GESTRA TK 23 Original Installation Instructions
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GESTRA TK 23 Original Installation Instructions

Steam trap for large condensate flowrates
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Steam Trap for Large Condensate
Flowrates
TK 23
TK 24
Original Installation Instructions
819309-01

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  • Page 1 Steam Trap for Large Condensate Flowrates TK 23 TK 24 Original Installation Instructions 819309-01...

  • Page 2: Table Of Contents

    Contents Foreword ............................3 Availability ............................. 3 Formatting features in the document ...................... 3 Safety ..............................3 Use for the intended purpose ......................... 3 Basic safety notes ..........................4 Information on property damage or malfunctions ..................4 Qualification of personnel ........................4 Protective gear ............................

  • Page 3: Foreword

    Certain text elements of this installation & operating efficiently for their intended purpose. manual feature a specific typographic design. You  TK 23 can easily distinguish the following text elements: Standard text  TK 24...

  • Page 4: Basic Safety Notes

    Note that the equipment is also used incorrectly if Risk of minor injuries the materials of the equipment are not suitable for  Sharp edges on internals present the danger of the fluid. cuts to hands. Always wear industrial gloves when servicing the equipment.

  • Page 5: Protective Gear

     protective helmet  work boots Equipment specification  industrial leather gloves TK 23 and TK 24 are operationally identical but differ in their limiting conditions and materials of Typographic features of warning construction. notes Equipment of type TK 23 is rated for nominal pressure PN16, TK 24 for nominal pressure PN 25.
  • Page 6 Explosion view of equipment DN 50 Item Designation Item Designation Cap nut Direction of flow arrow Hexagon-head cap bolts (4 pcs.) Type specification on body (instead of name plate) Cover Thermostatic (membrane regulator) Regulator unit capsule (3 pcs.) Body Adjustment screw Sealing plug...
  • Page 7 Explosion view of equipment DN 65 - 100 Item Designation Item Designation Cap nut (2 pcs.) Type specification on body (instead of name plate) Hexagon-head cap bolts (6 pcs. per cover) Thermostatic (membrane regulator) capsule (4 pcs.) Cover (2 pcs.) Sealing plug (2 pcs.) Regulator unit Adjustment screw for maximum flowrate...
  • Page 8 Markings on the membrane regulator capsule Application of European Directives The following membrane regulator capsules are Pressure Equipment Directive available: The equipment conforms to this directive (see  Type 5H2 (standard) "Manufacturer's Declaration" section) and can be  Type 0H2 (for differential pressures below 1 bar used for the following media: and operating pressures up to 5 bar) ...

  • Page 9: Task And Function

    Task and function Purpose The equipment is designed for discharging large condensate flowrates that are produced continuously and for air-venting pipelines. The equipment opens and closes as a function of the membrane regulator (thermostatic capsules) immediately below the pressure-dependent saturation temperature. At start-up and during operation the equipment automatically vents non-condensable gases.
  • Page 10 Function (equipment with DN 65 - 100)) The membrane regulator capsules and the upstream pressure of the condensate control the discharge of condensate. If undercooled or cold condensate, or air or other incondensable gases are present, the membrane regulator capsules are in the open position. The pressure in the chamber (18) increases until it reaches upstream pressure.

  • Page 11: Storing And Transporting The Equipment

    Transporting the equipment Storing and transporting the equipment  Meet the requirements for storage also when transporting the equipment.  Prior to transport seal off connections with Attention! sealing plugs. Equipment can be damaged if stored or If you do not have the sealing plugs transported improperly.

  • Page 12: Connecting The Equipment

    DANGER Attention! Personnel working on pipes are exposed to Equipment will be damaged if the end safety risks and may suffer severe injuries, connections are undersized. poisoning or even loss of life.  Make sure that the connections are  Make sure that no hot or hazardous strong and rigid enough to support the fluid is in the equipment or the pipes.

  • Page 13: Adapting Settings

    Use the adjustment screw on the bottom cover to  2 Spanners A. F. 8 mm regulate the minimum flowrate.  2 Spanners A. F. 19 mm (TK 23) or 24 mm (TK  Screwdriver 6 mm  Screwdriver 10 mm...

  • Page 14: Special Adjustments For Equipment With Dn 50

    Special adjustments for Attention! equipment with DN 50 Equipment with DN 50 has only one adjustment Equipment may leak if the gasket is damaged. screw. With this equipment you can only adjust either a maximum or a minimum flowrate ("leak ...
  • Page 15 Example  Make sure that the equipment is depressurized, cooled down to room temperature and free from The charts shown in this example are reduced in fluid. size. Use the charts in original size to ascertain the required setting.  To reduce the pressure through the bore in the cover slowly loosen the sealing plug by two A max.
  • Page 16  Put the sealing plug (10) into the bore. The torque for the sealing plug depends on the equipment type.  Equipment of type TK 23 requires a torque of 30 Nm.  Equipment of type TK 24 requires a torque of 40 Nm.
  • Page 17 Adjusting a minimum flowrate According to the lift-restriction chart a ratio of 10% (line "B") corresponds to ¾ turn to the left of the To adjust a minimum flowrate (partial flow, "leak adjustment screw. passage") change the valve travel in the closing direction.
  • Page 18  Make sure that the equipment is depressurized,  To change the minimum flowrate loosen the cooled down to room temperature and free from adjustment screw by the number of turns fluid. specified in the chart.  To reduce the pressure through the bore in the cover slowly loosen the sealing plug by two turns (10).
  • Page 19  Put the sealing plug (10) into the bore. The torque for the sealing plug depends on the equipment type.  Equipment of type TK 23 requires a torque of 30 Nm.  Equipment of type TK 24 requires a torque of 40 Nm.
  • Page 20 Adjustment to give steam-tight shut-off To prevent steam loss you can adjust the equipment to give steam-tight shut-off. To do so you have to set the minimum flowrate to zero. Attention! Malfunctions due to banking-up of condensate. Limiting the maximum flowrate changes the factory-set leak passage ("partial flow").
  • Page 21  Put the sealing plug (10) into the bore. The torque for the sealing plug depends on the equipment type.  Equipment of type TK 23 requires a torque of 30 Nm.  Equipment of type TK 24 requires a torque of 40 Nm.
  • Page 22 Restoring default factory settings  Loosen the adjustment screw a quarter turn. To re-adjust the factory settings of the flowrates proceed as follows:  Make sure that the equipment is depressurized, cooled down to room temperature and free from fluid. ...
  • Page 23  Put the sealing plug (10) into the bore. The torque for the sealing plug depends on the equipment type.  Equipment of type TK 23 requires a torque of 30 Nm.  Equipment of type TK 24 requires a torque of 40 Nm.

  • Page 24: Special Adjustments For Equipment With Dn 65

    Special adjustments for Example This example shows how to determine the equipment with DN 65 maximum flowrate for equipment with DN 65 or DN Equipment from DN 65 onwards is provided with two adjustment screws. With this equipment you The charts shown in this example are reduced in can adjust a maximum and a minimum flowrate (= size.
  • Page 25  Make sure that the equipment is depressurized, cooled down to room temperature and free from fluid.  To reduce the pressure through the bore in the cover slowly loosen the sealing plug by two turns (10).  Remove the cap nut (1). ...
  • Page 26 To adjust a minimum flowrate (partial flow, "leak type. passage") change the valve travel in the closing direction.  TK 23 requires 20 Nm. The adjustors for setting the minimum flowrate are  TK 24 requires 30 Nm. located at the bottom of the equipment.
  • Page 27 Example  Make sure that the equipment is depressurized, This example shows how to determine the cooled down to room temperature and free from minimum flowrate for equipment with DN 65 or DN fluid.  To reduce the pressure through the bore in the The charts shown in this example are reduced in cover slowly loosen the sealing plug by two size.
  • Page 28  Put the sealing plug (10) into the bore. The torque for the sealing plug depends on the equipment type.  TK 23 requires 20 Nm.  TK 24 requires 40 Nm.  Fasten the sealing plug with the specified torque.
  • Page 29 Adjustment to give steam-tight shut-off To prevent steam loss you can adjust the equipment to give steam-tight shut-off. To do so you have to set the minimum flowrate to zero. Attention! Malfunctions due to banking-up of condensate. Limiting the maximum flowrate changes the factory-set leak passage ("partial flow").
  • Page 30 The torques required for tightening the hexagon nut (25) and the cap nut (1) depend on the equipment type.  TK 23 requires 20 Nm.  TK 24 requires 30 Nm.  Fasten the hexagon nut with the specified torque.
  • Page 31 Restoring default factory settings  Screw out the adjustment screw (12) until a resistance is felt. To re-adjust the factory settings of the flowrates proceed as follows:  Remove the upper sealing plug (10).  Take the gasket (27) out of the bore for the Restoring the factory set minimum flowrate sealing plug.
  • Page 32 The torques required for tightening the hexagon nut (25) and the cap nut (1) depend on the equipment type.  TK 23 requires 20 Nm.  TK 24 requires 30 Nm.  Fasten the hexagon nut with the specified torque.
  • Page 33  Make sure that the equipment is depressurized, cooled down to room temperature and free from  TK 23 requires 20 Nm. fluid.  TK 24 requires 40 Nm.  To reduce the pressure through the bore in the ...

  • Page 34: Operation

     2 Spanners A. F. 8 mm temperatures.  2 Spanners A. F. 19 mm (TK 23) or 24 mm (TK  Wear protective clothing that is suitable for the fluid and, if necessary, ...
  • Page 35  To reduce the pressure through the bore in the Attention! cover slowly loosen the sealing plug by two turns (10). A deformed sleeve can cause  Remove the cap nut (1). malfunctions.  Remove the outer gasket (26).  When removing the cover take care ...
  • Page 36 Removing cover of equipment with DN 65 -  Remove the upper sealing plug (10).  Remove the gasket (27). Remove the two covers one after the other. The following section describes how to remove the upper cover. Remove the lower cover in the same way.
  • Page 37 Attention! A deformed sleeve can cause malfunctions.  When removing the cover take care that the sleeve does not fall out of the body.  Take the cover (3) off the body.  Remove the body gasket (31).  Make sure that the sleeve (30) cannot fall out of the body.
  • Page 38 Cleaning and checking the membrane  Put a new body gasket (31) onto the sleeve (30). regulator capsule  Screw the adjustment screw (9) with the The removal method for the membrane regulator regulator unit attached to it into the cover (3) capsule depends on the equipment type.
  • Page 39 (29) hand tight. The torque for the hexagon-head cap bolts depends on the equipment type.  Equipment of type TK 23 requires a torque of 40 Nm.  Equipment of type TK 24 requires a torque of 55 Nm.
  • Page 40 Mounting cover of equipment with DN 65 - Attention! Equipment may leak if the gasket is damaged.  It is therefore essential that you always insert a new gasket before re- attaching the cover.  Make sure that the cover is not tilted or skewed when refitted.
  • Page 41 The torque for the hexagon-head cap bolts depends on the equipment type. The torque for the sealing plug depends on the  Equipment of type TK 23 requires a torque of equipment type. 35 Nm.  Equipment of type TK 23 requires a torque of ...

  • Page 42: Servicing The Equipment And Installing Spare Parts

    After mounting the cover you have to readjust the settings of the equipment.  Proceed as described in section Adapting settings " " from page 13 onwards. Servicing the equipment and installing spare parts You may exchange the following component parts in case of wear or damage: Spare Parts Item no.
  • Page 43 Item no. Designation Stock code # DN50 DN65–80 DN100 8, 26, 27, 31 Capsule set 0H2 377234 – –  3 Membrane regulator capsules 0H2  1 Body gasket (31)  4 Gaskets (26/27) 8, 26, 27, 31 Capsule set 0H2 –...
  • Page 44  2 Spanners A. F. 8 mm  Turn the lift plate until the bores in the lift plate  2 Spanners A. F. 19 mm (TK 23) or 24 mm (TK and in the washer nut are aligned one on top of the other.
  • Page 45 Exchanging the membrane regulator capsule  To attach a new membrane regulator capsule to of equipment with DN 50 the regulator unit press the capsule into the seat until it snaps into place. DANGER  Push the capsule support onto the lift plate until it hits the stop (21.).
  • Page 46  Replace the gasket of the regulator unit with a Exchanging the membrane regulator capsule new one of the same type. of equipment with DN 65 -100  Assemble the regulator unit in reverse order of DANGER the disassembling procedure: Personnel working on pipes are exposed to Attention! safety risks and may suffer severe injuries,...
  • Page 47  Remove the hexagon nuts (38) on the Exchanging body gasket dampening plate (22).  Lift the dampening plate (21) off the body. DANGER  Detach the membrane regulator capsule (8) Personnel working on pipes are exposed to from the seat (37). safety risks and may suffer severe injuries, ...
  • Page 48 The following section shows equipment with DN 50.  Remove the cover as described in the respective section.  Replace the body gasket (31) with a new one. The mounting method for the cover depends on the equipment type. How to mount the cover of equipment with DN50 is described on page 38.

  • Page 49: Troubleshooting

    Troubleshooting Problem Cause Remedy The steam trap is cold or only The shut-off valves for Open the shut-off valves. hand-hot. condensate inlet or outlet are closed. The condensate inlet or outlet Clean the pipes. is dirt clogged. Clean the equipment. The steam trap is blowing off The steam trap is adjusted to Adjust the steam trap to give steam-tight...
  • Page 50 Problem Cause Remedy The differential pressure is too Increase the steam pressure. small. Lower the pressure in the condensate line. Check the size of the condensate line. Install a steam trap with a larger condensate discharge capacity or a condensate return unit. The distance between the drain Install the uninsulated steam trap approx.
  • Page 51 Problem Cause Remedy Fluid escapes (equipment is The end connections are not Seal off the end connections (e. g. leaking). tight. flanged or screwed ends). A gasket on the body is Replace the gasket with a new one. defective. The body has been damaged Check the resistance of the body material by corrosion or erosion.

  • Page 52: Putting The Equipment Out Of Operation

    Putting the equipment out of Caution operation Environmental damage may be caused by Removing harmful substances poisonous fluid residues.  Before disposing of the equipment DANGER make sure that it is clean and free of fluid residues. If the equipment is used in contaminated ...

  • Page 53: Re-Using Equipment After Storage

    TK 23 "Storing the equipment" from page 11 Body and cover 1.0619 A216WCB onwards. TK 24 Bolts TK 23, TK 24 1.7709 – Re-using equipment after storage DN50 Observe the following instructions if you want to Bolts TK 24 DN65– 1.7225...

  • Page 54: Technical Data

    Technical data Dimensions and weights TK 23 TK 24 Nominal [mm] size [inch] 2½ 2½ Dimensions [mm] – – – – approx. approx. 200 approx. approx. 200 Weight [kg] Withdrawal distance...

  • Page 55: Pressure & Temperature Ratings

    Pressure & temperature ratings Limiting conditions for body TK 23 TK 24 PMA (admissible service pressure) [barg] 14.2 TMA (admissible temperature) [°C] Limiting conditions for regulator unit TK 23 TK 24 Membrane Membrane Membrane Membrane regulator regulator regulator regulator capsule...

  • Page 56: Capacity Charts

    Capacity Charts Capacity chart for hot water Flowrate Differential pressure Δ PMX...
  • Page 57 Capacity chart for cold water Flowrate Differential pressure Δ PMX...

  • Page 58: Lift-Restriction Charts

    Lift-Restriction Charts Lift-restriction chart DN 50 Example of maximum capacity Example of minimum flowrate (leak passage) Max. capacity in % of max. possible flowrate Turns to the left Min. capacity in % of max. possible flowrate Turns to the right...
  • Page 59 Lift-restriction chart DN 65 - 80 Example of maximum capacity Example of minimum flowrate (leak passage) Max. capacity in % of max. possible flowrate Turns to the right for lower adjustment screw (minimum flowrate) Min. capacity in % of max. possible flowrate Turns to the right for upper adjustment screw (maximum flowrate)
  • Page 60 Lift-restriction chart DN 100 Max. capacity in % of max. possible flowrate Turns for lower adjustment screw (minimum flowrate) Min. capacity in % of max. possible flowrate Turns for upper adjustment screw (maximum flowrate)

  • Page 61: Manufacturer's Declaration

    Assessment according to European rules refer to our Declaration of Conformity or our Declaration by Manufacturer. To download the current Declaration of Conformity or Declaration by Manufacturer go to www.gestra.com/documents or contact: GESTRA AG Münchener Straße 77 28215 Bremen Germany...
  • Page 64 Agencies all over the world: www.gestra.de GESTRA AG Münchener Straße 77 28215 Bremen Germany Telefon +49 421 3503-0 Telefax +49 421 3503-393 E-Mail info@de.gestra.com www.gestra.de 819309-01/07-2017 kx_mm ( 803358-03) © GESTRA AG Bremen Printed in Germany...

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