10 40 100 125 150 200 250 300 350

NAF-Check DN40 1000

400 526 520 1) 528 530 2) 528 520 1) 528 530 2) 450 10 25 500 600 700 800 1000
1)

without spring 2) with spring

Materials
Design Part designation
Nominal size DN [mm]

Materials EN / ASME 1.4404 1.4308 1.4408 1.0619 ASTM A487 Gr CA6NM 1.4317 1.4406 1.4408 1.4470

Equivalent A316 L A351 CF8 A351 CF8M ASTM A 216 WCB EN 1.4313 ASTM A743 ASTM A316 L ASTM A351 CF8M ASTM A890

40 50 Body Steel Flap Body Flap 65 200 250 300 1000 40 + 50 65 1000 40 50 65 1000 40 1000

Stainless steel

Pressure/Temperature Ratings
Design Steel down to 10 C at nominal pressure Stainless steel down to 30 C at nominal pressure
3)

Type 526 620 / 30 526 520 / 30 528 620 / 30 528 520 / 30

PN 40 25 40 25

DN [mm] 40 250 300 1000 40 250 300 1000

Max. service pressure [bar] / related temperatures [C] 3) 20 40.0 25.0 40.0 25.0 100 36.3 23.2 40.0 25.0 150 32.7 22.0 36.3 22.7 200 26.9 20.8 33.7 21.0 250 27.6 19.0 31.8 19.8 300 25.7 17.2 350 24.5 16 400 23.8 14.8 450 500 525

Max. temperature rating for design with spring: + 300 C.

58

NAF-Check Valves DN40 1000 mm, PN10 40


Pressure Drop Chart
The curves given in the chart are valid for water at 20 C. To read the pressure drop for other fluids the equivalent water volume flowrate must be calculated and used in the graph. The values indicated in the chart are applicable to valves with horizontal flow. With vertical flow insignificant deviations occur only within the range of partial openings. The chart and flow characteristics are available up to and including PN 40. Higher PN increase the zeta values and pressure drops at the same flowrates by approx. 20 %. The kvs values decrease accordingly.
VW = V 1000 VW = Equivalent water volume flow in [l/s] or [m3/h]

= Density of fluid (operating condition) in [kg/m3] V = Volume of fluid (operating condition) in [l/s] or [m3/h]

, , ,

59

A2

GESTRA Control Valves ZK

GESTRA Control Valves ZK with Radial Stage Nozzle: Our high-performance control valves with tight shut-off are based on extensive experience and know how acquired over many years in the design of valves for power plants. Low repair and maintenance requirements combined with hight resistance to wear guarantee reliable operation and a long service life.

60

A4 A4 A4 A6 A7 A8

Return-Temperature Control Valves Self-Acting Pressure and Temperature Controllers Control Valves Safety Valves Strainers Stop Valves

Page Return-Temperature Control Valves Cooling-Water Control Valves CW GESTRAMAT................................................................... 62 63 Return-Temperature Control Valves BW KALORIMAT. .......................................................... 64 66 Self-Acting Pressure and Temperature Controllers Pressure-Reducing Valves 5801................................................................................................. 67 Pressure-Maintaining Valves 5610............................................................................................. 68 Self-Acting Temperature Controllers................................................................................... 69 71 Control Valves Single-Seat Control Valves with Electric or Pneumatic Actuator .............................................................................................................. 72 Control Valves ZK with Radial Stage Nozzle . ..................................................................... 73 76 Safety Valves GSV.......................................................................................................................... 77 Strainers GSF, SZ.................................................................................................................... 78 79 Stop Valves GAV..................................................................................................................... 80 81

61

A4-A8

Cooling Water Control Valves CW (GESTRAMAT)


Features of the CW Series

Direct acting proportional controller for regulating the cooling-water return temperature. Reduced capital costs (for new plants) coolant and energy consumption due to higher discharge temperatues The valve prevents short-circuiting and automatically balances large systems. Straight-through body with solid-state expansion thermostat and setting device. Standard valve type CW 41 with pressure gauge (0 6 bar) and thermometer (30 to +100 C). MCW 41 = CW 41 with diaphragm actuator. (Retro-fitting of diaphragm actuator possible).

Application
L CW 44 L

CW 41 CW 44 CW 41/4 CW 44 k MCW 41

for industrial cooling water for saline fluids, ammoniacal cooling water and chlorinated hydrocarbons (wetted internal parts made from stainless steel) for heavily contaminated cooling systems

Specification*)
P Type CW 41 CW 41/4 CW 44 CW 44 K
1)

Material EN EN-JS 1049 EN-JS 1049 1.0460 1.0460 ASTM 1)


1)

PN [bar] 16 16 25 25 6 6 16 16

Pressure/Temperature p / T 2) 3) PS TS 2) 3) [C] [bar / C] [bar] 16 16 25 25 32 / 110 32 / 110 2 / 110 37 / 85 16 / 110 16 / 110 25 / 110 25 / 85

A 1051) A 1051)


CW 41
2) 3)

ASTM nearest equivalent grade is stated for guidance only. Physical and chemical properties comply with EN. Temperature only admissible for a short time Admissible temperature depends on type of thermostat: type n (standard) 110 C, type w (wax) 100 C, type k (brine) 85 C

*) For more information on pressure/temperature ratings and end connections see data sheets.

Temperature Ratings
Type CW 41 CW 41/4 CW 44 CW 44 K w = wax thermostat n = standard thermostat k = thermostat for brine Thermostat/ cone combination Adjustment range wr or ws 20 C 60 C nr or ns 3 C 100 C kr or ks k r = s = reduced cone for small flowrates standard cone for large flowrates 32 C 74 C 37 C 71 C n 2 C 106 C

MCW 41

62

Cooling-Water Control Valves CW (GESTRAMAT)


End Connections and Overall Lengths
Type End connection DN 10 DN 15 DN 20 CW 41 CW 41/4 CW 44 CW 44 K Flanged EN PN 16 Flanged EN PN 16 Screwed sockets Screwed sockets
3/

Overall length L [mm] DN 25 DN 40 1" 160 160 95 95 11/


2"

DN 50 2" 230 230

DN 80 3" 310 310

DN 100 4" 350 350

8"

1/

2"

3/

4"

95 95

95 95

95 95

200 200

Flowrates (kv values)


Type CW 41 Cone Kvs value [m3/h] Kvo (Preset bleed flow) [m3/h] Kvs value [m3/h] Kvo (Preset bleed flow) [m3/h] DN 25 2.1 0.12 10.5 0.55 G 3/8 0.66 0.04 DN 40, DN 50 DN 80, DN 100 6.5 0.31 31 1.5 G 1/2 0.66 0.04 20 1.0 98 5.0 G1 1.37 0.04 r CW 41/4 s

CW 44 CW 44 K Kvs value [m3/h] Kvo (Preset bleed flow) [m3/h] ]

G 3/4 1.37 0.04

63

A4-A8

Return-Temperature Control Valves BW (KALORIMAT)


Features of the BW series

Direct acting proportional controller for maintaining constant return temperatures. Used for regulating large heating systems and tracing systems, or for the temperature control of individual heat exchangers (washing baths, chemical and galvanic baths). Also suitable for a supply system tailored to the needs of consumers that are installed in parallel. Straight-through valve with balanced valve sleeve. Closing temperature set at our works. Valves with external setting device available on request.

Application
BW 31
L

for hot water for thermal oils

BW 31 A

BW 31, DN1525 mm

Specification*)
Type BW 31 BW 31 BW 31A BW 31A DN 15-25 40 15-25 40 PN 40 25 40 25

P [bar]
6 6 6 6

Material EN 1.0460 1.0460 1.0460 1.0460 ASTM A 1051) A 1051) A 1051) A 1051)

Pressure / Temperature PS TS p/T [bar] [C] [bar / C]


40 25 40 25 400 400 400 400 23.1 / 400 14.4 / 400 23.1 / 400 14.4 / 400

1) ASTM nearest equivalent is stated for guidance only. Physical and chemical properties comply with EN. *) For more information on pressure/temperature ratings and end connections see data sheet.

End Connections and Overall Lengths L


Overall length L [mm] Type
External setting device for BW 31

Connections Flanged EN PN 25 Flanged ASME 150 Screwed sockets

DN 15
1/

DN 20
3/

DN 25 1" 160 160 95 160 160 95

DN 40 11/2" 200 215 130 200 216 130

2"

4"

BW 31

150 150 95 150 150 95

150 150 95 150 150 95

BW 31A

Flanged EN PN 25 Flanged ASME 150 Screwed sockets

Closing temperatures (without external setting device)1)


Adjustable range Type BW 31 BW 31A
1)

DN 15 mm
1/

DN 20 mm
3/

DN 25 mm 1" 40 C - 115 C 100 C - 280 C

DN 40 mm 11/2" 50 C - 110 C 100 C - 270 C

2"

4"

60 C - 130 C 120 C - 270 C

40 C - 115 C 100 C - 280 C

A fixed closing temperature can only be adjusted within the indicated adjustment range in steps of 5 C.

Adjustable closing temperatures (with standard external setting device)


BW 31 BW 31A
External setting device for BW 31A

60 C 130 C 90 C 270 C

40 C 115 C 70 C 270 C

40 C 115 C 70 C 270 C

50 C 110 C 70 C 270 C

Adjustable closing temperatures (with special external setting device)


BW 31 BW 31A 20 C 110 C 60 C 160 C 20 C 90 C 30 C 170 C 20 C 90 C 30 C 170 C 20 C 75 C 25 C 85 C

64

Return-Temperature Control Valves BW KALORIMAT


Capacity Charts
t = temperature difference in Kelvin [K] between closing temperature (temperature at which the valve is closed) and return temperature.

BW 31, DN 15
10000 8000 6000 4000 3000 2000

BW 31, DN 20 and 25
t = 35 K t = 30 K t = 25 K t = 20 K t = 15 K t = 10 K t= 5K

6000 5000 4000 3000 2000

20000

10000 8000 6000 5000 4000 3000 2000


t = 40 K t = 30 K t = 20 K t = 15 K t = 10 K

10000 8000 6000 4000 3000 2000

1000 800 600 500 400 300 200

t= 5K

1000 800 600 500 400 300 200

1000 800 600 500 400 300 200

1000 800
t= 0K

100 80 60 50 40 30 20
F

600 500 400 300 200

100 80 60 50 40

dm eo letr Bls h

ern w m o

dle eg se cloR em rnis ee lls os lo n htr o c c s e n hieg be ew te ag

100 80 60 50 40 30 20
0,1 0,2 0,3 0,4 0,6 0,8 1 2 3 4 5 6

t= 0K

Durchsatz Capacity

10 8

100 80

Durchsatz Capacity

6 5
0,1 0,2 0,3 0,4 0,6 0,8 1 2 3 4 5 6

60 50 40

h FB

w om m do tr le lse

ra ng e

5 6

10

20

30

40 50 60

80 100

5 6

10

20

30

40 50 60

80 100

BW 31, DN 40
50000

25000 20000

t = 30 K t = 25 K t = 20 K t = 15 K t = 10 K

20000

10000 8000 6000 5000 4000 3000 2000

10000 8000 6000 4000 3000 2000

t= 5K

1000 800 600 500 400 300 200


gler se ed cloR is em rn ee lls os tr lo n h o c c s ge e in
t= 0K

1000 800 600 500 400 300 200

100 80 60 50 40 30
0,1 0,2

hls FB

tee ag wern m o om ed letr

e w bh

Durchsatz Capacity

100

0,3 0,4

0,6

0,8 1

5 6

5 6

10

20

30

40 50 60

80 100

65

A4-A8

dg ee R los isecm ollsesren hlo ctr c sn eo n g e i h e teewb

ler

Return-Temperature Control Valves BW KALORIMAT


Capacity Charts
t = temperature difference in Kelvin [K] between closing temperature (temperature at which the valve is closed) and return temperature.

BW 31A, DN 15
10000 8000 6000 4000 3000 2000

BW 31A, DN 20 and 25
t = 70 K t = 60 K t = 50 K t = 35 K t = 30 K t = 20 K

6000 5000 4000 3000 2000

20000

10000 8000 6000 5000 4000 3000

t = 65 K t = 50 K t = 35 K t = 25 K

10000 8000 6000 4000 3000 2000

1000 800 600 500 400 300 200

t = 10 K

2000

t = 15 K t = 10 K

1000 800 600 500 400 300 200

1000 800 600 500 400 300 200


t= 5K

1000 800
t= 0K

100 80 60 50 40 30 20

600 500 400 300 200

100 80 60 50 40

be gew ate rn we om om trd lse Ble Fh

ise rn se se oll trlo nh oc cs ge in he

gle sed cloR m

100 80 60 50
e sllse loo htr cn so nec hieg be te ew a g r n e ow m dm eo letr Bls h

t= 0K

dler eg se R clo em rnis

100

Durchsatz Capacity

Durchsatz Capacity

10 8 6 5
0,1 0,2 0,3 0,4 0,6 0,8 1 2 3 4 5 6

80 60 50 40

40 30 20
0,1 0,2
F

0,3 0,4

0,6

0,8 1

5 6

5 6

10

20

30

40 50 60

80 100

5 6

10

20

30

40 50 60

80 100

BW 31A, DN 40
50000

25000 20000

t = 85 K t = 70 K t = 60 K t = 50 K t = 40 K t = 30 K t = 20 K t = 15 K t = 10 K

20000

10000 8000 6000 5000 4000 3000 2000

10000 8000 6000 4000 3000 2000

t= 5K

1000 800 600 500 400 300 200


s tro nlo oh cc es gn ie eh w eb gte ra w en o m dm o le tre ls hB le gd ee Rs clo ism ne ll ser r
t= 0K

1000 800 600 500 400 300 200

100 80 60 50 40 30
0,1 0,2
F

Durchsatz Capacity

100

0,3 0,4

0,6

0,8 1

5 6

5 6

10

20

30

40 50 60

80 100

66

Self-Acting Pressure Control Pressure Reducing Valve 5801


Application
L Type 5801 Pressure-reducing valve for use with steam and other fluids. In all energy and process systems.

Design
The pressure-reducing valve is a balanced single-seat proportional controller operating without auxiliary energy. The pressure-reducing valve consists of a body with internals, bellows, spring, handwheel and actuator. For steam and liquids at temperatures above 100 C a water-seal pot is required to protect the actuator diaphragm. H

Dimensions [mm] and Weights [kg] of Valve Body


DN 15 20 25 32 40 50 65 80 L H Weight 1.0619 Weight 1.4581 130 390 150 390 160 390 180 408 200 425 230 500 290 505 310 590 100 350 590 125 400 705 150 480 725 112 115 200 600 760 170 176

Weight 0.7043 7 8 9 12 14 18 26 40 50 77

h1 A
Pressure-reducing valve 5801

7 8 9 12 14 19 27 40 54 82

Actuator A h1
G 3/8"

A11 150 90 2.8

A2 160 100 4.5

A3 195 100 6.0

A4 270 120 4.5

A51 355 165 10

A61 510 200 27.5

B11 150 90 3.5

B2 160 110 5.5

Approx. weight
17.2 x 2.6

Dimensions [mm] and Weights [kg] of Water Pot Seal


G 1/8"

l
Water-seal pot

Size 1 2 3

l 172 250

Size DN

Weight 1.7 3.5 4.9

206 88.9 15 65 152.4 80 100 152.4 125 200

min. 1m min. 10 x D

Schematic Representation of a Compact-Design Pressure Reducing Station 9 5 8 7 4 9

Water-seal pot Strainer Sensing line 8 x 1.0 mm Pessure-reducing valve Sensing line connection

Schematic installation diagram

1 Pressure-reducing valve 5801 2 Steam drier and purifier TD 3 Float trap UNA 4 Safety valve GSV 5, 6, 7 Isolating valves GAV 8 Strainer GSF 9 Pressure gauge

67

A4-A8

Dimensions [mm] and Weights [kg] of Actuator

Self-Acting Pressure Control Pressure-Maintaining Valve 5610


Application
Type 5610 Pressure-maintaining valve for maintaining upstream pressures independent of downstream pressures for use with steam, gases and liquids.

Design
The pressure-maintaining valve is a self-acting proportional controller with single-seat and balanced valve. The pressure-maintaining valve consists of a body with internals, bellows, spring, handwheel and actuator. For steam and liquids at temperatures above 100 C a water-seal pot is required to protect the actuator diaphragm. H

Dimensions [mm] and Weights [kg] of Valve Body


DN 15 20 25 32 40 50 65 80 L H 130 405 150 405 160 405 180 410 200 425 230 495 290 500 310 590 100 350 590

Approx. weight 10 11 12 14 18 23 35 48 70

h1

Dimensions [mm] and Weights [kg] of Actuator


A
Pressure-maintaining valve 5610

Actuator A h1 Approx. weight

A11 150 90 2.8

A2 160 100 4.5

A3 195 100 6.0

A4 270 120 4.5

A51 355 165 10

B11 150 90 3.5

B2 160 110 5.5

G 8"
3/

17.2 x 2.6

Dimensions [mm] and Weights [kg] of Water-Seal Pot


Size 1 2 l 172 d Size DN Weight 1.7 4.9

G 8"
1/

l
Water-seal pot

206 88.9 15 65 152.4 80 100

min. 1m

Diagrammatic layout of pressure-maintaining control unit with flash-vessel

Strainer

Sensing line connection

Waterseal pot

Sensing line 8 x 1.0 mm

Pressure-maintaining valve

Schematic installation diagram

68

Self-Acting Temperature Controllers System Clorius


Application
Temperature control in heating and cooling processes in industrial plants, for h.v.a.c services and marine engineering. For liquids, gases, vapours.

Valves
Two-way valves, with single seat or pressure-balanced single/double seat. Double-seated, two-way reverse-acting valves or three-way valves for diverting and mixing applications. Valve components made of gunmetal, cast iron, nodular cast iron or cast steel, with flanged or screwed connections.

Design
Valve

Thermostat

Sensor

Examples of Industrial Process Applications


Hot water supply

Heating steam

Two-way valve with safety thermostat

Hot water return

Condensate

Heat exchanger with constant flow-temperature of the secondary circuit controlled on the steam side

Inlet

Cooler

Outlet

Cooling water return

Cooling-water return control for constant cooling-water return temperatures

69

A4-A8

The self-acting temperature controller consists of a valve featuring a thermostat and a sensor. According to the service conditions the controller is optionally equipped with a cooling unit, a sensor pocket or a safety thermostat. The temperature sensed by the sensor changes the volume of the measuring liquid in the capillary tube. The resulting pressure acts directly on the actuating piston which, in turn, operates the valve spindle. As the temperature rises, the regulating valve is held in closed positon (heating process) or open position (cooling process) until the pre-set release temperature is reached. When the temperature drops again, a builtin return spring resets the valve to original position.

Thermostat
The thermostat is firmly attached to the sensor capillary tube. The rod-, spiral- or airduct-type sensors are made of copper or high-alloy stainless steel. The capillary tube is available in different lengths, made of copper, high-alloy stainless steel or with PVC coating. Special designs: Duostat double-thermostat with two sensors Safety thermostat SH 4S.

Self-Acting Temperature Controllers System Clorius


Dimensions [mm] and Weights [kg] for Valves and Thermostats
Valve type DN 15 20 25 32 40 50 65 80 G L L M 1F
H1

100

125

150

130

150

1 160

1 180 105

1 200 110

2 230 125
27 50

H1 80 85 95 G 1F
G1 H2

H2 60 65 70 75 85 95 H 1F M1F/G1F kg H1F kg 3.1 3.4 4.2 4.6 5.5 6.1 160 180 6.0 6.0 6.0 8.1 9.7 14.7 9.0 180 195 9.0 9.0 9.0 10.8 15.5 200 205 230 225 290 260 110 310 275 115
1" 100 50 275

L L M 1 FB

H G 1 FB
H1 G1 H H1

H 1 FB H1 70 75 85 95 M1FB kg G1FB kg H1FB kg

13.0 16.0 23.0 38.0 13.0 16.0 13.0 16.0 23.0 38.0

L L 1S

L 75 87 99
Safety temperature limiter SH 4 S

H 65 67 67 H1 20 23 25 kg
L H1 H

0.7

0.8 90 82 1

1.1 100 80 1 113 82 1.6 113 129 118 2.9 129 153 122 71 3.8 153

L L 2S H kg
H

H1 48 53 58 68
L L 75 87 99 L 2 SR H1

H 43 45 50 55 65 70 H1 80 80 80 80 90 94 kg G1
G1 H1 H

1.0

1.0 150 112 5.0

1.0 160 117 6.5

1.5 180 151 9.0

3.0 200 155

4.0 230 163 290 110 180 310 155 195 350 145 240 400 160 260 400 180 293

L G 2 FR H2 H 2 FR kg L Thermostats K = sensor of copper N =sensor of high alloy S.S. Adjusting cylinder A B


H2

H1 63 70 75 85 95 M 2 FR

11.0 16.0 21.0 35.0 39.0 75.0 77.0 Type V 4.05 K 385 525 N 385 525 Type V 4.10 K 385 525 N 385 525 Type V 8.09 K 560 740 N Type V 8.18 K N 560 740

Type V 2.05 K 305 405 N 305 405

Type V 4.03 K 385 525 N 385 525

560 740

Rod- and spiral-type C sensor with BSP connection D

210 235

190 170

210 235

190 170

390 235

380 250

490 325

515 325

710 425

745 435

800 810

E 22 22 22 22 22 22 28 25 28 25 34 E 30 F F 49 49 49 49 49 49 49 49 49 49 49 G
C
3/

3/

1 2" 2.4 2.9

1 2" 2.4 2.9

1 2" 2.6 3.1

1 2" 2.6 3.1

1 2" 3.3 3.8

1 2" 3.3 3.8

2 2" 6.3 6.3

2 2" 6.3 6.3

2 2" 7.3 7.3

H kg G
H

2" 1.8 2.3

2" 1.8 2.3

kg

70

310

Self-Acting Temperature Controllers System Clorius


Closing Pressure Ratings for Valves and Sensors
Single-seated regulating valves with flanged ends and rod-type copper sensor with copper capillary tube (3 m)

pmax for sensor type Fluid: saturated steam Type M1F, G1F, H1F DN [mm] kvs value 2.05 4.05 4.10 8.09 15/6 0.45 21 40 15/9 0.95 13 38 15/12 1.7 9.3 24 15 2.75 5.3 15 20 5 1.9 6.7 16 25 7.5 0.9 4.1 10 32 12.5 1.9 5.8 40 20 0.8 3.5 50 30 2.3 65 50 80 80

Balanced, single-seated regulating valves with flanged ends and rod-type copper sensor with copper capillary tube (3 m)

pmax for sensor type Fluid: saturated steam Type M1FB, G1FB, H1FB DN [mm] kvs value 15/6 0.45 15/9 0.95 15/12 1.7 15 2.75 20 5 25 7.5 15 32 12.5 12 14 40 20 8.1 11 50 30 5.7 8.7 65 50 6.4 80 80 4.3

4.05 4.10 8.09 8.18

Single-seated regulating valves with screwed end connection and rod-type copper sensor capillary tube (3 m)

pmax for sensor type Fluid: saturated steam Type L 1S BSP kvs value 2.05 4.05 4.10
1/

2/

1/

2/

1/

2/

12

1/

3/

1 7.5 4.7

0.45 16 16

0.95 11 16

1.7

2.75 4.9 13

5 2.4 7.7

Double-seated regulating valves with screwed connection and rod-type copper sensor with copper capillary tube (3 m)

pmax for sensor type Fluid: water < 120 C Type L 2S BSP kvs value 2.05 4.10
1/

2/

1/

2/

1/

2/

12

1/

3/

1 7.5 40

11/4 12.5 7.8 25

11/2 20 21

2 30 14

0.45

0.95

1.7

2.75

5 40

Double-seated reverse-acting valve with screwed connection and rod-type copper sensor with copper capillary tube (3 m)

pmax for sensor type Fluid: water < 120 C Type L2SR BSP kvs value 2.05 4.05 4.10
1/

3/

1 7.5 7.1 7.1

11/4 12.5 4.6 4.6

11/2 20 2.7

2 30 1.8

2.75 15 15

5 11 11

Double-seated reverse-acting valve with flanged ends and rod-type copper sensor with copper capillary tube (3 m)

pmax for sensor type Fluid: water < 120 C Tye M2FR, G2FR, H2FR DN [mm] kvs value 2.05 4.05 4.10 8.09 8.10 20 5 8.3 8.3 25 7.5 8 8 32 12.5 7 40 20 6.6 50 30 5.3 65 50 10 80 80 6.7 100 125 12.1 12.1 125 215 9 150 310 7.5

Three-way valves available on request.

71

A4-A8

Control Valves with Electric and Pneumatic Actuators


Applications
Type V 725 Control of liquids, gases and steam up to 250 C. Ultra-compact pneumatic design thanks to directly attached positioner.

Max. Differential Pressure Ratings [bar] for Actuator Sizing


kvs DN
[mm]

Lift
[mm]

Pneumatic actuator
IP-127 FS1) IP-252 FS1) IP-502 FS1) IP-700 FS1)

Electric actuator
AP-102 AP-204 AP-208

(m3/h)

0.63
H2

40 40 15, 20, 25 40 40 40 15 20, 25, 32 20 25, 32, 40 25 32, 40, 50 32 40, 50 40 50 50 65 65,80 65 80, 100 80 100 100 40 20 40 40 40 40 35 35 17 17 12 10 6

40 40 40 40 40 40 40 40 40 40 40 40 40 31 28 19 40 38 23 23 15 14 9 40 40 34 34 23 21 14

40 40 40 40 40 40 40 40 40 32 32 15 15 10 9 6

40 40 40 40 40 40 40 40 40 40 40 40 40 30 27 18 27 16 9 9 6 5 3 40 32 19 19 13 11 8

1 1.6 2.5 4 5.6 6.3 8 10 14 16 22.4 25 31.5 40


L

47.5 40 63 80 100 125 160 180

Pneumatic actuators with spring range 2.0 4.8 bar. Other ranges on request. Max. differential pressure for control valves with PTFE rings. 1) Standard version spring to close, spring to open available on request.
H1

Dimensions [mm] and Weights [kg]



Length L H1
L

DN 15 20 25 32 40 50 65 80 D 130 355 362 508 508 150 355 362 508 508 198 265 352 405 177 177 177 Lift 20 mm 160 355 362 508 508 180 356 363 525 525 200 356 363 525 525 230 361 368 578 578 290 536 647 631 669 Lift 40 mm 310 536 647 631 669

100 350 539 650 635 673

IP-127 IP-252 IP-502 IP-700 AP-102 AP-204 AP-208

H2 Weight

IP-127 13 13 15 18 20 24 IP-252 17 18 19 23 24 28 IP-502 IP-700

57 65 79 72 77 93

AP-102 10 11 12 15 17 21 AP-208

AP-204 10 11 12 16 17 22 37 44 58 39 46 60

72

Control Valves ZK with Radial Stage Nozzle


Application
For the decrease of high pressure drops in industrial plants and power stations as:
Level

Features
Extremely Excellent

wear resistant

control valve valve control valve cooling valve control valve valve pot drain valve

sealing and control characteristic (EN 12266-1 leakage rate A)

Warm-up Level

Variable valve characteristics (linear and equal-percentage) Easy

Injection

Feedwater Leak-off Start-up And

assembly and inspection of nozzle insert shut-off for ZK 313 and ZK 213 sound level actuators available

Tandem Low

more applications

Different

Materials
Type ZK 29, DN 25, 50 ZK 29, DN 80, 100, 150
ZK 29/14 DN 50 with lift restriction (optional extra)

Body 1) 13 CrMo 4 4 GS-17 CrMo 5 5 13 CrMo 4 4 16 Mo 3 16 Mo 3 10 CrMo 9 10 X 10 CrMo VNb 9 1 (1.7335) / A182 F12 (1.7357) / A 217 WC6 (1.7335) / A 182 F12 (1.5415) (1.7383) / A182 F22 (1.4903) / A182 F91 (1.5415) (1.6368) (1.5423) / A182 F1

ZK 210 ZK 313

ZK 213 / 610 / 613


1)

16 Mo 3 WB 36

Butt-weld ends of other material by welding of pipe ends possible.

Actuators
Type Handwheel Electric rotary actuator Electric linear actuator
Radial stage nozzle with tandem shut-off for ZK 213

ZK 29

ZK 210

ZK 313

ZK 213

ZK 610 ZK 613

Electro-hydraulic linear actuator Pneumatic actuator Part-turn actuator

Controls
Complete PLC-based controls for applications such as injection cooler, leak-off valve etc. designed and manufactured according to customers' specifications.

73

A4-A8

Control Valves ZK with Radial Stage Nozzle


Technical Data
Kvs-values [m3/h] (linear characteristics), design, pressure/temperature ratings
ZK 29
DN 25 50 65 80 100 125 150 200 250 300 350 400 0.7 3 14 20 70 p 100 bar 1.4 6 21 33 100 2.1 9 28 46 130

ZK 210 Straight-through / angle


DN 25 50 65 80 100 125 150 200 250 300 350 400 0.8 3.3 9.5 p 100 bar 1.5 6.5 18 2.3 10 28 p 180 bar 0.5 2 5

ZK 412
DN p 100 bar p 180 bar Absperrventil 25 50 65 80 100 125 150 200 250 300 350 400 1 1.5 4 6 2 8 0.5 2 13 16

1.7335 / A 182 F12 1.7357 / A 217 WC6

p [bar] t [C]

Durchgang / Eck ZK 210


DN p 100 bar 2.3 10 28 p 180 bar 0.5 2 5 25 0.8 1.5 50 3.3 6.5 65 ZK 80 313 9.5 18 100 p 300 bar DN 125 t 150 25 200 1 1,5 50 250 1 65 300 1 1,5 80 350 100 400 125 Durchgang / Eck 150 200 ZK 213 sizes 1-5 250 300 DN p 300 bar 350 1 2 3 4 Bg. 400 25 Durchgang / Eck 50 65 80 13 100 13 26 125 13 26 39 150 26 39 60 200 39 60 250 60 300 350 400
p [bar] p [bar]

Durchgang / Eck ZK 412 Straight-through / angle


DN p 100 bar p 180 bar Absperrventil 25 1 1.5 2 0.5 50 4 6 8 2 65 ZK 513 80 100 DN p 560 bar 125 2 3 Bg. 1 150 25 200 50 3 5 250 65 3 5 9 300 80 3 5 9 12 350 100 5 9 12 t20 [C] 400 125 9 12 30 Durchgang / Eck 150 200 250 Angle / Z pattern 300 350 400
p [bar]

Durchgang / Eck

13 16
p [bar]

ZK 213
p 300 bar 2 3 4 5 p 560 bar 1 2 3 4 5

p 370 bar 9,5

DN Bg. 1

11 9,5 11 14,5 17 9,5 11 14,5 17 9,5

p 560 bar 5 1 2 3 4 5

25 50 65 80 13 10 100 13 26 10 20 125 13 26 39 10 20 30 150 26 39 60 20 30 46 200 39 60 90 30 46 70 250 60 90 46 70 300 90 70 350 400

Eck
10 10 20 10 20 30 20 30 46 90 30 46 70 90 46 70 90 70

Eck
p [bar]

p [bar]

Eck / Z-Form

p [bar]

p [bar]

p [bar]

t [C]

Eck / Z-Form

Nennweitenanpassung ist mglich possible Adaptation of nominal sizes is

p [bar]

74

p [bar]

Control Valves ZK with Radial Stage Nozzle


Technical Data
Kvs-values [m3/h] (linear characteristics), design, pressure/temperature ratings

ZK 313
DN
25 50 65 80 100 125 150 200 250 300 350 400

Straight-through / angle DN 25 80
p 370 bar
2.3 2.3 2.3 2.3 3.6 3.6 3.6 3.6 5.5 5.5 5.5 5.5 8 8 8 11 11 11 13 13 13 17 17 17 4.5 4.5 4.5 4.5 4.5 4.5 9.5 9.5 9.5 9.5 9.5 9.5

Angle / Z pattern up to DN80


1.4903 / A182 F91

p 300 bar
1 1 1 1 1.5 1.5 1.5 1.5

750 1.7383 / A182 F22 600 450 300 150 0 0 t [C] 100 200 300 400 500 600 650 1.5415 / A182 F1

11 14.5 11 14.5 11 14.5

p [bar]

Throttle variants ZK 313

Standard throttle pmax 300 bar

Special throttle pmax 40 bar (without tandem nozzle)

Special throttle pmax 370 bar (only angle-type)

75

A4-A8

Control Valves ZK with Radial Stage Nozzle ZK Range 600


Application
For large flowrates; used as Feedwater control valve Heating steam valve Start-up vessel drain valve
Extremely Valve

Features
Excellent

sealing and control characteristics

wear resistant designed on modular assembly principle Low sound level Easy assembly and inspection of nozzle insert Variable valve characteristics (linear and equal-percentage) kvs range from 18 to 969 m3/h Leakage-free pressure-balanced design

Technical Data
Max. kvs values [m3/h], designs, pressure/temperature ratings

ZK 610 / ZK 613 Angle / Z pattern


p (bar) DN 100
2-stage expansion with balanced pressure for ZK613

40 1-stage 44 98 71 154 112 243 177 385 281 611 446 969

80 2-stage 38 54 61 85 95 134 150 212 238 336 378 533

120 3-stage 33 47 51 74 81 117 128 185 216 294 322 465

150 4-stage 14 19 22 31 35 48 55 76 86 121 137 191

> 150 5-stage 13 18 20 29 32 46 50 73 78 116 125 184

125 150 200 250 300

ZK 610 Angle / Z pattern

600 480 360 240 120 0 0 t [C] 100 1.5415 1.7383

Throttling unit A1/ A2 with 4-stage expansion

p [bar]

200

300

400

500

600

ZK 613 Angle / Z pattern

600 480 360 240 120 0 0 t [C] 100 200 300 400 500 600 1.5415 1.7383

76

p [bar]

Safety Valves GSV

Application
For use with steam, liquids, and non-corrosive gases and vapours.
X

Dimensions [mm] and Weights [kg]


DN1 x DN2
H

20 x 32

25 x 40 100 105 233 234 150 4414

32 x 50 110 115 325 331 200

40 x 65 115 140 366 372 250

50 x 80 120 150 413 419 300

65 x100 80 x125 100 x150 125x200 150x250 60 74 92 98 140 170 526 529 350 160 195 603 606 400 180 220 660 663 450 200 250 660 663 450 125 225 285 735 735 450 131

d0 18 23 29 37 46 l 95 l1 H 1) H 2) X 85 215 150
2)


1)

Weight 9 9 12 16 22 32 56 75 85 4421, 4425, 4422

D2

DN2

Discharge Capacities for Saturated Steam [kg/h]


d0

Set pressure [bar] 0.2 0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 12.0 14.0 16.0 18.0 20.0 22.0 24.0 26.0 28.0 30.0 32.0

l1

DN 20 85 134 198 317 427 533 638 743 845 949 1053 1157 1365 1568 1775 1983 2191 2392 2600 2809 3018 3228 3439

DN 25 139 219 324 517 697 870 1041 1213 1380 1550 1719 1889 2228 2560 2898 3237 3577 3906 4246 4586 4928 5271 5615

DN 32 222 348 515 822 1108 1382 1656 1928 2193 2464 2733 3003 3542 4070 4608 5147 5686 6209 6750 7291 7835 8379 8926

DN 40 361 566 839 1339 1804 2250 2695 3138 3570 4010 4450 4889 5766 6625 7501 8378 9256 10107 10987 11869 12753 13640 14530

DN50 558 875 1296 2069 2788 3478 4165 4850 5518 6198 6878 7556 8913 10241 11594 12949 14306 15623 16982 18345 19712 21083 22459

DN 65 949 1489 2205 3520 4744 5918 7087 8252 9388 10545 11701 12856 15163 17423 19725 22030 24339 26579 28892 31211 33537 35869 38210

DN 80 1444 2265 3355 5355 7216 9002 10780 12552 14281 16041 17799 19555 23065 26502 30004 33510 37023 40430 43948 47475 51013 54561 58121

DN 100 2232 3502 5185 8277 11153 13913 16662 19401 22073 24794 27510 30225 35650 40962 46376 51795 57224 62491 67928 73380 78848 84333 89835

DN 125

DN 150

2532 4120 3973 5883 9392 12655 15787 18906 22014 25046 28133 31216 34296 40452 46479 52622 58772 6464 9572 15280 20589 25685 30758 35815 40748 45770 50786 55797 65812 75619 85612 95617

DN1 D1 l

Safety valve GSV

64932 105639 70907 115361 77078 125399

Calculation according to DIN 3320 and AD Bulletin A2, TRD 421. For discharge capacities for other set pressure ratings or fluids see data sheet.

77

A4-A8

Strainers GSF

Application
In piping systems upstream of equipment that is sensitive to dirt. For liquids, gases, steam and aggressive fluids.

Dimensions [mm] and Weights [kg] for Y-Type Strainers with Flanged Connections PN 6 - 40
Nominal size
Overall length
DN L 15 130 103 118 60 81 20 19 52 52 20 150 120 125 72 85 25 25 62 56 0.6 2.2 2.8 2.8 3.8 3.8 25 160 140 130 83 100 29 29 74 57 0.6 2.8 3.5 3.5 4.7 4.7 32 180 150 146 91 100 38 37 77 67 0.6 4 5.4 5.4 6.5 6.5 40 200 190 168 113 120 50 45 97 95 0.6 5.5 6.9 6.9 8.3 8.3 50 230 215 177 128 133 60 55 112 65 290 315 330 185 200 65 70 172 80 310 355 340 205 210 80 85 193 100 350 435 410 265 250 95 105 222 125 400 475 516 285 313 150 480 548 600 326 362 200 600 660 790 405 475 250 300 730 880 940 515 530 850 1100 1050 610 640

H1

DN
B

Overall height GSF 301, 303, 321, 322 H Overall height GSF 312, 319, 320
H

Overall height GSF 301, 303, 321, 322 H1 Overall height GSF 312, 319, 320
H1

Strainer series 300 and 310 with flanged connections GSF 301, PN 6, EN-JL 1040 GSF 303, PN 16, EN-JL 1040 GSF 321, PN 16, EN-JS 1049 GSF 322, PN 25, EN-JS 1049 GSF 319, PN 10/16, 1.4408 GSF 320, PN 25/40, 14408

Screen Screen

GSF 301, 303, 321, 322 S GSF 312, 319, 320 S

110 131.5 180 255.5 307.5 130 243 157 287 207 255.5 280 332 510 620

Screen length GSF 301, 303, 321, 322 B Screen length GSF 312, 319, 320 Mesh size Weight Weight Weight Weight Weight Plug GSF 301 GSF 303, GSF 321 GSF 322 GSF 319 GSF 312, 320 B

102 178.5 182.5 226.5 286.5 339.5 454.5 510 0.6 6.9 9.6 9.6 11.8 11.8 1.2 13.3 15.7 15.7 16.1 16.1 1.2 20.2 21.8 21.8 22 22.5 1.2 30.1 33.5 34 28 30.3 1.2 41.2 44.8 47.3 46 48 1.5 60.3 63.8 69.2 65.2 70 1.5 106 121 121 125 1.5 165 171 195 156 1.5 243 250 280 275 385

mm 0.6 1.5 1.9 1.9 2.6 2.6

134.2 178 G1

without plug

G 1/2

Application
In piping systems upstream of equipment that is sensitive to dirt. For liquids, gases, steam and aggressive fluids.

H1

Dimensions [mm] and Weights [kg] of Y-Type Strainers with Screwed Connections
Nominal size Overall height GSF 331 GSF 332, 333, 335, 337 GSF 334, 338 GSF 331 GSF 331 GSF 332, 333, 335, 337 GSF 332, 333, 335, 337 GSF 334, 338 GSF 334, 338 GSF 331 GSF 332, 333, 335, 337 GSF 334, 338 Overall height Overall height Overall height Overall height Overall height Overall height Overall height Overall height Mesh size Weight Weight Weight G L L L H1 H H1 H H1 H
3/

1/

3/

10 100 90 135 66 111 70 112 85 140 0.5 1.1 0.8 2.2

11/4 120 110 150 73 118 80 130 95 155 0.5 1.4 1.2 3.6

11/2 140 120 150 86 141 85 140 95 155 0.5 2.1 1.4 3.15

20 180 150 200 97 157 105 165 115 175 0.5 3.5 2.5 6.45

80 65 100 50 75 48 78 60 95 0,5 0.45 0.35 0.95

80 65 100 50 75 48 78 60 95 0.5 0.45 0.3 0.95

95 75 135 63 93 58 95 85 140 0.5 0.6 0.5 2.3

Y-type strainer with screwed connections series 330 GSF 331, PN 16, EN-JL 1040 GSF 332, PN 16, GP240GH GSF 333, PN 40, GP240GH GSF 334, PN100/160,GP240GH GSF 335, PN 40, CuZn39Pb3 GSF 337, PN 40, 1.4408 GSF 338, PN 100/160, 1.4408

78

Strainers SZ

Features
Cylindrical Robust, Body

body with drain plug

hemispherical screen pressure loss

and strainer made from corrosion-resistant stainless steel

Minimum

Application
In piping systems upstream of equipment that is sensitive to dirt. For liquids, gases, steam and aggressive fluids.

Dimensions [mm] and Weights [kg] for Wafer-Type Strainers


L
Wafer-type strainers SZ 36A DN 40 100 mm

Types SZ 36A

Nominal size Overall length


[mm]

[mm] [Inch] L Zmin Zmax Class 125/150 PN 10/16

40 11/2 31,5 83 104 1

50 2 40 96 118 1.6

65 21/2 46 110 136 2.1

80 3 50 128 158 2.9

100 4 60 151 186 4.7

125 5 90 194 194 194 194 216 10

150 6 106 220 220 226 226 251 14

200 8 140 275 286 293 308 26 275

Z min
D

PN 25 PN 40 Class 300

Weight

[kg]

Pressure/Temperature Ratings *)
Material

Zmax
Wafer-type strainers SZ 36A DN 40 100 mm

Type SZ 36A
*)

PN PN 40 / class 300

EN 1.4408

ASTM A351 CF8M

PS [bar] 49.6

Pressure / temperature TS p/T [C] [bar / C] 200 / 550 24 / 550

For more detailled pressure/temperature specifications as a function of the end connection refer to the data sheet.

Design
DN 40 100: Body with centering cams suitable for sandwiching between flanges PN 6-40. DN 50, 80 and 100 also suitable for flanges class 150 / 300. Standard strainer, mesh size 1.25 mm DN 125 200: Cylindrical body Standard strainer, mesh size 1.6 mm optional DN 40 200: Fine screen mesh size 0.25 mm

Wafer-type strainers SZ 36A DN 125 200 mm

79

A4-A8

Stop Valves GAV

Description
Straight-through bellows-sealed stop valve with flanges to EN 1092. The valve is designed for shutting off and throttling neutral gases, vapours and liquids in all sectors of industry.

Material
Type GAV 54F GAV 56F GAV 24F GAV 25F GAV 35F GAV 36F GAV 46F L1 DN 15 300 15 50 15 300 15 150 200 300 65 150 15 125 PN 16 40 16 25 25 40 40 EN GJL-250 GP240GH+N GJS-400-18-LT GJS-400-18-LT GP240GH+N GP240GH+N 1.4408 ASTM*) A48-40B A216WCB A536-60-40-18 A536-60-40-18 A216WCB A216WCB A351CF8M H1

*) ASTM nearest equivalent is stated for guidance only. Physical and chemical properties comply with EN.

Specification
Type GAV 54F GAV 56F GAV 24F GAV 25F GAV 35F GAV 36F GAV 46F PN 16 40 16 25 25 40 40 Material GJL-250 GP240GH+N GJS-400-18-LT GJS-400-18-LT GP240GH+N P250GH/GP240GH+N 1.4408 20 16.0 40.0 16.0 25.0 25.0 40.0 40.0 200 12.8 35.0 14.7 23.0 22.0 35.0 31.8
Temperature p / T (bar / C) 250 300 350 11.2 9.6 32.0 28.0 24.0 13.9 12.8 11.2 21.8 20.0 17.5 20.0 17.0 16.0 32.0 28.0 24.0 29.9 27.6 26.4

Bellows-sealed stop valve GAV...F with safety stuffing box

400 21.0 13.0 21.0 25.7

450 13.0 8.0 13.0

*) ASTM nearest equivalent is stated for guidance only. Physical and chemical properties comply with EN.

Dimensions [mm]
PN 16 40 flanged ends Overall length GAV 54F GAV 56F GAV 24F, GAV 25F GAV 35F, GAV 36F GAV 46F DN L1 H1 H1 H1 H1 H1 15 130 175 203 211 140 230 20 150 178 203 214 165 230 25 160 184 209 220 165 240 32 180 205 210 238 190 285 40 200 210 226 243 200 290 50 230 235 230 266 220 300 65 290 246 290 270 355 80 310 282 324 305 485 100 350 304 348 345 485 125 400 390 460 395 485 150 480 408 479 430 200 600 570 570 500 250 730 606 606 705 300 850 660 660 785

Weights [kg]
PN 16 40 flanged ends GAV 54F GAV 56F GAV 24F GAV 25F GAV 35F GAV 36F GAV 46F DN 15 3.1 4.6 3.1 3.1 3.8 6 20 4 4.9 4.1 4.1 4.6 8 25 4.7 6.5 4.7 4.7 5.2 8 32 7.3 7.5 8.1 8.2 9.4 12 40 7.7 11 8.5 8.5 10.6 14 50 10.2 13 11 11 13.6 17 65 80 100 17 22 32 17 21 31 17 28.9 400 22 33 46 25 37 54 125 54 51 65 67 83 150 70.5 68.5 89 98 200 130 139 169 175 250 230 239 270 300 300 328 343 385 430

If the following differential pressures are exceeded in valves with standard plug, a pressure balance plug is required.

Pressure balance plug


DN 65 GAV 54F, GAV 24F GAV 25F GAV 35F, GAV 36F Dp bar Dp bar Dp bar for valves with parabolic plug DN 15 GAV 54F GAV 56F GAV 24F, GAV 25F GAV 35F, GAV 36F GAV 46F PN 16, 25 PN 40 PN 16, 25 PN 25, 40 PN 40 4.8 4.8 4.8 4.8 20 8.3 7.3 8.3 7.3 25 11.9 12.0 11.9 9.6 32 19.9 19.0 19.9 17.8 40 27.1 30.0 27.1 27.3 50 43 45.0 43 40 65 80 100 125 150 200 250 300 1028 1028 860 75 117 172.3 171 204 457 714 75 117 172.3 171 204 457 714 61 78 105 130 210 350 570 70 111 172 264 80 100 125 150 200 250 300 33 21 21 12 12 14 9 9 9 6 6 6

Kvs Values [m3/h]

80

Stop Valves GAV

Description
Straight-through stuffing-box sealed stop valve with flanges to EN 1092 or butt-weld ends (BW) to EN 12627. The valve is designed for shutting off and throttling neutral gases, vapours and liquids in all sectors of industry.

Material
Type GAV 35 GAV 36 GAV 36 GAV 126 GAV 130 GAV 136 GAV 136 GAV 136SE GAV 136SE Up to 550 C GAV 126 GAV 130 GAV 136 GAV 136 GAV 136SE GAV 136SE DN 200 300 15 40 50 150 50 200 50 200 15 25 32 200 15 50 65 200 50 200 50 200 15 25 50 200 15 50 65 200 PN 25 40 40 63 100 160 160 160 160 63 100 160 160 160 160 EN GP240GH+N P250GH GP240GH+N GP240GH+N GP240GH+N P250GH GP240GH+N 16MO3 GP240GH+N G17CrMo5-5 G17CrMo5-5 13CrMo4-5 G17CrMo5-5 13CrMo4-5 G17CrMo5-5 ASTM*) A216WCB A105 A216WCB A216WCB A216WCB A105 A216WCB A182F1 A216WCB A217WC6 A217WC6 A182F11 A217WC6 A182F11 A217WC6 H1

L1
Stuffing-box sealed stop valve GAV...

*) ASTM nearest equivalent is stated for guidance only. Physical and chemical properties comply with EN.

Specification
GAV 35F GAV 36F GAV 126 GAV 130 GAV 136, GAV 136SE GAV 136SE GAV 126 GAV 130 GAV 136, GAV 136SE

25 40 63 100 160 160 63 100 160

GP240GH+N P250GH/GP240GH+N GP240GH+N GP240GH+N P250GH / GP240GH+N 16MO3 G17Cro5-5 G17Cro5-5 13CrMo4-5 / G17Cro5-5

20 25 40 63 100 160 160 63 100 160

550 8 13 14 21 35

Dimensions [mm]
PN 25 40 flanged ends Overall length GAV 35, GAV 36 PN 63 160 flanged ends Overall length GAV 126, GAV 130, GAV 136 PN 63 160 butt-weld ends Overall length GAV 136SE DN L1 H1 DN L1 H1 DN L1 H1 15 130 220 15 210 230 15 150 230 20 150 230 20 230 230 20 150 230 20 5.5 11 20 7.5 25 160 230 25 230 230 25 160 230 25 6.2 12.5 25 8.5 32 180 280 32 260 310 32 180 310 32 9.6 16.5 32 11 40 200 285 40 260 310 40 210 310 40 10.5 20.5 40 13.5 50 230 300 50 300 315 50 250 315 50 13.5 25 26 26 50 17 65 290 348 65 340 415 65 420 415 65 21.3 40 45 45 65 30 80 310 405 80 380 500 80 460 500 80 33.3 55 58 60 80 45 100 350 457 100 430 550 100 510 550 100 46 85 88 90 100 72 125 400 515 125 500 620 125 600 620 125 68 125 135 135 125 110 150 480 540 150 550 625 150 650 625 150 95 150 170 175 150 165 200 600 680 200 650 855 200 750 855 200 159 175 260 285 320 200 215 250 730 810 250 250 250 240 280 250 300 850 965 300 300 300 390 425 300

Gewichte [kg]
PN 25 40 flanged ends GAV 35 GAV 36 GAV 126 GAV 130 GAV 136 PN 63 160 butt-weld ends GAV 136SE

DN 15 4.3 9.5 DN 15 6.5

If the following differential pressures are exceeded in valves with standard plug, a pressure balance plug is required.

Pressure balance plug

GAV 35, GAV 36 GAV 126, GAV 130, GAV 136, GAV 136SE

DN 65 80 100 125 150 200 250 300 33 21 14 4 6 Dp bar 110 70 44 33 21 14

Kvs Values [m3/h]


GAV 35, GAV 36 GAV 126, GAV 130, GAV 136

for valves with parabolic plug DN 15 20 25 3.4 5.6 8.5 PN 40 PN 63, 100, 2.7 4 5 160 32 18 16 40 28 17 50 44 26 65 65 50 80 100 125 150 200 250 300 95 150 220 280 500 800 1200 80 125 200 280 580

81

A4-A8

Type

PN

Material

Temperature p / T (bar / C) 300 400 450 500 530 22 20 17 16 13 35 32 28 24 21 40 32 22 60 50 34 96 80 51 139 118 112 87 45 63 58 56 47 25 100 91 87 74 38 160 146 139 118 62

GESTRA Water Level Limiters reduce boiler damage to a minimum

The reliability of water level limiters made by GESTRA exceeds the requirement of EN directives for a SIL 2 safety chain. The system consists of two electrodes and a level switch. This solutiion has already proven its worth in Bus applications. The system is self-monitoring and features positive-action safety relays, extensive fault analysis for rapid detection of malfunctions and separate error messaging for both limiters.

The system is SIL 3 certied.

82

As Europe's largest provider of boiler equipment, GESTRA meets all the needs of today's market: a broad spectrum of products, faster time-to-market for new products, more performance for less money and customized solutions and services. This unique market position is based on extensive experience acquired over more than 40 years in the design and manufacture of high-quality safetyoriented control equipment. To compete in a truly global market, GESTRA is continuing to consolidate the domestic market and, simultaneously, stepping up its efforts to deepen international activities outside Europe in order to optimize and extend its network of sales and marketing organizations all over the world. GESTRA technology is tailored to your needs, offering you the right solution be it conventional or bus-based for your land or marine applications. Hight-tech for enhanced safety and reliability!

Industrial Electronics

Page

Boiler equipment in acc. with TRD 604 / EN 12952/..53......................................................... 84 85 How to read type codes.........................................................................................................86 87 Old/new equipment at a glance......................................................................................................88
Level Control, Monitoring and Limitation....................................................................................... 89 Principles of measurement and fields of application. ......................................................................90 Equipment for steam and hot-water boiler plants........................................................................... 91 Type Approvals at a Glance.................................................................................................... 92 94

SpecTORbus Basic principles................................................................................................................................... 95 Level limitation (low/high-level alarm). ...................................................................................96 97 Level control..........................................................................................................................98 99 SpecTORcompact Level control/limitation......................................................................................................100 101 SpecTORcontrol..........................................................................................................................102 Conventional Design Functional safety..........................................................................................................................103 Water level limiter / high level alarm / Boiler safety system SIL 3......................................104 105 Water level control............................................................................................................. 106 107 Accessories for Liquid-Level Alarms Fitted in External Level Pots Level electrodes and controls. ............................................................................................108 109 Level Probes and Control Units for Very High Pressure Ranges.............................................................................................110 111 Marine Applications. ........................................................................................................112 113 Temperature and conductivity monitoring, oil detection..........................................................116

83

GESTRA Steam Plant

Control room Service partner S A J B C D R

M C

A B

K J

P E D O G H P I F P P P N P O P T

Boiler equipment acc. to TRD604 (continuous operation without constant supervision for 24/72 hrs) or in accordance with other European guidelines, e. g. EN 12953 part 6
A Self-monitoring low-level electrode NRG 16-40 AJ Low-level alarm NRS 1-40 / NRS 1-40.1 K BR Modulating level control with fully integrated second level and conductivity (TDS) indicator: level electrode NRG 26-40, level controller NRR 2-40, control terminal and display unit URB 1/URB 2 C Self-monitoring high-level alarm: level electrode NRG 16-41, level switch NRS 1-41 L M N O P Q R S Safety valve GSV Pressure limiter DSH Pressure controller/transmitter DISCO Non-return valve RK 86 A Strainer GSF Bypass/isolating valve GAV Electric/pneumatic control valve V 725 Control terminal and display unit URB 1/URB 2 Operating data acquisition J Self-monitoring temperature limiter: resistance thermometer TRG 5-65, temperature switch TRV 5-40, NRS 1-40.1 (only with existing superheater)

DE TDS control /Continuous and intermittent boiler blowdown: Conductivity electrode LRG 16-40, continuous blowdown controller LRR 1-40, continuous blowdown valve BAE, intermittent blowdown valve MPA, 3/2 way pilot valve, strainer F G H I Sample cooler Flash vessel Residual blowdown heat exchanger Blowdown receiver (mixing cooler)

T Feedwater monitoring: On-line analysis of residual hardness of water Demineralization plant: TDS control (conductivity monitoring)

84

GESTRA Condensate Monitoring

Steam and Condensate System


U V W X Y Z Steam trap with trap monitoring equipment, test chamber VKE, electrode NRG 16-19, test station NRA 1-3 for up to 16 steam traps Contamination detectors (ingress of acids, alkalis, etc.): Conductivity electrode LRG 16-9, Conductivity switch LRS 1-7a Monitoring for the ingress of foreign substances such as oil, grease etc.: Oil and turbidity detector OR 52/5 Pneumatic three-way control valve for the discharge of contaminated condensate Condensate receiver tank Safety circuit

85

How to Read Type Codes

GESTRA Type Designations for Boiler Controls

NR G NR S

2 1 - 5 1 1 - 1

N R G S 1 6 - 1
Code of variants Measured variable
B = D = L = M = N = O = P = T = U = Z = Density (TDS) Pressure Conductivity Mechanical Quantity Level Oil and Turbidity Program control Temperature Universal Time Consecutively numbered

Pressure Rating
1 2 6 7 8 9 10 11 = = = = = = = = PN 6 PN 10 PN 40 PN 63 PN 63/100 PN 160 PN 250 PN 320

Closed-loop control

Function
A B C G N R S T V = = = = = = = = = Display Operating unit Control unit Sensor Power supply unit Controller Switch Transmitter Preamplifier

Principle of Measurement
1 2 3 4 5 = = = = = Conductivity Capacitance Ultrasonic Photoelectric Temperature

86

How to Read Type Codes

GESTRA Type Designations for Boiler Controls

Function:

N R ... ... T
(Transmitter)

Input signal (x)


Sensor

Output signal (y)


0/4.....20 mA

S
Sensor

(Switch)

R
Sensor

Three-position controller W (Setpoint)

R
Sensor

Continuous controller W (Setpoint)

0/4.....20 mA

Level Switch Type NRS 1-1 ..


a# b c* d e f
#

Enclosure for wall mounting Enclosure for installation in control cabinet 19" slide-in unit Spare plug-in card for 19" slide-in unit Case for panel mounting Integrated solenoid valve plug
Often design b with additional enclosure for wall mounting Installation in 19" mounting panel provided on site or separately supplied 19" mounting panel

87

Old/new equipment at a glance

Innovative new equipment


In our endeavour to provide equipment that meets all the latest requirements stipulated in the pertinent body of regulations, that guarantees safe and cost-efficient installation and the production of which reflects the current state of the art, approx. every 10 to 15 years we can offer a completely new and improved generation of system solutions. GESTRA equipment puts you at the forefront of technology in power plants.

Reasons for new product development:


n The

new EN Directives 12952 and 12953 demand new low and high level limiting systems. The type approvals of the old systems will expire and cannot be extended. The new systems have EC and TV approvals and are SIL 3 certified. With the new position-action safety relays for boiler protection the mechanical function of the output relays becames part of the safety feature (as is also the case in Bus-based equipment). Design 1", PN 6, 4-pole connector 3 switchpoints 1", PN 6, 6-pole connector 4 switchpoints New NRG 10-52

n As

part of the new product development variants will be reduced and, consequently, manufacturing costs and prices will be optimized. Unlike the old variants with 4 and 6 pole connectors used in ER 50 / 56, the new electrodes NRG 10-52 / 16-52 feature only 5-pole connectors, which means that all four electrode rods can be used for switchtpoints.

Function Water level controller

Old ER 50-1

Design 1", PN 6, 5-pole connector 4 switchpoints

ER 56-1

1", PN 40, 4-pole connector 3 switchpoints 1", PN 40, 6-pole connector 4 switchpoints

NRG 16-52

1", PN 40, 5-pole connector 4 switchpoints

Water level limiter

NRG 1x-11 NRS 1-7

" 24 V AC 230 V AC

NRG 1x-50

" SIL 3

NRS 1-50, for 2 electrodes 24 V DC 100...240 V AC SIL 3 replaces two NRS 1-7 NRS 1-50, for 1 electrode 24 V DC 100...240 V AC SIL 3 replaces one NRS 1-7 " SIL 3 24 V DC 100...240 V AC SIL 3

High level alarm

NRG 1x-12 NRS 1-8

" 24 V AC 230 V AC

NRG 1x-51 NRS 1-51

88

Level Control, Monitoring and Limitation

Principles of Measurement
Conductivity measurement The water level is detected between the electrode tips and the vessel wall (or reference electrode) and evaluated for control or limita tion purposes. In this case it is essential that the medium is electrically conductive. The high-integrity self-monitoring design of the level alarms ensures constant supervision of the insulating seal and electrode entry, immediately recognizing malfunctions in the system and failure of the electrode or supply cables. In addition, the equipment features periodic self-checking of the electronic control unit and the corresponding output contacts. Self-monitoring equipment with periodic selfchecking is required for boilers with temperature/pressure ratings > 1 bar and > 120 C and a volume > 50 l. Before installation, the length of the con ductivity electrode rods must be cut to the required switching levels. Capacitance measurement Electrode rod and vessel wall (or reference electrode) form a capacitor; air and the fluid to be controlled act as dielectric. Due to the different dielectric constants of air and boiler water the capacitance value between the electrode and the vessel wall changes concurrently with level changes. The switchpoints can be continuously adjusted during operation and multiplied by connecting in parallel several electronic control units.

Types of Controls
Water level limiters (High-level/low-level alarms) As soon as the water level exceeds or falls below the adjusted switch points the burner protection circuit is interrupted (low level) or the feed pump is switched off (high level). On-off level control The water level is controlled between two fixed or adjustable switchpoints. The signals are directly transmitted to the feed pump or valve. Modulating level control The water level is continuously monitored and the actual value is compared with the adjusted set point by the associated controller. If a deviation between the two values is detected, a signal will be sent to the control valve to re-adjust the flowrate accordingly, thereby enabling a more economic and efficient steam plant operation.

MIN

Field Bus System


Digital Data Exchange

The Spector Bus system transfers the digitized measurement data acquired by the level probe to the electronic control unit located in the control cabinet. The centerpiece of this system is the stable and sophisticated CAN bus (Controller Area Network). Several sensors and switches can be inter connected via one bus line. Apart from active cable monitoring a CAN bus system offers a host of benefits, such as increased design flexibility, reduced installation effort, optimized open and closed loop control, centralized operation and remote monitoring. The standardised network opens up highly flexible possibilities for con figuration. The CANopen protocol is used nowadays in medical equipment, electronic devices for marine applications, public means of transport and in burner and boiler controls of power plants. Thanks to the many CANbus applications a great number of equipment and interface components are widely available, providing an ideal addition to our product range.

URB 1
1 Max

NRS 2 -40
1

READY TO OPERATE
P
E

2 3 4 Min

E
Test

89

Fundamental Principles of Measurement and Applications


Technologically Advanced Liquid Level Control
With more than 40 years experience in the design and manufacture of industrial electronics and almost a century in all fields of steam trapping and shut-off valves, GESTRA enjoys a unique position in the industry as a trusted single-source partner for boiler equipment. Right from the outset GESTRA blazed a trail in advanced boiler safety. In our drive to set new safety standards, we were the first company to team up with the German Technical Super visory Association TV in order to design self-monitoring low-level alarm systems. Apart from low-level alarms GESTRA now offers an extensive range of electronic boiler equipment for power stations as well as industrial applications. Our latest, trend-setting innovation is the new Spector equipment featuring advanced busbased technology, which provides a futureproof framework for decentralized, flexible operations.

Application
Measurement Capacitance Conductivity

Steam boilers Hot-water boilers Steam regenerator Condensate tanks Feedwater tanks Fresh water tanks Pump sumps Holding tanks Product tanks Tunnel drainage Drainage systems in power stations Autoclave drainage Pump controls Oil detection in cooling-water systems Daily service tanks for oil Diesel fuel tanks

Examples of Industrial Applications


Purpose Level control Application

Fill or discharge control with protection against pump running dry and high-level alarm Fill or discharge control with protection against pump running dry and/or high-level alarm Fill or discharge control with protection against pump running dry and high-level alarm Fill or discharge control with protection against pump running dry and high-level alarm Modulating fill or discharge control with protection against pump running dry and high-level alarm incl. level indicator Modulating level detection for remote indication Modulating fill or discharge control with protection against pump running dry and high-level alarm Fill or discharge control with protection against pump running dry and high-level alarm Marine application Fill control with high-level alarm Marine application

Principle of Level Level electrode switch measurement Conductivity NRGS1.-1 meas. Conductivity NRS 1-5/NRS NRG 16-52 meas. 1-1/ NRS 1-2 Conductivity NRG 16-42 NRS1-42 meas. Conductivity/ NRG 26-40 NRS2-40 capacitance meas. Conductivity/ NRG 26-40 NRR 2-40/URB capacitance meas. Conductivity/ NRGT 26-1 URA 2 capacitance meas. Conductivity/ NRGT 26-1 KS 92-1 capacitance meas. Conductivity/ NRGT 26-1S NRS 2-3 capacitance meas. Conductivity/ NRGT 26-1S KS 92-1 capacitance meas.

Switch point fixed fixed fixed adjustable adjustable adjustable adjustable adjustable

90

Equipment for Steam and Hot-Water Boiler Plants


Boiler operating mode TRD 701 max. 1 bar*) TRD 802 for fast steam generating units TRD 604 24 hours 2 Low level limiter 1 Feedwater controller/ high-level alarm Low level limiter WB EN 12953 section 6 EN 12952 section 7 *) according to PED max. 0.5 bar Boiler operating mode TRD 604 72 hours 2 Low level limiters 1 Feedwater controller 1 High-level alarm Low level limiter WB 1 Conductivity sensing electrode Feedwater controller WR High level alarm HW 1) 1) 1) 1) 1) 1) 1) 1) 1) First low level alarm with superheater 1 Selfmonitoring temp. limiter
1) Only 2*) The

Feedwater controller WR

High level alarm HW

First low level alarm

Conduct. sensing electrode

Temperature limiter

PN 6 40 40 63 160 320 40 63 160 320 40 40 40 40 40 40 40 40 63 160

Level electrode NRGS 11-2 NRGS 16-2 NRG 16-40 (2x) NRG 17-40 (2x) NRG 19-40 (2x) NRG 111-40 (2x) NRG 16-50 NRG 17-50 NRG 19-50 NRG 111-50 NRG 16-42 NRGS16-1 NRG 26-40 NRG 26-21 NRG 26-40 NRGT 26-1 NRG 26-21 NRG 26-21 244 LD / 705 244 LD / 705

Level switch/ controller NRS 1-40 (1x) NRS1-40 (1x) NRS 1-40 (1x) NRS1-40 (1x) NRS 1-50 NRS 1-50 NRS 1-50 NRS 1-50 NRS 1-42 NRS 2-40 NRS 2-1 NRR 2-40/URB KS 92-1 NRR 2-2 NRR 2-1 KS 92-1 KS 92-1

Switchpoint fixed fixed fixed fixed fixed fixed fixed fixed fixed fixed fixed fixed adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable

On-off control

Modulating control

Conduct. sensing electrode

Temperature limiter

PN 40 63 160 320 40 63 160 320 40 40 40 40 40 40 40 63 160 40 40 63 160 40 63 160 40 40 63 40 40 63

Electrode NRG 16-40 (2x) NRG 17-40 (2x) NRG 19-40 (2x) NRG 111-40 (2x) NRG 16-50 NRG 17-50 NRG 19-50 NRG 111-50 NRG 16-42 NRGS16-1 NRG 26-40 NRG 26-21 NRG 26-40 NRG 26-21 NRGT 26-1 244 LD / 705 244 LD / 705 NRG 16-4 NRG 16-41 NRG 17-41 NRG 19-41 NRG 16-51 NRG 17-51 NRG 19-51 LRGT 16-1 LRGT 16-2 LRGT 17-1 LRG 16-40 LRG 16-41 LRG 17-40 TRG 5-5x

Switch/ controller NRS1-40 (1x) NRS1-40 (1x) NRS 1-40 (1x) NRS 1-40 (1x) NRS 1-50 NRS 1-50 NRS 1-50 NRS 1-50 NRS 1-42 NRS 2-40 NRS 2-1 NRR 2-40 / URB NRR 2-2 KS 92-1 KS 92-1 KS 92-1 NRS1-2 NRS 1-41 NRS1-41 NRS1-41 NRS 1-51 NRS 1-51 NRS 1-51 KS90 KS90 KS90 LRR1-40 / URB LRR1-40 / URB LRR1-40 / URB NRS 1-40.1 2*) TRS 5-6

Switchpoint fixed fixed fixed fixed fixed fixed fixed fixed fixed fixed adjustable adjustable adjustable adjustable adjustable adjustable adjustable fixed fixed fixed fixed fixed fixed fixed adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable

On-off control

Modulating control

40/160 TRG 5-6x/TRV 5-40 40/160

as first alarm. Low-level limiter and feedwater control electrodes or low-level limiter and high-level alarm electrodes can be installed together in one flange.

level switch NRS 1-40.1 can be used for up to 4 limiting functions, e. g. 2 x NRG 16-40 (low level), 1 x NRG 16-41.1 (high level), 1 x TRV 5-40 (self-monitoring temperature limiter)

91

Type Approvals at a Glance

GESTRA Boiler controls acc. to TRD 604, sheet 1, 24/72 hrs or EN 12953, part 6 TV, ECType Approval
Function 2 Low-level limiters TRD 604 required recommended yes Section 1.4 3.6.1 EN 12953, part 6 required recommended Section yes 4.3.1 5.7.1 Equipment NRG 16-40 / NRS 1-40 Self-monitoring equipment with automatic routine testing NRG 16-50 / NRS 1-50 Self-monitoring equipment with automatic routine testing NRG 16-40 / NRS 1-40 Self-monitoring equipment with automatic routine testing NRG 16-41 / NRS 1-41 Self-monitoring equipment with automatic routine testing NRG 16-40 Self-monitoring equipment NRG 16-41.1 Self-monitoring equipment TRG / TRV 5-40 Self-monitoring equipment NRS 1-40.1 / NRS 1-40.2 NRG 16-36 / NRS 1-50 / NRS 1-5 Self-monitoring equipment with automatic routine testing NRGS 16-1 Compact system for on-off control NRG 16-42 / NRS 1-42 Bus-based on-off control NRG 16-52 /NRS 1-5 On-off control with adjustable switchpoints - discontinued NRGT 26-1 Compact system for continuous monitoring, current output 4...20 mA NRG 26-40 /NRS 2-40 Bus-based on-off controller with adjustable switchpoints NRG 26-21 / NRS 2-1 On-off control with adjustable switchpoints NRG 26-40 / NRR 2-40 URB Bus-based modulating controller with adjustable limits NRG 26-21 / NRR 2-1 Modulating control NRG 26-21 / NRR 2-2 Modulating control with adjustable limits LD 244 NRG 16-41 / NRS 1-41 Self-monitoring equipment with automatic routine testing NRG 16-51 / NRS 1-51 Self-monitoring equipment with automatic routine testing NRG 16-4 / NRS 1-2 Conventional design According to TRD regulations you may only combine low-level limiters with level controls or high-level alarms. Type approval no. TV SWB/SHWS 07-403 EG BAF-MUC 02 02 103881 002 TV SWB 09-422 EG IS-TAF-MUC 0908 103881 005 SIL 3 TV SWB/SHWS 07-403 EG BAF-MUC 02 02 103881 002

Low-level limiter/ High-level alarm in Bus system

yes

1.4 3.6.1 1.8 5.1

yes

4.3.1 5.7.1

Low-level limiter/ High-level limiter/ Temperature limiter

yes

1.4 3.6.1 1.8 5.1 1.6 1.7 3.63 1.4 1.8 3.4 1.8 3.4

yes

4.3.1 5.7.1 4.4 5.7.2

TV SWB/SHWS STW (STB) 08-413 EG BAF-MUC 03 07 103881 004

Low-level limiter with control/ High level Feedwater controller with high-level alarm

yes

yes

4.3.1 5.7.1 4.5.2 4.5.2 5.5 5.6.1 5.6.2

yes

yes

TV SWB 09-422 EG IS-TAF-MUC 09 08 103881 005 SIL 3 TV WR 08-302 TV WRB 06-388

TV WR 09-399

TVWR 08-302

TV WR 07-391

TV WR 09-399

TV WR/WS 09-317

TV WR 09-399

Feedwater controller with high-level alarm

yes

1.4 3.4

yes

4.5.1 5.5 5.6.1 5.6.2

TV WR 09-317 TV WR 06-320

Separate high-level alarm

yes 72h

1.8 5.1

5.6.2

TV WRS 06-324 TV SWB/SHWS 07-403 EG BAF-MUC 02 02 103881 002 TV SHWS 09-423 EG IS-TAF-MUC 0908 103881 006 SIL 3 TV WR/WB 08-302

92

Type Approvals at a Glance

GESTRA Boiler controls acc. to TRD 604, sheet 1, 24/72 hrs or EN 12953, part 6 TV, ECType Approval
Function Safety temperature limiter required yes TRD 604 recommended Section 1.6 1.7 3.6.3 required yes EN 12953, part 6 recommended Section 4.4 5.7.2 Equipment TRG 5-6.. / TRV 5-40 PT 100 NRS 1-40.1 Type approval no. TV SWB/SHWS STW (STB) 08-413 EG BAF-MUC 03 07 103881 004 DIN CERTO STW (STB) 117906 STW(STB) 985 07 S EG 01 202 931-B-10-0002 STW (STB) 986 07 S EG 01 202 931-B-10-0002 www.tuev.com 0000006024 not available

Safety temperature limiter

yes

1.6 1.7 3.6.3 1.3 3.6.4 5.2

yes

5.7.2 4.4

Safety pressure limiter Conductivity (TDS) control for boiler water *) Automatic continuous boiler blowdown system *)

yes yes

yes

5.7.2

optional

yes

2.1 4.8

yes

C 1.8

Automatic continuous boiler blowdown with signalling of limit levels *) 1)

optional yes 72h

yes

5.2

yes

C 1.8

Automatic intermittent boiler blowdown Conductivity (TDS) control for make-up water *) Residual hardness of make-up water (process titration) *) Condensate monitoring: oil and turbidity detection *) Contamination detection of acids, alkalis etc. *) Explanatory notes:

optional

yes

2.1 / 5.2 4.8

yes

5.3.1

TRG 5-5.. / TRS 5-6 PT 100 TRG 5-.. / TRS 5-7 Thermocouple type K DSF ..F 001 Self-monitoring equipment LRG 16-4 /LRS 1-5 manual temperature compensation LRG 16-4 /LRS 1-5 On-off control LRGT 16-1 / LRGT 16-2 / KS 90 Three-position stepping control, automatic temperature compensation LRG 16-4 / LRR 1-5 / URS 2 On-operation-off manuel temperature compensation LRGT 16-1 / LRGT 16-2 / KS 90 Three-position stepping control, automatic temperature compensation Max. limit LRG 16-40 /LRG 16-41 / LRR 1-40 Bus-based continuous boiler blowdown, three-position stepping control, automatic temperature compensation Max. limit TA / MPA LRR 1-40 / MPA LRG 16-4 / LRS 1-6

not required TV WL 11-003 EG BAF-MUC 01 04 105620 001

not available

TV WL 11-003 EG BAF-MUC 01 04 105620 001

TV WL 07-007 EG BAF-MUC 02 03 103881 003

not required

yes 72h

2 4.8 5.2 5.2

not available

yes 72h yes 72h 2 detectors yes

2.1 / 4.8 5.2 2.1 / 4.8 5.2

yes

5.6.3

OR 52-5 / -6

TV WF 07-009

yes

5.6.3

LRG 16-9 / LRS 1-7

TV WL 09-014

*) Approximate values and limits according to TRD 611 / EN 12952-12 and EN12953-10
1)

Combining continuous boiler blowdown and limit control precludes the need for pure limit signalling. T.D.S. =Total Dissolved Solids

Abbreviations for temperature control equipment:


STW (STB) TW = Safety temperature controller = Safety temperature limiter designed with interlocking facility = Temperature controller

93

Type Approval Nos. at a Glance

Type Approval Number Code

T V
Safety Measured quantity W = Water T = Temperature D = Pressure Function B = Limiter R = Controller S = Switch W = Detector

S W B 02 4 0 3

Classification societies for marine applications


GL LR See BG RINA ABS KR BV DNV Germanischer Lloyd Lloyd's Register See-Berufsgenossenschaft Registro Italiano Navale American Bureau of Shipping Korean Register of Shipping Bureau Veritas Det Norske veritas

VdTV Bulletin Year of approval or extension

Function Water-level controller with high-level alarm

Equipment NRGS 16-1S Compact system for on-off control NRGT 26-1S Compact system for continuous level monitoring current output 4...20 mA NRS 2-3 On-off control KS 92-1 Continuous control NRG 16-11S NRS 1-7 discontinued NRG 16-50S NRS 1-50 with positive-action safety relay and SIL 3 certified

Type Approval Number GL99250-96 HH LR 98/20075 RINA No ELE/30298/1 GL 99249-96 HH LR 98/20074 BV 10617/Bo RINA No ELE/30298/2 KR HMB06190-MS002 DNV A-8394 LR 98/20076 GL WB-93-349001 BV 10617/Bo RINA No ELE/95695/1 KR HMB06190-MS002 GL 94277-10 HH DNV A-12022 NKK 11A001 NRS 1-7 LR 01/20026 GL 40 601-01 HH ABS 01-HG227959/1-PDA KR HMB06190-MS002 DNV A-8394 BV 11400/A1 BV NRS 1-50 GL 40 601-01 HH DNV A-12022 NKK 11A002 GL 99251-96 HH LR 00/20051 GL 33254-06 HH

Water-level limiter SMART (self-monitoring), with periodic self-testing for loss of redundancy

Combination electrode Water level controller Output 4-20 mA with 1 water level limiter SMART (self-monitoring), with periodic self-testing for loss of redundancy Combination electrode Water level controller Output 4-20 mA with 2 water level limiters SMART (self-monitoring), with periodic self-testing for loss of redundancy Safety temperature limiter Conductivity monitoring with automatic temperature compensation (feedwater) Monitoring of cooling water closed systems Condensate / feedwater monitoring open systems

NRG 16-38S NRS 1-7 discontinued NRS 1-50 1E with positive-action safety relay and SIL 3 certified NRG 16-39S NRS 1-7 (2x) discontinued NRS 1-50 2E (1x) oder NRS 1-50 1E (2x) with positive-action safety relay and SIL 3 certified TRG 5-5../TRS 5-6 LRGT 16-1 Compact electrode, current output 4...20 mA LRG 16-9/LRS 1-7 ORGS Compact system OR 52-5

GL 60444-09 HH GL 17106-00 HH LR 07/20031 BV 17515/A0 BV GL 94855-94 HH

94

Basics

TRV 5-40 100 % MAX Valve OPEN/ MIN CLOSED 0% Capacitance Conductivity level electrode electrode NRG 26-40 LRG 16-40 24 V DC 24 V DC bus signal bus signal

mA V

MIN(LW) MIN (NW) Self-monitoring conductivity level electrodes NRG 1...-40 24 V DC bus signal (2x)

MAX (HW) Self-monitoring conductivity level electrodes NRG 1...-41/.-41.1 24 V DC bus signal

STB Temperature sensor TRG 5-6...

Visual display unit

Level switch NRS 1-40 / NRS 1-40.1 with automatic testing routine (in control cabinet) (1x)

Level switch NRS 1-41 (in control cabinet)

Control terminal and display unit URB 2 (panel mounting)

Level controller Level controller NRS 2-40 NRR 2-40 (in control cabinet) (in control cabinet)

Blowdown controller LRR 1-40 (in control cabinet)

GESTRA Boiler Protection System

Wago I/O Control

NRS 1-40.1 (LW, HW*), Temp.)

LRR 1-40

NRS 1-41*)

*) The system can do without the separate NRS 1-41 if the burner is switched off by the high level function

SpecTORbus
With these systems, proven technology in the design of electrodes has been alloyed with innovative new level detection and evaluation techniques: All level electrodes feature now special electronic sensor units which, via a bus interface, can exchange data auto matically with level controllers or higher-level control systems. The next era in liquid level monitoring and control has dawned.

n Reduced cost of control cabinet

n GESTRA Boiler Protection System

Features and Benefits of SpecTORbus


n Patented thermal barrier in cylindrical body above

only one PG thread only five input terminals only one cable in control cabinet for all sensing units n Active cable monitoring through message identification for error detection and prioritisation of messages in the event of low-level alarm n Length of cable between sensor and controller 125 m; max. cable length 1000 m n Easy to integrate in visual display and automation systems n Thanks to increased functionality of controllers less component parts required
n Limiter

up to 4 limiters for one control unit (2 x LW, HW, safety temp. limiter in any combination).
n Controller

electrode flange n Terminal box equipped with excess temperature fuse (85 C) n Freely accessible connecting terminals n Large terminal box makes for easy installation n Standardized response sensitivity 0.5 S/cm simplifies stocking and spare part inventories n Optimum system adaptation/extension without any additional wiring n Reduced installation effort and material costs, since only a single four-core cable is required between boiler and control cabinet

Two electrodes but only one controller Switch-selectable one/two-electrode system (emergency operation) Instantaneous indication of low level by separate, flashing diode as soon as the liquid falls below low level (simplifies routine testing) After time delay has elapsed, the LEDs stop flashing and are permanently illuminated Separate, instantaneous signal output for low water level Self-test routine combined with automatic selfchecking of respective output relay contacts

Less time-consuming calibration of measur ing range; 100 % can be adjusted at level 50 %. No additional time relays required for system optimization. Built-in time delays individually adjustable between 1...25 sec. for each contact and position. Reduced wiring effort for control cabinet: Only a single four-core cable is required for wiring the panel-mounted control terminal and display unit, since all switchgear controls remain on the mounting panel where their functions are required. One operating and control terminal for all connected bus nodes. The control terminal features permanent level and conductivity indication according to TRD 401 (second water-level indication) and draft of rules concerning conductivity limiters. Easy parameterization of controls on control terminal or PC.

95

Level Limitation (Low and High Level Alarms) Level Limitation


Low-Level Limiter
Control unit NRS 1-40 in conjunction with one level electrode type NRG 16-40, 17-40, 19-40 or 111-40 constitutes a high-integrity self- monitoring low-level limiter with periodic self-checking and automatic routine testing of output relay contacts. Function:
Low-level alarm with one switch point.

Control unit NRS 1-40 in conjunction with two level electrodes type NRG 16-40, 17-40, 19-40 or 111-40 consti tutes a high-integrity self-monitoring low-level limiting system with periodic self-checking. The control unit features the following function:
Low-level alarm with two switch points.

The electric device complies with the regula tions for safety circuits to DIN EN 50156. The liquid level data are transferred from the electrode NRG 1...-40 to the control unit via CAN bus, using the CANopen protocol. The safety temperature limiter type TRG 5-6./ TRV 5-40 can be added to the system; for more information refer to pages 116 117.

The equipment detects min. water level (low-level alarm). Application in steam and pressurized hotwater boilers according to TRD 401, TRD 602 and TRD 604, EN 12952/..53.

The equipment combination detects lowwater level (low-level alarm system). Application in steam and pressurized hotwater boilers according to TRD 604, sheet 1 and 2 (operation without constant super vision for 24/72 hrs.).

High-Level-Alarm
Low-Level Limiter
Control unit NRS 1-41 in conjunction with one level electrode type NRG16-41, 17-41 or 19-41 consti tutes a high-integrity self-monitoring high-level alarm system with periodic self-checking and automatic routine testing of output relay contacts. Function:
High-level alarm

Application in steam and pressurized hotwater boilers according to TRD 401, TRD 602 and TRD 604, EN 12952/..53. The electric device complies with the regula tions for safety circuits to DIN EN 50156.

The liquid level data are transferred from the electrode NRG 1...-41 to the control unit via CAN bus, using the CAN open protocol.

The equipment detects the max. water level.

Boiler Protection System


Description
The control unit NRS 1-40.1 in combination with two level electrodes NRG 1.-40, the temperature sensor TRG 5-6../TRV 5-40 and, if required, the level electrode NRG 1.-41.1 constitutes a self-monitoring boiler protection system with periodic self-testing and con tinuous monitoring of the output relays. The control unit features the following functions:
Low-level alarm with two switchpoints

The equipment combination detects the min. water level (low-level limiting system).
Safety temperature limiter

Application in steam and (pressurised) hot water plants in accordance with TRD 604, sheet 1 and sheet 2 (24/72 hrs operation). The electrical equipment meets the requirements of the regulations for safety circuits according to DIN EN 50156. The data of the sensors are trans ferred to the control unit via CANbus, using the CANopen protocol.

The equipment combination detects the max. allowable temperature.


High-level alarm

The equipment combination detects the max. water level.


n Or other customized combination.

If more than four limiters are required, the control unit NRS 1-40.2 can also be integrated in the system.

Technical Data
Type NRG 16-40 NRG 17-40 NRG 19-40 NRG 111-40 NRG 16-41(.1) NRG 17-41(.1) NRG 19-41(.1) Pressure rating PN 40 PN 63 PN 160 PN 320 PN 40 PN 63 PN 160 End connection " " " 1" " " " Service pressure [bar] / Saturated steam temperature 32 / 238 60 / 275 100 / 311 180 / 357 32 / 238 46 / 260 100 / 311 Lengths supplied [mm] 500 3000 500 3000 500 3000 500 3000 500 1500 500 1500 500 1500 Ambient temperature [C] 70 70 70 70 70 70 70

96

Level Limitation (Low and High Level Alarms)


Self-monitoring low-level alarm system to TRD 604 (24/72 hrs without constant supervision)/EN 12952/53
Level electrodes NRG 16-40 Level switch NRS 1-40 Burner protection circuit
Flange DN 50 mm

Type NRG 16-40 NRS 1-40 NRG 17-40 NRS 1-40 NRG 19-40 NRS 1-40 NRG 111-40 NRS 1-40

PN 1000 mm 230 V 1000 mm 230 V 1000 mm 230 V 1000 mm 230 V 40 63 160 320

Stock code 3514042 3222541 3544042 3222541


3574042 3222541 3574142

Type approval TV SWB/SHWS 07-403 EG BAF-MUC 02 02 103881 002 If supervision is limited, the system can be operated with one electrode.

Low level

Low level

0525

High-level alarm TRD604, 72h


Level electrode NRG 16-41 Level switch NRS 1-41

Type NRG 16-41 NRS 1-41 NRG 17-41 NRS 1-41


Feed OFF or burner OFF

PN 500 mm 230 V 500 mm 230 V 500 mm 230 V 40 63 160

Stock code 3524041 3222741 3551241 3222741


3594041 3222741

NRG 19-41 NRS 1-41

Flange DN 50 mm

Type approval TV SWB/SHWS 07-403 EG BAF-MUC 02 02 103881 002

High level

Optional:NRS 1-4. special voltage: 115 V, 50..60 HZ

0525

For flanges see Price List

Self-monitoring boiler protection system TRD 604 24h/72h /EN 12952/53


Level electrode NRG 16-41.1 Level electrode NRG 16-40 Level switch NRS 1-40.1

24 V, DC

PS 300
GESTRA TRV 5-40

Flange DN 50 mm

Flange DN 50 mm

TRV 5-..

Burner Safety temp. monitor protection (limiter) circuit


TRG 5-6.

High level Low level Low level

0525

Type 1000 mm NRG 16-40 TRG 5-65 TRV 5-40 500 mm NRG 16-41.1 230 V NRS 1-40.1 NRG 17-40 1000 mm TRG 5-65 TRV 5-40 500 mm NRG 17-41.1 230 V NRS 1-40.1 NRG 19-40 1000 mm TRG 5-65 TRV 5-40 500 mm NRG 19-41.1 230 V NRS 1-40.1 Optional: NRS 1-40.2, 230 V

PN

40

63

160

Stock code 3514042 2671611 2691040 3524141 3222841 3544042 2671611 2691040 3551341 3222841 3574042 2671611 2691040 3594141 3222841 3222941

Type approval TV SWB/SHWS STW (STB) 03-413 EG BAF-MUC 03 07 103881 004 TRG 5-6... / TRV see pages 116 117

97

Level Control

The level electrode type NRG 16-42 works according to the conductivity measurement principle. With the NRG 16-42 a maximum of four levels can be signalled in conductive liquids: Four levels with one switchpoint each High-level alarm, first low-level alarm, pump ON, pump OFF, with one switchpoint each Use level electrode NRG 16-42 in com bi na tion with level switch type NRS 1-42 or other system components. The level data are transferred to the level switch or any other system component via a CAN data bus. Use level switch type NRS 1-42 in combination with level electrode type NRG 16-42 for level monitoring. The level switch has the following functions: Four levels with one switchpoint each High-level alarm, first low-level alarm, pump ON, pump OFF, with one switchpoint each The level data are transferred from the electrode NRG 16-42 to the level switch via a CAN bus.

Description 1. Conductivity Measurement NRG 16-42

The level data are transferred to the level switch or any other system component via the CAN data bus. Use level switch type NRS 2-40 in combination with level electrode type NRG 26-40 for level control and monitoring. The level switch has the following functions: Four liquid levels with one switchpoint each High-level alarm, first low-level alarm, pump ON, pump OFF, with one switchpoint each The level switch NRS 2-40 can be optio nally equipped with an actual value output for standard signal 4-20 mA. The level data are transmitted from the electrode NRG 26-40 to the level switch via a CAN data bus. If you want to connect a second NRS 2-40 in order to establish additional switchpoints please indicate this when ordering. Use level controller NRR 2-40 in combina tion with level electrode type NRG 26-40 for level control and monitoring. The level controller has the following functions: Two limit values with one switch point each (high-level alarm and first low-level alarm) Three-position or modulating control within a predefined proportional band All contacts feature time delays adjustable between 1 25 sec. Continuous level monitoring within defined measuring range of the electrode. The NRR 2-40 features an optional output for standard signal 4-20 mA, which can be used for actual value and/or modulating control. The level data are transferred from the electrode NRG 26-40 to the level controller via a CAN data bus.

URZ 40

NRS 2-40

As an alternative to the control system via a three-position stepping output, the URZ 40a can be mounted to the control valve in order to provide the control function for the CAN bus.

URB 1 / 2

NRS 1-42

The URB is a user-friendly control terminal and display unit for use with GESTRA CAN bus systems. With the URB all standard functions of the CAN bus system can be easily called up and adjusted. Furthermore, the URB makes the parameterization of the controller very convenient: The switchpoints and the proportional band can be adjusted by means of the keypad regardless of the actual level. The energizing and de-ener gizing times of the relays can be customized for the individual switchpoints. The LCD of the URB displays the following:
Current liquid level (second water level)

(TRD 401, EN 12952, ...53)


Current conductivity value (TSDcontrol) Proportional band of controller

NRR 2-40

2. Capacitance Measurement NRG 26-40

The level electrode NRG 26-40 works accord ing to the capacitance measurement prin ciple. The NRG 26-40 is used for detecting and signalling different levels in con ductive and non-conductive liquids: Level always within defined measuring range of electrode. Use level electrode NRG 26-40 in com bina tion with level switch type NRS 2-40 or further system components.

(NRR 2-40), (LRR 1-40) Switchpoints Position and value of switchpoint LOW LEVEL Position and value of switchpoint HIGH LEVEL Position of set point (NRR 2-40), (LRR 1-40) Deviation Valve position Manual/automatic operation Current CAN bus address Indication of high/low level alarm Temperature (URB 2) Pressure (URB 2)

Differences between URB 1 and URB 2


Function Display Colour display Basic window URB 1 Graphic display 124 x 64 pixel, 58 x 40 mm No Bar chart Numerical Level Level Conductivity Conductivity URB 2 VGA, monochrom 320 x 240 pixel, 115 x 85 mm Optional Bar chart Numerical Level Level Conductivity Pressure Temperature Via control knob Via control knob Yes Yes, Flash Yes, software update Yes, colour display

Operation Navigation in the menu Password protection (to avoid operating errors) Software update System freely expandable Connection for camera (e. g. local water level indicator)

Via push-button Via push-button No No No No

98

Level Control

On-off control with fixed switchpoints Spector BUS system


Multiple level electrode NRG 16-42 1" BSP Level switch NRS 1-42

Control terminal and display unit URB 1 (2) (optional) High-level alarm First low-level alarm

Type NRG 16-42 L = 1000 mm NRS 1-42 230 V Optional: URB VDU Optional 115 V, 50..60 Hz

PN 40

Stock code 3534248 3222241 3381043

Connecting flange DN 50 mm High level Pump OFF Pump ON First low-level alarm

Type approval TV WR 09-399

On-off control with adjustable switchpoints Spector BUS system


Level electrode NRG 26-40 " BSP Level switch NRS 2-40

Control terminal and display unit URB 1 (2) (optional) High-level alarm First low-level alarm

Type NRG 16-40 H = 1000 mm NRS 2-40 230 V Optional: URB VDU NRS 2-40 optional 115 V, 50..60 Hz

PN 40

Stock code 3484047 3223041 3381043

Actual value output 4-20 mA Second device Type approval TV WR 09-399 TV SWB/SHWS 07-403

.57 .59

Connecting flange DN 50 mm

High level Pump OFF Pump ON First low-level alarm

Second device

High-level alarm First low-level alarm

Modulating control with high-level alarm and first low-level alarm Spector Bus system
Level electrode NRG 26-40 " BSP

Power 0.5 230 V AC 24 V DC

Type NRG 26-40 H = 1000 mm NRR 2-40 230 V URB VDU NRR 2-40 optional 115 V, 50..60 Hz

PN 40

Stock code 3484047 3225041 3381043

Level controller NRR 2-40 High-level alarm Control terminal and display unit URB 1 (2)

Actual value output 4-20 mA Output for continuous controller 4-20 mA Type approval TV WR 09-399

.57 .58

Connecting flange DN 50 mm High level Level control First lowlevel alarm URZ 40a

First low-level alarm Feedwater control valve V 725 DN 50 mm

Optional: URZ 40a CANbus-Interface

For flanges see Price List

99

Level Control

SpecTORcompact
Where formerly two devices were required, all you need now is just a single Spectorcompact. As a combined level electrode and controller, it presents the economical alternative for monitoring liquid levels in small installations and steam boilers. Since the entire electronic control unit is located within the terminal box, the trans mission path is short and reliability is higher than with comparable systems.

System Description NRGS1...-1


The compact system NRGS 11-1 or NRGS 16-1 works according to the conductivity measurement principle. With the NRGS 1...-1 a maximum of four levels can be signalled in conductive liquids:
High-level alarm, first low-level alarm,

System Description NRGS 1...-2


The compact system NRGS 11-2, NRGS 16-2 works according to the conductivity measure ment principle. With the NRGS 1...-2 a maximum of three levels can be signalled in conductive liquids:
Low-level alarm, pump ON, pump OFF, with

pump ON, pump OFF, with one switchpoint each. The NRGS 1...-1 has a level switch integrated in the electrode case for the control of all functions. An external switching device is not required.

one normally open contact. The NRGS 1...-2 has a level switch integrated in the electrode case for the control of all functions. An external switching device is not required. The NRGS 1...-2 has two electrode tips for the detection of low-water level. The low-level alarm is signalled via two separate switching channels.

Features and Benefits SpecTORcompact


Patented temperature barrier in cylindrical Simplified logistics

System Description NRGT 26-1


Only one item of equipment has to be ordered and checked upon receipt Reduced inventory requirements and simplified stocking dures No onerous assignment proce of individual component parts to mechanical engineering dept. (boiler) and measurement and control engineering dept. (control cabinet) Interchanges with old float-operated systems since they have their output contacts also integrated in the terminal box. The compact system NRGT 26-1 works according to the capacitance measurement principle. The NRGT 26-1 is used for signalling different levels in conductive and insulating liquids.
Modulating control ensures that the liquid

body above electrode flange Terminal box equipped with excess temperature fuse (102 C) Level electrode and controller in one unit Optimum system adaptation thanks to modular design No mounting of component parts in control cabinet No space requirements No installation No wiring Easy planning No special cable required for wiring sensing unit to control cabinet

level is always within the predefined measuring range of the electrode. The NRGT 26-1 has a level trans mitter integrated in the electrode case which produces a standard analogue output of 4 20 mA. An external switching device is not required.

Pump Control Units


Standard features Pump protection against running dry Pump protection against running dry and high-level alarm Time-dependent pump switching device Switching-on of stand-by pump Collective malfunction alarm (visible) Collective malfunction alarm (visible and audible) Volt-free contacts Remote level indication Type NRSP 1-11

NRSP 1-12

100

Level Control

Compact system for on-off level control with fixed switchpoints


High-level alarm Pump ON/OFF

Water-level controller with two additional limit contacts, power supply 115/230 V, 50 Hz.

First low-level alarm


NRGS 11-1 NRGS 16-1 1"

Max. length supplied NRGS 11-1 6 1000 1500 NRGS 16-1 40 1000 1500 Optional 24 V, 50..60 Hz Type PN

Stock code

3532048 3532054 3533048 3533054 .51

Type approval TV WRB 06-388


High-level alarm Pump OFF Pump ON First low-level alarm

Compact system for water-level limitation and on-off control


Pump ON/OFF

Low-level alarm and liquid level controller, power supply 115/230 V, 50 Hz.

Reset Test NRGS 11-2 NRGS 16-2 1"

Burner protection circuit

Max. length supplied NRGS 11-2 6 1000 1500 NRGS 16-2 40 1000 1500 Optional 24 V, 50..60 Hz Type PN

Stock code

3532148 3532154 3533148 3533154 .51

Type approval TV WR/WB 07-392


Pump OFF Pump ON Low-level alarm (redundancy)

Compact system for modulating level control


4 20 mA
see page 104 NRGT 26-1 " 24 V AC/DC

Type
High-level alarm Control valve Pump protection

KS 92-1

PLC

100 %

Modulating level control with current output 4 20 mA, power supply 115/230 V, 50 Hz.

0%

Max. length supplied NRGT 26-1 40 300 400 24 V AC/DC 500 600 700 800 900 1000 1100 1200 1300 1400 1500 2000 Optional 115 V, 50..60 Hz 230 V, 50..60 Hz PN

Stock code

3481040.57 3481041.57 3481042.57 3481043.57 3481044.57 3481045.57 3481046.57 3481047.57 3481048.57 3481049.57 3481050.57 3481051.57 3481052.57 3481053.57 .56

Pump control

Type approval TV WR 07-392

Control cabinet NRSP... Optional for two pumps


NRGS 11-1 1"

Equipment Stock code NRGS 11-1 / NRSP 1-11 3532048 / 3261140 .. .. NRGS 11-1 / NRSP 1-12 3532048 / 3261240 .. .. L = 1000 mm / H = 1000 mm

For flanges see Price List

101

GESTRA SPECTOR Family

SPECTORcom/control
SPECTORcom
Higher-level control system Ofce PC, laptop

Control the Controls SPECTORcontrol


Higher-level control system Ofce PC, laptop

Fixed network via modem

Fixed network via modem

Service partner,supplier

Service partner,supplier

I/O module

I/O module

SpecTORcom GESTRA has taken the next big step in boiler automation: as the first manufacturer worldwide, GESTRA is offering the remote monitoring of boiler systems with Spector com. No matter whether you want to use your companys intranet, the World Wide Web, your mobile phone, palmtop or Cassiopeia the current operating data are available anywhere, any time. Malfunctions can be detected and remedied at an early stage. SPECTORcom another milestone on the road to increased operational safety.

SpecTORcontrol If you want to undertake even more complex control tasks such as recording trend and quantity curves, producing malfunction or maintenance logs or interfacing the system with other control systems then you need the latest newcomer to the SPECTOR family SPECTORcontrol. The equipment acquires all measured values arriving from the electronic sensing units and relays them to the control centre. There the incoming data are combined in order to establish higher-level statements which are displayed on a colour monitor. Pressure, temperature, conductivity etc. will be controlled automatically.

102

Self-Monitoring Low/High-Level Alarms Conventional Design


Description Functional Safety
Since the international standards IEC 61508 and IEC 61511 for functional safety came into effect there has been an ever-increasing demand for analyzing equipment and process instruments that meet the requirements according to the SIL (Safety Integrity Level) classification. The European directives EN 12952 and 12953 demand that a hazard analysis shall be carried out for each limiting device function and appropriate levels of functional safety be implemented. Note 1 states: Typical Safety Integrity Level (SIL) requirements for boiler protective systems are not less than 2. Functional safety is part of the overall safety of a system that depends on the correct functioning of safety-related (sub)systems and external equipment for risk reduction. This means that functional safety covers only one aspect of the overall safety. Other issues such as electrical safety, fire and radiation protection etc. do not fall within the scope of functional safety. In modern systems electronic and, in particular, programmable systems perform safety functions to an ever increasing extent. As a consequence it is of utmost importance to assure the correct functioning of complex programmable systems. It is therefore essential to establish suitable methods for preventing systematic faults (usually due to human error committed during the specification and implementation phase) and for controlling failures, abnormalities and loss of function (usually physical phenomena). In this context the term safety integrity of the protective or safety function is used. The European standard IEC 61508 Functional safety of electrical/electronic/ programmable electronic safety-related systems defines procedures, techniques, measures etc. for the functional safety of E/E/PE systems.

Low-level limiter NRG 16-50 / NRS1-50 b


Application and Purpose Use self-monitoring low-water limiter with periodic self-checking type NRG 16-50 in combination with level switch NRS 1-50 in steam boilers and hot-water plants. The equipment meets the German regulations for use in steam boiler plants operating without constant supervision (TRD 604 sheet 1 and 2). For boiler operation acc. to TRD 604 two selfmonitoring low-level limiters are required and for boiler operation to TRD 602 only one selfmonitoring low-level limiter is necessary. The system is certified to SIL 3. The level electrode NRG 16-50 can be combined with the following GESTRA systems:
NRG 26/NRR 2-2 (modulating level control) NRG 26/NRR 2-1 (modulating level control) NRG 26/NRS 2-1 (on-off level control) NRG 16-52/NRS 1-5 (on-off level control) NRG 16-4/NRS 1-2 (high-level alarm) NRG 16-51/NRS 1-51

Combination of low-level limiter and controller NRG 16-36 / NRS 1-50 / NRS 1-5
Application and Purpose Level controller and self-monitoring lowwater level limiter with periodic self-checking feature to be used in conjunction with level electrode NRG 16-36 for on-off boiler feed water control, high level detection (alarm) and low-water level limiting (min. level alarm). Application in steam and pressurized hotwater boiler installations in accordance with TRD 602 and TRD 604, sheet 1 and 2. Design NRS 1-50 Plastic case with freely accessible terminals, for installation in control cabinets. The equipment can be snapped onto a 35 mm support rail. Field enclosure for one or more units available on request. The system is certified to SIL 3. Design NRS 1-5 b Plug-in unit in plastic case for installation in control cabinets. The terminals are accessible after unplugging the cover from the housing base. The equipment can be snapped onto a 35 mm standard support rail or attached to a mounting panel. Field enclosure for one or more plug-in units available on request.

(self-monitoring high-level alarm) The level electrode NRG 17-50 can be combined with the following GESTRA systems:
NRG 17-51/NRS 1-51 (high-level alarm)

The level electrode NRG 19-50 can be combined with the following GESTRA systems:
NRG 19-51/NRS 1-51 (high-level alarm)

103

Self-Monitoring Low/High-Level Alarms Conventional Design

High-Level Alarms
Description Conventional Design NRG 16-4 / NRS1-2
Application and Purpose Use in combination with level switch NRS 1-2 for water-level limiting (low-level alarm), on-off liquid control and signalling of levels of conductive liquids. The stainless steel design is particularly suited for aggressive fluids. For vessels and steam boilers up to PN 40 with level switch in accord ance with TRD 604 (boiler oper ation without constant super vision). Sensing unit for high-level alarm and level control. Design The level electrode NRG 16-4 is available with screwed connection 3/8" BSP Material: X6CrNiMoTi17-12-2 (DIN no. 1.4571) The electrodes are supplied in different lengths (see data sheet). For switching levels between these dimensions the electrode tip can be cut to length as required. Wiring to the electrode is effected by a four-pole connector.

Self-Monitoring NRG 16-51 / NRS 1-51


Application and Purpose Use in combination with level switch NRS 1-51 as self-monitoring high-level alarm with periodic self-checking according to TRD 604 sheet 1 and 2 for high-water level detection (high-level alarm) in steam and pressurized hot-water boilers. Design The high-level limiting system comprises level electrode NRG 16-51, NRG 17-51 or NRG 19-51 and level switch NRS 1-51. The system is certified to SIL 3.

The level electrodes NRG 16-51, NRG 17-51 and NRG 19-51 consist of a measuring electrode fitted in a body. The electrode is insulated by special insulating seals. The pressure-tight connection of the electrode is effected coaxially with a contact ring and a stud. A system of compression springs in the electrode body ensures sufficient sealing forces at the insulating seals, even if tem peratures vary. The stud is insulated by a PTFE foil. Contact ring and body are connected to the four-pole connector base by PTFE insulated wires. The level electrode is available in various lengths up to 1500 mm. Observe mounting instructions (see examples of installation). The system (electrode + level switch) complies with the regulations con cerning protection circuits for firing equipment of furnaces in accordance with DIN 57116 / VDE 0116.

Technical Data
Type NRG 16-50 NRG 16-36 NRG 17-50 NRG 19-50 NRG 111-50 NRG 16-4 NRG 16-51 NRG 17-51 NRG 19-51 Pressure rating PN 40 PN 40 PN 63 PN 160 PN 320 PN 40 PN 40 PN 63 PN 160 End connection " 1" " " 1" 8" " " " Service pressure [bar] / Saturated steam temperature 32 / 238 32 / 238 60 / 275 100 / 311 180 / 357 32 / 238 32 / 238 46 / 260 100 / 311 Lengths supplied [mm] 500 3000 1000 1500 500 3000 500 3000 500 3000 500 1500 500 1500 500 1500 500 1500 Ambient temperature [C] 70 70 70 70 70 70 70 70 70

104

Self-Monitoring Low/High-Level Alarms Conventional Design


Self-monitoring low-level limiter
Level electrode NRG 16 -50 " BSP DN 50 mm Connecting flange Alarm LW1 Alarm LW2

Level switch NRS 1-50, 2E

Burner protection circuit

Type NRG 16-50, NRS 1-50, 2E NRG 17-50, NRS 1-50, 2E NRG 19-50, NRS 1-50, 2E NRG 111-50, NRS 1-50, 2E

PN L = 1000 mm 24 V DC L = 1000 mm 24 V DC L = 1000 mm 24 V DC L = 1000 mm 24 V DC 40 63 160 320

Stock code 3131642 3101241 3131942 3101241 3132042 3101241 3132142 3101241

Low level

Low level

0525

Type approval TV SWB 09-422 EG IS-TAF-MUC 0908 103 881 005 SIL 3 Optional voltages: NRS 1-50 Special voltage: 100..240 +10 %/-15 % V, 47..62 HZ
Type L = 1000 mm NRG 16-36, NRS 1-50, 1E 100...240 V 230 V NRS 1-5 PN 40

Low-level limiter, on-off control and high-level alarm


Combination electrode NRG 16-36 1" BSP NRS 1-50

Stock code 3581047 310114150 3232841

DN 50 mm Connecting flange High level Level control Low level

Burner protection circuit High-level alarm (pump OFF)


Pump ON/OFF NRS 1-5

Type approval NRS 1-50 TV SWB 09-422 EG IS-TAF-MUC 0908 103 881 005 SIL 3 NRS 1-5 TV WR 10-302

0525

Optional voltages: NRS 1-50 Special voltage: 24 V DC Optional voltages: NRS 1-5 Special voltage 115 V, 24 V, 50-60 Hz

For flanges see Price List

High-Level Alarms Conventional Design


High-level alarm (conventional design)
Level electrode NRG 16-4 3/8" BSP Deactivation of make-up water for boiler

Type NRG 16-4, NRS 1-2

L = 1000 mm 230 V

40

Type approval TV WR 10-302

DN 50 mm Connecting flange High level Level switch NRS 1-2

Self-monitoring high-level alarm


Level electrode NRG 16-51 3/4"BSP Alarm HW

DN 50 mm Connecting flange Level switch NRS 1-51 High level

Type NRG 16-51, NRS 1-51 NRG 17-51, NRS 1-51 NRG 19-51, NRS 1-51

PN L = 500 mm 24 V DC L = 500 mm 24 V DC L = 500 mm 24 V DC 40 63 160

Stock code 3132241 3101541 3132341 3101541 3132441 3101541

Deactivation of make-up water for boiler/safety chain

Type approval TV EG IS-TAF-MUC 0908 103 881 006 SIL 3 Optional voltages: NRS 1-2 Special voltage: 115 V, 24 V, 50..60 HZ Optional voltages: NRS 1-51 Special voltage: 100..240 +10 %/-15 % V, 47..62 HZ

For flanges see Price List

105

PN

Stock code 3441241 3231441

Modulating Level Control Conventional Design


Description Level control NRG 26-21/ NRR 2-2e
This modulating level control system comprises the level electrode NRG 26-... and the level controller NRR 2-2. The level-dependent actual value sensed by the electrode is continuously compared by the controller with the adjusted setpoint. Any deviation is immediately detected and a signal is transferred to the motorized feedwater control valve in order to regulate the flowrate accordingly. The level controller is of the pro portional type and provided with a manual control facility. In addition it features a signal for high-level alarm, first low-level alarm and a current output for the display unit URA used for remote level indication. The switchpoints are adjustable within the whole measuring range of the level electrode.

Level control NRG 26-21/ NRS 2-1


This water-level controller is to be used in conjunction with one level electrode NRG 26-... and one limit switch NRS 2-1. A second max.-min. limit switch enables establishing additional switchpoints such as high level alarm and first low-level alarm. Using level transmitter NRT 2-1 and display unit URA makes remote level indication possible. The advantage of this switching controller lies in customized switchpoints which can be adjusted during operation and the simultaneous use of several control units.

Level control LD 244 /KS 92-1


Used in conjunction with P controller type KS 92-1 for modulating water level control (pressure range > PN40). The intelligent buoyancy transmitter works on the Archimedean buoyancy principle. The buoyancy is proportional to the liquid level and transformed by the measuring trans ducer into the standard output signal 4...20 mA.

Level control 705 /KS 92-1


Used in conjunction with P controller type KS 92-1 for modulating water level control (pressure range > PN40). Can also be used as combination electrode together with limiters. The 705 is a radarbased level transducer. The reflexion time is a function of the level and will be trans formed into a 4...20 mA standard output signal by the measuring transducer.

106

Modulating Level Control Conventional Design


Modulating control with adjustable switchpoints
Level probe NRG 26-21
Pressure rating PN 40

Equipment NRG 26-21 NRR 2-2e URA 2 Type approval TV WR 06-320

L = 1000 mm 230 V 230 V

Stock code 3452147 3241343 3311344

High-level alarm
DN 50 mm Connecting flange

First low-level alarm Level controller NRR 2-2 Remote level indicator URA2

High level Level control Low level

Feedwater control valve V 725

Control valve with isolating bypass valve, strainer, non-return valve and feedback potentiometer
Pressure rating PN 40

Equipment

3 x GAV 36, Control valve V 725, GSF, RK 230 V, 50 Hz

Control valve V 725 GAV 36 GAV 36 GSF GAV 36

Boiler capacity t/h < 2.5 < 8.0 < 16.0 < 28.0

DN 20 40 50 65

RK

GAV 36 with throttling plug

For other nominal sizes refer to pages GAV 80 81 GSF 78 RK 38 49 V 725 72


Equipment NRG 21-11 NRS 2-1 NRT 2-1 URA 2
H = 1000 mm 230 V 230 V 230 V Bestell-Nr. 3421247 3231741 3301441 3311344

On-off control with adjustable switchpoints


Pressure rating PN 6

Level transmitter NRT 2-1 Level probe NRG 21-11


DN 50 mm Connecting flange

Remote level indicator URA 2

Limit switch NRS 2-1 High-level alarm First low-level alarm Limit switch NRS 2-1
Pump Pump ON OFF

Optional voltages: NR. 2-., URA. Special voltages: 115 V, 24 V, 50..60 HZ

Type approval TV WR/WS 04-317

High level Pump OFF Pump ON First low-level alarm

For flanges see Price List

High-Pressure Level Control / Pump Control


Continuous level monitoring for high-pressure applications
4..20 mA

LD 244 (705)

50 %

High-level alarm Control valve


KS 92-1

100 % 0%

PLC

Continuous level monitoring by means of intelligent buoyancy transmitter, output 4-20 mA, compl. with cover flange kit.

Design DN 80 DIN 3526 Form E 160 DN 80 DIN 2696 Form L Type approval TV WRS 06-324 705 100 DN 50 DIN 2696 24 V, DC Form E 160 DN 50 DIN Form E Approval GL/Stoomwezen

Type LD 244 24 V, DC

PN 100

Measuring range 350 500 1000 350 500 1000

600 800 1000 600 800 1000

107

Accessories for Liquid-Level Alarms Fitted in External Level Control Pots


Description Level pot for external installation of level electrodes Stop Valve GAV
Purpose For isolating and throttling non-corrosive and aggressive gases, steam and liquids, e. g. air, steam, gas, oil etc. in all industries. GAV Features With stuffing box Detachable locking device for all sizes Optional limit switch(es) Y-type drain valve 17/213

Additional equipment for the external installation of liquid level alarms SRL-63
Purpose In combination with external low-level alarms for monitoring the periodic purging of level pots or, generally, as timer for monitoring any periodic function. Particularly suitable for steam plant operation to TRD 602/604. Design All-electronic logic unit SRL-50 for continuous monitoring, with three LEDs (stand-by, purging, switching off) with case for mounting on walls. Operation The monitoring equipment with Mini-PLC periodically activates a memory for a defined period of time. During this period the memory registers all functional operations, e. g. purging of the level pot. If this signal is not received within the fixed period, the plant is shut down. The plant is also shut down if the purging process lasts for more than five minutes.

Type code of level pots


Feature Component Design: (side connection) Nominal pressure Size Material In accordance with Approved by Connection (N 1) Boiler connection (N 2) Drain connection (N 3) Side connection 3 + 4 (N 4) Side connection 5 + 6 (N 5) Value Level pot 1 Side connection 2 Side connection 4 Side connection 90r 4 Side connection 90l 4 Side connection 180 4 Side connection 90R+90L PN 16 PN 40 PN 63 PN 160 88.9 114.3 Steel type ST 35.8 High-temperature steel 15 MO 3 Austenitic AD-Bulletin TRD Others TV Works inspector Others 3/ " BSP 4 1" BSP 1 1 /4" BSP 11/2" BSP DN50 mm DN80 mm DN100 mm DN15 mm DN20 mm DN25 mm DN50 mm 1/ " BSP 2 DN20 mm DN25 mm DN20 mm DN25 mm DN20 mm DN25 mm Designation MF 10 20 40 41 42 60 4 6 7 9 1 2 S W A A T S T W S 114 G 115 G 116 G 117 G 118 P 120 P 121 P 212 P 214 P 215 P 218 P 312 G 314 P 315 P 414 P 415 P 514 P 515 P ME 1500 Spec. > Spec. > Spec. > Spec. > MF 206-1STT 118 P / 214 P / 312 G >

not required in this example not required in this example

Centre distance 1500 Length (top) e. g. 230 Length (bottom) e. g. 170 Volume 11 l Serial no. e. g. 123460

Additional specification Centre distance ME =1500 mm Length (top) = 230 (not < 190 mm) Length (bottom) =170 (not < 140 mm) 11 l Serial no. = 123460

108

Accessories for Liquid Level Alarms Fitted in External Level Control Pots
Accessories for liquid level alarms fitted in external level control pots
NRG 26 GAV Flange DN 50 mm

Type

PN

Pressure/Temp. Ratings Pmax tmax


32 bar 60 bar 75 bar 100 bar 96 bar 238C 275C 290C

Level pot GAV

1) MF 2061 STT GAV 36, DN 20 40 17/213, 1/2"BSP 2) MF 2071 STT 63 GAV 136, DN 25 2) MF 2091 STT 160 GAV 136, DN 25 2) MF 2091 WTT 160 GAV 136, DN 25 1) Approval acc. to PED 97/23/EC, module A1 2) Approval acc. to PED 97/23/EC

311 C 300 C

GAV

Accessories for high-integrity level controls fitted in an external level control pot
SRL 50 NRS 1-50

Type

DN / PN

Pressure/Temp. Ratings Pmax tmax


32 bar 238C

NRG GAV Flange DN 50 mm

GAV

Level pot

1) MF 2061 STT GAV 36-II 20 / 40 GAV 36-I SRL 50 2) MF 2071 STT GAV 136-II 25 / 63 GAV 136-I SRL 50 2) MF 2091 STT GAV 136-II 25 / 160 GAV 136-I SRL 63 2) MF 2091 WTT GAV 136-II 25 / 160 GAV 136-I SRL 50 1) Approval acc. to PED 97/23/EC, module A1 2) Approval acc. to PED 97/23/EC

60 bar

275C

75 bar 100 bar 96 bar 96 bar

290C

311 C 300 C 300 C

GAV

Accessories for high-integrity level controls fitted in an external level control pot Bus based
SRL 6-40 NRS 1-40.1

Type

PN / PN

Pressure/Temp. Ratings Pmax tmax


32 bar 238C

NRG GAV Flange DN 100 mm Level pot

GAV

GAV

1) MF 2062 STT GAV 36-II 20 / 40 GAV 36-I SRL 6-40 2) MF 2072 STT GAV 136-II 25 / 63 GAV 136-I SRL 6-40 2) MF 2092 STT GAV 136-II 25 / 160 GAV 136-I SRL 6-40 2) MF 2092 WTT GAV 136-II 25 / 160 GAV 136-I SRL 6-40 1) Approval acc. to PED 97/23/EC, module A1 2) Approval acc. to PED 97/23/EC Optional SRL: Voltage 115 V, 24 V, 50..60 Hz

60 bar

275C

75 bar 100 bar 96 bar 96 bar

290C

311 C 300 C 300 C

More measuring pots see page 129

109

Level Probes and Control Units for Very High Pressure /Temperature Ranges
Design
The probe works without any moving parts. The probe rod, which is insulated by a ceramic tube, is inserted through a hole in the probe flange such that pressure-tight sealing is ensured. The ceramic tube is closed at the lower end and covered by a protection tube. The electronic control unit is housed in the terminal box. The wiring is effected via a 6 pole connector with crimp connection.

Operation
The principle of capacitance measurement is used to sense liquid levels. The probe rod and the protection tube form a capacitor, with air or the particular liquid being the dielectric. In electrically conductive liquids the probe insulation serves as dielectric. As the level rises or falls, the capacitance of this assembly changes, is converted in the integral measur ing transducer into a signal, and is then fed to the associated electronic control unit.

NRG 211
In combination with level switch NRS 2-4 for indicating high-water level at very high pressures and temperatures (up to PN 320, 550 C). Application in draining systems of conven tional power stations and high-pressure steam boilers.

NRS 2-4
The level switch NRS 2-4 is an analogue electronic amplifier for the capacitance electrode type NRG 211. In combination with this level electrode the unit can detect high water level. In addition, the level switch evaluates possible malfunction signals coming from the electrode and monitors the electrode supply cable and can therefore be used as part of a controlled draining system in power stations.

110

Level Control for Very High Pressure /Temperature Ranges

NRS 2-4 (two) Malfunction (alarm)

Steam line

Control signal 24 V DC

NRG 211

NRG 211

Control signal Malfunction (alarm) 24 V DC NRS 2-4 (two) Control signal

Bypass steam trap BK

Control valve ZK

Type NRG 211 *)

Material 1.5415

PN 320

1.7380 1.4922 NRS 2-4


HW

200 bar at 450 C 320 bar at 120 C 200 bar at 500 C 320 bar at 120 C 230 bar at 550 C 320 bar at 120 C

Stock code 350100130 DN 100 350100140 > DN 100 350100231 DN 100 350100241 > DN 100 350100332 DN 100 350100342 > DN 100 3233142

*) with welding connection, nuts, bolts and seals for pipes > DN 100 or < DN 100

111

Marine Applications Level Electrodes and Controls


Description
Steam boiler equipment for marine applications has to comply with the same requirements as those placed on land installations. In addition to that further demands regarding environmental conditions such as climate, vibrations etc. have to be met. The acceptance certificates are to be issued by the classification society responsible for the ships acceptance inspection. Approvals for marine application see page 94.

Self-monitoring low-level limiter

Type NRG 16-50S NRS 1-50, 1E NRS 1-50, 2E

PN L = 1000 mm 100...240 V, 15s 100...240 V, 15s 40

Stock code 31317742 31011415053 31012415053

NRG 16-50S DN 50 mm

DN 50 mm Connecting flange Level switch NRS 1-50, 1E Low level

Optional 24 V DC NRG 16-50, 1E NRG 16-50, 2E


Burner protection circuit

310114153 310124153

Self-monitoring low-level limiter and continuous level control

Type NRG 16-38S 24 V AC/DC

PN

4 20 mA

High-level alarm Control valve KS 92-1

40

max. length supplied 779 884 989 1095 1513

Stock code

NRG 16-38S DN 100 mm Connecting flange 100 % Low level

NRS 1-7 230 V, 15s


Burner protection circuit

3582044.57 3582045.57 3582046.57 3582047.57 3582051.57 323254153

Level switch NRS 1-7

Optional NRG 16-38s, 115 V 50-60 HZ .56 NRG 16-38s, 230 V 50-60 HZ e. g. 3582044.

0%

112

Marine Applications Level Electrodes and Controls


Self-monitoring limiter and modulating level control
max. length supplied 779 884 989 1199 1513

Type

PN 40

Stock code

4 20 mA

High-level alarm Control valve KS 92-1

NRG 16-39 S 24 V AC/DC

2 x LW

2x Burner protection circuit

NRS 1-7 2x 230 V, 15s

3584044.57 3584045.57 3584046.57 3584047.57 3584051.57 323254153

NRG 16-39 S DN 150 mm Connecting flange


100 % Low level

Optional NRG 16-39s, 115 V 50-60 HZ .56 NRG 16-39s, 230 V, 50-60 HZ e. g. 3584044.

Level switch NRS 1-7

0%

Compact system for modulating level control


4 20 mA High-level alarm Control valve KS 92-1 NRGT 26-1S DN 50 mm 100 % PLC

Type NRGT 26-1S 24 V AC/DC

PN 40

max. length supplied 316 420 526 631 737 842 947 1053 1579

Stock code

3211452.53 3211453.53 3211454.53 3211455.53 3211456.53 3211457.53 3211458.53 3211459.53 3211460.53

0%

Optional 115 V 50-60 HZ .52 230 V, 50-60 HZ e. g. 3211452. Modulating level control with current output 4-20 mA power supply 230 V, 50 Hz.

Compact system for on-off level control with fixed switchpoints


High-level alarm Pump ON/OFF

Type

PN 40

Water-level controller with two additional limit contacts, power supply 115/230 V, 50 Hz.

NRGS 16-1S 230 V, 50-60 Hz

max. length supplied 938 1438

Stock code

3534053 3534056

NRGS 16-1S DN 50 mm

First low-level alarm

Optional 24 V AC

.51

High-level alarm Pump OFF Pump ON First low-level alarm

113

GESTRA Equipment for Energy Supply Centres

GESTRA's SPECTORbus Boiler Equipment GESTRA offers the world's first control system package for energy supply centres working with an open CAN bus system, thereby permitting an easy integration into other open bus systems.

114

Industrial Electronics

Page Temperature Control..........................................................................................................116 119 Conductivity Basic Principles and Applications.................................................................................................120 Technical Specification................................................................................................................121 SPectORbus/compact Conductivity/Intermittent Boiler Blowdown.........................................................................122 123 Conventional Conductivity Control with Manual or Automatic Temperature Compensation ..............................................................................................124 126 Conductivity Control with Manual or Automatic Temperature Compensation and Condensate Monitoring ...................................................126 127 Ancillaries: Tee Pieces, Level Pots and Portable Measuring Instruments VRM. .....................128 129 Continuous Blowdown Valves ........................................................................................130 131
Intermittent Blowdown Programme Controlled Blowdown Systems .........................132 133
Intermittent Blowdown Valves .........................................................................................134 135

Contamination Detectors for Condensate and Process Liquids Detecting ingress of oil in condensate systems and marine installations . .........................136 137 Detecting ingress of acids, alkalis, raw water ...................................................................136 137 Digital indicator (ingress of oil in cooling water)...........................................................................138 Flowmeters................................................................................................................................... 139. SPectORcontrol. .......................................................................................................................... 140

115

Temperature Control Bus


NRS 1-40.1
Self-monitoring temperature switch with periodic self-checking feature to be used in conjunction with a resistance thermometer type TRG 5-6.. and pre-amplifier TRV 5-40. The equipment operates as a safety tem perature controller, or in con junction with an external lock-out in accordance with DIN EN 50156 as a safety temperature limiter. An alarm is given as soon as the temperature exceeds a preset limit value. The TRV 5-40 features digital indicators for the actual temperature and switching-off tem perature.

Examples of Installation
Superheaters for steam boiler plants

TRS 5-40
The min/maX temperature switch TRS 5-40 in combination with tem perature sensor TRG 5-63 and pre-amplifier TRV 5-40 serves as temperature controller. Appli cation in steam boilers, pressurized hot-water plants oper ating without constant super vision (TRD 604) as well as any other type of heat generator. The equipment raises an alarm when the preset MIN/MAX limit value is attained.

perating without constant super o vision (TRD 604). Superheater cascades with up to 4 steps In pressurized hot-water plants as tem perature limiter for the secondary circuit in accordance with TRD 604 or 12952/..53. Furnaces in accordance with DIN 30 683 up to 800 C. Control systems for product heating or cooling

Technical Data of Temperature Sensor


Type TRG 5-63 TRG 5-64 Accuracy class A TRG 5-65 TRG 5-66 TRG 5-67 TRG 5-68 Accuracy class A/B 160 160 160 160 5-40 5-40 5-40 5-40 form 4 form 4 form 4 form 4 1 1 1 1 540 C 540 C 650 C 650 C 100 C 100 C 100 C 100 C 115 140 200 200 PN 40 40 Screwed " " Connections TRV... 5-40 5-40 Welding stub Pt 100 1 2 Max. temperature 400 C 400 C Ambient temperature 100 C 100 C Lengths available L [mm] 100 to 400 100 to 400

Technical Data of Temperature Pre-Amplifier


Type TRV 5-40 Output CANopen Adjustment range 650 C Auxiliary power 24 V, DC Version a Performance test annual TV EC

Technical Data of Temperature Switches / Controllers / Indicators


Type
NRS1-40.1

Outputs Switchpoint 0/4-20 mA 1 1 4

Control characteristic T MIN MAX


Mains supply Standard

Version c

Performance test in acc. with DIN3440 annual

TV approval

EC

230 V 230 V 230 V

NRS 1-40.2 TRS 5-40

116

Temperature Detection and Control

Safety temperature limiter


Temperature switch NRS1-40.1

Safety temperature limiter


Combination PT 100 TRG 5-67 TRG 5-68
TRV 5-40

PN T < 650 C L = 200 mm L = 200 mm 24 V, DC 230 V, 50-60 Hz 160 160 PN T < 540 C L = 115 mm L = 140 mm 24 V, DC 230 V, 50-60 Hz 160 160

Stock code 2671822 2671923 2691040 3222841 Stock code 2671611 2671712 2691040 3222841

TRV 5-40 NRS 1-40.1 Combination PT 100 TRG 5-65 TRG 5-66 TRV 5-40 NRS 1-40.1

Steam boiler

Superheater

Temperature sensor TRG 5-. . .

Burner

0525

Type approval TV SWB/SHWS/STW (STB) 08-413 EG MUC 03 07 103881 004 DIN CERTO STW (STB) 117906

Pressurized hot-water boiler acc. to EN 12953


NRS 1-40.1
NRS 1-40.2 URB 2 TRV 5-40 TRS 5-40

Pressurized hot-water boiler


Combination PT 100 TRG 5-63 TRV 5-40 NRG 16-40
TC

PN T < 400 C L = 100 mm 2x 24 V, DC 1x 40 40 230 V, 50-60 Hz

Stock code 2671110 2691040 3514041 3222841 3228941 2554041 3382043

NRS 1-40.1 NRS 1-40.2 TRS 5-40 URB 2

STB STW WB TC

STB STW TC WB

= = = =

Safety temp. limiter Safety temp. controller Thermocouple High level alarm

TV STW 1182 06 DIN CERTO TR/TW 118206

Burner

For other PT 100 see Price List.

Pressurized hot-water boiler acc. to TRD604


NRS 1-40.1 NRS 1-40.2 URB 2 TRS 5-40

Pressurized hot-water boiler


Combination PT 100 TRG 5-63 TRV 5-40 NRG 16-40 NRS 1-40.1 NRS 1-40.2 TRS 5-40 URB 2 230 V, 50-60 Hz T < 400 C L = 100 mm 2x 24 V, DC 2x 40 40 2671110 2691040 3514041 3222841 3228941 2554041 3382043 PN Stock code

TRV 5-40 2x

STW(B) STW(B) WB TC

TC

Burner

117

Temperature Control Conventional


TRS 5-6
Self-monitoring temperature switch with periodic self-checking feature to be used in conjunction with a resistance thermometer type TRG 5-... . The equipment operates as a safety temperature controller, or in con junction with an external lock-out in accordance with EN 14597 as a safety temperature limiter. An alarm is given as soon as the temperature exceeds a preset limit value. Use in combination with a twin PT 100 for temperature indication.

Examples of Installation
Superheaters for steam boiler plants

TRS 5-8
The min./max. temperature switch TRS 5-8 in combination with tem perature sensor TRG 5-53, TRG 5-54, TRG 5-55, TRG 5-57, serves as temperature controller according to EN 14597. Application in steam boilers, pressurized hot-water plants oper ating without constant supervision (TRD 604) as well as any other type of heat generator. The equipment raises an alarm when the preset MIN/MAX limit value is attained.

perating without constant super o vision (TRD 604).


In

TRS 5-7
Self-monitoring temperature switch with periodic self-checking feature to be used in conjunction with a resistance thermometer type TRG 5-... . The equipment operates as a safety temperature controller, or in conjunction with an external lock-out in accordance with EN 50156 as a safety temperature limiter. An alarm is given as soon as the temperature exceeds a preset limit value.

pressurized hot-water plants as emperature limiter for the t secondary circuit in accordance with TRD 604 or EN 12952/..53. Furnaces in accordance with DIN 30 683 up to 1000 C. Return-temperature control acc. to TRD 604. Control systems for product heating or cooling.

Technical Data of Temperature Sensor


Type TRG 5-11 TRG 5-41 TRG 5-53 TRG 5-54 TRG 5-55 TRG 5-57 Accuracy class B PN 1 160 40 40 160 160 Screwed " " " Connections TRS... Welding stub 5-7 5-7 5-6, 5-8 5-6, 5-8 5-6, 5-8 5-6, 5-8 form 4 form 4 form 4 Pt 100 1 2 1 1

Thermocouple type K
2 2

Max. temperature 1000 C 650 C 400 C 400 C 540 C 540 C

Ambient temperature 120 C 120 C 100 C 100 C 100 C 100 C

Lengths available L [mm] 710 200 100 to 400 100 to 400 115 140

Technical Data of Temperature Switches / Controllers / Indicators


Type
TRS5-6

Outputs Switchpoint 0/4-20 mA 1 1 2 3


Control characteristic T MIN MAX


Mains supply Standard

Version c e

Performance test in acc. with DIN3440 annual annual


Temperature range 30 C to 540 C 0 C to 1000 C 30 C to 540 C 70 C to 620 C

TV approval

EC


PID

230 V 230 V 230 V 230 V

TRS 5-7
TRS5-8

KS 92-1

118

Temperature Control

Safety temperature limiter


Temperature switch TRS5-6

Safety temperature limiter


Combination PT 100 TRG 5-54 TRS 5-6 T < 400 C L = 160 mm 230 V/50...60 Hz 40 2651716 2551741 PN Stock code

Temperature indicator

Type approval DIN STW (STB) 985 07 S EG 01 202 931-B-01-0008 Combination Thermocouple
Temperature sensor TRG 5-54

PN

Stock code

Type K TRS 5-7

T > 540 C to < 650 C 160 2671541 2551841 230 V/50...60 Hz

Steam boiler

Superheater

TRG 5-41 L = 200 mm

Burner

0525

Type approval DIN STW (STB) 986 07 S EG 01 202 931-B-01-0007

Pressurized hot-water boiler acc. to TRD604

Return-temperature controller
Combination PT 100 T < 400 C L = 160 mm 230 V/50...60 Hz 40 2651610 2551941 TRG 5-53 TRS 5-8 PN Stock code

TRS 5-6 TRG 5-5.. TRS 5-6 TRG 5-5.. TRS 5-8

Type approval DIN TW 106807 TV TW 106807

TRG 5-5..

For other PT see Price List. Option:TRS 5-... Voltage 24 V or 115 V AC on request

119

Conductivity Monitoring Basic Principles Application


Function
All boiler water contains some dissolved solids. These impurities are constantly concentrated due to the evaporation process, i. e. the total dissol ved solids (TDS) level increases. If the TDS level were to exceed the permissible maximum stipulated by the boiler manu facturer, foaming and carry-over would take place, leading to conta mination of the steam distribution system. As a result, the operational reliability of the plant will be impaired, and the boiler and steam system can be badly damaged. Effective blowdown can be provided by use of blowdown controller in conjunction with conductivity electrode and con tinuous blowdown valve BAE 46-211/ball valve 510. Deposits of fine suspended solids forming scale on the heating surfaces and settling at the bottom of the boiler are the result of residual hardness or an excessive phosphate content within the boiler water. These scale formations form a heat insulating layer, surfaces which means that the heat transfer are now subject to design pressure, but at ele vated temperature, which in turn can cause deformation and even an explosion. The answer to this problem is the use of continuous blowdown controller TA 5 / 6 / 7, solenoid valve 340 and intermittent blowdown valve MPA 46 / MPA 47 / MPA 110.

Principles of Measurement
Conductivity measurement, 2-electrode system An alternating voltage is applied to two electrode tips (polarization). The current flow is directly proportional to the specific con ductivity of the fluid. Particularly suitable for pure fluids applications up to 500 S/cm (e.g. steam regenerators, condensate/feedwater tanks, steam generating units > PN 40 etc.). Conductivity measurement, 4-electrode system The 4-electrode method is used in order to improve the quality of the measuring result and to avoid polarisation. This measuring method separates the current-carrying from the voltage-carrying measuring electrodes, which means that the measurement is performed without current and therefore free of polarisation and that dirt deposits can be compensated to a large extent. Particularly well suited for boiler water with high conductivities (e.g. industrial steam boilers up to PN 40). Temperature compensation (T Comp) In plants with temperatures above 25 C the influence of temperatures on conductivity is an important factor to be considered. Due to electrolytic dissociation (desintegration of a compound in a solution) conductivity increases considerably: Degree of dissociation 3 5 %/C. Manual temperature compensation is suitable for plants with steady service temperatures. The actual conductivity is obtained by carrying out a com parison measurement (calibration) to offset thermal errors. Automatic temperature compen sation (ATC) is ideal for plants with varying service temperatures in order to make conductivity values independent of changes in ambient temperatures. The measured and the indicated values always refer to 25 C and are constantly compensated for changes in pressure and temperature.

Application
Steam boilers

Boiler water, feedwater and condensate monitoring acc. to TRD Condensate monitoring Condensate monitoring Condensate monitoring Condensate monitoring Conductivity monitoring Dyebath monitoring Detection of different products Maintaining defined conductivity Continuous blowdown control Quality monitoring

District-heating plants Paper industry Pulp industry Catering kitchens Water-treatment plants Dyeworks Filling/bottling plants Electric boilers Cooling towers Pickling baths

120

Technical Specification Conductivity


Technical Data of Conductivity Electrodes
Type LRGT 16-1 LRGT 16-2 LRGT 17-1 LRG 16-40 LRG 16-41 LRG 17-40 LRG 16-4 LRG 16-9 PN 40 40 63 40 40 63 40 40 Connection 1" 1" 1" 1" 1" 1"
3/ 3/ 8" 8"

Max. service pressure [bar]/ Integrated temp. sensor saturation temperature 32 / 238 C 32 / 238 C 60 / 275 C 32 / 238 C 32 / 238 C 60 / 275 C 32 / 238 C 32 / 238 C

Max. admissible ambient temp. at terminal box 70 C 70 C 70 C 70 C 70 C 70 C 70 C 70 C

Lengths supplied [mm] 200 1000 180 1000 200 1000 200 1000 180 1000 200 1000 100 1200

TV approval

EC

Designs a = Field case b = Plug-in unit in plastic case c = 19" slide-in unit e = Case for panel mounting

Technical Data of Electronic Control Units


Type LRR 1-40 / LRG 16-40 / LRG 16-41 / LRG 17-40 LRR 1-40 / LRG 16-41 LRS 1-5 LRS 1-6 LRS 1-7 LRR 1-5 LRR 1-6 KS 90 / LRGT 16-1 / LRGT 17-1 KS 90 / LRGT 16-2 Outputs switchpoints 0/4 20 mA 3 3 1 1 2 1 1 2 2 optional optional optional Main supply Standard 230 V 230 V 230 V 230 V 230 V 230 V 230 V 230 V 230 V Protection IP 40 IP 40 IP 40 IP 40 IP 65 IP 40 IP 40 IP 54 / IP 20 IP 54 / IP 20 Design a b c e Measuring range (recommended) 0.5 to 10000 S/cm (0.5 to 500 S/cm) 100 to 10000 S/cm 40 to 10000 S/cm 0.4 to 100 S/cm 0.5 to 10000 S/cm 40 to 10000 S/cm 0.4 to 100 S/cm 20.5 to 10000 S/cm (0.5 to 500 S/cm) 100 to 10000 S/cm TV approval EC

121

Conductivity Spector Bus/Compact

LRG 16-40 / 17-40


The conductivity electrode LRG 16-40 / 17-40 works acc. to the conductivity measurement principle.

LRR 1-40
The conductivity controller LRR 1-40 is used in conjunction with conductivity electrode LRG 16-40 / 17-40 for conductivity monitoring and control. The conductivity controller has the following functions:
Two limits with one switchpoint each (high-

URB see page 98

LRG 16-41
The conductivity electrode LRG 16-41 features 4 electrodes working according to the conductivity measurement principle. The LRG 16-4x / 17-40 is designed for signalling the TDS value (conductivity) in electrically conductive liquids:
Conductivity permanently within predefined

level alarm, low-level alarm) or high-level alarm and intermittent blowdown program control.
Three-position control with predefined pro-

portional band.
Conductivity maintained within the control

control range of the electrode. The LRG 16-4x / 17-40 is to be used in conjunction with the conductivity controller LRR 1-40 or further system components. The conductivity data are transferred to the conductivity controller or other system com ponents via CAN data bus.

band defined by preset limits. The LRR 1-40 features an optional output for a standard signal 4-20 mA. The conductivity data are transferred from the electrode to the controller via CAN data bus.

LRGT 16-1 / LRGT 17-1


The compact system LRGT16-1 / 17-1 features 2 electrodes working acc. to the con ductivity measurement principle.

LRGT 16-2
The compact system LRGT 16-2 features 4 electrodes working acc. to the conductivity measurement principle. The LRGT 16-x / 17-1 is designed for signalling the TDS value (conductivity) in elec trically conductive liquids:
Conductivity permanently within predefined

control range of the electrode. The LRGT 16-x / 17-1 has a conduc tivity transmitter integrated in the terminal box for producing a standard signal 4-20 mA.

KS 90
The industrial controller KS 90 comes with a self-optimising feature as standard. In addition to the controller output it has also an integrated max. limit value so as to fulfill the requirements of TRD 604 for 72 hrs operation. The setpoint and the actual value are indi cated by a LED display.

Power 05
The Power 05 serves as a 24 V DC power supply unit for the compact system LRGT16-1 / 17-1.

122

Conductivity Monitoring Spector Bus/Compact with Automatic Temperature Compensation


Automatic continuous blowdown with limit signalling and intermittent blowdown automatic temperature compensation
Spector Bus LRG 16-41, 600 mm Tee piece 50/251) LRR 1-40 URB 2 BAE 46-40 < DN 15 mm < DN 20 mm < DN 25 mm < DN 40 mm < DN 50 mm MPA 46 < 6 t/h DN 25 mm < 28 t/h DN 40 mm Solenoid valve 340C " BSP Strainer GSF 335 " BSP Reducer " BSP " BSP LRG 17-40, 600 mm Tee piece 50/251) LRR 1-40 URB 2 BAE 47-40 < DN 25 mm < DN 40 mm < DN 50 mm MPA 47 < 6 t/h DN 25 mm < 28 t/h DN 40 mm Solenoid valve 340C " BSP Strainer GSF 335 " BSP Reducer " BSP " BSP
1)

24 V, DC

= ~
24 V, DC

Power 05 230 V, AC

PN 40 40

Stock code 3772946 147095 3802241 3382043 3891204 3891404 3891504 3891704 3891804 3661500 3661700 050334 067688 051539 3772846 1500989 3802241 3382043 3901504 3901704 3901804 3671500 3671700 050334 067688 051539

URB 2 LRG 16-41 1" BSP LRR 1-40 MAX GAV 811 Spector Bus

40 40 40 40 40 40 40 40 40 40 63

BAE 46-40

MV

GAV 811

MPA 46

0525

Signalling of max. conductivity value/automatic intermittent blowdown automatic temperature compensation


24 V, DC

63 63 63 63 63

= ~

Power 05 230 V, AC

24 V, DC LRGT 16-2 MAX 4-20 mA KS 90

Approval in acc. with PED97/23/EC, module A

Type approval: TV WL 07-007 EG BAF-MUC-02 03 103881 003

PLC

BAE 46 or BAE 46-3

0525

T-piece

Spector Compact LRGT 16-2, 380 mm KS 90 Power supply unit Power 05 LRGT 17-1, 400 mm

3373041 63 3772645

DN 50 mm

LRG 1.-41 LRGT 1.-2

KS 90 2661444 Power supply unit 3373041 Power 05 BAE46-3 and BAE210 see Price List Type approval: TV WL 06-003 EG BAF-MUC-02 04 105620 001 TV and EC type approval only in combination with KS 90.

GAV 811

BAE

For flanges see Price List


T-piece connector Approved in acc. with PED 97/23 EC PN 40 Approved in acc. with PED 97/23 EC PN 63

123

PN 40

Stock code 3773145 2661444

Conductivity Monitoring with Manual or Automatic Temp. Compensation LRG... / LRR 1. (Conventional Design)
Manual Temp. Compensation LRG 16-4
Purpose and Application The conductivity electrode LRG 16-4 is used in con junction with conductivity switch LRS 1-5/6 b or conductivity controller LRR 1-5/6 b to sense continuously the conductivity of process or boiler water.

LRR 1-5 b/LRR 1-6 b


Purpose and Application For automatically controlled blow down to reduce blowdown wastage and increase safety in operation. Use in conjunction with GESTRA conductivity electrode LRG 16-4 or LRG 17/19 as sensing unit, and GESTRA continuous blowdown valve BAE as control valve. Automatic closing of blowdown line during boiler shut-down. Current output for remote indication or recording of conductivity. Application in steam boilers, evaporators or similar plant, in particular plants operated auto matically, e. g. in accordance with the regulations for operation without constant super vision (TRD 604). Design Plug-in unit in plastic case for installation in control cabinets. The terminals in the case are accessible after undoing two screws and unplugging the unit from its base. To avoid confusion with other plug-in units of the GESTRA range, inserts are fitted in the bases so that only the correct unit may be plugged into each base. The plug-in units may be snapped onto a 35 mm supporting rail or screwed into position on a mounting panel. Field enclosures for several plug-in units are available on request.

URS2-b
Purpose and Application Universal signalling of two limit values as MAX and MIN alarm. Connection to a meas uring transducer with current output 0/4 20 mA. Application for instance with GESTRA level transmitter NRT 2-1b, continuous blowdown controller LRR 1-5 b and conductivity transmitter LRT 1-5b/LRT 1-6b. Design Plug-in unit in plastic case for installation in control cabinets. The terminals in the case are accessible after undoing two screws and unplugging the unit from its base. To avoid confusion with other plug-in units of the GESTRA range, inserts are fitted in the bases so that only the correct unit may be plugged into each base. The plug-in units may be snapped onto a 35 mm supporting rail or screwed into position on a mounting panel. Field enclosures for several plug-in units are available on request.

Automatic compensation LRG 16-9


Purpose and Application The LRG 16-9 in conjunction with LRS 1-7a monitors the electrical conductivity as well as the temperature of process, condensate, boiler and feed water thanks to the integrated resistance thermometer. The system is used for limit monitoring and/or automatic continuous boiler blowdown.

LRS 1-7a
Purpose and Application Used in conjunction with conductivity electrode LRG 16-9 for automatically controlled continuous boiler blowdown and/or limit monitoring in order to increase the economic viability and safety of the plant. Controlled boiler blowdown with temperature compensated indication of the electrical conductivity (TDS control). Application in steam boilers, evaporators, steam regenerators, condensate liners etc. Design Plastic casing for wall mounting with indicators and adjustors behind clear lid.

124

Conductivity Monitoring with Manual or Automatic Temp. Compensation LRG... / LRR 1. (Conventional Design)
Automatic Continuous Blowdown Control Manual Temp. Compensation < 275 C
4...20 mA LRR 1-5 URS 2 MAX MIN LRG 16-4

Equipment LRG 16-4 3/8" BSP LRR 1-5b URS 2 BAE 46-3 DN 15 mm BAE46-3 DN 20 mm BAE 46-3 DN25 mm

PN 40

Stock code 3772245 3801441 3351041

40 40 40

3891203 3891403 3891503

BAE GAV

0525
GAVsee pages 80 81 Flanges see Price List. Tee piece connector for LRG 16-4 see Price List. Level pots LRG 17-1/19-1 see page 129 (optional)

Automatic Continuous Blowdown Control Automatic Temp. Compensation


LRS 1-7 MAX 4...20 mA

Equipment LRG 16-9 " BSP LRS 1-7 Connecting cable male / female 5m BAE 46-3 DN 15 mm BAE46-3 DN 20 mm BAE 46-3 DN25 mm
Type approval: TV WL 09-014

PN 40

Stock code 3771839 3781641 1502563

40 40 40

3891203 3891403 3891503

LRG 16-9 BAE GAV

Optional LRS 1-7 Current output 4...20 mA Special Voltage 24 V AC

.57 .51

For cable see Price List

125

Conductivity Monitoring with Manual or Automatic Temperature Compensation LRG... / LRR 1- 5/6
Manual Temp. Compensation LRS 1-5 b, LRS 1-6 b
Continuous monitoring of the conductivity of liquids with GESTRA conductivity electrodes LRG 16-4, LRG 17 or LRG 19. Signalling of preset conductivity limits. Application in steam boiler plants for condensate and feedwater monitor ing; for condensate monitoring in district heating plants, in the paper and pulp industry and in catering kitchens; for conductivity monitoring in water treatment plants; for monitoring of cooling towers, for dyebath monitoring in dye works.

Automatic Temp. Compensation LRG 16-9


Purpose and Application The LRG 16-9 in conjunction with LRS 1-7a monitors the electrical conductivity as well as the temperature of process, condensate, boiler and feed water thanks to the integrated resistance thermometer. The system is used for limit monitoring and/or automatic continuous boiler blowdown.

LRS 1-7a
Purpose and Application Used in conjunction with conductivity electrode LRG 16-9 for automatically controlled continuous boiler blowdown and/or limit monitoring in order to increase the economic viability and safety of the plant. Controlled boiler blowdown with temperature compensated indication of the electrical conductivity (TDS control). Application in steam boilers, evaporators, steam regenerators, condensate liners etc. Design Plastic casing for wall mounting with indicators and adjustors behind clear lid.

Design The conductivity electrode LRG 16-9 works with 2 electrodes and uses the electrical conductivity of water for measurement. The integrated PT 100 measures the temperature, thereby enabling automatic temperature compensation.

126

Conductivity Monitoring with Automatic Temperature Compensation LRG... / LRS 1-7


Automatic temperature compensation Temperature > 275 C
BAE 210 GAV LRS 1-7

Sample valve unit > 275 LRG 16-9 Connecting cable male / female 5m
MAX-Alarm

Stock code 3771839 1502563

PK-250 PE2A LRS 1-7 BAE 210 DN 25 Fl. GAV see page 80 81
Type approval: TV WL 09-014

3781640 393150001

4...20 mA

PK Sample valve unit followed by conductivity electrode LRG 16-9


LRG 16-9

PK

Signalling of MAX and MIN conductivity values automatic temperature compensation


LRS 1-7

Automatic temperature compensation


Equipment LRG 16-9
MAX alarm 4...20 mA

PN 40

Stock code 3771839 1502563 3781641

Connecting cable male / female 5m LRS 1-7a


Type approval: TV WL 09-014 Optional LRS 1-7a Current output 4...20 mA Special voltage 24 V AC

.57 .51

Conductivity electrode LRG 16-9

BAE

127

Ancillaries: Level Pots and Portable Measuring Instruments VRM


VRM 2 The service case VRM 2 contains the conductivity meter GMH 3410. The GMH 3410 is equipped with a built-in measuring cell which measures the conductivity of water. Function The GMH 3410 is suitable for conductivities within a range from 0 to 200 mS/cm. Design VRM 2 Plastic case with foamed plastics insert. Conductivity measuring instrument GMH 3410 with built-in measuring cell. VRM 3 The service case VRM 3 contains the conductivity meter GMH 3410 and the pH measuring device GMH 3530. The GMH 3410 is equipped with a built-in measuring cell which measures the con ductivity of water. The GMH 3530 is equipped with pH electrode type GE 100 BNC and Pt 100 temperature probe type GTF 401. The electrode and the probe are plugged into the equipment. The service case contains also the handling and calibration set GAK 1400, consisting of:
5 orange capsules for the calibration

solution pH 4.01 and a plastic bottle


5 green capsules for the calibration

solution pH 7.01 and a plastic bottle


5 blue capsules for the calibration

solution pH 10.01 and a plastic bottle


1 bottle 3mol KCL-solution 1 bottle pepsin cleaning agent

Function The GMH 3410 is suitable for conductivities within a range from 0 to 200 mS/cm. The GMH 3530 together with the pH electrode GE 100 BNC can measure pH values from 0.00 to 14.00. The temperature probe measures tempera tures between 50 C and +250 C. For pH measuring the temperature range is limited to 10 C to 50 C. Design VRM 3 Plastic case with foamed plastics insert. Conductivity measuring instrument GMH 3410 with built-in measuring cell. pH meas. device GMH 3530 with pH electrode GE100 BNC and temperature probe GTF 401. Calibration set GAK 1400.

128

Ancillaries: Tee Pieces, Level Pots and Portable Measuring Instruments VRM
Tee Pieces for Conductivity Electrodes
Connections DN 2)
DN 15 40 Boiler DN 15 40 BAE DN 50 Boiler DN 15 40 BAE DN 50 Boiler DN 25 BAE 1" 1"
1)
3/8"

Stock code 141873 141874 141875 141876 147093 147094 147095 147096

1)

15 / 15 To suit electrode LRG 16-4 Material:C 22.8 / St 35.8 Pressure rating: PN 40 20 / 20 25 / 25 401) / 40 15 To suit conductivity electrodes LRGT 16-1 / LRG 16-40/41 Material: C 22.8 / St 35.8 Pressure rating: PN 40 20 25 40 To suit conductivity electrodes LRGT 17-1 / LRG 17-40 Material: C 22.8 / St 35.8 Pressure rating: PN 63

25

1502890

Level Pots for Conductivity Electrodes


Connections DN 2)
DN 15 40 mm BAE DN 15-40 mm Boiler DN 15-40 BAE DN 15-40 Boiler 1" DN 25 mm Boiler connection DN 25 mm 3) BAE 1" 1"

Stock code 1500632 1500633 1500634 1500635 1502520 1502521 1502522 1502523

MF 1161 STT For installing level electrodes outside the boiler LRGT 16-1 / LRG 16-40 Material: C 22.8 / St 35.8 / 60.3 Pressure rating: PN 40 MF 1162 STT For installing level electrodes outside the boiler LRGT 16-2 / LRG 16-41 Material: C 22.8 / St 35.8 / 139.7 Pressure rating: PN 40 MF 1171 STT To suit electrode type LRGT 17-1, LRG 17-40 Material: C 22.8 / St 35.8 / 60.3 Pressure rating: PN 63

15 20 25 401) 15 20 25 401)

25

1500989

DN 25 mm Boiler connection

DN 25 mm BAE

DN 50 mm 3) Electrode connection

3MF 88.9 To suit electrode type LRG 17-1/LRG19-1 For continuous blowdown valve BAE (automatic continuous blowdown control)

PN 63 25

1500987

PN 160 25

1500988

1) 2)

Approval acc. to PED 97/23/EC module A1 69. Please state nominal size (DN) when ordering. 3) Approved in acc. with PED 97/23/EC module 6 435.

Portable Measuring Instruments for Conductivity + pH Value


Type Stock code

VRM 2

Conductivity

3821040

VRM 3

Conductivity, temperature and pH value

3821141

129

Continuous Blowdown Valves

Application
BA 46, BA47, BA 210, BA 211, ZK29 BAE 46, BAE 47, BAE 210, BAE 211, ZKE 29 Valve with adjustable stage nozzle and sample valve for continuous blowdown of steam boilers and evaporators. Valve with adjustable stage nozzle, sample valve, and electric actuator for automatically controlled continuous blowdown. Especially suited for boilers operating without constant supervision (TRD 604).

Pressure/Temperature Rating According to EN 1092-1 (2001) for: 1.0460 in accordance with PED and AD 2000 or A105 according to Pressure Equipment Directive (PED).
Type BA 46 / BAE 46
L

Ratings according to PN 40 1.0460 PN 40 A105 Class 150 A105 Class 300 A105 PN 63 1.0460 PN 63 A105 Class 600 A105 PN 250 1.0460 PN 320 1.7335 PN 160 1.7335 EN 1092-1 EN 1092-1 ASME B16.34 ASME B16.34 EN 1092-1 EN 1092-1 ASME B16.34 DIN 2401 DIN 2401 EN 1092-1

BA 46, BA 47

BA 47 / BAE 47

BA 210 / BAE210 BA 211 / BAE 211 ZK 29 / ZKE 29

max. pressure [bar] at boiling temperature [C] = ts/p max 234/29 246/36 198/14 254/42 257/44 271/55 271/55 337/142 374/221 336/138

End connections
Type BA 46 / BAE 46 BA 47 / BAE 47 Flanged DIN
[mm]

Flanged ANSI

Socket-weld

Butt-weld

Dimensions BA 46, BAE 46


Connections Flanged DIN Flanged ANSI Class 150 Flanged ANSI Class 130 Socket-weld DN L L L L

15 150 150 150 200


[mm]

20 150 150 150 200

25 160 160 160 200

32 180 180 180 200

40 200 230 230 250

50 230 230 230 250

Dimensions BA 47, BAE 47


L

BA 210, BA 211

Connections Flanged DIN Flanged ANSI Class 600 Socket-weld

DN L L L

15

20

25 190 216 200

32

40 220 216 250

50 250 250 250

ZK 29

BAE46, BAE 47

BAE210, BAE 211

ZKE29

130

Continuous Blowdown Valves

Capacity Charts
Chart 1: BA 46, BA 47, DN 15-32 BAE 46, BAE47, DN 15-32
Differential pressure [bar]

Chart 2:

BA 46, BA 47, DN 40/50 BAE 46, BAE47, DN 40/50


Differential pressure [bar]

Hot-water capacity [kg/h]

Hot-water capacity [kg/h]

Position of control lever

Position of control lever

Chart 3:

BA 210, BA 211 BAE 210, BAE211

Chart 4:

ZK 29 ZKE 29

1) For

relatively small quantities (dotted line in chart) use 210 k or 211 k (with special stage nozzle).

Chart 5:

BAE 210k, 211k

131

Programme-Controlled Blowdown Systems

Description
A short boiler blowdown is performed by quickly opening the blowdown valve. This creates a short-term low- pressure area around the blowoff opening at the bottom of the boiler, causing a suction effect that removes accumulated sludge and sediments that have settled out in the lower part of the boiler. The suction effect of an intermittent blowdown is only effective at the moment when the valve is being opened. For this reason the valve should only be opened for approx. 2 seconds. Longer opening periods waste boiler water. For the closing process the design of the valve is of great importance. The closing force of the spring of the intermittent blowdown valves (M)PA is increased by the boiler pressure, which means that the valve is in a good condition for breaking up any dirt particles settled on the valve seat/plug, thus ensuring a positive shutoff. The service life of the valve seat/plug is further increased by the pressure reduction that takes place in the radial stage nozzle installed downstream of the valve. The time interval between bottom blowdown processes can only be calculated indirectly by taking the boiler efficiency, the feedwater quality and the admissible boiler water quality into account.

Application
In steam boiler plants operating without constant super vision. Automation of intermittent blowdown by generating electric pulses to initiate a blowdown cycle via the GESTRA rapid-action intermittent blowdown valve MPA. If space underneath the boilder is of concern, (M)PAs that can be tilted by 45 are available on request.

Controls
Type LRR1-40 TA 5 Design Continuous/intermittent blowdown controller for installation in control cabinet, with strainer and solenoid valve Cycling timer PRS 7 as plug-in unit in plastic case, strainer, solenoid valve Cycling timer PRS 7 in sheet-steel case, strainer, solenoid valve, all component parts assembled and interconnected on a mounting panel Cycling timer PRS 8 integrated in solenoid valve plug, strainer, solenoid valve Interval time 1 h 120 h 30 min 31.5 h Pulse duration sec 1 60 1 63 Mains voltage 230 V /50 Hz 230 V /50 Hz a Version b f

TA 6

30 min 31.5 h

1 63

230 V / 50 Hz

TA 7

30 min 10 h

0.5 10

230 V / 50 Hz

Three-Way Solenoid Valve


Max. service pressure [bar] 16 1)
1)

Min. differential pressure [bar] min. 0.5

Connection " BSP

Protection IP 65

Max. admissible pressure for diaphragm actuator: 6 bar

Version a = Field case b = Plug-in unit in plastic case c = 19" slide-in unit e = Case for panel mounting f = Integrated in solenoid valve plug

Strainer
Material Body Gun metal Rg 5 Filter 1.4571 Connection " BSP

Mesh size [mm]


0.5

132

Programme-Controlled Blowdown Systems

LRR 1-40

LRR 1-40

Pressure reducing station

Strainer

GAV

MPA

TA 5

PRS 7

Type TA 5
Pressure reducing station MPA 46 < 6 t/h
Strainer

DN

PN

Stock code
3602040 146474

Pressure reducing station

25 40 25 40 25

40

3661500 3661700

< 24 t/h MPA 47 < 6 t/h < 24 t/h MPA 110 p 160 bar GAV see page 80 81

Solenoid valve GAV MPA

63 250 Fl.

3671500 3671700

365150002

TA 6

PRS 7

Pressure reducing station

Type TA 6
Pressure reducing station MPA 46 < 6 t/h < 24 t/h MPA 47 < 6 t/h < 24 t/h

DN

PN

Stock code
3602141 146474

25 40 25 40 25

40

3661500 3661700

63 250 Fl.

3671500 3671700

GAV

MPA

MPA 110 p 160 bar GAV see page 80 81

365150002

TA 7
Type
Pressure reducing station

DN

PN

Stock code
3602242 146474

TA 7
Pressure reducing station MPA 46 < 6 t/h < 24 t/h MPA 47 < 6 t/h

Strainer

25 40 25 40

40

3661500 3661700

PRS 8

63

3671500 3671700

GAV

MPA

< 24 t/h GAV see page 80 81

133

Rapid-Action Intermittent Blowdown Valves

Application
PA 46, PA 47, PA 110 MPA 46, MPA47, MPA 110 Manual intermittent blowdown of steam boilers and pressurized hot-water boilers. Automatic, programme-controlled intermittent blowdown of steam boilers and waste-heat boilers. Especially suited for boilers operating without constant super vision (TRD 604).

Pressure/Temperature Rating According to EN 1092-1 for: 1.0460 in accordance with PED and AD 2000 or A105 according to Pressure Equipment Directive (PED).
Type PA 46 MPA 46
L

Ratings according to PN 40 1.0460 PN 40 A105 Class 150 A105 Class 300 A105 EN 1092-1 EN 1092-1 ASME B16.34 ASME B16.34 EN 1092-1 EN 1092-1 ASME B16.34 EN 1092-1 EN 1092-1 ASME B16.34 ASME B16.34

max. pressure [bar] at boiling temperature [C] = ts/p max 234/29 246/36 198/14 254/41 257/44 271/55 271/55 369/206 374/221 300/85 326/124 363/196

Control fluid MPA...

Max. control pressure MPA...

PA 46, PA 47

PA 47 MPA 47 PA 110 MPA210

PN 63 1.0460 PN 63 A105 Class 400/600 A105 PN 250 1.7335 PN 250 A182-F12 Class 900 A182-F12 Class 1500 A182-F12

Water or compressed air

8 bar

Class 400/600 A182-F12 ASME B16.34

Compressed air

6 bar

End Connections
Type
PA 46, MPA 46 PA 47, MPA47 PA 110, MPA 110
L

Flanged DIN

Flanged ANSI

Socket-weld

Butt-weld

MPA 46, MPA 47

Dimensions PA 46, MPA 46


Connection
Flanged DIN Flanged ANSI Class 150 Flanged ANSI Class 300 Socket-weld

[mm]

DN L L L L

20 150 150 150 200

25 160 160 160 200

32 180 180 180 200

40 200 230 230 250

50 230 230 230 250

Dimensions PA 47, MPA 47


Connection
Flanged DIN Flanged ANSI CI 600 Socket-weld

[mm]

DN L L L

20

25 190 216 200

32

40 220 216 250

50 250 250 250

Dimensions PA 110, MPA 110


Connection
Flanged DIN Flanged ANSI CI 600
L

[mm]

DN L L L L

20

25 410 410 440 300

32

40

50

Flanged ANSI CI 900 / 1500 Socket-weld

MPA110

134

Intermittent Boiler Blowdown as a Function of Differential Pressure


Capacity Charts
Chart 1: PA 46, MPA46 PA 47, MPA 47 Chart 2: PA110, MPA110

/ PA

A MP

11

0,

DN

25

Hot-water capacity

Differential pressure

Hot-water capacity

Differential pressure

The Benefits of the New GESTRA Intermittent Blowdown Valves


Improved blowdown effectiveness through integrated pressure

chamber in the outlet section of the body


Greater tightness through additional wiper rings between the

packing seals
Longer service life and availability through radial stage nozzle

downstream of the valve seat


Insensitive to waterhammer through absence of large body cover Reduced wear through new arrangement of the seals on the low Consistent implementation of the work safety regulations

through novel distance tube


Quick and easy installation thanks to multifunction parts Reduced maintenance and service effort through additional

cup springs acting on the compression spring and through the possibility of tensioning the seals from outside
Better checking functionally through relief vent for leak detection

from outside
Greater convenience through innovative clip fastening of the hand

lever PA 46/47

135

pressure side

Contamination Detectors for Condensate and Process Liquids


Liquid Monitoring Detecting Ingress of Oil in Condensate Systems and Marine Installations

Purpose
Continuous monitoring of transparent liquids to detect any ingress of insoluble foreign matter causing turbidity, such as emulsified oils and greases. Measuring of turbidity and signal evaluation for indication, recording and control. Tripping of alarms, control valves etc. The oil turbidity detector OR 52/. consists of a measuring sensor ORG 12/ORG 22 and the ORT 6.

Application
Condensate monitoring in steam boilers to detect any ingress of oils and greases in accordance with TRD 604, EN 12952/..53. Monitoring of cooling water, drinking water, condensate and beverages for turbidity. Monitoring of cooling water, drinking water, condensate and beverages for turbidity in hazardous areas zone 1(on request). Hot-water monitoring in district heating plants. Filter and cooling-water monitoring on ships.

Technical Data
Type Sensor PN Connection Material Measuring transducer ORT 6 Wall-mounting case, measuring range 0 25 ppm 2 alarm relay outputs (instantaneous/delayed) LED bar chart display 4 20 mA current output

OR 52/5 OR 52/6 OR 52/5 EX OR 52/6 EX

ORG 12 ORG 22 ORG 12 ORG 22

10 10 10 10

3/8" 3/8" 3/8" 3/8"

GG 25 1.4580 GG 25 1.4580

Liquid Monitoring Detecting Ingress of Acids, Alkalis, Raw Water, Dyes, etc.
Purpose
Monitoring conductive liquids for contamina tion by foreign matter that increases the TDS concentration; conductivity monitoring (TDS control), signalling and display.

Application
For condensate and feedwater monitoring in steam and (pressurised) hot water plants to detect ingress of acids, alkalis, raw water, dyes, etc.

Technical Data of Conductivity Electrodes


Type LRG 16-9 LRGT 16-1 PN 40 40 Connection " 1" Service pressure [bar] saturated steam temp. 32 / 238 C 32 / 238 C Integrated temp. sensor Ambient temperature at terminal 70 C 70 C Lengths supplied [mm] 43 200 / 300 / 400 TV GL

Technical Data of Electronic Control Unit/Controller


Type LRS 1-7a Outputs Mains voltage switching 4 20 mA Standard optional 230 V Protection IP 65 Design a b c e Measuring range 0,5 10.000 S/cm TV GL

136

Contamination Detectors for Condensate Systems

Condensate monitoring to detect any ingress of oil


Measuring transducer ORT 6

Type OR 52/5 OR 52/6

Stock code 4003040 4003140 1500554

Delayed alarm output


4...20 mA CANopen (option)

Pneumatic three-way control valve PN16, DN 50 with pilot valve Non-return valve DISCO RK 86a, SF 20 mbar PN 40, DN 50 Optional CANopen interface
Three-way control valve

Solenoid valve

121180182 .60

Non-return valve see pages 38 49


Type approval: TV WF 07- 009

Sensor ORG 12, 22

Condensate monitoring and conductivity monitoring


LRS 1-7a Alarm output 4...20 mA

Type LRG 16-9 Connecting cable male / female LRS 1-7 Pneumatic three-way control valve PN16, DN 50 with pilot valve
Type approval: TV WL 09-014 Optional Current output 4...20 mA Special voltage 24 V AC

Stock code 3771839 5m 1502563 3781641 1500554

LRG 16-9

Solenoid valve

Three-way control valve

.57 .51

137

Ingress of Oil in Cooling Water Systems Digital Indicator


Purpose and Application of Oil Detector
The oil detector ORGS 11-2 is used for monitoring cooling water to detect any ingress of oil. An alarm and control unit installed downstream of the detector will dump contaminated cooling water, thereby preventing oil contamination of the installation to be cooled. The equipment detects all low-density matter that is insoluble in water, not emulsified, and has a lower electrical conductivity than water. Antirust oils, which emulsify in cooling water, do not trigger an alarm. The output contact relays of the contamina tion detector are self- monitoring and of the normally closed type, and will therefore trigger an alarm in the event of a malfunc tion. Tested and approved by Germanischer Lloyd GL .

Technical Data
Type ORGS 11-2 PN 6 Connection Inlet E0-15-L Outlet E0-12-L/S Drain E0-15-L Material C 22.8

Cooling-water monitoring with oil detector

Type ORGS 11-2

Stock code 4041140

Type approval for marine applications see page 94


Oil detector ORGS 11-2 Cooler

138

Flowmeters for Steam, Gases and Liquids


Principle of Measurement
The design is based on the Krmn vortex street principle using a body installed perpendicular to the axis of the pipe. The vortices generated in the flow stream produce pressure oscillations which are converted into electrical signals by a sensor. The output signal is then evaluated and processed in the flow computer.
in [kg/h] for Vortex flowmeter 83 *) Recommended steam flowrate m Absolute pressure [bar] 1.0 1.4 1.6 1.8 2.0 2.5 3.0 4.0
Vortex flowmeter

DN 20 30 40 45 50 60 70 85 110 135 160 235 285 360 535 790

DN 25 45 65 72 80 90 110 130 170 210 250 370 440 560 830 1230

DN 40 120 165 185 210 230 280 335 440 540 645 745 950 1150 2140 3150

DN 50 180 250 290 320 350 440 520 680 850 1000 1450 1790 2250 3350 4930

DN 80 480 650 750 830 920 1130 1340 1750 2170 2550 3780 4580 5780 8550 12600

DN 100 750 1030 1150 1300 1430 1700 2100 2750 3400 4030 5900 7150 9030 13400 19700

DN 150 1700 2300 2600 2900 3200 4000 4700 6200 7600 9050 13300 16100 20300 30100 44300

DN 200 3000 4100 4650 5200 5700 7050 8400 11000 13500 16100 23500 28500 36000 53500 78800

DN 250 4500 6400 7200 8100 8900 11000 13000 17000 21000 25000 37000 44000 56000

DN 300 6700 9200 10500 11700 12900 15900 18500 24500 30500 36000 53000 64000 81000

5.0 6.0 9.0 11.0 14.0 21.0 31.0

83000 120000 123000 177000

*) For minimum and maximum flowrates see data sheet.


Flow computer Installation example of a flowmetering system with tapered pipeline and pressure/temperature compensation

Specially shaped vortex shedder

3.5 x D 5xD 14 x D 6xD

Steam-flow measurement system for constant saturated steam pressure consisting of: Vortex flowmeter type 83 WA and flow computer type Flow 20

Steam-flow measurement system for fluctuating saturated steam pressure (temperature compensated) consisting of: Vortex flowmeter type 83 WA, flow computer type Flow 100 and temperature sensor TRG 5-53, L = 160 mm

Steam-flow measurement system for fluctuating saturated steam pressure (pressure compen sated) consisting of: Vortex flowmeter type 83 WA, flow computer type Flow 100 and pressure transmitter DRT with syphon and pressure gauge.

Steam-flow measurement system for superheated steam (temperature and pressure compensated) consisting of: Vortex flowmeter type 83 WA, flow computer type Flow 100, temperature sensor TRG 5-53 and pressure transmitter DRT with syphon and pressure gauge

139

Control & Visual Display System

SPECTORcontrol The Operating, Control & Visual Display System


Description
The system SPECTORcontrol consists of a 6.5" or 10.4" colour infrared touch screen PLC, the operating system WIN CE4.2, interfaces for Ethernet, Serial RS 232, CANopen, digital/ PS/2 keyboard, Profibus DP (optional), analog input and output terminals and the software.

Function
The SPECTORcontrol system integrates control and operating functions of the individual SPECTOR devices in one PLC, which means that stand-alone components such as NRR 2-40, NRS 1-42 and URB can be dispensed with. Apart from the actual control tasks performed by SPECTOR equipment, additonal control functions (plus a threeelement control function) can be implemen ted by means of the five integrated control systems. The advantage of this new operat ing, control & display unit lies in the standardised graphical user interface: The boiler attendant does not have to adapt himself to different user interfaces. Thanks to the smart input/output terminals (2 x analog input/output, 10 x digital input/output) mounted on site, the data are transferred from the PLC to the final controlling element via a BUS line. This approach offers considerable cost advantages, also with regard to boiler equipment. The interface permits the technicien to query not only data concering water level and conditions (as detected by Spectorbus equipment) but also data from various burner controls (LAMTEC, HIMA, SIEMENS, HAMWORTY) and to integrate the data into the control functions or to visualise them. All operating data, controller settings etc. can be sent via Ethernet, modem etc. to service partners (remote servicing) or higher ranking control systems where parameters can be set, too.

Visual display of operating data


Apart from various control tasks Spectorcontrol offers a wide range of software solutions for the visual display of water and burner data. The standard package comprises: n 5 freely selectable trend graph pairs n 5 quantity protocols n 5 maintenance protocols for freely selectable units n Malfunction lists

Service partner

Process control level

Type SPECTORcontrol Infrared Touch PLC incl. 2 DE/DA, 10 AE/AA, software

SPECTORcontrol RS 232 Ethernet Profibus (OPC) CANbus

MODbus Office PC

140

GESTRA pressure equipment is designed, constructed and tested to PED1) 97/23/EC and AD Bulletin 2000. Pressure equipment of category I, II, III and IV bears the CE marking. The Declaration of Conformity certifies that the equipment satisfies the applicable safety requirements of the PED. Pressure equipment that falls within the scope of article 3 section 3 of the PED is designed and manufactured in accordance with what is recognised as sound engineering practice. This equipment will not be CE marked but must be accompanied by a Declaration of Manufacturer.
1)

PED = Pressure Equipment Directive

Special Equipment and Vessels for Heat Recovery

Page

Condensate Recovery and Return System SDR A .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Open-Type Condensate Recovery and Return Tank SDL 100.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Closed-Type Condensate Recovery and Return Tank SDL 130.. . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Steam-Powered Condensate Return Unit KH .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Steam-Powered Condensate Return Unit FPS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Desuperheaters EK, KD.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Steam Regenerators GRDE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Heat exchanger unit PWT-XPS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Feedwater Deaerating Plants NDR, SW.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Flash Vessels VD.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Blowdown Receiver (Mixing Cooler) VDM .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Condensate Dampening Pot ED.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Control units with independent controllers or PLC.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 156 Questionnaire for preparing offers .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 164 Air/Steam Driers and Purifiers TD/TP (Steam Separators) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

141

Condensate Recovery and Return System SDR A


Condensate tank of rectangular design type SDR A with high-pressure centrifugal pump(s) installed next to the tank

Application
Condensate tanks are used to collect the condensate coming from steam users or flash vessels. From the tank the conden sate is pumped into the feedwater tank by a level-controlled pump, in most cases via a deaerator.

Rectangular condensate tank type SDR A


The standard range of rectangular condensate tanks is designed for condensate flowrates of up to 10 t/h and a max. service pressure of 0.1 bar g. Tank made of steel type S235JRG2, inside: untreated, outside: anti-corrosion coating with two condensate pumps and accessories installed next to the tank, e. g. bimetal dial thermo meter, water-level indicator, GESTRA level electrode and control for auto matic pump operation, non-return valves, shut-off valves, high-pressure centrifugal pump(s) and pressure gauge. Completely assembled and inter connected, control cabinet supplied but not mounted.

Size 1 2 3 4 5 6

Volume [l] 340 550 750 1000 1500 2000

Pumping capacity [m3/h] 1 2 3 4 6 8

Vessels in compliance with Conformity Assessment Section 3, Paragraph 3


Tanks and valves made of other materials available on request. Other pumping capacities and discharge heads on request.

142

Open-Type Condensate Recovery and Return Tank SD L 100

Condensate receiver tank of cylindrical design type SD L (S) with high-pressure centri fugal pump(s) installed next to the tank L = horizontal design; S =vertical design

Application
Condensate tanks are used to collect the condensate coming from steam users or flash vessels. From the tank the conden sate is pumped into the deaerator by level-controlled pumps.

Size I II III IV V VI VII VIII IX X

Volume [l] 250 390 850 1370 2100 2900 3800 4500 5900 6900

Pumping capacity [m3/h] 1 2 4 6 9 12 16 20 25 30

Open condensate tank of cylindrical design type SD L (S)


The standard range of cylindrical condensate tanks is designed for condensate flowrates of up to 30 t/h and a max. service pressure of 0.5 bar. Condensate tanks for larger flowrates available on request. Tanks available as horizontal or vertical design, made of steel S235JRG2, inside: untreated, outside: anti-corrosion coating. Two high-pressure pumps and associated valves and accessories installed next to the tank: e. g. bimetal dial thermometer, pressure gauge unit, water-level indicator, GESTRA level control and level electrode for automatic pump operation and non-return valves are part of the installation. Completely assembled and interconnected, control cabinet supplied but not mounted.

Max. condensate temperature 90 C

Other valve and tank materials available on request. Other pumping capacities and discharge heads on request.

143

Closed-Type Condensate Recovery and Return Tank SD L 130

Condensate receiver tank of cylindrical design type SD L (S) with horizontal-type centrifugal pump(s) installed next to the tank L = horizontal design; S =vertical design

Application
Condensate tanks are used to collect the condensate coming from steam users or flash vessels. From the tank the conden sate is pumped into the deaerator by level-controlled pumps.

Size I II III IV V VI VII VIII IX X

Volume [l] 250 390 850 1370 2100 2900 3800 4500 5900 6900

Pumping capacity [m3/h] 1 2 4 6 9 12 16 20 25 30

Closed condensate tanks of cylindrical design type SD L (S)


The standard range of cylindrical condensate tanks is designed for conden sate flowrates of up to 30 t/h and a max. service pressure of 4 bar. Condensate tanks for larger flowrates available on request. Tanks available as horizontal or verti cal design, made of steel boiler plate type P265GH, inside: untreated, outside: anticorrosion coating. Two horizontal-type centrifugal pumps and associated valves and accessories installed next to the tank: e. g. bimetal dial thermometer, pres sure gauge assembly, magnetically operated liquid level gauge, level elec trode and control for auto matic pump operation, safety device, overflow, air vent, vacuum breaker, shut-off valves and nonreturn valves are part of the installation. Completely assembled and inter connected, control cabinet supplied but not mounted.

Other valve and tank materials available on request. Other pumping capacities and discharge heads on request.

144

Steam Powered Condensate Return Tank KH


Application
Condensate tanks are used to collect the condensate from steam pro cessors or flash vessels. From the tank the condensate is returned to the main condensate tank or deaerator with the aid of level- controlled booster steam.

Steam-powered condensate return unit KH...


The standard version is suitable for condensate flowrates of up to 10 t/h and a max. service pressure of 12 bar g.

The condensate return tank is made from steel type P265GH. Outside: anti-corrosion coating. Inside: untreated.
Associated valves and equipment such as pressure gauge assembly, solenoid valve, level electrode and control for automatic booster steam supply, non-return valves are completely assembled and inter connected.

Size KH 13-2 KH 13-3 KH 13-5 KH 13-10

Volume [l] 50 75 100 390

Pumping capacity [m3/h] 2 3 5 10

Booster steam pressure 12 12 12 13

Pump capacity [bar] 8.4 8.4 8.4 8.4

Other tank and valve materials available on request.

145

Steam Powered Condensate Return Tank FPS

Size

Volume [l]

Booster steam pressure [bar, ] 3 6 13 3

Pumping capacity [m3/h] at a back pressure of 1 bar 2 bar 3 bar 4 bar [kg/h] [kg/h] [kg/h] [kg/h] 1860 1800 1650 2140 3400 3600 2570 3400 3600 1500 1600 1550 1630 2180 2480 1700 1900 1850 1330 1260 1260 1000 1300 1100 1040

Application
Condensate tanks are used to collect the condensate from steam processors or flash vessels. From the tank the condensate is returned to the main condensate tank or deaerator with the aid of float-controlled booster steam.

FPS 11-13

45

FPS 23-13

75

6 13 3

Steam-powered condensate return unit type FPS 14...


The condensate is returned to the main condensate tank with the aid of booster steam, without electric power. The standard version of the FPS 14 is suitable for condensate flowrates of 3,6 t/h and a max. service pressure of 12 bar g. The discharge capacity decreases with rising back pressure. The tank is made of steel type S235JRG2 or of P265GH. Outside: anticorrosion coating. Inside: untreated. The nonreturn valves are completely assembled and inter connected, inclusive of counter- flanges, bolts and gaskets.

FPS 14-13

100

6 13

UNA 25-PS and UNA 25-PK are also available for flowrates of approx. up to 600 kg/h. For more details on the equipment see page 26 and the Price List.

146

Desuperheating Plants

System 1
Superheated steam outlet Electric temperature control Cooling water inlet Superheated steam inlet

Application
Heating installations in all industries Heating of drying calenders in the paper industry Heating of boiling pans in the foodstuff industry Heating of cable presses Radiant panels for hardware production in the electrical industry Steam moistening plants in the textile industry

Questions concerning System Design


1. Maximum steam flow at inlet? 2. Minimum steam flow at inlet? 3. Maximum service pressure? 4. Maximum temperature at inlet? 5. Standard temperature at inlet? 6. Temperature at outlet? 7. Saturated-steam temperature? 8. Temperature of injected cooling water? 9. Injected cooling-water flow? 10. Cooling-water pressure at cooler? 11. Pump pressure? 12. Design pressure? 13. Design temperature? 14. Length of installation?

Electric pressure regulation Cooler with equipment

Drain

Pressure reducing station

Injection cooler with fixed jet orifices

System Description
System 1 Injection cooler with fixed jet orifices The cooling water is injected through special jet orifice into the steam flow. The amount is adjusted by a control valve upstream of the desuperheater and controlled by the high differential pressure. The type and number of nozzles are dictated by the operating data. The internals of the pipe installed downstream of the equipment prevent temperature shocks at the external pipe.
System 2 Water-bath desuperheater

System 2
Saturated steam outlet Steam inlet Pressure reducing station Desuperheater
Cooling water

Water level control Drain Pump unit

The heat of the superheated steam causes the cooling water/condensate to evaporate, thereby cooling the superheated steam. The
steam produced is conducted through steam separating units and has a steam content of

Water-bath desuperheater

more than 98 % (i.e. less than 2 % residual moisture).

Criteria for System Selection


1. What is the ratio between minimum and maximum steam quantity in the control range? 2. What is the pressure and the temperature of the available cooling water? 3. How close must the temperature of the desuperheated steam be to that of saturated steam?

Technical Data
System 1 Pressure rating Maximum temperature Cooling water pressure above steam pressure Steam flowrate Steam flow ratio Set point above saturation temperature [K] [bar] [C] [bar] [t/h] 28 450 59 100 1:5 5 System 2 28 380 1 15 1 : 100

Higher pressures, temperatures and steam flowrates available on request.

147

Steam Regenerators

Steam regenerator

Pure steam Heating steam Intermittent/continuous blowdown Condensate

Application
Steam regenerators are used to produce saturated steam for a secondary system from steam or pressurized hot water. Pure steam, without any contaminants that might be detrimental to health such as hydrazine, is produced. Steam regenerators are therefore especially suited for sterilizing equipment in hospitals, steaming and drying chambers in the foodstuff industry, and for the production of distillates.

Technical Data (standard)


Service pressure Service temperature Service pressure Service temperature Capacity range Feedwater quality Boiler water quality primary primary [bar] [C] 28 250 12 200 5000

secondary [bar] secondary [C] [kW]

[S/cm] < = 5 [S/cm] < = 100

Steam regenerators for higher pressure/tem pera ture ratings and larger capacities on request.

Standard Installation
Steam regenerators with self-acting, electric or electropneumatic heating-steam control
Compact system with manual intermittent / continuous boiler blowdown and the required basic equipment of a feedwater supply control system Limiting conditions: Quality of feedwater 5 S/cm, pressure of heating steam: 6 barg, pressure of pure steam: 4 barg

Type GRDE 5 GRDE 6 GRDE 7 GRDE 8

Pure steam flowrate [kg/h] 300 600 1000 1200

[mm] 450 500 600 700

Overall length approx. [mm] 3300 3800 3500 4000

Max. design pressure/ temperature primary [bar/ C] 12/200 12/200 12/200 12/200

Max. design pressure/ temperature secondary [bar/ C] 6/200 6/200 6/200 6/200

148

Feedwater

Heat Exchanger Unit PWT-XPS


GESTRA Heat exchanger unit type PWT-XPS
consists of: plate-type heat exchanger, completely welded, in shell & plate design equipped with: on steam side: shut-off valve, strainer and electrically operated control valve with safety resetting device on condensate side: pump steam trap, non-return valve, shut-off valve measuring & control equipment: safety temperature limiter, safety pressure limiter, temperature sensor, temperature controller, thermometer, pressure gauge, safety valve The unit is completely assembled and interconnected and mounted on a stable base frame. Auxiliary energy: 230 V, 50 Hz

Type PWT-XPS 50-24 H11 50-32 H11 50-44 H11 50-72 H11

Capacity kW 40 160 380 700

Saturated steam barg 1 1 1 1

Water C 70/90 70/90 70/90 70/90

Capacity kW 80 300 675 1100

Saturated steam barg 3 3 3 3

Water C 70/90 70/90 70/90 70/90

Capacity kW 130 500 700 1400

Saturated steam barg 6 6 6 6

Water C 70/90 70/90 70/90 70/90

Larger capacities available on request.

149

Feedwater Deaerating Plants

Application
To avoid corrosion damage to steam boiler plants, the content of aggres sive gases, such as oxygen and carbon dioxide, in the feed water must be as low as possible. The German Technical Supervisory Association (VdTV) has issued directives concerning boiler feedwater quality which are applied by German boiler manufacturers when giving a warranty on their boilers. Thermal deaeration in addition to chemical deaeration is very important for maintaining the required feedwater quality. Recommendation: For quality of soft water: Concentration of chloride approx. 50 mg/l Conductivity approx. 250 S/cm
Deaerating dome NDR Type 250 350 450 550 650 800 900 1000 Capacity m3/h 0.5 1.6 1.7 3.0 3.1 5.0 5.1 8.0 8.1 11.0 11.1 15.0 15.1 19.0 19.1 24.0 mm 250 350 450 555 650 800 900 1000 Height approx. mm 1050 1260 1280 1300 1820 1850 1870 1880

Feedwater tank SW Size I II III IV V VI VII VIII IX X mm 800 1000 1200 1200 1600 1600 1600 2000 2000 2500 Length Volume of tank approx. mm l 2360 2940 3050 3550 3680 4680 5680 5000 7850 7050 1000 2000 3000 4000 6000 8000 10000 16000 22000 30000

Technical Data (Standard)


Max. service pressure 0.5 bar Max. service temperature 111C Capacity range 0.5 24 m3/h Materials (DIN reference) S235JRG2 1.4571 Residual oxygen < 0.02 mg/l

Higher capacities and pressures on request

150

Flash Vessels VD Flash Vessels Systems VD 23 and VD 26


Application
Flash steam outlet

Condensate from H.P. user Gas balance pipe

Condensate flash vessel Condensate flash vessels can be used in all steam plants where condensate from steam consumers is reduced to a lower pressure. This pressure drop constitutes a change of the energy content that causes some of the condensate to revaporize and form flash steam. In the flash vessel the flash steam is separated from the water, and then fed into a low-pres sure steam system. The condensate remaining in the flash vessel is discharged into a condensate tank.

Blowdown flash vessel Blowdown flash vessels are used if the flash steam formed downstream of continuous blowdown valves is to be utilized. Blowdown receiver In a blowdown receiver the sludge and water mixture withdrawn from the boiler by the intermittent blowdown valve is separated into flash steam and boiler blowdown.

to condensate tank Drain

Condensate Flash Vessel

Blowdown flash-vessel system

Feedwater-tank with deaerator

Live steam supply Blowdown flash vessel Blowdown cooler Continuous blowdown valve Blowdown receiver Intermittent blowdown valve Cooling water Pulse from intermittent blowdown valve

Steam boiler

from feedwater tank

Technical Data
Type VD VD 23-0.3 VD 23-1.0 VD 26-0.2 VD 26-0.7 Service pressure [bar] 0.5 12 12 12 28 28 Service temperature [C] 111 250 200 200 250 250 Condensate flowrate [t/h] 1.2 40 0.3 1.0 0.2 0.7 Volume [l] 50 1400 15 15 15 15 Material (DIN reference) S235JRG2 / P265GH S235JRG2 / GG 25 P265GH / GS-C 25

151

Blowdown Receiver (Mixing Cooler) VDM

Flash steam discharge or vent

Cooling water Hot water from intermittent/ continuous blowdown, overflow etc.

Thermostat

Drain

Mixed cooled water to drain

Mixing cooler with cooling-water control and, if requested, additional flash-steam condensation

Technical Data
Max. service pressure Max. temperature Capacity range Material S235JRG2 (RSt 37-2) 0.5 bar 111C up to 15 t/h P265GH (H II) 1.4541 1.4541

Description
Mixing coolers are blowdown receivers that cool hot waste water that can no longer be used for heat recovery and therefore is discharged into pits, drains or sewage systems.

Application
Process plants where contaminated, hot waste water is being formed. Steam boiler plants where the blowdown is cooled with untreated water. Mixing coolers for vapours.

152

Condensate Dampening Pot ED

Steam main = 3 bar Outlet Condensate main = 0.25 bar

Heat exchanger

Passage or door frame

Inlet Drain connection Steam trap

1.25 bar

Condensate dampening pot

Condensate Dampening Pot ED

Technical Data
Service pressure 18 bar Related temperature 250C Capacity range up to 15 t/h Material S235JRG2 / P265GH Volume [l] 4 to 50

Description
The condensate dampening pot provides a cushioning effect to neutralize waterhammer. The condensate is discharged without noise.

Application
Steam and condensate systems.

153

Air / Steam Driers and Purifiers TD/ TP (Steam Separators)


Description
Steam separators are used to remove condensate and dirty water carry-over from steam. By this means trouble-free operation and a long service life of the heat exchanger and steam consumer is obtained.

Application
Downstream of steam boilers and steamgenerating units. Between boiler and superheater. In steamlines ahead of steam manifolds. In district-heating lines and flash steam lines. Upstream of turbines, steam engines, steam tools. For direct heating with steam. In spray-vapour humidifier systems for airconditioning plants.

Technical Data
Pressure rating Nominal sizes DN Materials St 37.0 / St 35.8 PN 16 PN 40 PN 63 PN 100 PN 160 S235JRG2 P265GH 15 to 500 mm 16 Mo 3 13 Cr Mo 4-5 1.4541 1.4571

Steam drier (separator) Desuperheater

Steam drier (separator)

Heat exchanger Steam generator

Steam drier upstream of a heat exchanger


Steam drier (separator) Heat exchangers

Turbine Steam generator

Steam drier downstream of a steam generator

Steam generator

Steam drier upstream of a turbine

154

Controls

Pump Controls
Function The pump controls consist of the level sensor and the control cabinet with the associated accessories such as auxiliary relays, contactors, switches, control lamps etc. The control cabinets are tested and the wiring is effected via a terminal strip, ready for connection.
Standard equipment Run-dry alarm Run-dry and high-level alarms Time-dependent pump changeover Connection point for stand-by-pump Collective malfunction message (visual) Collective malfunction message (visual & acoustic) Volt-free contacts Remote level indication

Design Pump controls are divided into two groups: systems with fixed digital switchpoints (NRSP 1-1.) where the switchpoints are determined by the length of the electrode tips, and systems with variable switchpoints that can be adjusted to the varying process conditions (NRSP 2-1).
Type NRSP 1-11

NRSP 1-12

NRSP 2-11

NRSP 2-12

Programmable logic controller (PLC)


Function The PLC are customised system solutions for individual control functions and used in pump controls, steam regenerators, steam pressure reducing stations, injection coolers etc. The control systems are based on the S7-300 module and feature a malfunction log and an Operator Panel that allows the user to visualise and parameterise controlled systems. A connection to higher ranking bus-based control systems or volt-free digital signals is available as optional extra. Design The PLC is based on the Simatic S7-300 and consists of a CPU (optional extra: Profibus DP interface) and digital and analog input and output components. To monitor and operate the equipment the Operator Panel is designed as line display or with full graphical display capability for installation in control cabinets. The conventional controllers can therefore be dispensed with and the variable switchpoints, e.g. for the NRSP 2-1, can be adjusted. The malfunction log lists and stores all malfunction messages, with time and date being added.

155

Controls

Pump Control

Combination NRGS 11-1 / NRSP 1-11 NRGS 11-1 / NRSP 1-12

NRGS 11-1

L = 1000 mm
Control cabinet NRSP...

1" BSP

Optional: for two pumps

Pump Control
NRGT 26-1 Control cabinet NRSP... Optional: for two pumps

Combination NRGT 26-1 / NRSP 2-11 NRGT 26-1 / NRSP 2-12

H = 1000 mm

" BSP

PLC System Controls


Operator Panel

digital/ analog sensor inputs

digital/ analog control

Interface: Profibus DP

156

Questionnaire for preparing offers for GESTRA Condensate Recovery and Return Systems

GESTRA Fax: ++49 (0) 421 - 35 03-149


Condensate flowrate Condensate temperature Condensate pressure Tank design: kg/h C bar(a) Discharge control: Level electrode Supply options:

yes

no


Rectangular

Qty.

Cylindrical

Horizontal

Vertical

Accessories detached No accessories Condensate tank made of: Steel

Accessories assembled and interconnected

Condensate pumps:

mWS

Discharge head Mains voltage

Stainless steel grade 1.4541 (X6CrNiTi18-10) Stainless steel grade 1.4571 (X6CrNiMoTi17-12-2)

Horizontal pump

Vertical pump

Typical Installations
Open System Condensate receiver tank of cylindrical design type SDL (S) with high- pressure centrifugal pump(s) installed next to tank L = horizontal design S =vertical design Condensate tank of rectangu lar design type SDR A with highpressure centrifugal pump(s) installed next to tank

Closed System Condensate receiver tank of cylindrical design type SDL (S) with horizontal-type centrifugal pump(s) installed next to tank L = horizontal design S =vertical design

Please enter:
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157

Questionnaire for preparing offers for GESTRA Desuperheating Plants

GESTRA Fax: ++49 (0) 421 - 35 03-149


Reducing of steam pressure If yes, Cooling fluid: no P4 bar/psi upstream of cooler t4 C upstream of cooler

yes

Self-acting control Electro-pneumatic

Electric

if not fitted Water-bath desuperheater Injection cooler

with pump

yes

no

Steam flowrate Steam pressure: P1 P2 P3 bar/psi upstream of pressure reducing station bar/psi downstream of pressure reducing station or when no more pressure reduction takes place bar/psi downstream of cooling station

t3 = ts t3 = ts + > 5 controllable

Supply options for water-bath desuperheater:

Accessories detached

Accessories assembled

Optional equipment: High-temperature alarm Low-water level alarm Excess temperature protection

Steam temperature: t1 or t2 t3 C upstream of pressure reducing station or when no more pressure reduction takes place C downstream of cooling station

Special requirements concerning cooler: Material

Steel

Stainless steel grade 1.4571 (X 6CrNiMoTi 17-12-2)

Typical Installations

System 1 Injection cooler with fixed jet orifices

System 2 Water-bath desuperheater

Please enter:
Name / Title Company Name Telephone Fax E-mail Date

158

Questionnaire for preparing offers for GESTRA Steam Regenerators

GESTRA Fax: ++49 (0) 421 - 35 03-149


Thermal output Service data (primary) Medium: Pressure

Steam

Hot water C C

Thermal oil Flowrate kg/h

bar/psi

Temperature On Temperature Off

Services data (secondary) Medium: Pressure

Steam

bar/psi Self-acting

Feedwater Temperature

Flowrate

kg/h

Control (pressure side) Feedwater control Application

Electric

Pneumatic Feedwater pump

Solenoid valve or motorized valve

Typical Installation
Steam regenerator
Pure steam Heating steam Internittent/continuous boiler blowdown Condensate

Please enter:
Name / Title Company Name Telephone Fax E-mail Date

Feedwater

159

Questionnaire for preparing offers for GESTRA Deaerating Plants

GESTRA Fax: ++49 (0) 421 - 35 03-149


Boiler capacity Make-up water flowrate Steam pressure Service pressure (deaerator) Make-up feed control Pressure control kg/h kg/h bar(a) Temperature approx. C

Electric Self-acting

Pneumatic Electric

Pneumatic

Typical Installation

Condensate

Please enter:
Name / Title Company Name Telephone Fax E-mail Date

160

Boiler blowdown

Questionnaire for preparing offers for GESTRA Flash Vessel Systems

GESTRA Fax: ++49 (0) 421 - 35 03-149


Pressure p 1 upstream of steam trap at steam user (boiler pressure at flash vessel) Pressure p 2 of flash steam at flash outlet to low pressure system Pressure p 3 downstream of steam trap after the flash vessel Condensate flowrate to flash off Flash vessel material fr die Entspanneranlage Please state all pressure specifications in bara or psia! P1 = P2 = P3 = m = bar(a)/psi(a) bar(a)/psi(a) bar(a)/psi(a) kg/h

Typical Installation
Flash-steam outlet

P2

Condensate from H.P. user

P1

Gas balance pipe

to condensate tank

P3
Drain

Please enter:
Name / Title Company Name Telephone Fax E-mail Date

161

Questionnaire for preparing offers for GESTRA Blowdown Receiver (Mixing Cooler)

GESTRA Fax: ++49 (0) 421 - 35 03-149


Hot-water flowrate Hot-water temperature Hot-water pressure Cooling-water temperature Cooling-water pressure kg/h C bar(a) C bar(a) Material

Steel

Stainless steel grade 1.4571 (X 6CrNiMoTi 17-12-2)

Application Boiler blowdown Other

Typical Installation
Mixing cooler with cooling-water control and, on request, with additional flash-steam condensation

Flash-steam discharge or vent

Cooling water

Hot water from blowdown, overflow etc.

Thermostat

Drain

Mixed cooled water to drain

Please enter:
Name / Title Company Name Telephone Fax E-mail Date

162

Questionnaire for preparing offers for GESTRA Heat Exchanger

GESTRA Fax: ++49 (0) 421 - 35 03-149


Thermal output Service data (primary) Medium: Pressure Material: Control

Steam

Hot water C

Thermal oil kg/h

Self-acting Pneumatic

Electric

Controlled from the condensate side Design

bar/psi Steel

Temperature (in) Temperature (out)

C Flowrate

Service data (secondary) Medium: Pressure Material:

horizontal tube bundle heat exchanger vertical tube bundle heat exchanger GESTRA heat exchanger unit type PWT-XPS

Stainless steel grade 1.4571 (X6CrNiMoTi 17-12-2)

Steam

Hot water C

Thermal oil kg/h

bar/psi Steel

Temperature (in) Temperature (out)

C Flowrate

Stainless steel grade 1.4571 (X6CrNiMoTi 17-12-2)

Typical Installation
GESTRA Heat Exchanger controlled from the steam side with constant temperature of the secondary circuit GESTRA heat exchanger unit type PWT-XPS

GESTRA heat exchanger, controlled on the condensate side and with safety shut-off on the steam side

Please enter:
Name / Title Company Name Telephone Fax E-mail Date

163

Questionnaire for preparing offers for GESTRA Steam Separator

GESTRA Fax: ++49 (0) 421 - 35 03-149


Medium: Flowrate: Service pressure: Service temperature: Approved pressure: Approved temperature: Inspection and certification: Connections: Material: Inlet/Outlet: Condensate outlet: DN/PN DN/PN

Saturated steam

Superheated steam

Air

Gas Nm3/h

m = p = t = p = t =

kg/h bara/psia C barg/psig C

N = V

S235JRG2 (RSt 37-2) 1.4541 (V2A)

P265GH (H II) 1.4571 (V4A)

16 Mo 3

Connection arrangements:

Please enter:
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164

Academy

Page

Mobile Testing Station, See-Through Demo Facility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Technical Advice and Training Seminars.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Tools for Design Engineers, Users & Operators

Page

Programs & Sizing Software.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 GESTRA Steam Traps & Valves Library (2D and 3D CAD drawings).. . . . . . . . . . . . . . . . . . . . . . . . 168 Technical Literature .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Documentation and Reference Literature

Page

Technical References Guide and Condensate Manual.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Brochures and Leaflets.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Technical Infos.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

General Information

Page

Useful Information / Conversions .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Useful Conversions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Information on ATEX Directive 94/9/EC.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Information on Pressure Equipment Directive (PED) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 176 Combined Imperial and S. I. Steam Tables .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 178 DIN Material Reference Chart.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Design of GESTRA Valves.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Product Index.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 187

165

GESTRA Academy

Our GESTRA Academy offers a broad portfolio of in-depth vocational training seminars for design engineers, consultants, manufacturers and operators. As part of the workshops there will be practical hands-on demonstrations at our stateof-the-art simulation facilities on site. Evaluating and understanding what is going on in a steam system helps preventing costly malfunctions and downtime. Mobile Testing Station
Our mobile testing station is a testing, demonstration and training facility on wheels. We would be happy to send our mobile testing station together with our experienced support engineers to you in order to solve your operating problems directly on site and conduct training seminars on your premises. You provide steam, water and electricity and, by means of our mobile testing station, we provide a comprehensive and personalized workshop tailored to your specific requirements and focusing on steam and condensate systems.

SPECTOR Demonstration Facility


This simulation facility provides the opportunity to demonstrate the newest and most effective boiler equipment. Design engineers, manufacturers and operators can observe different operating modes and simulations of in-service failures. Thanks to these demonstration sessions individuals gain the knowledge needed to prevent expensive failures and downtime.

See-Through Demo Facility


Our custom-built see-through demo facility makes thermodynamic processes in steam and condensate systems visible. The whole installation is completely made from glass and allows the spectators to see effects and properties otherwise hidden from the human eyes. This facility illustrates in a practical manner some of the more abstract concepts discussed during the workshops and seminars.

Demonstration of up-to-date electronic monitoring equipment for steam traps up to 20 bar service pressure. The installation clearly illustrates the operational mode of the various systems.

Please call us so that we can schedule a demonstration with our mobile testing station at your facility. Telephone: 0049 (0) 421 - 35 03 - 311

166

Technical Advice and Training Seminars

The GESTRA Academy offers training programs and project management assistance for technical staff to help implement future-oriented and complex projects in all fields of steam, condensate and process fluid control. The tremendously fast progress of technology combined with the recent eco nomic developments are placing ever greater demands on the training and qualification of employees and managers alike. A companys wealth of technical know ledge and the know-how of its personnel in particular constitute nowadays the most important non-material asset of an enter prise. In many seminars held over the last few years our customers have often expressed a keen interest in authoritative theoretical and practical support. To assist with this objective, the GESTRA Academy was set up in order to provide comprehensive technical literature and conduct workshops, seminars and personalized consulting and training programs. Our hands-on seminars place great emphasis on the exchange of experience and the active presence and collaboration of the participants. Various practical examples of projects already implemented in different industries will be considered in order to outline the problems involved and their solutions. The focus of the training seminars is on the following subjects:

GESTRA training seminars are geared to the needs of technical staff working for engineering companies, project-, design- and plant engineers, foremen, interested specialists and personnel responsible for commissioning, servicing and maintenance.

The seminar is divided into four main topics:

Module 1: Module 2: Module 3: Module 4:

Steam Basics Design and Function of Steam Traps Boiler Plant Operation and Equipment Sizing of Control Valves

Objective

Optimization of steam and condensate


systems for cost-efficient and trouble-free operation

Facilitate peer interaction and discussions with other


participants

Practical hands-on experience Various installation examples based on actual projects will
illustrate problems and their respective solutions

Evaluation of energy-saving measures


The seminars are rounded off with some practical demonstrations given at our in-house testing facilities:


Certificate

Open steam system Closed steam system Transparent testing and demonstration facility Steam boiler demonstration facility
GESTRA Diploma

Fundamental principles of steam and


condensate systems

Sizing and design of pipework Efficient utilization of energy in


steam systems

Boiler automation and operation


(without constant supervision for 72 hrs)

Sizing of control valves


and other related topics and practical examples.

Venue Hotline

GESTRA AG Mnchener Strae 77 28215 Bremen Fax ++49 - 421- 35 03 - 142 Tel. ++49 - 421- 35 03 - 279; - 311 E-Mail: ihoeft@flowserve.com

A world first
Our various state-of-the-art test & demo facilities focus on hands-on experience and practical demonstrations. GESTRA is proud to present the world's first see-through steam system with secondary steam generator completely made of glass. This unique installation facilitates a clearer understanding of thermodynamic processes and visually illustrates the physical properties of steam and condensate.

167

Tools for Design Engineers, Users & Operators

Sizing Software
CAESar Steam trap selecting & sizing software (multilingual) www.gestra.com Select by application or by type. Filter criteria: functional type, nominal pressure, end connection and material. Output with specication text and ordering details. The GESTRA Steam Trap Guide an interactive PowerPoint program in English for steam trap selection is the ideal addition to the steam trap selecting & sizing software. CAESar (multilingual) selecting software for non-return valves range www.gestra.com Intuitive menue-driven software for valve selection, with ltering options, calculation of pressure drops, indication of specication texts and ordering information. CAESar selecting software for special equipment and vessels for heat recovery Parameters such as heat content, mass ow or condensate owrate are used for selecting and sizing pressure vessels, heat recovery installations, desuperheaters etc. and for price quotations. Furthermore the program can carry out an economic analysis, indicate potential savings and calculate payoff periods and, in addition, it can also compute the size of heating surfaces, kvs values for control valves and superheat temperatures. Note that the CAESar selecting software programs are linked with the current GESTRA Product Range and Price List and, as a consequence, must be updated every year. GESTRA CALCUquick For this Excel-based software tool for determining nominal sizes, ow velocities, quantity of ash steam, steam prices, steam loss etc. go to www.gestra.com and click on Technical Support.

GESTRA Boiler Automation (on CD)


Computer animation featuring various operating modes of steam boilers and illustrating safety, reliability and economic aspects of boiler equipment.

GESTRA Steam Traps & Valves Library

To help you design and plan an installation we offer you our extensive library with 2- and 3-dimensional drawings. 2D drawings available in the following formats: DWG and DXF for AutoCAD 14 and AutoCAD 2000 3D drawings available in the following formats: IGS, IPT, SAT and STEP To download the les go to www.gestra.com and click on Technical Support and CAD Valves Library.

Technical Documentation
To view and download datasheets, installation & operating manuals, GESTRA Technical References Guide, Gestra Condensate Manual, and our brochures, leaets and other technical literature go to www.gestra.com and click on Documents.

To order these programs, documents and CDs go to www.gestra.com and click on Documents and then on Order.
168

Documentation and Technical Literature

GESTRA Technical References Guide


Important reference work used in the eld of steam and condensate technology. Essential formulae and charts & tables specifying materials, units, standards, inspection requirements, European standards EN, ASME, and useful conversation tables are just some of the issues covered by this useful technical guide.

GESTRA Condensate Manual


This handbook is intended for operators and users and illustrates typical applications encountered in steam and condensate systems, shows examples of installation and describes processes and equipment.

Brochures & Leaets


For more detailed information on products, properties, designs, function and application.

Technical Infos
Answers are given to frequently asked questions regarding condensate lines, steam, boiler equipment, non-return valves and many more topics.

169

To view and download these documents go to www.gestra.com and click on Documents or click on Order to order the complete documentation on CD.

Useful Information /Conversions

Useful Information
Abbreviations used throughout this catalogue: DN Dimension, nominal. The nominal size of a pipe or fitting in mm or inch, if stated. PN Pressure, nominal. The nominal pressure rating (Maximum cold working pressure) in bar. PMX Maximum differential pressure (inlet pressure minus outlet pressure) PMA Maximum allowable working pressure PMO Maximum operating pressure TMA Maximum allowable working temperature PAMAX Maximum service pressure BSP British Standard Pipe (DIN ISO 228) NPT American Standard Taper Pipe Thread (National Pipe Tapered)

Conversions
In this catalogue the International System of Units (SI) is applied. The following conversions into the Imperial System for the units used in this catalogue might be useful: SI Units Imperial Units Conversion bar psi 1 bar = 14.504 psi C F 1F = C x 9/5 + 32 kg/h lb/h 1 kg/h = 2.204 lb/h l/s gpm 1 l/s = 13.22 igpm = 15.85 usgpm kv Cv Cv = 1.13 kv (usgpm)

Pressure-Temperature Ratings
It is not possible to give direct conversions between DIN and ANSI ratings, and space does not permit a detailed comparison. When selecting valves against specific duties, all service data must be fully considered. The following table is provided to guide the reader who may not be familiar with the general relationship between DIN and ASME ratings. DIN Rating ASME Class Equivalent nominal sizes
DN 8 mm 10 mm 15 mm 20 mm 25 mm 32 mm 40 mm 50 mm 65 mm 80 mm 100 mm 125 mm 150 mm 200 mm = = = = = = = = = = = = = =
1/4" 3/8" 1/2" 3/4" 1" 11/4" 11/2" 2" 21/2" 3" 4" 5" 6" 8"

PN 10 125 lb PN 16 150 lb PN 25 PN 40 300 lb PN 63 PN 100 600 lb 900 lb PN 160 PN 250 1500 lb PN 320 PN 400 2500 lb PN 630

DN 300 mm 350 mm 400 mm 450 mm 500 mm 600 mm 700 mm 750 mm 800 mm 900 mm 1000 mm 1050 mm 1200 mm

= = = = = = = = = = = = =

12" 14" 16" 18" 20" 24" 28" 30" 32" 36" 40" 42" 48"

170

Useful Conversions

Mass
1 kilogramme, kg 1 metric ton, tonne = = 2.204 pound, lb 1000 kilogramme, kg

PRESSURE
1 bar = = = 1 foot of water 1 kilogramme-force/sq. centimetre, kgf/cm2 = = = = = = 14.504 pound-force/sq. inch, lbf/in2 100 kilonewton/sq. metre, kN/m2 1.020 kilogramme-force/square centimetre, kgf/cm2 0.4332 pound-force/sq. inch, lbf/in2 0.8824 inch of mercury, in Hg 29.87 millibar, mbar 14.223 pound-force/sq. inch, lbf/in2 98.07 kilonewton/sq. metre, kN/m2 0.9807 bar 0.145 pound-force/sq. inch, lbf/in2 0.0102 kilogramme-force/square centimetre, kgf/cm2 0.01 bar 6.895 kilonewton/sq. metre, kN/m2 0.0703 kilogramme-force/square centimetre, kgf/cm2 0.0689 bar 14.696 pound-force/sq. inch, lbf/in2 1.013 bar 1 millimetre of mercury, mm Hg 0.0193 pound-force/sq. inch, lbf/in2 1.333 millibar, mbar

Length
1 foot, ft 1 inch, in 1 metre, m = = = = 0.3048 metre, m 25.4 millimetre, mm 3.28 foot, ft 39.37 inch, in

AREA
1 square inch, in2 1 square metre, m2 = = = = 645.2 square millimetre, mm2 10.76 square foot, ft2 1550 square inch, in2 1.196 square yard, yd2

1 kilonewton/sq.metre, = kN/m2, (kilopascal, kPa) = = 1 pound-force/sq.inch, = lbf/in2 (psi) = = 1 standard atmosphere, atm 1 torr = = = = =

VOLUME
1 cubic inch, in3 1 cubic foot, ft3 1 U.S. gallon, US gal = = = = = 16387 cubic millimetre, mm3 0.0283 cubic metre, m3 6.24 imperial gallon, gal 28.32 litre, l 0.833 imperial gallon, gal

FOR WATER
1 cubic foot of water weighs 62.4 pound 1 imperial gallon of water weighs 10 pound 1 cubic metre of water weighs 1000 kilogramme 1 litre of water weighs 1 kilogramme

FLOWRATE
1 cubic foot/minute, ft3/min = 1.698 cubic metre/hour, m3/h 13.22 imperial gallon/minute, gal/min 793 imperial gallon/hour, gal/h
1.605 normal cubic metre/hour, Nm3/h (measured at 1 atm, 0C)

PREFIXES
tera giga mega kilo hecto*) deca*) deci*) centi*) milli micro nano pico femto atto symbol T G M k h da d c m u n p f a factor 1012 109 106 103 102 10 10-1 10-2 10-3 10-6 10-9 10-12 10-15 10-18

1 litre/second, l/s = = For Gases 1 standard cubic = foot/min, SCFM (measured at 1 atm, 60F)

DENSITY
1 kilogramme/cubic metre, kg/m3 1 pound/cubic foot, lb/ft3 = = = 1 gramme/litre, g/l 0.0624 pound/cubic foot, lb/ft3 16.018 kilogramme/cubic metre, kg/m3

ENERGY & POWER


1 British thermal unit, Btu 1 therm 1 British thermal unit/ pound, Btu/lb 1 kilocalorie, kcal = = = = 1.055 kilojoule, kJ 105 British thermal unit, Btu 2.326 kilojoule/kilogramme, kJ/kg 4.187 kilojoule, kJ 1 kilojoule/second, kJ/s 1.341 horsepower, hp 0.948 British thermal unit/second, Btu/s

*) These prefixes are not recommended for scientific or engineering use.

1 kilowatt, kW = = =

171

GESTRA Information on ATEX Directive 94/9/EC

Equipment and protective systems intended for use in potentially explosive atmospheres ATEX Directive 94/9/EC is a so-called New Approach Directive which provides the technical requirements to be applied to equipment intended for use in potentially explosive atmospheres. The term potentially areas for valves and steam traps refers to the ambient atmosphere. The Directive has been mandatory in all member states of the EU from 1st July 2003. Steam traps:

The equipment listed above is suitable for application in the following areas:

Zone 0, 1, 2 (gases) and 20, 21, 22 (dusts) Equipment group II Category 1, 2, 3

Note:
Some of the electrical and non-electrical devices not listed here can be used in potentially explosive atmospheres. Please contact us if you have questions regarding the use of GESTRA equipment not indicated on this page in potentially explosive environments. Please note that some GESTRA devices in accordance with the Pressure Equipment Directive (PED) and ATEX bear the CE marking and have a Declaration of Conformity. For more information refer to the corresponding data sheets and installation instructions.

Type AK, BK, DK, MK, SMK, TK, UBK, UC (Universal Connector), UNA, VK.
Non-return & check valves:

Type BB, CB, MB, RK, SBO.


Self-acting controller:

Type BW, CW.


Strainer:

Type SZ.
The equipment listed above has been examined regarding its suitability for application in potentially explosive atmospheres as defined by Directive 94/9/EC. Based on Annex II, section 1.3 the equipment does not have its own source of ignition and is therefore excluded from the scope of this Directive according to Art. 1, Paragraph (3)a). In compliance with Art. 10, Paragraph 3 the equipment is not entitled to bear the CE marking in connection with Directive 94/9/EC. Consequently a declaration of con formity in accordance with 94/9/EC must not be issued. When using the equipment according to its intended purpose as specified in the corresponding data sheets and installation instructions issued by GESTRA the application of the above-mentioned equipment in potentially explosive atmospheres is not limited since the equipment does not have its own source of ignition.

172

EC Pressure Equipment Directive (PED) No. 97/23


CE Marking for GESTRA Series Equipment

Fluid group 1: hazardous substances, poisonous, flammable Fluid group 2: non-hazardous substances, e.g. water, steam, air

Pressure CL acc. to name plate Type no. PN/CL Size (DN)


10/15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 600 700 800 900 1000 1200

CE Fluid marking yes Module Gr. 1 Gr. 2 A1 Steam Traps X X H X X H X X X H X X H X X X X X X

Valve / Type AK BK BK BK BK BK BK BK BK BK

X X X (X) (X)

H H H H H

(X) X

H H H

X X (X) (X) (X) (X) (X) (X) (X) (X) (X) X X X X X (X) H H H H H H H H H H H H H H H H X X X X X X X X X X X X X

X BK X BK X BK X DK X DK X DK X GK X GK X MK X MK X MK X MK X MK X MK X MK X MK X MK X MK X MK X MK X MK X MK X MK X NRG X SMK X TK X TK X TS X UBK X UC, UCY X UNA X UNA X UNA X UNA X UNA X UNA X UNA X UNA X UNA X UNA X UNA X X X X X X X X X X X X X X X X UNA UNA UNA UNA UNA UNA UNA UNA UNA UNA V VK VK VK VKE VKE

1)

(X) H incl. Fl. CL300

451) 845 40 15 716 40 15 716 CL300 15 716 CL150 27N1) 712 40 27N 712 63 (incl. Fl. CL400/600) 28 713, 870 100/CL600 29 714, 871 160/CL900 36, 36A/7 (Swivel) 707, 846 40/CL300 63-100/ 37 719, 717 CL400/600 451) 708 40 461) 711 40 212 715, 872 630/CL2500 36A/7 (Swivel) 846 CL300 45 877 40 47, 57 878,879 63/CL600 11 750 10/16 21 750 16 20 720 6 25/2 729 40 25/2 729 CL300 25/2 729 CL150 25/2S 734 40 25/2S 734 CL300 25/2S 734 CL150 25/2S3 740 40 36A/7 (Swivel) 846 CL300 35/2S 735 40/CL300 35/2S3 736 40/CL300 35/3 724 25 36/51 749 37/1 881 63 45/45A1) 725 40 16-19, -27, -28 053 40 22 885 10 23 742 16 24 743 25 36 849 CL300 461) 886 40 Universal Connector 847 CL300 14 (incl. CL150) 851, 852 25 14P 853, 854 25 16 855, 856 40/CL150 16A Stainless steel 857, 858 40/CL150 23 770, 771 16 25 798, 799 40 25-PK, 25-PS 794, 795 CL150 261) 780, 781 40 26 780 CL150 40 26h Stainless steel 786 CL150 26h Stainless steel 786 27h 820 63 (incl. Fl. CL400/600) 27h 820 CL300 38 791, 792 100 39 814 160 39 (incl. Fl. CL600) 814 100 Special Type 62 800 16 Special 801 25 PN 801 25 Special 804 63 Special 804 40 21.9, 21.9/K 899, 898 40 14 041 16 161) 042 40 16 042 CL150 16, 26 048 40 16a 044 40

A3.3 A3.3 A3.3 CE CE CE CE A3.3 A3.3 CE CE CE CE

A3.3 A3.3 A3.3 A3.3 A3.3 A3.3

A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 BK 36A/7 in conjunction with UC/UCY A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 in conjunction with UC/UCY A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE CE CE CE CE* *) DN 150 = PN 10 A3.3 A3.3 A3.3 A3.3 CE CE CE CE A3.3 A3.3 A3.3 CE CE A3.3 CE CE A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 in conjunction with UC/UCY A3.3 replaces MK 25/2S DN 25 (734) A3.3 replaces MK 25/2S3 DN 25 (740) A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE CE CE CE CE CE CE A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE CE A3.3 A3.3 A3.3 A3.3 A3.3 CE CE A3.3 A3.3 A3.3 CE CE A3.3 A3.3 A3.3 CE CE A3.3 A3.3 A3.3 CE CE A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE CE A3.3 A3.3 CE CE A3.3 A3.3 CE CE CE CE CE CE

173

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CE Marking for GESTRA Series Equipment

Fluid group 1: hazardous substances, poisonous, flammable Fluid group 2: non-hazardous substances, e.g. water, steam, air

Pressure CL acc. to name plate Type no. PN/CL Size (DN)


10/15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 600 700 800 900 1000 1200

CE Fluid marking yes Module Gr. 1 Gr. 2 A2 Check Valves X X X X X X X X X X X X X X (X) X X (X) (X) X X H H H H H H H H H H H H H H H H H H H H H X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X (X) (X) (X) (X) (X) (X) (X) (X) (X) (X) (X) (X) (X) (X) (X) H H H H H H H H H H H H H H H H H H X X X X X X X X X X X X X X

Valve / Type

BB 12A / 22A BB 14A / 24A BB 15A / 25A BB 16A / 26A BB 17A BB 18A BB 19A BB 12C / 22C BB 14C / 24C BB 15C / 25C BB 16C / 26C BB 17C BB 18C BB 19C BB 11G / 21G BB 12G / 22G BB 14G / 24G CB 14 CB 24S CB 26 CB 26a MB 14 526520/530 528520/530

149 149 149 149 149 149 149 143 143 143 143 143 143 143 140 140 140 138 132 133 134 091 448 448 448 118 124 117 125 114 109 102 103 110 107 095 100 120 101 121 086, 088, 090

10 16 25/CL150 40/CL300 63 100/CL600 160/CL900 10 16 25/CL150 40/CL300 63 100/CL600 160/CL900 6 10 16 16 16 40 40 16 25 40 100 40 40 40 40 16 16 16 160 6 16 40

CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE 1. BB DIN- & ASME 2. DN 800 = ASME 30" (DN 750) CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE A3.3 CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE A3.3 CE CE CE CE CE CE CE CE A3.3 CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE A3.3 A3.3 A3.3 CE CE CE CE CE CE A3.3 A3.3 A3.3 CE CE CE CE CE CE A3.3 A3.3 A3.3 CE CE CE CE CE CE A3.3 A3.3 A3.3 CE CE CE CE CE CE A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE CE A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE CE A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE CE CE CE CE CE A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE CE A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE CE CE A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE

X NAF-Check

X NAF-Check 526620/630 X NAF-Check 526822/832 X X X X X X X X X X X X X X X RK 16a RK 16b RK 16c RK 16t RK 26a RK 29a RK 41 RK 44 RK 44s RK 49 RK 70 RK 71 RK 76 RK 86 RK 86a 11, SBO 21, 31

40/CL300 A3.3 A3.3 A3.3 CE CE CE CE CE CE

160/CL.. A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE CE

X1) X

40/CL300 A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE CE 40/CL300 A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE CE 6 A3.3 A3.3

1)

RK 41, DN65-100, approved only for liquids of fluid group 1 but not for gases as specified in the PED 97/23/EC.

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CE Marking for GESTRA Series Equipment

Fluid group 1: hazardous substances, poisonous, flammable Fluid group 2: non-hazardous substances, e.g. water, steam, air

Pressure CL acc. to name plate Type no. PN/CL Size (DN)


10/15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 600 700 800 900 1000 1200

CE Fluid marking Valve / Type yes Module Gr. 1 Gr. 2 A4 Self Acting Temperature & Pressure Controller (X) (X) (X) (X) (X) (X) (X) (X) (X) H H H H H H H H H X X X X X X X X X X X X X1) X1) X1) X X X X X X (X) (X) (X) (X) (X) (X) (X) (X) (X) (X) (X) (X) (X) (X) (X) (X) X X X X X X X X X X X X X X X X X X A4 Control Valves (X) (X)* (X) (X) (X)* (X) (X) (X)
1)

5801 5801 5801 5801 5610 5610 5610 BW 31 BW 31A BW 31A CW 41 CW 41/4 CW 44 CW 44k Clorius L1S Clorius L2S Clorius L2SR, L3S Clorius L3F Clorius M1F Clorius M1FB Clorius M2F Clorius M2FR Clorius M3F Clorius M3F/M3FM Clorius H1F Clorius H1FB Clorius H2F Clorius H2FR Clorius H3F Clorius G1F Clorius G1FB Clorius G2F Clorius G2FR Clorius G3F 2.05, 4.03, 4.05, Clorius 4.10, 8.09, 8.18 V725 Foxpak ZK 29 ZK 210 ZK 213 ZK 313 ZK 412 ZK 513 ZK 610, 613

270 270 272 273 274 274 275 032 033 033 035 035 036 036 235 235 235, 239 239 236 236 236 236 239 239 237 237 237 237 239 238 238 238 238 239 245

16 25 40 40 16 25 40 25+40 CL150 16 16 25 25 16 16 16 10 16 16 16 16 16 10 40 40 40 40 40 25 25 25 25 25

A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE CE CE CE CE CE A3.3 A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE A3.3 A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE A3.3 A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE CE CE A3.3 A3.3 A3.3 A3.3 CE CE CE CE CE A3.3 A3.3 A3.3 A3.3 CE CE CE CE CE A3.3 CE CE A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE CE A3.3 A3.3 A3.3 A3.3 A3.3 CE CE CE CE CE A3.3 A3.3 A3.3 CE CE CE CE CE A3.3 A3.3 A3.3 A3.3 CE CE CE CE CE A3.3 A3.3 CE CE A3.3 A3.3 A3.3 A3.3 CE CE A3.3 A3.3 CE CE CE CE A3.3 A3.3 CE CE CE CE CE CE CE A3.3 A3.3 CE CE CE CE CE CE CE A3.3 A3.3 CE CE A3.3 A3.3 A3.3 A3.3 A3.3 CE A3.3 A3.3 A3.3 CE A3.3 A3.3 A3.3 A3.3 CE A3.3 A3.3 A3.3 CE A3.3 A3.3 A3.3 CE A3.3 A3.3 A3.3 DN 15-25 = PN 40 as from 2002 DN 15-25 = PN 40 as from 2002

25+40+CL150 A3.3 A3.3 A3.3

H A1, H A1, H A1, H A1, H A1, H A1, H A1, H

X X X X X X X X

285, 286 754 013, 393 757 758 759

40 40 - 160 250

A3.3 A3.3 A3.3 CE CE CE CE CE CE A3.3 A3.3 CE CE CE CE CE A3.3 A3.3 CE CE CE CE CE CE CE CE CE CE CE CE A3.3 A3.3 CE CE CE CE CE CE A3.3 A3.3 CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE

for liquid uids only

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EC Pressure Equipment Directive (PED) No. 97/23


CE Marking for GESTRA Series Equipment

Fluid group 1: hazardous substances, poisonous, flammable Fluid group 2: non-hazardous substances, e.g. water, steam, air

Pressure CL acc. to name plate Type no. PN/CL Size (DN)


10/15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 600 700 800 900 1000 1200

CE Fluid marking yes Module Gr. 1 Gr. 2 A6 Safety Valves X X X X (X) (X) (X) (X) (X) B+D B+D B+D B+D A H H H H X X X X X X X X X X X X*) X X X X

Valve / Type

GSV 4421 GSV 4425 GSV 4422 GSV 4414 GSF 303 GSF 312 - 317, 319, 320 GSF 332 - 334, 336 - 338 GSF 341 - 348 SZ 36A 14F, 24F, 35F, 36F, 36, 56F

300 300 300 300 430 430 430 430 437 440 416 440 416 453 443 017,389 017,389 013, 393 394 005, 366 005, 366 006, 367 006, 367 002, 365 351/352 + 322 265/267 + 255 377 + 266 351/357 + 323 358 + 323 377 + 380 + 338 350 377 377 40 40-160 40 40 320 63 160 X 16*

CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE CE A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE *) liquids max. 10 bar

A7 Strainer 16 - 160 A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE CE 16 - 160 A3.3 A3.3 A3.3 CE CE CE 6 - 25 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE 40/CL300 A3.3 A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE

A8 Stop Valves, Sight Glasses (X) (X) (X) (X) (X) (X) (X) (X) H H H H H H H H X X X X X X X X X X X X X X X X X X (X) H X X (X) (X) H H X X X X X X X X X X X X X B+D B+D B+D B+D B+D B+D H H H X X X GAV 16, 40/25 A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE CE* CE* CE* *) = GAV 35, 35F PN 25 25 16 16 16 110 63-160 40 CL150 250 302 40 CL150 63 CL600 250 40-160 CE CE CE CE CE CE CE CE CE CE For more information see Price List CE on request
(X) CE-marking depending on size (X)* on request For special versions of GESTRA series equipment, e. g. other connection sizes, it is necessary to ascertain whether the equipment must be accompanied by the declaration of conformity and has to bear the CE marking.

GAV 25F GAV 54F GSG 405 GSG 424 Vortex 83 WA / FA LD 144 BA / BAE 46 BA / BAE 47 BA / BAE 46 BA / BAE 210 BA / BAE 211 PA / MPA 46 PA / MPA 46 47 (inkl. Fl. PA / MPA CL400) PA / MPA 47 PA / MPA 110 1x-40/41 + NRG NRS 1-40/41 TRG 5-xx + TRS 5-6/TRS5-7

A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE CE A3.3 A3.3 A3.3 CE CE CE CE CE CE CE CE CE CE A3.3 A3.3 A3.3 CE CE CE A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE CE A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 A3.3 CE CE A3.3 A3.3 A3.3 CE CE A3.3 CE CE A3.3 CE CE A3.3 CE CE CE CE CE

B Intermittent & Continuous Blowdown Valves BA, BAE, MPA, PA & Boiler Electronics

018,390 63/CL600 A3.3 A3.3 A3.3

LRGT 16-1 + KS 90 NRG NRG LRG 1x-11 + NRS 1-7 16-36 + NRS 1-9 16-40 + LRR 1-40 + URB 1

NRG 211 LRG 17-1 LRG 19-1 Vessels

C Heat Recovery Systems & Vessels A1, G (X) X

A3.3 Not PED relevant or must not be CE-marked Not part of GESTRA product range CE

CE Is declared conform

Based on GESTRA standard types, e.g. BK 28 with non-std bw-connection 60.3 x 2.9 is not considered.

176

Combined Imperial and S. I. Steam Tables

Gauge Pressure
bar g 0.96 0.91 0.86 0.81 0.76 0.71 0.66 0.61 0.56 0.51 0.46 0.41 0.36 0.31 0.26 0.21 0.16 0.11 0.06 0.01 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.2 2.4 2.6 2.8 3.0 3.2 3.4 3.6 3.8 4.0 4.2 4.4 4.6 4.8 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.0 15.5 16.0 16.5 17.0 17.5 psi g 28.4 27.0 25.5 24.0 22.5 21.1 19.6 18.1 16.6 15.1 13.7 12.2 10.7 9.24 7.77 6.29 4.81 3.34 1.86 0.38 0 1.45 2.90 4.35 5.80 7.25 8.70 10.2 11.6 13.1 14.5 16.0 17.4 18.9 20.3 21.8 23.2 24.7 26.1 27.6 29.0 31.9 34.8 37.7 40.6 43.5 46.4 49.3 52.2 55.1 58.0 60.9 63.8 66.7 69.6 72.5 79.8 87.0 94.3 102 109 116 123 131 138 145 152 160 167 174 181 189 196 203 210 218 225 232 239 247 254

Absolute Pressure
bar a psi a

Saturation Temperature
ts
C


Water Sensible heat (hf) KJ/kg

Specific Enthalpy
Evaporation Latent heat (hfg) kJ/kg Water Sensible heat (hf) Btu/lb Evaporation Latent heat (hfg) Btu/lb

Specific Volume Steam


Vg
m3/kg ft3/lb

0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8 0.85 0.9 0.95 1.0 1.013 1.11 1.21 1.31 1.41 1.51 1.61 1.71 1.81 1.91 2.01 2.11 2.21 2.31 2.41 2.51 2.61 2.71 2.81 2.91 3.01 3.21 3.41 3.61 3.81 4.01 4.21 4.41 4.61 4.81 5.01 5.21 5.41 5.61 5.81 6.01 6.51 7.01 7.51 8.01 8.51 9.01 9.51 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.0 15.5 16.0 16.5 17.0 17.5 18.0 18.5

0.725 1.45 2.18 2.90 3.63 4.35 5.08 5.80 6.53 7.25 7.98 8.70 9.43 10.2 10.9 11.6 12.3 13.1 13.8 14.5 14.696 16.1 17.5 19.0 20.5 21.9 23.4 24.8 26.3 27.7 29.2 30.6 32.1 33.5 35.0 36.4 37.9 39.3 40.8 42.2 43.7 46.6 49.5 52.4 55.3 58.2 61.1 64.0 66.9 69.8 72.7 75.6 78.5 81.4 84.3 87.2 94.4 102 109 116 123 131 138 145 152 160 167 174 181 189 196 203 210 218 225 232 239 247 254 261 268

32.9 91 45.8 114 54.0 129 60.1 140 65.0 149 69.1 156 72.7 163 75.9 169 78.7 174 81.3 178 83.7 183 85.9 187 88.0 190 90.0 194 91.8 197 93.5 200 95.1 203 96.7 206 98.2 209 99.6 211 100 212 103 217 105 221 107 225 110 230 112 234 114 237 115 239 117 243 119 246 120 248 122 252 123 253 125 257 126 259 128 262 129 264 130 266 131 268 133 271 134 273 136 277 138 280 140 284 142 288 144 289 146 293 147 297 149 298 150 302 152 304 153 307 155 309 156 313 158 315 159 316 162 324 165 329 168 333 171 338 173 343 175 347 178 351 180 354 182 360 184 363 186 367 188 370 190 374 192 376 193 379 195 383 197 385 198 388 200 392 202 394 203 397 204 399 205 401 207 405 209 408

138 192 226 251 272 289 304 318 330 341 351 360 369 377 384 392 399 405 411 418 419 430 441 450 460 468 476 484 492 499 506 512 519 525 531 536 542 547 552 557 562 572 581 589 597 605 613 620 627 634 641 647 653 659 665 671 685 698 710 721 733 743 753 763 773 782 790 798 807 815 823 830 838 845 852 859 866 872 879 885 891

2423 2392 2373 2358 2346 2336 2327 2319 2312 2305 2299 2294 2288 2283 2279 2274 2270 2266 2262 2258 2257 2250 2243 2237 2231 2226 2220 2215 2211 2206 2201 2197 2193 2189 2185 2181 2177 2174 2170 2167 2163 2157 2151 2145 2139 2133 2128 2123 2118 2113 2108 2104 2099 2095 2090 2086 2076 2066 2057 2048 2039 2031 2023 2015 2008 2000 1993 1986 1979 1973 1966 1960 1953 1947 1941 1935 1929 1923 1918 1912 1907

59 82 97 108 117 124 131 137 142 147 151 155 159 162 165 169 172 174 177 179 180 185 190 194 198 201 205 208 212 215 218 220 223 226 228 230 233 235 237 240 242 246 250 253 257 260 264 267 270 273 276 278 281 283 286 289 295 300 305 310 315 319 324 328 332 336 340 344 347 350 354 357 360 363 366 369 372 375 378 381 383

1042 1029 1020 1014 1009 1004 1000 997 994 991 988 986 984 982 980 978 976 974 972 971 970 967 964 962 959 957 954 952 951 948 946 945 943 941 939 938 936 935 933 932 930 927 925 922 920 917 915 913 911 908 906 905 902 901 899 897 893 888 884 880 877 873 870 866 863 860 857 854 851 848 845 843 840 837 834 832 829 827 824 822 820

28.2 14.7 10.0 7.65 6.20 5.23 4.53 3.99 3.58 3.24 2.96 2.73 2.54 2.37 2.22 2.09 1.97 1.87 1.78 1.69 1.67 1.53 1.41 1.31 1.23 1.15 1.08 1.02 0.971 0.923 0.881 0.841 0.806 0.773 0.743 0.714 0.689 0.665 0.643 0.622 0.603 0.568 0.536 0.509 0.483 0.461 0.440 0.422 0.405 0.389 0.374 0.361 0.348 0.336 0.325 0.315 0.292 0.272 0.255 0.240 0.227 0.215 0.204 0.194 0.185 0.177 0.171 0.163 0.157 0.151 0.146 0.141 0.136 0.132 0.128 0.124 0.120 0.117 0.114 0.110 0.108

452 236 160 123 99.3 83.8 72.6 63.9 57.3 51.9 47.4 43.7 40.7 38.0 35.6 33.5 31.6 30.1 28.5 27.1 26.8 24.5 22.6 21.0 19.7 18.4 17.3 16.3 15.6 14.8 14.1 13.5 12.9 12.4 11.9 11.4 11.0 10.7 10.3 9.96 9.66 9.10 8.59 8.15 7.74 7.38 7.05 6.76 6.49 6.23 5.99 5.78 5.57 5.38 5.21 5.01 4.68 4.36 4.09 3.84 3.64 3.44 3.27 3.11 2.96 2.84 2.74 2.61 2.51 2.42 2.34 2.26 2.18 2.11 2.05 1.99 1.92 1.87 1.83 1.76 1.73

VACUUM These figures are in inches of Mercury

VACUUM

14.5 psi = 1 bar

177

Combined Imperial and S. I. Steam Tables

Gauge Pressure
bar g 18.0 18.5 19.0 19.5 20.0 21.0 22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0 34.0 35.0 36.0 37.0 38.0 39.0 40.0 41.0 42.0 43.0 44.0 45.0 46.0 47.0 48.0 49.0 50.0 52.0 54.0 56.0 58.0 60.0 62.0 64.0 66.0 68.0 70.0 72.0 74.0 76.0 78.0 80.0 82.0 84.0 86.0 88.0 90.0 92.0 94.0 96.0 98.0 100.0 105.0 110.0 115.0 120.0 125.0 130.0 135.0 140.0 145.0 150.0 155.0 160.0 165.0 170.0 175.0 180.0 185.0 190.0 195.0 200.0 psi g 261 268 276 283 290 305 319 334 348 363 377 392 406 421 435 450 464 479 493 508 522 537 551 566 580 595 609 624 638 653 667 682 696 711 725 754 783 812 841 870 899 928 957 986 1015 1044 1073 1102 1131 1160 1189 1218 1247 1276 1305 1334 1363 1392 1421 1450 1523 1595 1668 1741 1813 1886 1958 2031 2103 2176 2248 2321 2393 2466 2538 2611 2683 2756 2828 2901

Absolute Pressure
bar a psi a

Saturation Temperature
ts
C


Water Sensible heat (hf) KJ/kg

Specific Enthalpy
Evaporation Latent heat (hfg) kJ/kg Water Sensible heat (hf) Btu/lb Evaporation Latent heat (hfg) Btu/lb

Specific Volume Steam


Vg
m3/kg ft3/lb

F 410 412 415 417 419 423 428 432 435 439 442 446 450 453 457 460 462 466 469 471 475 477 480 482 486 487 491 493 496 498 500 502 505 507 509 514 518 522 525 531 534 538 541 545 549 552 556 559 561 565 568 570 574 576 579 581 585 588 590 594 599 606 612 617 622 628 633 639 644 649 653 658 662 667 671 675 680 684 687 691

19.0 19.5 20.0 20.5 21.0 22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0 34.0 35.0 36.0 37.0 38.0 39.0 40.0 41.0 42.0 43.0 44.0 45.0 46.0 47.0 48.0 49.0 50.0 51.0 53.0 55.0 57.0 59.0 61.0 63.0 65.0 67.0 69.0 71.0 73.0 75.0 77.0 79.0 81.0 83.0 85.0 87.0 89.0 91.0 93.0 95.0 97.0 99.0 101.0 106.0 111.0 116.0 121.0 126.0 131.0 136.0 141.0 146.0 151.0 156.0 161.0 166.0 171.0 176.0 181.0 186.0 191.0 196.0 201.0

276 283 290 297 305 319 334 348 363 377 392 406 421 435 450 464 479 493 508 522 537 551 566 580 595 609 624 638 653 667 682 696 711 725 740 769 798 827 856 885 914 943 972 1001 1030 1059 1088 1117 1146 1175 1204 1233 1262 1291 1320 1349 1378 1407 1436 1465 1537 1610 1683 1755 1828 1900 1973 2045 2118 2190 2263 2335 2408 2480 2553 2625 2698 2770 2843 2915

210 211 213 214 215 217 220 222 224 226 228 230 232 234 236 238 239 241 243 244 246 247 249 250 252 253 255 256 258 259 260 261 263 264 265 268 270 272 274 277 279 281 283 285 287 289 291 292 294 296 298 299 301 302 304 305 307 309 310 312 315 319 322 325 328 331 334 337 340 343 345 348 350 353 355 357 360 362 364 366

897 903 909 915 920 931 942 952 962 972 982 991 1000 1009 1017 1026 1034 1042 1050 1058 1066 1073 1080 1087 1095 1102 1108 1115 1122 1129 1135 1142 1148 1155 1161 1173 1185 1197 1208 1219 1230 1241 1251 1262 1272 1283 1293 1303 1312 1322 1331 1341 1350 1359 1368 1377 1386 1395 1404 1412 1433 1454 1475 1495 1515 1535 1555 1575 1595 1614 1634 1654 1674 1694 1715 1736 1759 1782 1806 1833

1901 1896 1890 1885 1880 1870 1860 1850 1841 1831 1822 1813 1804 1796 1787 1779 1770 1762 1754 1746 1737 1730 1722 1714 1706 1699 1691 1684 1676 1669 1662 1654 1647 1640 1633 1619 1605 1591 1577 1564 1551 1538 1525 1512 1499 1486 1473 1460 1447 1435 1422 1410 1398 1385 1368 1360 1348 1336 1323 1311 1280 1249 1218 1188 1157 1125 1093 1060 1027 994 960 925 888 850 811 769 726 679 628 562

386 388 391 393 396 400 405 409 414 418 422 426 430 434 437 441 445 448 451 455 458 461 464 467 471 474 476 479 482 485 488 491 494 497 499 504 509 515 519 524 529 534 538 543 547 552 556 560 564 568 572 576 580 584 588 592 596 600 604 607 616 625 634 643 651 660 668 677 686 694 702 711 720 728 737 746 756 766 776 788

817 815 813 810 808 804 800 795 792 787 783 779 776 772 768 765 761 758 754 751 747 744 740 737 733 730 727 724 721 718 715 711 708 705 702 696 690 684 678 672 667 661 656 650 644 639 633 628 622 617 611 606 601 595 590 585 580 574 569 564 550 537 524 511 497 484 470 456 442 427 413 398 382 365 349 331 312 292 270 242

0.105 0.103 0.100 0.0972 0.0949 0.0906 0.0868 0.0832 0.0797 0.0768 0.0740 0.0714 0.0689 0.0666 0.0645 0.0625 0.0605 0.0587 0.0571 0.0554 0.0539 0.0524 0.0510 0.0498 0.0485 0.0473 0.0461 0.0451 0.0441 0.0431 0.0421 0.0412 0.0403 0.0395 0.0386 0.0371 0.0356 0.0343 0.0330 0.0319 0.0308 0.0297 0.0288 0.0278 0.0270 0.0261 0.0253 0.0246 0.0239 0.0232 0.0226 0.0219 0.0213 0.0208 0.0202 0.0197 0.0192 0.0187 0.0183 0.0178 0.0168 0.0158 0.0149 0.0141 0.0133 0.0126 0.0120 0.0114 0.0108 0.0102 0.00972 0.00922 0.00875 0.00829 0.00785 0.00743 0.00701 0.00660 0.00619 0.00577

1.68 1.65 1.60 1.56 1.52 1.45 1.39 1.33 1.28 1.23 1.19 1.14 1.10 1.07 1.03 1.00 0.97 0.94 0.915 0.887 0.863 0.839 0.817 0.798 0.777 0.758 0.738 0.722 0.706 0.690 0.674 0.660 0.646 0.633 0.618 0.594 0.570 0.549 0.529 0.511 0.493 0.476 0.461 0.445 0.432 0.418 0.405 0.394 0.383 0.372 0.362 0.351 0.341 0.333 0.324 0.316 0.308 0.300 0.293 0.285 0.269 0.253 0.239 0.226 0.213 0.202 0.192 0.183 0.173 0.163 0.156 0.148 0.140 0.133 0.126 0.119 0.112 0.106 0.0992 0.0924

14.5 psi = 1 bar

178

DINMaterial Reference Chart

EN Material Designation Number EN-JL 1040 EN-JS 1030 EN-JS 1025 EN-JS 1049 EN-JM 1030 1.0038 1.0315 1.0345 1.0460 1.0619 1.4006 1.4008 1.4107 1.4301 1.4308 1.4317 1.4404 1.4408 1.4435 1.4541 1.4550 1.4552 1.4571 1.4581 1.4901 1.4903 1.4922 1.4980 1.4496 1.5415 1.5419 1.7225 1.7335 1.7357 1.7380 1.7383 1.7709 2.4600 2.4610 2.4632 2.4669 3.7035 CW608N CW614N CW617N CW710R CW718R CC332G CC480K-GS CC483K-GS
1)

Old Material Designation (DIN) Number 0.6025 0.7040 0.7043 0.7043 0.8040 1.0038 1.0315 1.0345 1.0460 1.0619 1.4006 1.4008 1.4107 1.4301 1.4308 1.4404 1.4408 1.4435 1.4541 1.4550 1.4552 1.4571 1.4581 1.4903 1.4922 1.4980 1.4986 1.5415 1.5419 1.7225 1.7335 1.7357 1.7380 1.7709 2.4600 2.4610 2.4632 2.4669 3.7035 2.0371 2.0401 2.0402 2.0540 2.0561 2.0970.01 2.1050.01 2.1052.04 Symbol GG-25 GGG-40 GGG-40.3 GGG-40.3 GTW-40 RSt 37-2 ST 37.8 ST 35.8 (HI) C22.8 GS-C 25 X10 Cr 13 G-X 8 CrNi 13 G-X 8 CrNi 12 X5 CrNi 18 10 G-X 6CrNi 18 9 X2CrNiMo17132 G-X 6CrNiMo 18 10 X2 CrNiMo 18 14 3 X6 CrNiTi 18 10 X6 CrNiNb 18 10 G-X 5 CrNiNb 18 9 X6 CrNiMoTi 17 12 2 G-X 5 CrNiMoNb 18 10 X10 CrMoVNb 91 X20 CrMo V12 1 X5NiCrTi 26 15 X8 CrNiMo BNb 16 16 15 Mo 3 GS-22 Mo 4 42CrMo4 13 CrMo 4 4 GS-17 CrMo 5 5 10 CrMo 9 10 21CrMoV 5 7 NiMo 29Cr NiMo 16Cr 16Ti NiCr20 Co18Ti NiCr15 Fe7 TiAL CuZN 38 Pb 1.5 (MS60) CuZn 39 Pb 3 CuZn 40 Pb 2 CuZn 35 Ni 2 CuZn 40 Al 1 G-CuAl 9 Ni G-CuSn 10 GC-CuSn 12

ASTM equivalent 1) A126-B A536 60-40-18 A284-B A285-CA A105 A216-WCB A182-F6A A217-CA15 A182-F304 A351-CF8 A743 CA6NM A182 F316L A351-CF8M AISI 316L A182-F347 A351-CF8C AISI 316Ti A182-F92 A182-F91 A182-F1 A217-WC1 A193-B7 A182-F12-2 A217-WC6 A182 F22-3 A182 F22-3 B335/564 B574 B348/381 Material Grey cast iron S. G. (ductile) iron S. G. (ductile) iron S. G. (ductile) iron to AD 2000 A4/W3/2 DIN EN 1563 Whiteheart malleable cast iron Constructional steel Constructional steel High-quality steel (structural steel) Forged steel, unalloyed (carbon steel) Cast steel (carbon steel) Chromium steel Cast stainless steel Chromium steel Forged stainless steel, austenitic Cast stainless steel, austenitic Cast stainless steel Forged stainless steel, austenitic Cast stainless steel, austenitic Stainless steel, forged, austenitic Forged stainless steel, austenitic Forged stainless steel, austenitic Cast stainless steel, austenitic Forged stainless steel, austenitic Cast stainless steel, austenitic Forged steel, highly heat resistant Forged steel, highly heat resistant Forged steel, heat resistant Forged steel, heat resistent Forged steel, heat resistant Forged steel, heat resistant Cast steel, heat resistant Forged steel, heat resistant Forged steel, heat resistant Cast steel, heat resistant Forged steel, heat resistant Forged steel, heat resistant Forged steel, heat resistent Hastelloy B Hastelloy C Nimonic 90 Titan Hot-pressed brass Brass Brass Special brass Special brass Bronze Bronze Bronze

Symbol EN-GJL-250 EN-GJS-400-15 EN-GJS-400-18-LT EN-GJS-400-18-U-LT EN-GJMW-400-5 235JRG2 P235G2TH P235GH P250GH GP240GH X12Cr13 GX7CrNiMo12-1 GX8CrNi12 X5CrNi18-10 GX5CrNi19-10 GX4CrNi13-4 X2CrNiMo17-12-2 GX5CrNiMo19-11-2 X2CrNiMo18-14-3 X6CrNiTi18-10 X6CrNiNb18-10 GX5CrNiNb19-11 X6CrNiMoTi17-12-2 GX5CrNiMoNb19-11-2 X10CrWoMoVNb9-2 X10CrMoVNb9-1 X20 CrMo V11-1 X6NiCrTiMoVB25-15-2 X7 CrNiMo BNb 16-16 16Mo3 G20Mo5 42CrMo4 13CrMo4-5 G17CrMo5-5 10CrMo9-10 11CrMo9-10 21CrMoV 5-7 Hastelloy B-3 NiMo 16Cr 16Ti Nimonic 90 Inconel X750 Ti 2 CuZn 38 Pb 2 CuZn 39 Pb 3 Cu Zn 40 Pb 2 CuZn 35 Ni3Mn2Al Pb CuZn 39 Mn1Al Pb Si CuAl10Ni3Fe2-C CuSn10-Cu CuSn12-C

B637, NACE MR-01-75 Inconel X750

Physical and chemical properties comply with DINgrade. ASTMnearest equivalent grade is stated for guidance only.

179

Design of GESTRA Valves

GESTRA equipment with flanges or as wafer design for sandwiching between flanges DIN/EN now available in accordance with EN 1092-1

Raised Faces at a glance Comparison Flange Standard DIN with EN 1092-1


old (DIN)
Raised face C D E F N V R V14 R14 L M Standard up to PN 63 Tongue Groove Male face Female face Male face with turned groove Female face to V14 Turned groove with convex seal Bevel with welded diaphragm seal Designation Standard up to PN 40 Admissible tolerance for roughness N11/N10 N9/N8 N8/N7 N9/N8 N9/N8 N11/N10 N11/N10 N11/N10 N11/N10 N6 N8/N7

new (EN 1092-1)


Raised Designation face ./. B1 B2 C D E F H G ./. ./. Standard up to PN 40 Standard up to PN 63 Tongue Groove Male face Female face O-ring groove O-ring for male face N10/N8 N8/N6 N8/N6 N8/N6 N10/N8 N10/N8 N8/N6 N8/N6 Admissible tolerance for roughness
Remark

Form C (old) is replaced by form B1 (new) Like form D but with def. groove Different tolerance for roughness Tongue heights do not match! Groove depths do not match! Heights of male faces do not match! Heights of female faces do not match! Dimensions identical Dimensions identical

Since some flange faces are not interchangeable with the associated DINversions please state the standard and the form of the face. Example: BK 45 DN 20 PN 40 flanged to DIN 2635 form D [standard flat face, roughness Ra = 3.2 6.3 m (N8/N9)] or: RK 16A DN 65 PN 40 for flange to EN 1092-1 form D (groove/groove face)

Roughness Characteristics
Roughness class (old)
N1 N2 N3 N4 N5 N6 N7 N8 N9 N10 N11 N12 Ra [m] 0.025 0.05 0.1 0.2 0.4 0.8 1.6 3.2 6.3 12.5 25 50 Rz [m] 0.22 - 0.30 0.45 - 0.60 0.8 - 1.1 1.0 - 1.8 1.6 - 2.8 3.0 - 4.8 5.9 - 8.0 12.0 - 16.0 23 - 32 46 - 57 90 - 110 160 - 220 Rt [m] 0.24 - 0.40 0.49 - 0.80 0.85 - 1.45 1.10 - 2.40 1.75 - 3.60 3.2 - 6.0 6.3 - 10 13.0 - 19.5 25 - 38 48 - 68 95 - 130 190 - 250 CLA " [in] 1 2 4 8 16 32 63 125 250 500 1000 2000

Definition of frequently used abbreviations for valves & steam traps


PN, Class PMA TMA p/T P PMX TMO PMO PMOB PO TO PS TS Pressure class acc. to EN, ASME body of rules Maximum allowable pressure that the valve / trap body can withstand Maximum allowable temperature that the valve / trap body can withstand Maximum pressure as a function of temperature that the valve / trap body can withstand Operating differential pressure Maximum differential pressure (difference between operating pressure and operating back pressure) Maximum operating temperature for which the operation of the equipment is guaranteed Maximum operating pressure for which the operation of the equipment is guaranteed Maximum operating backpressure for which the operation of the equipment is guaranteed Operating pressure, measured at the valve / trap inlet Operating temperature, measured at the valve / trap inlet Maximum service pressure Maximum service temperature

180

Product Index

181

Index by Product Name

Product

Type

Product-Range

Page

Academy GESTRA Air vent ATEX Directive 94/9/EC Ball oat trap, oat steam trap Bar chart indicator Blowdown receiver, mixing cooler Blowdown system, programme-controlled Blowdown valve, continuous (with electric actuator) Blowdown valve, continuous (without actuator) Blowdown valve, intermittent (with pneumatic actuator) Blowdown valve, intermittent (without actuator) Boiler safety system SIL 3 Buoyancy transmitter Capsule trap Check valve Check valve, dual-plate Combined imperial and S.I. steam tables Condensate collector Condensate dampening pot Condensate drain valve Condensate lifter Condensate recovery and return systems Condensate recovery and return systems, horizontal Condensate recovery and return systems, vertical Condensate return units, steam-powered Conductivity control unit Conductivity controller / limiter Conductivity electrode Conductivity switch Connector for electrode LRG Continuous blowdown valve, with electric actuator Continuous blowdown valve, without actuator Control PLC Control unit, conductivity Control valve Control valve, High-pressure control valve Controller, level Conversions Cooling water control valve, GESTRAMAT Design of GESTRA Valves Desuperheater, water bath Detector, oil Detector, oil & turbidity DISCO non-return valve DISCO swing check valve DISCOCHECK dual-plate check valve Display unit for process data Documentation and Reference Literature Drain valve

BK, MK UNA URA VDM TA BAE BA MPA PA LD MK NAF-Check BB V 21.9/K, V 20.8/K ED AK UNA 25 PS SDR SDS SDL KH, FPS LRR KS 90 LRG LRS BAE BA LRR V 725 ZK NRR CW KD ORGS OR RK CB BB SPECTORcontrol AK

D A1 D A1 B C B B B B B B B A1 A2 A2 D A1 C A1 A1 C C C C B B B B B B B C B A4 A4 B D A4 D C B B A2 A2 A2 B D A1

166 167 69 172 10 15 107 152 132 133 130 131 130 131 134 135 134 135 103 105 106 107 89 58 59 50 53 177 178 30 31 153 21 22 26 142 143 144 143 144 145 146 121 125 121 123 121 125 124 127 121 125 130 131 130 131 155 156 121 - 125 72 73 76 98 99, 106 107 170 171 62 63 180 147 138 136 137 38 49 54 55 50 53 102, 140 169 21 22

182

Index by Product Name

Product

Type

Product-Range

Page

Draining module Dual-plate check valve Electrode, conductivity Feedwater tank Flash vessel systems Float steam trap, ball oat trap Flow computer, owmeter Flowmeter, Vortex GESTRAMAT, cooling water control valve Gravity circulation check Heat Exchanger Unit High-capacity steam trap High-level alarm High-pressure control valve, control valve Indicator, bar-chart Indicator, digital Injection cooler Intermittent blowdown valve, with pneumatic actuator Intermittent blowdown valve, without actuator Kalorimat, return temperature control valve Level controller Level controller Level electrode Level limiter Level monitoring, Bus Compact Level pot for electrodes Level switch Level transmitter Limiter, temperature Low-level alarm Low-pressure trap Material reference chart, DIN Measuring pot for level electrodes Mixing cooler, blowdown receiver Monitoring equipment for steam traps Monitoring unit NAF check valvw Non-return valve Non-return valve, screwed Oil & turbidity detector Oil detector PED PLC Control Pressure Equipment Directive (PED) Pressure-maintaining valve Pressure-reducing valve Programme-controlled blowdown system Programs & Sizing Software Pump control

QuickEM, QuickEM-Control BB LRG SW VD UNA Flow 20, Flow 100 83 W/FA CW SBO PWT-XPS TK 23, TK 24 NRS ZK URA URB EK MPA PA BW NRG NRR NRG NRG NRG, NRGS, NRGT MF NRS NRT TRS 5-6/7, TRS 5-8 NRS MK 20 MF VDM VK, VKE, VKP 10, VKP 40, VKP 40 Ex SRL NAF-Check RK MB OR ORGS 5610 5801 TA NRSP

A1 A2 B C C A1 B B A4 A2 C A1 B A4 B B C B B A4 B B B B B B B B B B A1 D B C A1 B A2 A2 A2 B B D C D A4 A4 B D B

32 33 50 53 121 125 150 151 10 15 139 139 62 63 37 149 21 22 96 97, 104 105 73 76 107 98 99 147 134 135 134 135 64 65 96 105 98 99, 106 107 104 107 104 107 106 107 109, 129 98 99, 106 107 106 107 118 119 96 97, 104 105 21 22 179 109 , 129 152 28 29 108 109 58 59 38 49 38 39 136 137 138 173 176 155 156 173 176 68 67 132 133 168 106 107, 155 156

183

Index by Product Name

Product

Type

Product-Range

Page

Pump steam trap Remote data transfer Resistance thermometer, temperature sensor Return temperature control valve, Kalorimat Rhombusline steam trap Roughness caracteristics Safety valve Screwed non-return valve Self-acting pressure controller, pressure-maintaining valve Self-acting pressure controller, pressure-reducing valve Self-acting temperature controller Service case Sightglass, Vaposcope SIL (Safety Integrity Level) SPECTORcontrol Stainless steel, Material reference chart Steam drier/purier, steam separator Steam manifold Steam regenerator Steam separator, steam drier/purier Steam tables Steam trap for large condensate owrates Steam trap for large-scale installations Steam trap for SIP applications, Steriline Steam trap monitoring equipment Steam trap testing unit Steam trap units for UNIVERSAL (Swivel) connectors Steam trap with adjustable discharge temperature Steam trap with Duo S.S. (Bimetallic) regulator Steam trap with membrane regulator Steam Traps & Valves Library (2D and 3D CAD drawings) Steam-powered condensate return units Steriline Stop valve Strainer Swing check valve Switch, conductivity Switch, level Switch, TDS Switch, temperature Tank for feedwater Technical Infos Technical literature Temperature control valve Temperature controllers, self-acting Temperature limiter, temperature switch Temperature monitor Temperature preamplier Temperature sensor, resistance thermometer

UNA 25 PK SPECTORcom TRG BW GSV MB 5610 5801 Clorius VRM VK TD, TP V 21.9, V 20.8 GRDE TD, TP GK 11/21, TK 23/24 DK SMK VK, VKE, VKP 10, VKP 40, VKP 40 Ex NRA BK 36A/7, MK 36A/7, DK 36A/7 UBK BK MK KH, FPS SMK GAV GSF, SZ CB, WB LRS NRS LRS TRS 5-6/7 SW BW Clorius TRS 5-6/7 TRS 5-8 TRV TRG

A1 B B A4 A1 D A6 A2 A4 A4 A4 B A1 B B D C A1 C C D A1 A1 A1 A1 A1 A1 A1 A1 A1 D C A1 A8 A7 A2 B B B B C D D A4 A4 B B B B

26 102 116 119 64 65 6 9, 16 17 180 77 38 39 68 67 69 71 128 129 28 103 105 102, 140 179 154 30 31 148 154 177 178 21 22 16 17 18 19 28 28 22 21 22 67 89 168 145 146 18 19 80 81 78 79 54 57 124 127 98 99 106 107, 124 127 118 119 150 169 168 64 65 69 71 118 119 118 119 116 117 116 119

184

Index by Product Name

Product

Type

Product-Range

Page

Temperature switch, temperature limiter Test set, steam trap monitoring Testing unit for steam traps Thermodynamic steam trap Thermostatic steam trap Thermostatic/Thermodynamic steam trap Tools for design engineers, users & operators Training seminars, Technical Advice Transmitter, buoyancy Transmitter, level Trap for draining compressed air and gases Trap testing unit Traptest, steam trap monitoring UNIVERSAL connector unit Universal controller Useful information, Conversions Vapophone Vaposcope, sightglass Vortex owmeter Wafer-type non-return valve Water bath, desuperheater,

TRS 5-6/7 VKE NRA DK BK, MK, SMK, TK BK LD NRT UNA NRA VK, VKE, VKP 10, VKP 40, VKP 40 Ex TS 36 KS 92 VKP 10 VK 83 W/FA RK KD

B A1 A1 A1 A1 A1 D D B B A1 A1 A1 A1 B D A1 A1 B A2 C

118 119 28 29 28 16 17 6 9, 18 - 21 67 168 167 106 107 106 107 25 28 28 29 23 24 106 107 170 171 28 28 139 38 49 147

185

Index by Product Code

Type

Product

Product-Range A1 B B A2 A1 A1 A1 A4 A2 A4 A4 A1 C C B C A8 A1 C A7 A6 C C B B B B B B A2 B A1 A1 A1 A1 B A2

Page 20 21 130 131 130 131 50 53 67 67 22 64 65 50 55 69 71 62 63 16 17 153 147 139 146 80 81 20 21 148 78 77 147 145 121 123 106 107 106 107 121 125 121 125 124 127 38 39 109, 129 89 89 20 21 22 134 135 58 59

AK BA
BAE BB BK

Condensate drain valve


Continuous blowdown valve, without actuator Continuous blowdown valve, with electric actuator Dual-plate check valve

Air vent Steam trap with Duo S. S. (Bimetallic) regulator Steam trap for universal connector Return temperature control valve, Kalorimat Swing check valve Self-acting temperature controllers Cooling water control valve, GESTRAMAT Thermodynamic steam trap Condensate dampening pot Injection cooler Flow computer, flowmeter Steam-powered condensate return units Stop valve Steam trap for large condensate flowrates Steam regenerator Strainer Safety valve Desuperheater, water bath Steam-powered condensate return units Conductivity controller / limiter Universal controller Buoyancy transmitter Conductivity electrode Conductivity control unit Conductivity switch Screwed non-return valve Level pot for electrodes
Air vent

BK
BK 36A/7 BW CB

Clorius
CW DK

ED EK Flow 20, Flow 100


FPS

GAV
GK 11/21

GRDE
GSF GSV

KD KH
KS 90 KS 92

LD LRG
LRR LRS

MB
MF MK MK

Steam trap with membrane regulator Low-pressure trap Steam trap for universal connector
Intermittent blowdown valve, with pneumatic actuator Check valve

MK 20
MK 36A/7 MPA

NAF-Check
NRA NRG NRG NRR

Trap testing unit Level limiter Level controller Level controller Level switch Pump control Level transmitter
Oil & turbidity detector

A1 B B B B
B B B B B C A1

28 29 104 107 96 107 98 99, 106 107 98 99, 106 107


106 107, 155 156 106 107 136 137 138 134 135 149 32 33

NRS
NRSP

NRT
OR

ORGS
PA PWT-XPS

Oil detector Intermittent blowdown valve, without actuator Heat Exchanger Unit Draining module

QuickEM, QuickEM-Control

186

Index by Product Code

Type

Product

Product-Range A2 A2 C C C A1 B B B C A1 A7 B C A1 C B B B B A1 A1 A1 A1 A1 A1 B B A1 A1 A1 A1 A4 C C A1 A1 A1 A1 A1

Page 38 49 37 143 144 142 143 144 18 19 102 140 108 109 150 22 79 132 133 154 20 21 154 116 119 118 119 118 119 116 117 22 20 21 25 10 15 26 26 107 98 99 31 31 30 30 72 151 152 28 29 28 29 28 29 28 29 28 29

RK SBO
SDL SDR SDS SMK SPECTORcom SPECTORcontrol

Non-return valve Gravity circulation check


Condensate recovery and return systems, vertical Condensate recovery and return systems

Condensate recovery and return systems, horizontal Steam trap for SIP applications, Steriline
Remote data transfer

Display unit for process data Monitoring unit Feedwater tank Steam trap for UNIVERSAL connectors Strainer Blowdown system, programme-controlled Steam separator, steam drier/purifier High-capacity steam trap
Steam drier/purifier Temperature sensor, resistance thermometer Temperature switch, temperature limiter Temperature monitor Temperature preamplifier Universal connector unit

SRL
SW Swivel SZ

TA
TD TK 23, TK 24 TP

TRG
TRS 5-6/7 TRS 5-8 TRV TS 36

UBK
UNA

Steam trap with adjustable discharge temperature Trap for draining compressed air and gases Float steam trap, ball float trap Pump steam trap Condensate lifter Bar chart indicator Indicator, digital Steam manifold Condensate collector Steam manifold Condensate collector Control valve Flash vessel systems Mixing cooler, blowdown receiver Vaposcope, sightglass Test set, steam trap monitoring Steam trap monitoring system Traptest, steam trap monitoring Traptest, steam trap monitoring Service case
Swing check valve High-pressure control valve, control valve

UNA
UNA 25 PK UNA 25 PS URA URB

V 20.8
V 20.8/K V 21.9 V 21.9/K V 725 VD VDM VK

VKE VKP 10
VKP 40 VKP 40 Ex

VRM

B A2 A4
A4 A4 B

128 129 56 57 73 76
68 67 139

WB ZK 5610 5801
83 W/FA

Pressure-maintaining valve Pressure-reducing valve Vortex flowmeter

187

Note: Responable care has been taken in preparing this illustrated catalogue. GESTRA reserves the right to make corrections and changes. Illustrations in our printed literature are liable to alteration and are not intended to be binding. We also reserve the unrestricted property and copyright in all estimates, drawings or related documents, which must not be made available to third parties.

Revised

2012

GESTRA AG
Mnchener Str. 77, D-28215 Bremen P. O. Box 10 54 60, D-28054 Bremen Tel. 0049 (0) 421-35 03-0 Fax 0049 (0) 421-35 03-393 E-Mail gestra.ag@flowserve.com Web www.gestra.de

810564-09/01-2012 2012 GESTRA AG Bremen Printed in Germany

With Energy into the Future