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Spirax Sarco DN15 Installation And Maintenance Instructions Manual
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Spirax Sarco DN15 Installation And Maintenance Instructions Manual

Spirax Sarco DN15 Installation And Maintenance Instructions Manual

Automatic or manually actuated boiler blowdown valves
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4057050/4
Automatic or Manually Actuated
PN/M
automatically
actuated
M
manually
actuated
BBV Automatic or Manually Actuated Boiler Blowdown Valves
IM-P405-54 EMM Issue 4
Boiler Blowdown Valves
Installation and Maintenance Instructions
DN15 - DN50
BBV
1. Safety information
2. General product information
3. Installation & commissioning
4. Maintenance of the actuator
5. Maintenance of the valve
6. Spare parts
IM-P405-54
EMM Issue 4
© Copyright 2021
1
Printed in France

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Summary of Contents for Spirax Sarco DN15

  • Page 1 4057050/4 IM-P405-54 EMM Issue 4 Automatic or Manually Actuated Boiler Blowdown Valves Installation and Maintenance Instructions DN15 - DN50 1. Safety information PN/M 2. General product information automatically actuated 3. Installation & commissioning 4. Maintenance of the actuator 5. Maintenance of the valve 6.
  • Page 2 1. Safety information Safe operation of these products can only be guaranteed if they are properly installed, commissioned, used and maintained by qualified personnel (see Section 1.11) in compliance with the operating instructions. General installation and safety instructions for pipeline and plant construction, as well as the proper use of tools and safety equipment must also be complied with.
  • Page 3 1 and 2 of the above mentioned Pressure Equipment Directive. The products’ use on other fluids may be possible but, if this is contemplated, Spirax Sarco should be contacted to confirm the suitability of the product for the application being considered.
  • Page 4 BBV boiler blowdown valves - PED categories Group 1 Group 2 Group 1 Group 2 Product Gases Gases liquids liquids DN15 - DN25 PN40 DN32 JIS 20/KS 20 DN40 - DN50 DN15 - DN25 NPT screwed SW DN32 DN40 - DN50 DN15 - DN25...
  • Page 5 Group 2 Group 1 Group 2 Product Gases Gases liquids liquids ASME 600 DN15 - DN25 PN63/PN100 BBV83 JIS 30/KS 30 DN32 JIS 40/KS 40 DN40 - DN50 BW/SW 1.3 Lighting Ensure adequate lighting, particularly where detailed or intricate work is required.
  • Page 6 1.9 Tools and consumables Before starting work ensure that you have suitable tools and/or consumables available. Use only genuine Spirax Sarco replacement parts. 1.10 Protective clothing Consider whether you and/or others in the vicinity require any protective clothing to protect against the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling objects, and dangers to eyes and face.
  • Page 7 Customers and stockists are reminded that under EC Health, Safety and Environment Law, when returning products to Spirax Sarco they must provide information on any hazards and the precautions to be taken due to contamination residues or mechanical damage which may present a health, safety or environmental risk.
  • Page 8 The valve is spring-to-close on power failure and the manual version 'M' can easily be upgraded to an automatic version 'PN/M'. When used with a Spirax Sarco blowdown controller the automatic version provides timed control of blowdown, ensuring that the recommended blowdown occurs with the minimum of heat loss and avoids duplication and omissions.
  • Page 9 Note: All certification/inspection requirements must be stated at the time of order placement. Note: For additional product data see the following Technical Information sheet TI-P405-51. 2.2 Size and pipe connections DN15, DN20, DN25, DN32, DN40 and DN50 Other available options: Butt weld ½", ¾", 1", 1¼", 1½", 2"...
  • Page 10 2.4 Materials (Parts 1 to 15) Part Material BBV4_ Carbon Steel Body BBV6_ Stainless Steel BBV8_ Alloy Steel Plug Stainless Steel + stellite Seat Stainless Steel + stellite Seat gasket Reinforced exfoliated graphite Seat retainer Stainless Steel BBV4_ Carbon Steel Cover BBV6_ Stainless Steel...
  • Page 11 9, 10 Fig. 2 DN15 BBV_3 PN/M shown BBV Automatic or Manually Actuated Boiler Blowdown Valves IM-P405-54 EMM Issue 4...
  • Page 12 2.4 Materials (Parts 16 to 42) (continued) Part Material Hex. head screw Carbon Steel Carbon Steel Upper housing Carbon Steel Diaphragm Reinforced NBR Gasket Reinforced Graphite Vent plug Brass Bolt Carbon Steel Diaphragm plate Aluminium Spindle Stainless Steel Lever stem Stainless Steel Screw Carbon Steel...
  • Page 13 16, 17 32 - 35 33 - 36 Fig. 3 DN15 BBV_3 PN/M shown BBV Automatic or Manually Actuated Boiler Blowdown Valves IM-P405-54 EMM Issue 4...
  • Page 14 2.5 Capacities Size DN15 DN20 DN25 DN32 DN40 DN50 Capacity (m 12.7 10.0 18.0 15.5 22.8 31.6 56.9 21.9 32.2 44.7 80.5 26.8 39.4 54.8 98.6 Pressure 31.0 45.5 63.2 113.8 (bar) 34.6 50.9 70.7 127.3 38.0 55.8 77.5 139.4 41.0...
  • Page 15 Pressure/temperature limits Section Page EN 1092 BBV43 ASME JIS / KS EN 1092 BBV63 2.10 ASME 2.11 JIS / KS 2.12 EN 1092 BBV83 2.13 ASME 2.14 JIS / KS BBV Automatic or Manually Actuated Boiler Blowdown Valves IM-P405-54 EMM Issue 4...
  • Page 16 BBV43 Pressure/temperature limits - EN 1092 Steam saturation curve Pressure bar g The product must not be used in this region. An extended cover is required for use in this region. High temperature packing required for use in this region. Notes: Where the process fluid temperature is sub-zero and the ambient temperature is below +5 °C, the external moving parts of the valve and actuator must be heat traced to maintain normal operation.
  • Page 17 Body design conditions PMA Maximum allowable pressure 100 bar g @ 50 °C PMO Maximum operating pressure TMA Maximum allowable temperature 400 °C @ 59.5 bar g A - B - B Minimum allowable temperature -29 °C PN100 Standard packing PTFE chevron (P) 250 °C @ 76.1 bar g TMO Maximum operating temperature...
  • Page 18 BBV43 Pressure/temperature limits - ASME 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 Pressure psi g 1000 1200...
  • Page 19 Body design conditions ASME 600 PMA Maximum allowable pressure 102.1 bar g @ 38 °C 1480 psi g @ 100 °F PMO Maximum operating pressure TMA Maximum allowable temperature 425 °C @ 57.5 bar g 797 °F @ 834 psi g A - E - E Minimum allowable temperature -29 °C...
  • Page 20 BBV43 Pressure/temperature limits - JIS/KS Steam saturation curve Pressure bar g The product must not be used in this region. An extended cover is required for use in this region. High temperature packing required for use in this region. Notes: 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 Where the process fluid temperature is sub-zero and the ambient temperature is below +5 °C, the external moving parts of the valve and actuator must be heat traced to maintain normal operation.
  • Page 21 Body design conditions PMA Maximum allowable pressure 68 bar g @ 120 °C PMO Maximum operating pressure TMA Maximum allowable temperature 425 °C @ 40 bar g A - H - H Minimum allowable temperature -29 °C JIS/KS 40 Standard packing PTFE chevron (P) 250 °C @ 60 bar g TMO Maximum operating temperature...
  • Page 22 BBV63 Pressure/temperature limits - EN 1092 Steam s at ur at i o n curve Pressure bar g The product must not be used in this region. An extended cover is required for use in this region. High temperature packing required for use in this region. Notes: 1.
  • Page 23 Body design conditions PMA Maximum allowable pressure 100 bar g @ 100 °C PMO Maximum operating pressure TMA Maximum allowable temperature 580 °C @ 62.7 bar g A - J - J Minimum allowable temperature -29 °C PN100 Standard packing PTFE chevron (P) 250 °C @ 79.6 bar g TMO Maximum operating temperature...
  • Page 24 2.10 BBV63 Pressure/temperature limits - ASME Pressure psi g 1000 1400 1200 1000 Steam saturation curve 99.3 Pressure bar g The product must not be used in this region. An extended cover is required for use in this region. High temperature packing required for use in this region. Notes: Where the process fluid temperature is sub-zero and the ambient temperature is below +5 °C (+41 °F), the external moving parts of the valve and actuator must be heat traced to maintain normal operation.
  • Page 25 Body design conditions ASME 600 PMA Maximum allowable pressure 99.3 bar g @ 38 °C 1 440 psi g @ 100 °F PMO Maximum operating pressure TMA Maximum allowable temperature 538 °C @ 50 bar g 1000 °F @ 725 psi g Minimum allowable temperature -29 °C -20 °F...
  • Page 26 2.11 BBV63 Pressure/temperature limits - JIS/KS Steam saturation curve Pressure bar g The product must not be used in this region. An extended cover is required for use in this region. High temperature packing required for use in this region. Notes: Where the process fluid temperature is sub-zero and the ambient temperature is below +5 °C, the external moving parts of the valve and actuator must be heat traced to maintain normal operation.
  • Page 27 Body design conditions PMA Maximum allowable pressure 68 bar g @ 120 °C PMO Maximum operating pressure TMA Maximum allowable temperature 425 °C @ 40 bar g A - P - P Minimum allowable temperature -29 °C JIS/KS 40 Standard packing PTFE chevron (P) 250 °C @ 60 bar g TMO Maximum operating temperature...
  • Page 28 2.12 BBV83 Pressure/temperature limits - EN 1092 Steam saturation curve Pressure bar g The product must not be used in this region. An extended cover is required for use in this region. High temperature packing required for use in this region. Notes: Where the process fluid temperature is sub-zero and the ambient temperature is below +5 °C, the external moving parts of the valve and actuator must be heat traced to maintain normal operation.
  • Page 29 Body design conditions PMA Maximum allowable pressure 100 bar g @ 250 °C PMO Maximum operating pressure TMA Maximum allowable temperature 490 °C @ 68 bar g A - R - R Minimum allowable temperature -29 °C PN100 Standard packing PTFE chevron (P) 250 °C @ 100 bar g TMO Maximum operating temperature...
  • Page 30 2.13 BBV83 Pressure/temperature limits - ASME Pressure psi g 1000 1200 1400 1000 Steam saturation cover 103.4 Pressure bar g The product must not be used in this region. An extended cover is required for use in this region. High temperature packing required for use in this region. Notes: Where the process fluid temperature is sub-zero and the ambient temperature is below +5 °C (+41 °F), the external moving parts of the valve and actuator must be heat traced to maintain normal operation.
  • Page 31 Body design conditions ASME 600 PMA Maximum allowable pressure 103.4 bar g @ 38 °C 1 499 psi g @ 100 °F PMO Maximum operating pressure TMA Maximum 538 °C @ 29.8 bar g 1000 °F @ 432 psi g allowable temperature A - T Minimum allowable temperature...
  • Page 32 2.14 BBV83 Pressure/temperature limits - JIS/KS Steam saturation curve Pressure bar g The product must not be used in this region. An extended cover is required for use in this region. High temperature packing required for use in this region. Notes: Where the process fluid temperature is sub-zero and the ambient temperature is below +5 °C, the external moving parts of the valve and actuator must be heat traced to maintain normal operation.
  • Page 33 Body design conditions PMA Maximum allowable pressure 68 bar g @ 120 °C PMO Maximum operating pressure TMA Maximum allowable temperature 510 °C @ 36 bar g A - U Minimum allowable temperature -29 °C JIS/KS 40 Standard packing PTFE chevron (P) 250 °C @ 60 bar g TMO Maximum operating temperature...
  • Page 34 3. Installation and commissioning Note: Before actioning any installation, observe the 'Safety information' in Section 1. Referring to the Installation and Maintenance Instructions, name-plate and Technical Information Sheet, check that the product is suitable for the intended installation: Check materials, pressure and temperature and their maximum values. Do not exceed the performance rating of the valve.
  • Page 35 4. Maintenance of the actuator Note: Before actioning any installation, observe the 'Safety information' in Section 1. 4.1 Disassembly of the actuated system Dismantle the lever before removing the actuator assembly. To do this, remove the retaining ring's (35) and remove the axis pin (32). Then remove the lever assembly of the yoke.
  • Page 36 Unscrew the 12 screw (16) and nut (17) and remove it Remove the housing upper (18) Unscrew the kit diaphragm and remove it Fig. 7 BBV Automatic or Manually Actuated Boiler Blowdown Valves IM-P405-54 EMM Issue 4...
  • Page 37 Warning: Be careful as the spring is preloaded. Studs Fig. 8 Fig. 9 BBV Automatic or Manually Actuated Boiler Blowdown Valves IM-P405-54 EMM Issue 4...
  • Page 38 Remove the spring (28) and unscrew the connector (30). M6 Screw Mounting Nut Fig. 10 BBV Automatic or Manually Actuated Boiler Blowdown Valves IM-P405-54 EMM Issue 4...
  • Page 39 4.2 Assembly of the actuated system Note: If the valve is to be serviced, these actions should be completed prior to the actuator being reassembled and fitted Fit the yoke (14) and the connector (30) onto the valve. Tighten the mounting nut to indicated thread (see the valve instruction). Fit the spring guide (29) and fix it into position by hand tightening the M6 screw and then proceeed to fit the spring (28).
  • Page 40 Fit the seal (27) into the closed plate (15). Fit the gasket (20) onto the yoke and then place the the closed plate (15) on to it. Then place the second gasket (20) and the lower housing (34) onto the yoke (14) and fix in place with the screw (26). Put loctite glue in the four screws (26).
  • Page 41 Assemble the spindle (24) to the diaphragm (19), placing the washer (35) in place as indicated. Fit the diaphragm plate (23),the 'O' ring (38), the spacer (39), the washer (40) and fix in place using M12 screw (22) and tighten to the recommended torque of 35 Nm (25.8 lbf/ft).
  • Page 42 Fit the rollers (33) onto the lever (31) with the circlip (36). Fit the lever (31) onto the yoke with the axis pin (32) and the circlip (35) Fit the lever handle (25) onto the lever (31) and add the lever handle protection (41). Fit the screw (42) and tighten to a recommended torque of 15 N m (11 lbf/ft) to position the spring guide (29).
  • Page 43 Note 2: It is recommended that all soft seals and gaskets be replaced whenever the valve is disassembled. Table 1 Recommended tightening torques BBV valve size Torque (N m) DN15 - DN25 DN32 - DN50 Fig. 16 Bonnet tightening sequence...

  • Page 44: Table Of Contents

    5.2 Removal of valve bonnet Note: This procedure is necessary before carrying out any of the maintenance procedures detailed below: Ensure that the valve is depressurised and clear of media and isolate it both upstream and downstream. Caution: care should be taken when disassembling the valve in case of residual pressure being trapped between the isolation points.
  • Page 45 5.3 Replacement of PTFE gland packings (reference Figure 18, page 42) Remove the lock-nut (34), gland nut (18), 'O' rings (7a and 7b) and scraper ring (13) from the gland nut, ensuring that the grooves are clean and undamaged, replace with new items. The use of silicone grease on the 'O' rings is recommended.
  • Page 46 5.4 Replacement of graphite gland packing (reference Figure 19) Remove the lock-nut (34), gland nut (12) from the gland nut, ensuring that the groove is clean and undamaged, replace with new item. Remove the upper Stellite bearing (7a) and retain, withdraw the graphite packing (7c) and discard. Remove the spacer and lower bearing (7e).
  • Page 47 Removal and refitting of the valve plug/ stem assembly and seat Lift out the seat retaining cage (5) followed by the seat (3). Remove the seat back gasket (4) and discard. Clean all components, including the seat recess in the valve body. Examine the seat and plug/stem assembly for damage or deterioration and renew as necessary.
  • Page 48 5.6 Refitting the bonnet Caution: The following must be carefully followed to enable the correct reassembly of the control valve, and the subsequent test that is required to ensure that the plug moves freely inside the valve seat: Fit new bonnet gasket. Ensure the plug stem is fully extended without the upper stem threads making contact with stem seals on the top of the bonnet.
  • Page 49 Using a spanner lightly and After each tightening Firmly and briskly push the evenly tighten each bolt or nut sequence lift the stem fully. stem fully down. by 45°, following the sequence illustrated in Figure 5, page Repeat Steps 5, 6 and 7 until the bonnet nuts or bolts have an even tension. Continue Steps 5, 6 and 7 but use a torque wrench set at 10% of maximum required torque setting.
  • Page 50 The following new torque values should be used with lubricated nuts/bolts: Table 2 Recommended tightening torques BBV valve size Torque (N m) DN15 - DN25 DN32 - DN50 Fig. 24 DN15 - DN50 bonnet tightening sequence BBV Automatic or Manually Actuated Boiler Blowdown Valves IM-P405-54 EMM Issue 4...

  • Page 51: Between The Isolation Points

    5.8 Removal of valve bonnet Note: This procedure is necessary before carrying out any of the maintenance procedures detailed below: Ensure that the valve is depressurised and clear of media and isolate it both upstream and downstream. Caution: care should be taken when disassembling the valve in case of residual pressure being trapped between the isolation points.
  • Page 52 5.10 Replacement of graphite gland packing Remove the lock-nut (34), stuffing box nuts, gland flange and gland follower (12), ensuring that the groove is clean and undamaged, replace with new item. Remove the gland follower (7c) and retain, withdraw the graphite packing (7d) and discard. Remove the spacer and lower bearing (7g).

  • Page 53: Fig. 30

    5.11 Removal and refitting of the valve plug/ stem assembly and seat Lift out the seat retaining cage (5) followed by the seat (3). Remove the seat back gasket (4) and discard. Clean all components, including the seat recess in the valve body.
  • Page 54 5.12 Refitting the bonnet Caution: The following must be carefully followed to enable the correct reassembly of the control valve, and the subsequent test that is required to ensure that the plug moves freely inside the valve seat: Fit new bonnet gasket. Ensure the plug stem is fully extended without the upper stem threads making contact with stem seals on the top of the bonnet.
  • Page 55 Using a torque wrench lightly After each tightening Firmly and briskly push the and evenly tighten each bolt sequence lift the stem fully. stem fully down. or nut by 45°, following the sequence illustrated in Figure 24, page 48. Repeat Steps 5, 6 and 7 until the bonnet nuts or bolts have an even tension. Continue Steps 5, 6 and 7 but use a torque wrench set at 10% of maximum required torque setting.
  • Page 56 Always order spares by using the description given in the column headed 'Available spares', and state the size and type of valve including the full product description of the product. Example: 1 - PTFE stem seal kit for a Spirax Sarco BBV ASME Class 300 boiler blowdown valve. How to fit spares Full fitting instructions are given in the Installation and Maintenance Instructions supplied with the spare.
  • Page 57 Fig. 32 BBV Automatic or Manually Actuated Boiler Blowdown Valves IM-P405-54 EMM Issue 4...
  • Page 58 Always order spares by using the description given in the column headed 'Available spares', and state the size and type of valve including the full product description of the product. Example: 1 - PTFE stem seal kit for a Spirax Sarco BBV ASME Class 300 boiler blowdown valve. How to fit spares Full fitting instructions are given in the Installation and Maintenance Instructions supplied with the spare.
  • Page 59 Fig. 33 BBV Automatic or Manually Actuated Boiler Blowdown Valves IM-P405-54 EMM Issue 4...
  • Page 60 Always order spares by using the description given in the column headed 'Available spares', and state the size and type of actuator including the full product description of the valve. Example: 1 - Stem seal kit for a Spirax Sarco BBV actuator for use on a BBV boiler blowdown valve. How to fit spares Full fitting instructions are given in the Installation and Maintenance Instructions supplied with the spare.
  • Page 61 Fig. 34 BBV Automatic or Manually Actuated Boiler Blowdown Valves IM-P405-54 EMM Issue 4...
  • Page 62 BBV Automatic or Manually Actuated Boiler Blowdown Valves IM-P405-54 EMM Issue 4...
  • Page 63 BBV Automatic or Manually Actuated Boiler Blowdown Valves IM-P405-54 EMM Issue 4...
  • Page 64 BBV Automatic or Manually Actuated Boiler Blowdown Valves IM-P405-54 EMM Issue 4...

This manual is also suitable for:

Dn50